EGO POWER BC1500E-F, Repair Manual Line

Page 1: ...REPAIR GUIDELINE Bike Handle Line Trimmer _BC1500E F Version 1 Issue Data 12 02 2016...

Page 2: ...s NO Contents Page 1 Troubleshooting 3 2 Tool list 4 3 Part1 Replacing the Connecting Tube 5 12 4 Part2 Replacing the Motor Assembly 13 34 5 Part3 Replacing the PCB Assembly 35 48 2 BC1500E F Bike Han...

Page 3: ...to start The cables that connect to the motor are loose Motor Open the motor housing check the cable connection with motor Motor is burned Motor If the cables are well connected check the motor and t...

Page 4: ...ist SPEC Remark 1 Phillips PH2 2 Socket wrench 14mm 3 Torx screwdriver T 15 4 Hex wrench M5 5 Electric soldering iron 6 Heat gun 7 Heat shrinkable sleeves 8 Scissors To remove the shrinkable sleeve BC...

Page 5: ...Part 1 Replacing the Connecting Tube 5...

Page 6: ...Rotate the wing bolt counterclockwise to separate the connecting tube base set from the shaft base set and put the connecting tube aside Replacing the Connecting Tube 6 Shaft base set Connecting tube...

Page 7: ...ng the Connecting Tube 3 Remove the label on the right handle housing to expose the screw which is beneath it and continue to loosen the 4 screws and 1 bolt on the right handle housing to open it Labe...

Page 8: ...the left handle housing set to separate it from the connecting tube NOTICE if the left handle housing set is broken or worn replace it with a new one Description Part Number Qty Left handle housing se...

Page 9: ...with a new one Replacing the Connecting Tube 9 Description Part Number Qty Description Part Number Qty Upper connecting tube base 3421812001 1 Upper shaft base 3421813001 1 Lower connecting tube base...

Page 10: ...assembling the shaft base set and shaft with screws 7 Align the slot on the connecting tube with the rib on the left handle housing as well as aligning the hole on the connecting tube with the pole on...

Page 11: ...n the housing as well as aligning the location pole on the housing with the hole on the connecting tube to mount the right handle housing set onto the connecting tube 9 Lock the right handle housing s...

Page 12: ...12 Replacing the Connecting Tube 10 Rotate the wing bolt to connect the shaft base set with the connecting tube base set BC1500E F Bike Handle Line Trimmer...

Page 13: ...Part 2 Replacing the Motor Assembly 13...

Page 14: ...ex bolts in the guard with the M5 hex wrench remove the guard from the shaft Description Part Number Guard Assembly 2824870002 Hex Bolt 5620216003 Spring Washer 5650015012 14 Bolts Guard assembly Hex...

Page 15: ...se tabs on the lower housing assembly to remove the lower housing assembly 15 Description Part Number Qty Lower Housing Assembly 2824808001 1 Release tab Replacing the Motor Assembly BC1500E F Bike Ha...

Page 16: ...4 Pull the spring out of the motor shaft 16 Replacing the Motor Assembly BC1500E F Bike Handle Line Trimmer...

Page 17: ...5 Rotate the nut counterclockwise to remove the nut 17 Replacing the Motor Assembly BC1500E F Bike Handle Line Trimmer...

Page 18: ...6 Pull washer out of the motor shaft 18 Replacing the Motor Assembly BC1500E F Bike Handle Line Trimmer...

Page 19: ...7 Pull the upper housing assembly out of the motor shaft and then pull the outer flange out of the motor shaft 19 Replacing the Motor Assembly BC1500E F Bike Handle Line Trimmer...

Page 20: ...ver 3127655001 1 Screw 5610059007 1 washer 5650396003 1 8 Loosen the three screws on the shield cover remove the shield cover from the motor assembly Shield cover Screw Washer Replacing the Motor Asse...

Page 21: ...er Qty Rear housing 2824012001 1 Lower cover 3127675002 1 Upper cover 3127650001 1 Rear housing Replacing the Motor Assembly 9 Loosen the 7 screws in the rear housing Remove the housing upper cover an...

Page 22: ...m the housing Move the shaft to the side and pull out the three cables wrapped with heat shrinkable sleeves This makes replacing the motor assembly easier Screw Fixed ring Plain washer Description Par...

Page 23: ...or assembly from the motor housing 12 Remove the heat shrinkable sleeves from the cables and disconnect the cables Motor housing Motor assembly Motor assembly Replacing the Motor Assembly BC1500E F Bi...

Page 24: ...kable sleeves through the cables Connect the cables with electric soldering iron Correct connection White to White Black to Black Blue to Green Replacing the Motor Assembly Blue Green Black Black Whit...

Page 25: ...nts and use a hot air gun to shrink the sleeves shield cover Replacing the Motor Assembly 17 Position the motor assembly into the motor housing mount the shield cover on the motor assembly and lock it...

Page 26: ...18 Put the outer flange onto the shaft and then put the upper housing assembly onto the shaft 26 Replacing the Motor Assembly BC1500E F Bike Handle Line Trimmer...

Page 27: ...19 Mount the washer onto the motor shaft 27 Replacing the Motor Assembly BC1500E F Bike Handle Line Trimmer...

Page 28: ...20 Mount the nut onto the motor shaft and then rotate the nut clockwise with socket wrench 28 Replacing the Motor Assembly BC1500E F Bike Handle Line Trimmer...

Page 29: ...21 Mount the spring onto its position 29 Replacing the Motor Assembly BC1500E F Bike Handle Line Trimmer...

Page 30: ...e tabs on the lower housing assembly with the holes on the upper housing assembly to mount the lower housing assembly onto the upper housing assembly Replacing the Motor Assembly BC1500E F Bike Handle...

Page 31: ...lower housing assembly counterclockwise as necessary to align the mark LOAD on the lower housing assembly with the eyelets on the upper housing assembly Replacing the Motor Assembly BC1500E F Bike Han...

Page 32: ...f the other side of the upper housing assembly Pull the line from the other side until equal amounts of line appear on both sides of the spool 25 Rotate the lower housing assembly counterclockwise to...

Page 33: ...cables into its groove and assemble shaft with the rear housing with fixed ring Screw Fixed ring Plain washer Description Part Number Qty Fixed ring 3705178001 1 Screw 5610032004 1 Plain washer 56500...

Page 34: ...ear housing 2824012001 1 Lower cover 3127675002 1 Upper cover 3127650001 1 Rear housing Replacing the Motor Assembly 27 Mount the lower cover and upper cover onto the rear housing and assemble the rea...

Page 35: ...Part 3 Replacing the PCB Assembly 35...

Page 36: ...36 Replacing the PCB Assembly 1 Disassemble the right handle housing set as shown in Replacing the Connecting Tube section BC1500E F Bike Handle Line Trimmer...

Page 37: ...n washer 5650005002 1 37 Fixed ring Replacing the PCB Assembly 2 Disassemble the rear housing as shown in the Replacing the motor section and then loosen the locking screw on the fixed ring to separat...

Page 38: ...y 3 Remove the heat shrinkable sleeves from the connectors with a scissor 4 Move the transparent sleeves aside and pull the connectors to separate PULL Transparent sleeve Heat shrinkable sleeve BC1500...

Page 39: ...Description Part Number Qty PCB assembly 2830211001 1 PCB assembly Replacing the PCB Assembly 5 Remove the PCB assembly from the housing and replace it with a new one BC1500E F Bike Handle Line Trimm...

Page 40: ...three connectors ensuring they are fully inserted Correct direction blue to green white to white black to black 8 Move the transparent sleeves and the heat shrinkable sleeves to cover the connectors...

Page 41: ...B Assembly 9 Align the hole in the shaft with the pole on the housing and then fasten the fixed ring with the screw and the washer to connect the shaft with the rear housing Hole Pole BC1500E F Bike H...

Page 42: ...ce the wires in the housing grooves in sequence a Align the thin cables green white and black into the bottom of the housing groove through channel 1 b Align the two red cables into the groove through...

Page 43: ...43 c Align the cables connected with the motor through channel 2 Replacing the PCB Assembly Channel 2 BC1500E F Bike Handle Line Trimmer...

Page 44: ...60013003 1 Spring 2 3660129002 1 Battery ejection lever Latch Battery release button Spring 1 Spring 2 Replacing the PCB Assembly 11 Position the PCB assembly into the housing 12 The battery release b...

Page 45: ...45 Replacing the PCB Assembly 13 Assemble the rear housing BC1500E F Bike Handle Line Trimmer...

Page 46: ...ht handle housing a Align the hole in the switch trigger with the pole on the right handle housing b Place the switch in position and align the thin wires as shown Switch Switch trigger Description Pa...

Page 47: ...e by one d Place the interlock trigger into the right handle housing NOTICE if the switch trigger or interlock trigger is broken or worn replace it with a new one Description Part Number Qty Interlock...

Page 48: ...48 Replacing the PCB Assembly 15 Assemble the right handle housing set as shown in the Replacing the Connecting Tube section THE END BC1500E F Bike Handle Line Trimmer...