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REPAIR GUIDELINE

Version: 1
Issue Date: 2015/03/05

Hedge Trimmer_HT2400E

Summary of Contents for HT2400E

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

Page 2: ...s 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 Repla...

Page 3: ...y 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...

Page 4: ...gon 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 Solde...

Page 5: ...5 Part 1 Replace the Front Handle Set...

Page 6: ...rew 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 P...

Page 7: ...s 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 Tappin...

Page 8: ...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 L...

Page 9: ...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 s...

Page 10: ...place 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 housin...

Page 11: ...gn 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...

Page 12: ...ont 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 sp...

Page 13: ...13 Part 2 Replace the Blade Assembly...

Page 14: ...lace 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...

Page 15: ...h 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 Sw...

Page 16: ...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 o...

Page 17: ...hers 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 Pla...

Page 18: ...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 wash...

Page 19: ...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 Par...

Page 20: ...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 tow...

Page 21: ...The clamp support of the blade assembly should point towards the gear box The eccentric block should be mounted onto washer with the circular convexity of the eccentric block sitting into the concave...

Page 22: ...asher bush through the bolts put the bolts through the locking holes in the blade assembly mount the nuts onto the bolts from the backside of the gear case and tighten the bolts 14 Add some grease on...

Page 23: ...Notice the assembly direction The concave of the outer washer should be mounted towards the eccentric block and make sure the circular convexity of the eccentric block sitting into the concave of the...

Page 24: ...Use a vernier caliper to measure the depth of the shaft end which is lower than the outer washer surface It should be less than 0 6mm If the depth exceeds 0 6mm reassemble the blade set step by step f...

Page 25: ...hrough the locking bolt and mount the bolt into the gear shaft tighten the locking bolt The reference tightening torque is 10 NM 12 NM 17 Position the blade assembly into the left housing close the ri...

Page 26: ...ttery press the switch trigger and switch lever at the same time check if the blade works properly at least 30s If not reassemble all the parts make sure every step is correct 19 Following the instruc...

Page 27: ...27 Part 3 Replace the PCB Assembly...

Page 28: ...ns in Replace the Front Handle Set to remove the hand guard front handle and front trigger switch 2 Loosen and remove the 12 screws in the right housing and open the housing 28 Right housing Front Tri...

Page 29: ...assembly and gear box assembly from the left housing 4 Remove the battery ejection lever and take out the battery connection terminal from the left housing 29 Motor assembly Gear box assembly Battery...

Page 30: ...c soldering iron and solder sucker to disconnect the two solder joints as indicated on the below figure and remove the PCBA from the motor 30 PCB assembly PCB assembly includes the PCB on the top of t...

Page 31: ...ints with the two terminals on the motor The solder joint 2 close to the red wire connected to the positive terminal on the motor The solder joint 1 close to the black wire connected to the negative t...

Page 32: ...32 Replace the PCB Assembly 9 Position the battery connection terminal rear trigger switch and main PCBA in the left housing Battery connection terminal Rear trigger switch Main PCBA...

Page 33: ...33 Replace the PCB Assembly 10 Internal wire alignment a Align the green wire connecting battery connection terminal to main PCBA in the groove...

Page 34: ...34 Replace the PCB Assembly 10 Internal wire alignment b Align the red wire connecting battery connection terminal to rear trigger switch in the groove...

Page 35: ...35 Replace the PCB Assembly 10 Internal wire alignment c Align the black wire connecting battery connection terminal to main PCBA in the groove...

Page 36: ...36 Replace the PCB Assembly 10 Internal wire alignment d Align the black wire connecting rear trigger switch to main PCBA in the groove...

Page 37: ...y 10 Internal wire alignment e Pass the three wires red brown and blue connecting to the trigger switch in the front handle through the hole in the left housing Three wires connecting to the trigger s...

Page 38: ...38 Replace the PCB Assembly 10 Internal wire alignment f Align the black wire connecting the rear trigger switch to the trigger switch in the front handle in the groove...

Page 39: ...39 Replace the PCB Assembly 10 internal wire alignment g Align the red wire connecting main PCBA to the trigger switch in the front handle in the groove...

Page 40: ...40 Replace the PCB Assembly 10 Internal wire alignment H Move the motor assembly and gear box assembly aside align the red and black wires connecting main PCBA to the motor in the groove...

Page 41: ...41 Replace the PCB Assembly 10 Internal wire alignment I Align the blue wire connecting rear trigger switch to the trigger switch in the front handle in the groove...

Page 42: ...42 Replace the PCB Assembly 11 Position the motor assembly together with the gear box assembly into the left housing make sure they are rested in position...

Page 43: ...3 Replace the PCB Assembly 12 Fix the switch lever and switch trigger in turn Make sure the rotation side of the lever is rested in the switch trigger Switch lever Switch trigger Rested in the trigger...

Page 44: ...44 Replace the PCB Assembly 13 Rest one side of the spring in the limit cave of housing push the ejection lever and position it into the housing Rest this side in the housing Push...

Page 45: ...sure they are fine located in the grooves close the right housing and locked with 12 screws 15 Following the instructions in Replace the Front Handle Set to connect the wires to the trigger switch in...

Page 46: ...46 Part 4 Replace the Motor and Gear Box Assembly...

Page 47: ...to remove the hand guard front handle 2 Loosen and remove the 12 screws in the right housing and open the housing 3 Following the instructions in Replace the Blade Assembly to separate the blade assem...

Page 48: ...lowing the instructions in Replace the PCB Assembly to separate the main PCBA from the motor 6 Replace with a new motor and gear box assembly Replace the Motor and Gear Box Assembly Description Part N...

Page 49: ...tructions in Replace the PCB Assembly to connect the main PACB to the motor 8 Following the instructions in Replace the Blade Assembly to mount the blade assembly onto the gear shaft Replace the Motor...

Page 50: ...50 Part 5 Replace the Gears in Gear Box...

Page 51: ...lace the Gears in Gear Box 1 Turn the motor clockwise to release the latch from the gear box 2 Pull the motor upwards to separate the motor from the gearbox Loosen Motor Gearbox 51 Pull to separate La...

Page 52: ...Replace the Gears in Gear Box 3 Take out the parts in the gear box in turn 52 Washer 1 1st planet gear Sun gear 1st ring gear Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Height 9 15mm...

Page 53: ...Replace the Gears in Gear Box 53 Washer 2 2st planet gear Step 9 Step 10 Step 11 Step 12 Step 13 Step 14 2st ring gear Height 13 15mm Gear case Step 15 Carrier Step 16 Carrier...

Page 54: ...Replace the Gears in Gear Box 54 Step 17 Gear case...

Page 55: ...331000 Washer1 1 13 8x34 4x0 5 21 3520292000 1st Planet Gear 4 m 0 7 z 11 22 3520511000 Sun Gear 1 m 0 7 z 14 23 3520391000 1st Ring Gear 1 m 0 7 z 38 24 3705616000 Washer 2 1 13x 24 5x1 0 25 35205400...

Page 56: ...mble the parts in the gear box in turn 1 Place the carrier into the gear case make sure the flat position of the carrier align the knob of the gear case Step 3 56 slot of the carrier Knob of the gear...

Page 57: ...ring gear into the gear case Do not mix the 2st ring gear with 1st ring gear distinguish them by the different height size Then assemble the five 2st planet gears same as 1st planet gears into positi...

Page 58: ...Gears in Gear Box 58 hole Cylinder of carrier 3 Place the washer 2 into position make sure the holes of the washer 2 inserted into the cylinder of the carrier Then insert the sun gear among the plane...

Page 59: ...of the gear case place the 1st ring gear into the gear case Do not mix the 1st ring gear with 2st ring gear distinguish them by the different height size Then assemble the four 1st planet gears same a...

Page 60: ...the washer 1 into the gear case 6 Check if the surface of the washer 1 is under the lower edge of the slot in the gear case If not reassemble all the parts from Step 1 make sure every step is correct...

Page 61: ...ox 6 With the red wire on the motor PCBA facing outside align the knob of the gear case cover on the motor with the slot of the gearbox mount the gear case cover onto the gear box 61 Knob Knob Slot Sl...

Page 62: ...Box 7 Turn the motor counterclockwise until the knob latch of the gear case cover moved and locked on the gear case 8 Follow the instructions in Replace the PCB assembly to align the wires and close t...

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