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Summary of Contents for Echo shindaiwa DCS-1600
- Page 1 DCS-1600 ECHO: (Serial number: 24000001 and after) (Serial number: 35000001 and after) REVISED May 2022 Ref. No. 401-43 Copyright C 2019 YAMABIKO Corporation All rights reserved.
- Page 2 INTRODUCTION This service manual contains information for service and maintenance of ECHO BATTERY CHAINSAW, model DCS-1600. For systematic diagnosis, to avoid extra work and time loss, please refer to “Troubleshooting chart” that describes problems, testing, reme- dies and references. We recommend you make use of Operator’s Manual and Parts Catalogue...
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Page 3: Table Of Contents
TABLE OF CONTENTS DCS-1600 Page Page SERVICE INFORMATION ………………… 2 BATTERY AND CHARGER ……………… 43 1-1 Specifications ………………………………… 2 9-1 Battery LED indicator ……………………… 44 1-2 Technical data ………………………………… 3 9-2 Charger LED indicator …………………… 44 1-3 Torque limits ………………………………… 3 9-3 Inspecting battery …………………………... -
Page 4: Service Information
SERVICE INFORMATION DCS-1600 1 SERVICE INFORMATION 1-1 Specifications Dimensions* Length mm(in) 459 (18.1) Width mm(in) 219 (8.6) Height mm(in) 262 (10.3) Dry weight** kg(lb) 3.1 (6.8) Motor Type DC electric motor Rotation Clockwise as viewed from the output end Rated current 42.5 Rated voltage 50.4... -
Page 5: Technical Data
SERVICE INFORMATION DCS-1600 1-2 Technical data Motor Speed at maximum power r/min 8,940 Speed control r/min Low (6,000 r/min) - High (10,000 r/min) Battery Battery type: LBP-560-200 LBP-50-250 LCJQ-560: 45(80%) / 64(100%) LCJQ-560: 60(80%) / 89(100%) Charging time min. LCJU-560: 22(80%) / 39(100%) LCJU-560: 30(80%) / 57(100%) Operating time/one charge* min. -
Page 6: Wiring Diagram
SERVICE INFORMATION DCS-1600 1-6 Wiring diagram Battery Control board ＋ ＋ Power supply Power supply Identification of battery type Sensor (Over discharge) Sensor (Temperature) D− − Black Blue Sensor (Temperature) White Identification of battery type Brake switch Yellow Sensor (Over discharge) Brake signal 2 Black Brake signal 2 Brake signal 1... -
Page 7: Troubleshooting
TROUBLESHOOTING DCS-1600 TROUBLESHOOTING WARNING DANGER Do not open, crush, heat above 60°C or incinerate batteries. Do not use damaged or deformed batteries. Failure to follow these rules may result in electric shock, fire, and/or serious personal injury. 2-1 Error indicator Power indicator LED on power switch flashes as shown when trouble occurs.(Refer to section 2-2) LED indicator Cause How to recover... -
Page 8: Troubleshooting Chart
TROUBLESHOOTING DCS-1600 2-2 Troubleshooting chart Be sure to begin with “STEP0” when troubleshooting. Troubleshooting "STEP0" NOTE: Be sure to release chain brake. Start A: Is battery fully charged? Step1 & Step2 B: Press power switch. Is LED indicator lighting or flashing? Step3 C: Press power switch. - Page 9 TROUBLESHOOTING DCS-1600 2-2 Troubleshooting chart (Continued) Troubleshooting "STEP1" ~Checking battery and charger~ Start A: Press battery buttton to indicate charging status. Step2 B: Is LED indicator of battery lighting? C: Go to “Step 2” to find cause of battery failure. After passing Step2 then replace the battery to new one and continue to diagnosis.
- Page 10 TROUBLESHOOTING DCS-1600 2-2 Troubleshooting chart (Continued) Troubleshooting "STEP2" ~Checking unit in case of battery failure~ Start A: Are there conductive substances (water, metal pieces, etc.) on the surface of control board? (Refer to Section 6-1) B: Remove conductive substances (water, metal pieces, etc.) on the surface of control board. C: Is control board damaged? (Refer to Section 6-1) D: Replace the control board with new one.
- Page 11 TROUBLESHOOTING DCS-1600 2-2 Troubleshooting chart (Continued) Troubleshooting "STEP3" ~Checking power supply circuit~ WARNING DANGER Start Verify the safety of the surroundings when doing Troubleshooting STEP3. The machine may run unexpectedly. A: Install battery on the unit correctly. B: Release chain brake and press power switch with- out holding trigger lever. C: Is LED indicator lighting or flashing? D: Remove battery from the unit.
- Page 12 TROUBLESHOOTING DCS-1600 2-2 Troubleshooting chart (Continued) Troubleshooting "STEP4" ~Checking degradation and overdischarge of battery~ Start A: Install battery on the unit correctly. B: Release chain brake and press power switch without holding trigger lever. C: Press power switch. Is LED indicator flashing 1 time per second? D: Inspect the unit as follows: 1) Each connection between terminals is secure.
- Page 13 TROUBLESHOOTING DCS-1600 2-2 Troubleshooting chart (Continued) Troubleshooting "STEP5" ~Checking each sensor and switch~ WARNING DANGER Verify the safety of the surroundings when doing Troubleshooting STEP5. The machine may run unexpectedly. Start A: Install battery on the unit correctly. B: Release chain brake and press power switch From page 12 or 13 without holding trigger lever. C: Press power switch.
- Page 14 TROUBLESHOOTING DCS-1600 2-2 Troubleshooting chart (Continued) Troubleshooting "STEP5" ~Checking each sensor and switch (Continued)~ Inspecting temperature sensor of battery A: Is battery hot?. From page 11 B: Cool the battery to normal temperature. C: Go to page 11 (9). D: Is resistance between battery terminal (T) and (C-), (T) and (D-) 20 kΩ...
- Page 15 TROUBLESHOOTING DCS-1600 2-2 Troubleshooting chart (Continued) Troubleshooting "STEP5" ~Checking each sensor and switch (Continued)~ Inspecting variable resistance part A: Inspect resistance between terminal “1” and “2” of variable speed switch as follows: (Refer to Section 5-1) 1) Its value is 100 Ω or less when pressing the switch to the end.
- Page 16 TROUBLESHOOTING DCS-1600 2-2 Troubleshooting chart (Continued) Troubleshooting "STEP6" ~Checking brake switch and over load ~ WARNING DANGER Start Verify the safety of the surroundings when doing Troubleshooting STEP6. The machine may run unexpectedly. A: Install battery on the unit correctly. B: Release chain brake and press power switch without holding trigger lever. And then hold trigger lever.
- Page 17 TROUBLESHOOTING DCS-1600 2-2 Troubleshooting chart (Continued) Troubleshooting "STEP7" ~Checking other failure~ WARNING DANGER Start Verify the safety of the surroundings when doing Troubleshooting STEP7. The machine may run unexpectedly. A: Install battery on the unit correctly. B: Release chain brake and press power switch without holding trigger lever. And then hold trigger lever.
- Page 18 TROUBLESHOOTING DCS-1600 2-2 Troubleshooting chart (Continued) Troubleshooting "STEP7" ~Checking other failure (Continued)~ A: Motor speed can not be increased or is not stable. (10) From page 15 B: Inspect the unit as follows: 1) Sprocket is clogged with saw dust or something. 2) Unsuitable saw chain or guide bar is used. 3) Saw chain tension is too tight.
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Page 19: Diagnosis Of Abnormal Condition
TROUBLESHOOTING DCS-1600 2-3 Diagnosis of abnormal condition DCS-1600 has a function that records abnormalities when they occur. It also diagnoses the type of abnor- mality in the following procedure. NOTE: Before you do this diagnosis, make a note the following. 1. -
Page 20: Chain Brake System
CHAIN BRAKE SYSTEM DCS-1600 3 CHAIN BRAKE SYSTEM (A) Brake lever (J) Tapping bolt (M4) (B) Tapping bolt (M4) (K) Brake cover (C) Washer (L) Collar (D) Collar (M) Brake connector (E) Tapping bolt (M5) (N) Compression spring (F) Collar (P) Spacer (G) Torsion spring (Q) Brake band... -
Page 21: Inspecting Brake Switch
CHAIN BRAKE SYSTEM DCS-1600 3-1 Inspecting brake switch 1. Remove cover (S). 2. Clean saw dust and/or dirt around brake switch (H). 3. Connect one probe of multimeter to terminal “1” of brake switch (H). Connect the other probe to ter- minal “2”... -
Page 22: Replacing Brake Lever
CHAIN BRAKE SYSTEM DCS-1600 3-2 Replacing brake lever [Disassembling] 1. Remove brake switch from motor cover. 2. Remove bolt (E) and collar (F). 3. Remove bolt (B), washer (C) and collar (D). 4. Remove brake lever (A). 5. Check torsion spring (G). If deformed or broken, replace with new one. - Page 23 CHAIN BRAKE SYSTEM DCS-1600 3-2 Replacing brake lever (Continued) 11. Move brake lever (A) forward to activate chain brake. 12. Place brake switch (H) on motor cover as shown. 13. Pass leads (h3) of brake switch (H) through cutout of motor cover as shown. 14.
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Page 24: Replacing Chain Brake Parts
CHAIN BRAKE SYSTEM DCS-1600 3-3 Replacing chain brake parts WARNING DANGER Wear eye protection and safety gloves when disassembling or assembling chain brake to protect eye and hand from injury. [Disassembling] 1. Remove E-ring (U), washer (V) and drum (W). 2. Move brake lever (A) forward to activate chain brake. NOTE: Make sure that brake lever (A) is in acti- vated position before removing brake cover (K), otherwise compression spring (N) may jump out. -
Page 25: Saw Chain Lubrication System
SAW CHAIN LUBRICATION SYSTEM DCS-1600 4 SAW CHAIN LUBRICATION SYSTEM (A) Oil cap (G) Oil line (B) O-ring (H) Grommet (C) Cap connector (J) Pipe joint (D) Oil tank (K) Oil line (E) Oil tank vent (M) Auto-oiler (F) Oil strainer (N) Worm gear... -
Page 26: Inspecting Oil Cap And Strainer
SAW CHAIN LUBRICATION SYSTEM DCS-1600 4-1 Inspecting oil cap and strainer 1. Remove oil cap (A). 2. Inspect oil cap (A) for cracks and O-ring (B) for cuts or damage. Replace worn or damaged part(s) as required. 3. Replace cap connector (C) if damaged. 4. -
Page 27: Inspecting Oil Line
SAW CHAIN LUBRICATION SYSTEM DCS-1600 4-2 Inspecting oil line 1. Remove oil line (K) from oil line (G). NOTE: Be careful not to enter oil line (G) into mo- tor cover. Otherwise, it’s difficult to reconnect oil line (G) and oil line (K). 2. -
Page 28: Inspecting And Replacing Worm Gear
SAW CHAIN LUBRICATION SYSTEM DCS-1600 4-3 Inspecting and replacing worm gear [Disassembling and inspecting] 1. Remove E-ring (P), washer (Q), drum (R) and worm gear (N). 2. Inspect worm gear (N). If worn, damaged or de- formed, replace with new one. NOTE: If worm gear (N) is replaced, inspect gear of auto-oiler and replace the auto-oiler as needed. -
Page 29: Replacing Auto-Oiler
SAW CHAIN LUBRICATION SYSTEM DCS-1600 4-4 Replacing auto-oiler NOTE: Changed auto-oiler to use for auto-oiler of DCS-1600 Auto-oiler puller 【Before change】 【After change】 For DCS-1600 dia.13mm dia.11.5mm Part number Part number Y089-000130 Y089-000131 Auto-oiler installer 【Before change】 【After change】 For DCS-1600 Part number Part number dia. - Page 30 SAW CHAIN LUBRICATION SYSTEM DCS-1600 4-4 Replacing auto-oiler (Continued) [Assembling] 4. Place auto-oiler (M) on hole (a) of motor cover while aligning groove (m1) of auto-oiler with mark of motor cover as shown. 5. Push auto-oiler (M) in hole of motor cover until it bottoms out using the oiler installer 91073A (V) as shown.
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Page 31: Seperating Motor Cover And Replacing Oil Line
SAW CHAIN LUBRICATION SYSTEM DCS-1600 4-5 Seperating motor cover and replacing oil line [Disassembling] 1. Remove cover and brake lever. (Refer to Sec- tion 3-2) 2. Remove drum and worm gear. (Refer to Section 4-3) 3. Remove four bolts (W) and front handle. 4. -
Page 32: Switch And Trigger
SWITCH AND TRIGGER DCS-1600 5 SWITCH AND TRIGGER (A) Power switch (B) Variable speed switch (C) Trigger lever (D) Torsion spring (E) Lockout button (F) Compression spring... -
Page 33: Inspecting Power Switch And Variable Speed
SWITCH AND TRIGGER DCS-1600 5-1 Inspecting power switch and variable speed switch [Disassembling] 1. Separate motor cover. (Refer to Section 4-5) 2. Remove power switch (A) from motor cover put- ting flat head screw driver or suitable tool between power switch (A) and motor cover as shown. 3. - Page 34 SWITCH AND TRIGGER DCS-1600 5-1 Inspecting power switch and variable speed switch (Continued) (4) Inspection of LED using coin battery CR2032, ECR2032, DL2032 or SB-T51 NOTE: Be sure to use coin battery CR2032, ECR2032, DL2032 or SB-T51, otherwise LED can be damaged due to overcurrent (150 mA or more) through it.
- Page 35 SWITCH AND TRIGGER DCS-1600 5-1 Inspecting power switch and variable speed switch (Continued) [Inspecting variable speed switch] 5. Inspect variable speed switch (B) as follows. If Terminal position the switch (B) is not as follows, replace with new 1 2 3 4 one. (1) Inspection of short circuit Connect one probe of multimeter to terminal “1”...
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Page 36: Installing Switches And Trigger Lever
SWITCH AND TRIGGER DCS-1600 5-2 Installing switches and trigger lever 1. Connect power switch (A) and 6-pole terminal (G) of wire harness. 2. Connect variable speed switch (B) and 4-pole terminal (H) of wire harness. 3. Install power switch (A) on motor cover as shown. 4. - Page 37 SWITCH AND TRIGGER DCS-1600 5-2 Installing switches and trigger lever (Continued) 6. Install trigger lever (C) on motor cover while placing the end (d) of torsion spring on motor cover as shown. NOTE: Check the position of trigger lever (C) and torsion spring (D).
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Page 38: Motor And Control System
MOTOR AND CONTROL SYSTEM DCS-1600 6 MOTOR AND CONTROL SYSTEM (A) Motor (B) Control board... -
Page 39: Inspecting Motor And Control Board
MOTOR AND CONTROL SYSTEM DCS-1600 6-1 Inspecting motor and control board 1. Separate motor cover. (Refer to section 4-5) 2. Remove battery connection terminal (C) of con- trol board from motor cover. 3. Determine whether control board is short-cir- cuited between positive terminal (c1) and negative terminal (c2). -
Page 40: Installing Motor And Control Board
MOTOR AND CONTROL SYSTEM DCS-1600 6-2 Installing motor and control board 1. Reconnect 8-pole terminal (E) of control board (B). 2. Install control board (B) on motor cover as shown. 3. Place battery connection terminal (C) between ribs of motor cover as shown. 4. -
Page 41: Cleaning And Replacing Air Filter
AIR FILTER DCS-1600 7 AIR FILTER 7-1 Cleaning and replacing air filter 1. Remove cover (A) from unit. 2. Push two hooks (B) inside using flat head screw driver or suitable tool as shown. 3. Remove cleaner lid (C) and air filter (D) together as shown. -
Page 42: Guide Bar Mounting System
GUIDE BAR MOUNTING SYSTEM DCS-1600 8 GUIDE BAR MOUNTING SYSTEM (A) Drum (B) Washer (C) Retaining ring (D) Stud (J) Collar (E) Tensioner screw (K) Tapping bolt (F) Chain tensioner (M) Sprocket guard (G) Bevel gear (N) Hook (H) Bevel gear (P) Nut 8-1 Replacing nut for fixing guide bar [Disassembling]... -
Page 43: Assembling Chain Tensioner
GUIDE BAR MOUNTING SYSTEM DCS-1600 8-2 Assembling chain tensioner 1. Place bevel gear (G) on sprocket guard (M). 2. Screw chain tensioner (F) on tensioner screw (E). 3. Install beval gear (H) into collar (J). 4. Put bevel gear (H) on the end of tensioner screw (E). 5. -
Page 44: Inspecting Sprocket
GUIDE BAR MOUNTING SYSTEM DCS-1600 8-3 Inspecting sprocket Inspect sprocket of drum. If worn out 0.5 mm 0.5mm (0.02in.) or more, replace with new one. (Refer to section 4-3) 8-4 Replacing guide bar stud [Disassembling] 1. Install two nuts on defective stud (D) and tighten them against each other. -
Page 45: Battery And Charger
BATTERY AND CHAGER DCS-1600 9 BATTERY AND CHARGER Battery Terminal Battery pack latch Press button LED indicator Charger Cooling passage Terminal Mains plug Cooling passage LED indicator WARNING DANGER Do not open, crush, heat above 60°C or incinerate batteries and do not use damaged or deformed batteries. Failure to follow these rules may result in electric shock, fire, and/or serious personal injury. NOTE: - Charge battery in ambient temperature of 5 - 40°C (41 - 104°F). - Repeated discharges and recharges can cause reduced battery capacity. -
Page 46: Battery Led Indicator
BATTERY AND CHAGER DCS-1600 9-1 Battery LED indicator Battery LED indicator shows battery charging capacity as follows when pressing button. Press button LED indicator Capacity Capacity Battery LED indicator Battery LED indicator 4 LED is lighting 80 - 100% 1 LED is lighting 0 - 25% 3 LED is lighting 55 - 80%... -
Page 47: Inspecting Battery
BATTERY AND CHAGER DCS-1600 9-3 Inspecting battery NOTE: This check must be done when the battery can be fully charged but does not have capacity to run the unit. If battery is found defective by the following check, do Troubleshooting “Step2” (Refer to section 2-2) before installing a new battery. -
Page 48: Maintenance Guide
MAINTENANCE GUIDE DCS-1600 10 MAINTENANCE GUIDE 10-1 Disassembly chart Sprocket Cover guard (3-1) Chain Cleaner lid, Brake Drum tensioner Air filter lever (3-2) (3-3) (8-2) (7-1) Front Worm handle gear Chain (4-3) (4-5) brake (3-2) Auto oiler Motor cover (4-4) (4-5) Control Trigger... - Page 49 MEMORANDUM DCS-1600...
- Page 50 Published by YAMABIKO Corp. Tokyo Japan 1904...