Efco DS Series Workshop Manual
  1. Manuals
  2. Brands
  3. Efco Manuals
  4. Brush Cutter
  5. DS Series
  6. Workshop manual

Efco DS Series Workshop Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

WORKSHOP MANUAL
BRUSCHCUTTERS DS 2200 - DS 2400

Advertisement

Table of Contents
loading

Related Manuals for Efco DS Series

Summary of Contents for Efco DS Series

  • Page 1 WORKSHOP MANUAL BRUSCHCUTTERS DS 2200 - DS 2400...
  • Page 3 MODEL DS 2200 TR DS 2200 S DS 2200 T DS 2400 S DS 2400 T ENGINE TYPE Emak, 2-stroke (EPA 3, 125h) KAT DISPLACEMENT cu. in. BORE inch 1.26 STROKE inch 1.06 HP/kW MAXIMUM POWER OUTPUT 1,1 / 0,82 (8500) 1,2 / 0,9 (8500) (rpm) MAXIMUM TORQUE...

  • Page 4: Table Of Contents

    BRUSCHCUTTERS DS 2200 - DS 2400 INDEX 1. GENERAL INFORMATION ................ 5 2. SAFETY ....................7 3. FASTENER TORQUES ................10 3.1 Metric Fastener Torque Values ................10 3.2 Inch Fastener Torque Values ................11 3.3 Fastener torques of the DS 2400 ................12 3.4 Fastener torques of the DS 2200 ................

  • Page 5: General Information

    50:1 fuel/oil mixture. ventilated to prevent possible igniting • If EFCO 2-Cycle Engine Oil or its equivalent IS NOT of fumes by an open flame or spark, this being used, mix alternative 2-cycle engine oil to includes any appliance with a pilot light.
  • Page 6 United States and Canada may require different lubricant recommendations than the ones printed in this technical manual or the operator’s manual. Consult with your EFCO Dealer, to obtain the alternative lubricant recommendations. Synthetic Lubricants Synthetic lubricants may be used in EFCO equipment if they meet the applicable performance requirements.

  • Page 7: Safety

    BRUSCHCUTTERS DS 2200 - DS 2400 2. SAFETY Recognize Safety Information containers. • Make sure machine is clean of trash, grease, and debris. • Do not store oily rags; they can ignite and burn spontaneously. • Be prepared if a fire starts. •...
  • Page 8 BRUSCHCUTTERS DS 2200 - DS 2400 2. SAFETY Support Machine Properly and Use Proper Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear a suitable Lifting Equipment hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.
  • Page 9 BRUSCHCUTTERS DS 2200 - DS 2400 2. SAFETY Work In Ventilated Area Handle Chemical Products Safely Engine exhaust fumes can cause sickness or Direct exposure to hazardous chemicals can cause death. If it is necessary to run an engine in an serious injury.

  • Page 10: Fastener Torques

    BRUSCHCUTTERS DS 2200 - DS 2400 3. FASTENER TORQUES 3.1 Metric Fastener Torque Values Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9 Lubricated a Dry a Lubricated a Dry a Lubricated a Dry a Lubricated a Dry a SIZE N●m lb-ft...

  • Page 11: Inch Fastener Torque Values

    BRUSCHCUTTERS DS 2200 - DS 2400 3. FASTENER TORQUES 3.2 Imperial inch Fastener Torque Values Grade 1 Grade 2b Grade 5, 5.1 or 5.2 Grade 8 or 8.2 Lubricated a Dry a Lubricated a Dry a Lubricated a Dry a Lubricated a Dry a SIZE...

  • Page 12: Fastener Torques Of The Ds 2400

    BRUSCHCUTTERS DS 2200 - DS 2400 3. FASTENER TORQUES 3.3 Fastener torques of the DS 2400 Tightening torques in lb (kgm) / lubrication * = Loctite 243 22.13 159.3 ∆ = Loctite 270 (0.25) * (1.8) G = Grease O = Oil 22.13 39.83 (0.25) *...
  • Page 13 BRUSCHCUTTERS DS 2200 - DS 2400 3. FASTENER TORQUES Tightening torques in lb (kgm) / lubrication * = Loctite 243 ∆ = Loctite 270 22.13 159.3 G = Grease (0.25) * (1.8) O = Oil 22.13 39.83 (0.25) * (0.45) 70.80 (0.8) * 12.39...
  • Page 14 BRUSCHCUTTERS DS 2200 - DS 2400 3. FASTENER TORQUES 61.95 26.55 30.98 (0.7) * (0.3) * (0.35) * 22.13 35.4 (0.25) * (0.4) 132.76 35.4 (1.5) (0.4) * 70.80 26.55 (0.8) * (0.3) * 26.55 35.4 (0.3) * (0.4) 53.1 44.25 (0.6) * 35.4...

  • Page 15: Fastener Torques Of The Ds 2200

    BRUSCHCUTTERS DS 2200 - DS 2400 3. FASTENER TORQUES 3.4 Fastener torques of the DS 2200 Tightening torques 159.3 in lb (kgm) / lubrication (1.8) * = Loctite 243 9.74 (0.11) * ∆ = Loctite 270 G = Grease O = Oil 30.98 (0.35) * 70.80...
  • Page 16 BRUSCHCUTTERS DS 2200 - DS 2400 3. FASTENER TORQUES Tightening torques in lb (kgm) / lubrication 159.3 (1.8) * = Loctite 243 ∆ = Loctite 270 9.74 (0.11) * G = Grease O = Oil 30.98 (0.35) * 70.80 (0.8) * 30.98 (0.35) * 39.83...
  • Page 17 BRUSCHCUTTERS DS 2200 - DS 2400 3. FASTENER TORQUES 30.98 (0.35) * 35.4 (0.4) * 26.55 61.95 (0.3) * (0.7) * 132.76 35.4 (1.5) (0.4) 70.80 (0.8) * 26.55 (0.3) * 26.55 35.4 (0.3) * (0.4) 44.25 (0.5) * 30.98 53.1 (0.35) * (0.6) *...

  • Page 18: Serial Number

    BRUSCHCUTTERS DS 2200 - DS 2400 4. SERIAL NUMBER The serial number identifies the machine model, date of production and progressive number of produced machines. EXAMPLE 1 = MODEL 9 1 6 2 0 3 0 0 0 1 2 = YEAR 3 = WEEK 4 = PROGRESSIVE NUMBER pag.

  • Page 19: Starter

    BRUSCHCUTTERS DS 2200 - DS 2400 5. STARTER STARTER ASSEMBLY Remove the 4 screws Torx 25. Release the tension on the recoil spring, slowly wind anticlockwise the pulley. Remove the inner starter assist spring. Lift out spring assist pulley. pag. 19 Workshop manual...
  • Page 20 BRUSCHCUTTERS DS 2200 - DS 2400 5. STARTER Check condition of pulley especially in the assist spring seat. During re-assembly make sure the end of the spring is correctly through the seat in the pulley. Inspect the condition of the spring and lubricate with a light grease or oil.
  • Page 21 BRUSCHCUTTERS DS 2200 - DS 2400 5. STARTER Reassemble in reverse order. Make sure that when fitting the pulley that the seat and the spring loop coincide to avoid damage. Make sure the knots are not too large which can interfere with a correct assembly.
  • Page 22 BRUSCHCUTTERS DS 2200 - DS 2400 5. STARTER Use Loctite. Pull the rope through the eyelet and wind the pulley and spring 8 turns. You should have at least ½ turn before the spring bottoms out. The recoil handle should snap into its seat. When reassembling pull out some rope to facilitate the seating against the pawls of the pulley.
  • Page 23 BRUSCHCUTTERS DS 2200 - DS 2400 5. STARTER When removing the pawl holder you need to stop the piston. Use a suitable sized pliers and rotate anticlockwise the pawl holder. Reassemble with loctite. Inspect the pawls for wear or damage. Replace if necessary, be careful not to damage the retaining spurs on the rear.

  • Page 24: Muffler

    BRUSCHCUTTERS DS 2200 - DS 2400 6. MUFFLER MUFFLER Remove the 4 screws. The cover can be removed without removing the whole engine shroud. Remove muffler bolts. Remove 3 point fitting screw. pag. 2 Workshop manual...
  • Page 25 BRUSCHCUTTERS DS 2200 - DS 2400 6. MUFFLER Inspect the muffler port for excess deposits. If the engine has been running dirty you can clean out the exhaust port with a plastic scraper. Make sure residue is not scratched against the piston. Scratch clean or use a fine wire brush.

  • Page 26: Ignition

    BRUSCHCUTTERS DS 2200 - DS 2400 7. IGNITION IGNITION Check the spark plug for the correct temperature rating and for the correct colour deposit. Light brown or grey Air gap is 0.5 mm (.020”) (Fig.1). Flywheel to coil air gap is 0.3 mm (.012”), use the spacer in the tool kit (Fig.2).
  • Page 27 BRUSCHCUTTERS DS 2200 - DS 2400 7. IGNITION Check for spark with tester P/N 001000515R. Flywheel inspection. Remove the clutch. Remove the retaining nut Use the flywheel removal punch to avoid any damage P/N 001001036. pag. 2 Workshop manual...
  • Page 28 BRUSCHCUTTERS DS 2200 - DS 2400 7. IGNITION Make sure the timing key way is not damaged. Check flywheel for a strong magnetic field on N and S poles. Remember that there are two spacers behind the coil. Inspect the cables for wear and that contacts are clean. Make sure during reassembly the contacts are clean and the cables are routed correctly pag.
  • Page 29 BRUSCHCUTTERS DS 2200 - DS 2400 7. IGNITION The units are fitted with an “always on switch” which returns to the on position after the engine has stopped Make sure you replace the components and wires in the correct order before reassembling the triggers Make sure contacts are clean and no oxidation is present.

  • Page 30: Clutch

    BRUSCHCUTTERS DS 2200 - DS 2400 8. CLUTCH CLUCTH Remove the two shoulder bolts Remember the order for the spacers and washers when removing the clutch shoes. 2 on each bolt under the clutch and the thinner under the head of the bolt. Check the clutch shoes for wear it should be changed if less than 0,8 mm (.030”).

  • Page 31: Transmission

    BRUSCHCUTTERS DS 2200 - DS 2400 9. TRANSMISSION TRANSMISSION Remove the circlip Punch out lightly the clutch drum. With the shaft removed inspect the conditions of rubber AV mount. The bearing can be removed and exchanged if necessary pag. 31 Workshop manual...
  • Page 32 BRUSCHCUTTERS DS 2200 - DS 2400 9. TRANSMISSION Check that circlips are not deformed during removal. They will need to be changed if this happens. Seat the bearing correctly during assembly. Grease drive shaft with lithium based molybendium bisulfide grease pag.

  • Page 33: Bevel Gear

    BRUSCHCUTTERS DS 2200 - DS 2400 10. BEVEL GEAR Bevel gear Remove gear box from Shaft for bevel gear inspection. Remember to grease the gears after reassembly. Remove upper circlip. Remove secondary circlip. pag. 33 Workshop manual...
  • Page 34 BRUSCHCUTTERS DS 2200 - DS 2400 10. BEVEL GEAR Remove oil /dust seal. Remove lower circlip. Use the shaft extractor P/N 001001104 in this order. Wind extractor lever onto the drive shaft thread. pag. 3 Workshop manual...
  • Page 35 BRUSCHCUTTERS DS 2200 - DS 2400 10. BEVEL GEAR Once bottomed out wind out the gear. The bearing will remove also. With a small punch tap out the upper gear shaft. Inner parts stack up. pag. 3 Workshop manual...
  • Page 36 BRUSCHCUTTERS DS 2200 - DS 2400 10. BEVEL GEAR Use the punch P/N 4138347 to reassemble. You also need the spacer P/N 61040137. Drive the upper gear in. pag. 36 Workshop manual...

  • Page 37: Short Block

    BRUSCHCUTTERS DS 2200 - DS 2400 11. SHORT BLOCK Short block Attention: Always do a leakdown test to check gaskets and crankseals. Short block with thermal flange and gasket (Fig.1). Remove the 4 cylinder screws. When reassembling tighten in X4 mode (Fig.2). Slide cylinder off carefully to avoid breaking the piston rings (Fig.3).
  • Page 38 BRUSCHCUTTERS DS 2200 - DS 2400 11. SHORT BLOCK When rebuilding the unit you need to use new piston pin retainers. Slide out piston pin. Check for discolouration as this is a sign of overheating. Note that the piston alignment washers. Remove the three screw.
  • Page 39 BRUSCHCUTTERS DS 2200 - DS 2400 11. SHORT BLOCK Use a rubber hammer to tap apart the two cranckcase halves. Lightly tap the crankshaft out of the cranckcas half. Inspect the big end bearing for discolouration or cracking. The shoulder bearings are retained with circlips. pag.

  • Page 40: Piston Failure Analysis

    BRUSCHCUTTERS DS 2200 - DS 2400 11. SHORT BLOCK When reassembling, use the ring squeezer kit P/N 1042901A Make sure that the piston rings are aligned with the anitrotation pin before puittting the cylinder on, make sure that it is lightly oiled. Compression test Apply the Emak compression tester (P/N 001000392A) to cylinder.
  • Page 41 BRUSCHCUTTERS DS 2200 - DS 2400 12. PISTON FAILURE ANALYSIS Bad fuel-oil ratio: insufficient quantity of oil (1) b. Incorrect oil: bad oil or oil for outboard, diesel, 4-stroke engines; does not lubricate enough the engine (2) Lean carburetor adjustment: incorrect air/fuel ratio (4) Worn, damaged or missing air fi lter: dust particles and water go through the engine causing faster wear or components failure (6)

  • Page 42: Fuel System

    BRUSCHCUTTERS DS 2200 - DS 2400 13. FUEL SYSTEM Impulse tube Fuel in Attention: inspect all hoses for cracks or Breather deterioration. They need to be replaced to avoid Primer in leak issues. Primer out Fuel system Make sure all filters are clean. If filters are damaged they must be replaced.
  • Page 43 BRUSCHCUTTERS DS 2200 - DS 2400 13. FUEL SYSTEM Check filters for clear passage. Breathers need to be inspected for pressure retention and for easy d e p r e s s i o n f l o w i n towards the fuel tank.
  • Page 44 BRUSCHCUTTERS DS 2200 - DS 2400 13. FUEL SYSTEM Idle setting Throttle valve closed. The air and fuel mixture is formed at the outlets of the idle jets. Full-throttle setting Throttle valve open. The air and fuel mixture is formed in the Venturi. Fuel jet –...
  • Page 45 BRUSCHCUTTERS DS 2200 - DS 2400 13. FUEL SYSTEM Setting the needle lever The correct position of the needle lever is found using a special gauge (see fig.) and influences: • normal running and idling characteristics of the engine; • running at high speed;...
  • Page 46 BRUSCHCUTTERS DS 2200 - DS 2400 13. FUEL SYSTEM Stripping the carburetor undo the four fixing screws and remove the cover; separate the diaphragm and g a s k e t c a r e f u l l y f r o m t h e carburetor body, exposing the lever pivot beneath;...
  • Page 47 BRUSCHCUTTERS DS 2200 - DS 2400 13. FUEL SYSTEM Inspecting the carburetor Check carefully when reassembling the carburetor that there are no components showing signs of wear or loss of shape, so as to avoid any fuel or air leaks. If the body of the carburetor itself is clearly worn or degraded to the point of being potentially unfit for use, the entire carburetor must be replaced.

  • Page 48: Carburetor Tuning

    BRUSCHCUTTERS DS 2200 - DS 2400 13. FUEL SYSTEM Needle, spring, lever and lever pivot • inspect the tip of the needle with a magnifying glass to verify its integrity and detect any signs of wear; replace if necessary; • check the sprIng for signs of damage or distortion, and replace if necessary;...

  • Page 49: Trouble Shooting

    BRUSCHCUTTERS DS 2200 - DS 2400 15. TROUBLE SHOOTING ENGINE DOES NOT START Symptoms Causes Remedies 1.a Starter assy defect or 1.a Check starter assy or starter rope broken starter rope replacement 1. The engine does not turn over 1.b Check thermal group and replace worn 1.b Internal damage components 2.a Spark plug looses...
  • Page 50 BRUSCHCUTTERS DS 2200 - DS 2400 15. TROUBLE SHOOTING LOW PERFORMANCE Symptoms Causes Remedies 1.a Carburetor mixture too 1.a Set the carburetor lean 1.b Air leaking in the engine 1.b Find air leaking and eliminate it or in fuel system 1.c Replace with fresh fuel and right oil 1.
  • Page 51 BRUSCHCUTTERS DS 2200 - DS 2400 pag. 1 Workshop manual...
  • Page 52 It’s an Emak S.p.A. trademark Member of the Yama Group 42011 Bagnolo in Piano (RE) Italy Tel. +39 0522 956611 • Fax +39 0522 951555 service@emak.it • www.emak.it...

This manual is also suitable for:

Ds 2200 trDs 2200 sDs 2200 tDs 2400 sDs 2400 t

Table of Contents