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Yamabiko echo DCS-2500T Service Manual

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DCS-2500T
ECHO:
(Serial number: 35000001 and after)
Ref. No. 401-46
Copyright C 2020 YAMABIKO Corporation All rights reserved.

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Summary of Contents for Yamabiko echo DCS-2500T

  • Page 1 DCS-2500T ECHO: (Serial number: 35000001 and after) Ref. No. 401-46 Copyright C 2020 YAMABIKO Corporation All rights reserved.
  • Page 2 INTRODUCTION This service manual contains information for service and maintenance of ECHO BATTERY CHAINSAW, model DCS-2500T. 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 together with this manual when servicing.
  • Page 3 TABLE OF CONTENTS DCS-2500T Page Page 1 SERVICE INFORMATION ........2 7 GUIDE BAR MOUNTING SYSTEM ....36 Replacing nut for fixing guide bar ....36 Specifications ...........2 Assembling chain tensioner ......37 Technical data ..........3 Inspecting sprocket ........38 Torque limits .............3 Special repairing materials .......3 8 BATTERY AND CHARGER ........39 Special tools .............3 Battery LED indicator ........40...
  • Page 4 SERVICE INFORMATION DCS-2500T 1 SERVICE INFORMATION 1-1 Specifications Dimensions* Length mm(in) 259 (10.2) Width mm(in) 188 (7.4) Height mm(in) 209 (8.2) Dry weight** kg(lb) 1.6 (3.5) Motor Type DC electric motor Rotation Clockwise as viewed from the output end Rated current 22.1 Rated voltage 50.4...
  • Page 5 SERVICE INFORMATION DCS-2500T 1-2 Technical data Motor Speed at maximum power r/min 10000 Speed control r/min Low (4000 r/min) - High (10000 r/min) Battery Charging time min. 24 (80%) / 42 (100%) Operating time/one charge* min. 20.8 Chain oil discharge volume at 7,000 r/min Adjustable : 1.8 - 12.5 (0.06 - 0.42) mL/min (US.fl .oz./min) *It varies according to work.
  • Page 6 SERVICE INFORMATION DCS-2500T 1-6 Wiring diagram Battery Control board ＋ ＋ Power supply Power supply Identification of battery type Identification of battery type Blue Sensor Sensor (Over discharge) White (Over discharge) Sensor Sensor Yellow (Temperature) (Temperature) D− − Black Brake switch Brake signal 2 White Brake signal 2 Brake signal 1...
  • Page 7 TROUBLESHOOTING DCS-2500T 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 Flashing...
  • Page 8 TROUBLESHOOTING DCS-2500T 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. Is LED indicator flashing 1 time per second? Step4 D: Press power switch.
  • Page 9 TROUBLESHOOTING DCS-2500T 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-2500T 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-2500T 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-2500T 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-2500T 2-2 Troubleshooting chart (Continued) Troubleshooting "STEP5" ~Checking each sensor of battery~ 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 without holding trigger lever. C: Press power switch. Is LED indicator flashing 4 time per second? D: Are battery and unit hot or cold? E: Cool or warm the battery and the unit to normal...
  • Page 14 TROUBLESHOOTING DCS-2500T 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 15 TROUBLESHOOTING DCS-2500T 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 16 TROUBLESHOOTING DCS-2500T 2-2 Troubleshooting chart (Continued) Troubleshooting "STEP7" ~Checking other failure (Continued)~ M: Motor speed can not be increased or is not stable. From page 13 N: 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.
  • Page 17 CHAIN BRAKE SYSTEM DCS-2500T 3 CHAIN BRAKE SYSTEM (A) Brake lever (F) Collar (G) Brake connector (B) Tosion spring (C) Tapping bolt (M5) (H) Compression spring (D) Brake cover (J) Brake band (E) Tapping bolt (M4, 3pcs.) (K) Pin...
  • Page 18 CHAIN BRAKE SYSTEM DCS-2500T 3-1 Replacing brake lever and 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. Pull brake lever (A) to release chain brake and then remove retaining ring (L), washer (M) and drum (N). 2. Remove bolt (Q), chain catcher (R) and sprocket guard plate (S).
  • Page 19 CHAIN BRAKE SYSTEM DCS-2500T 3-1 Replacing brake lever and chain brake parts (Continued) 10. Install brake lever (A) on motor cover. 11. Tighten brake lever (A) with bolt (C). 12. Assemble brake connector (F), collar (G), brake band (J), compression spring (H) and pin (K) as shown.
  • Page 20 SAW CHAIN LUBRICATION SYSTEM DCS-2500T 4 SAW CHAIN LUBRICATION SYSTEM (A) Oil cap (G) Oil line (B) O-ring (H) Grommet (C) Cap connector (J) Oil outlet (D) Oil tank (K) Auto-oiler (E) Oil tank vent (L) Tapping bolt (M4) (F) Oil strainer (M) Worm gear (N) Clip...
  • Page 21 SAW CHAIN LUBRICATION SYSTEM DCS-2500T 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 22 SAW CHAIN LUBRICATION SYSTEM DCS-2500T 4-2 Inspecting and replacing worm gear 1. Remove drum and brake related parts (Refer to “3-1 Replacing brake lever and chain brake parts”). 2. Remove worm gear (M) from auto-oiler (K). 3. Inspect worm gear (M) for damage, wear, or de- formation.
  • Page 23 SAW CHAIN LUBRICATION SYSTEM DCS-2500T 4-4 Cleaning and repairing auto-oiler 1. Inspect if plunger gear (P) of auto-oiler is rotated or not, using small flat blade driver or equivalent. 2. When plunger gear (P) can be rotated even though it is not smooth, go to step 3. When plunger gear (P) can not be rotated, go to step 10.
  • Page 24 SAW CHAIN LUBRICATION SYSTEM DCS-2500T 4-4 Cleaning and repairing auto-oiler (Continued) 12. Screw the bolt (X) of puller Y089-000111 into the hole of plug (W), and connect PTO shaft puller P021-044871 as shown. 13. Hold auto-oiler body by one hand. Hold puller shaft end (y1) by another hand.
  • Page 25 SAW CHAIN LUBRICATION SYSTEM DCS-2500T 4-4 Cleaning and repairing auto-oiler (Continued) 22. Push in plunger gear (P) with small screw- driver, and hold plunger gear (P) to direction of arrow with finger. Remove screwdriver. 23. Install adjuster needle (S) with spring (T) into oiler body.
  • Page 26 SAW CHAIN LUBRICATION SYSTEM DCS-2500T 4-5 Replacing oil tank vent NOTE: Oil tank vent prevents a vacuum from forming in oil tank when chain oil in the tank is con- sumed. 1. Remove brake cover and brake lever (Refer to “3-1 Replacing brake lever and chain brake parts”). 2.
  • Page 27 SWITCH AND TRIGGER DCS-2500T 5 SWITCH AND TRIGGER (A) Power switch (B) Variable speed switch (C) Trigger lever (D) Torsion spring (E) Trigger lockout...
  • Page 28 SWITCH AND TRIGGER DCS-2500T 5-1 Inspecting power switch and variable speed switch Disassembling 1. Remove brake cover and brake lever (Refer to “3-1 Replacing brake lever and chain brake parts”). 2. Separate motor cover (Refer to “4-5 Replacing oil tank vent”). 3. Remove power switch (A) and variable speed switch (B) from motor cover.
  • Page 29 SWITCH AND TRIGGER DCS-2500T 5-1 Inspecting power switch and variable speed switch (Continued) (3) Inspecting of short circuit Connect one probe of multimeter to terminal “2” of power switch (A). Connect the other probe to terminal “3”.Multimeter should indicate infinite resistance.(Electrical current can not flow be- tween terminal “2”...
  • Page 30 SWITCH AND TRIGGER DCS-2500T 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 and pass wire harness (J) between ribs of motor cover as shown.
  • Page 31 SWITCH AND TRIGGER DCS-2500T 5-2 Installing switches and trigger lever (Continued) 7. Install trigger lever (C), torsion spring (D) and trigger lockout (E) on motor cover as shown. NOTE: Make sure to place the end of throttle trig- ger and throttle lockout inside of motor cover. 8.
  • Page 32 MOTOR AND CONTROL SYSTEM DCS-2500T 6 MOTOR AND CONTROL SYSTEM (A) Motor (B) Control board...
  • Page 33 MOTOR AND CONTROL SYSTEM DCS-2500T 6-1 Inspecting control board 1. Remove brake cover and brake lever (Refer to “3-1 Replacing brake lever and chain brake parts”). 2. Separate motor cover. (Refer to “4-5 Replacing oil tank vent”) 3. Remove battery connection terminal (C) of con- trol board from motor cover.
  • Page 34 MOTOR AND CONTROL SYSTEM DCS-2500T 6-2 Inspecting motor 1. Remove brake related parts (Refer to “3-1 Re- placing brake lever and chain brake parts”). 2. Separate motor cover. (Refer to “4-5 Replacing oil tank vent”) 3. Remove auto-oiler. 4. Remove 3 bolts (F). 5.
  • Page 35 MOTOR AND CONTROL SYSTEM DCS-2500T 6-3 Installing motor and control board 1. Place control board (B) on motor cover as shown. 2. Put brake switch (H) into slot of motor cover as shown. NOTE: Make sure not to cross brake switch leads (J) and other leads. 3.
  • Page 36 MOTOR AND CONTROL SYSTEM DCS-2500T 6-3 Installing motor and control board (Contimued) 10. Install motor (A) to motor cover. 11. Route leads (U) of motor (A) under leads (M). 12. Connect motor (A) and 5-pole terminal (V) of control board. 13.
  • Page 37 MOTOR AND CONTROL SYSTEM DCS-2500T 6-3 Installing motor and control board (Contimued) 15. Connect 3-pole terminal (D) of control board and 3-pole terminal (E) of motor. 16. Put the terminals (D) and (E) into slot on fan case assembly as shown. NOTE: Make sure not to route any leads above pin (X) of motor cover.
  • Page 38 GUIDE BAR MOUNTING SYSTEM DCS-2500T 7 GUIDE BAR MOUNTING SYSTEM (A) Drum (J) Tensioner screw (B) Washer (K) Chain tensioner (C) Retaining ring (L) Bevel gear (D) Stud (M) Bevel gear (E) Sprocket guard plate (N) Sprocket guard (F) Sprocket guard plate (P) Hook (Q) Nut (G) Torx tapping bolt...
  • Page 39 GUIDE BAR MOUNTING SYSTEM DCS-2500T 7-2 Assembling chain tensioner 1. Place bevel gear (M) on sprocket guard (N). 2. Screw chain tensioner (K) on tensioner screw (J). 3. Put bevel gear (L) on the end of tensioner screw (J). 4. Install sub assembled tensioner screw in slot of sprocket guard (N) confirming engagement of bevel gear (M) and (L).
  • Page 40 GUIDE BAR MOUNTING SYSTEM DCS-2500T 7-3 Inspecting sprocket Inspect sprocket of drum. If worn out 0.5 mm (0.02 0.5mm in.) or more, replace with new one.
  • Page 41 BATTERY AND CHAGER DCS-2500T 8 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 42 BATTERY AND CHAGER DCS-2500T 8-1 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 43 BATTERY AND CHAGER DCS-2500T 8-3 Inspecting battery NOTE: This check must be done when the battery can be fully charged but has a shorted cell or 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 44 MAINTENANCE GUIDE DCS-2500T MAINTENANCE GUIDE 9-1 Disassembly chart Sprocket guard Chain Chain Drum catcher tensioner (3-1) (3-1) (7-2) Sprocket Worm guard plate gear (3-1) (4-2) Brake Auto cover oiler (3-1) (4-3) Brake Chain lever brake (3-1) (3-1) Oil cap Motor cover Control Trigger Throttle Variable speed...
  • Page 45 MAINTENANCE GUIDE DCS-2500T 9-2 Service intervals IMPORTANT: Service intervals shown above are maximum. Actual use and your experience will determine the frequency of required maintenance. Intervals Inspecting point Service Reference Before use Monthly Battery Inspect / Clean / Charge Chain brake Inspect / Clean / Replace Saw chain Inspect / Clean / Sharpen / Replace Guide bar...
  • Page 46 Published by YAMABIKO Corp. Tokyo Japan 2008...

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