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Echo DCS-3500 Service Manual

Battery chain saw
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SER
SERVICE MANU
VICE MANUAL AL
BA BATTER
TTERY CHAIN S
Y CHAIN SA A W W
DCS-3500
ECHO:
(Serial number : C87835000001 - C87835999999)
22-003-EN
R e f e r e n c e N o .
I S S U E D :
202409

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Summary of Contents for Echo DCS-3500

  • Page 1 SERVICE MANU VICE MANUAL AL BA BATTER TTERY CHAIN S Y CHAIN SA A W W DCS-3500 ECHO: (Serial number : C87835000001 - C87835999999) 22-003-EN R e f e r e n c e N o . I S S U E D :...
  • Page 2 Introduction This manual contains description for the maintenance and repair on this product. Technical improvement of this product can cause changes to the maintenance, repair and spare parts. All specifications, illustrations and directions in this manual are based on the latest product information available at the time of publication.
  • Page 3 Table of Contents DCS-3500 1 Basic Information .......... 3 4-7 Attach the Stud Bolt ........36 1-1 Product Specifications ........3 5 Disassemble/Assemble the Chain Brake .. 38 1-2 Torque Limits ..........4 5-1 Chain Brake Components ......38 1-3 Required Tools and Special Maintenance 5-2 Remove the Chain Brake Parts ....
  • Page 4 Table of Contents DCS-3500 10-4 Inspect the Power Switch ......62 10-5 Inspect the Variable Speed Switch ... 63 10-6 Inspect the Air Filter........64...
  • Page 5 DCS-3500 1. Basic Information 1-1 Product Specifications Item Unit Details Dimensions Length mm (in) 471 (18.5) Width mm (in) 219 (8.6) Height mm (in) 262 (10.3) Weight kg (lb) 2.9 (6.4) Motor Type Brushless motor Rotation direction Clockwise as viewed from the output end Rated current 42.1...
  • Page 6 DCS-3500 1-2 Torque Limits M5*20 4.0 - 5.5 N·m (40 - 55 kgf•cm) M4*16(TAP) M4*16 M4*16(TAP) 2.0 - 3.0 N·m (20 - 30 kgf•cm) 8.0 - 10 N·m (80- 100 kgf•cm) Loctite #272 M4*16(TAP) M4*20(TAP) Figure : Torque Limits (1)
  • Page 7 DCS-3500 M4*20(TAP) 20 - 30 N·m (200 - 300 kgf•cm) M5*12(TAP) 3.0 - 4.0 N·m (30 - 40 kgf•cm) M5*20(TAP) M4*12(TAP) M5*12(TAP) 2.0 - 3.5 N·m (20 - 35 kgf•cm) M4*16(TAP) Figure : Torque Limits (2) Remark TAP : Tapping Related Topics 1-3 Required Tools and Special Maintenance Materials (p.6)
  • Page 8 DCS-3500 1-3 Required Tools and Special Maintenance Materials Part Number Part Name X602-000340 Torx wrench (T27) To loosen/tighten Torx bolts 897803-30133 Pressure tester To check oil line leakage Y089-000131 Auto-oiler puller To remove a pencil type auto-oiler 91073A Auto-oiler installer...
  • Page 9 DCS-3500 1-4 Disassembly Chart Cover Sprocket guard Cleaner lid Spur Chain Brake lever Front handle Air filter sprocket tensioner element Worm gear Brake cover Auto-oiler Motor cover Lockout Variable Control board Trigger lever Power switch Oil line button speed switch...
  • Page 10 DCS-3500 1-5 Wiring Diagram Battery Control board Power supply Power supply Identification of battery type Black Sensor (Over-discharge) Sensor Blue (Temperature) Sensor (Temperature) Identification of battery type White Brake switch Sensor Yellow (Over-discharge) Brake signal 2 White Brake signal 2...
  • Page 11 DCS-3500 2. Troubleshooting 2-1 Flow of Troubleshooting Problems with the unit may have several causes. Perform troubleshooting according to the flow below in order to identify the cause of the problem. (1) Checking the power indicator The flashing of the power indicator enables you to identify possible error causes.
  • Page 12 DCS-3500 2-2 Power Indicator Error Display The flashing of the power indicator enables you to identify possible error causes. Figure : Power switch Slow flashing (1 time/second) Low battery voltage. Battery voltage is too low to charge. Low motor drive voltage.
  • Page 13 DCS-3500 2-3 Diagnosis with Maintenance Mode CAUTION Do not pull the trigger lever when releasing the chain brake. The saw chain may run unexpectedly. Start Attach the battery to the unit, then turn off the power. Push the brake lever to activate the chain brake.
  • Page 14 DCS-3500 2-4 List of Maintenance Mode Error Numbers and Remedies You can identify the error number by counting the number of slow power indicator flashes in the maintenance mode. The error number indicates the most recent error. Maintenance mode retains the last error number after the error is resolved.
  • Page 15 DCS-3500 2-5 Troubleshooting "STEP 0" (Error Diagnosis) CAUTION Do not pull the trigger lever when releasing the chain brake. The saw chain may run unexpectedly. Start Go to flow STEP 1 Can the battery be charged? Attach the battery to the unit, then turn off the power.
  • Page 16 DCS-3500 Related Topics 2-6 Troubleshooting "STEP 1" (Check the Battery and Charger) (p.15) 2-7 Troubleshooting "STEP 2" (Check the Unit When Battery Failure Occurs) (p.17) 2-8 Troubleshooting "STEP 3" (Check the Power Supply Circuit) (p.18) 2-9 Troubleshooting "STEP 4" (Check Low Voltage and Over-Discharge) (p.20) 2-10 Troubleshooting "STEP 5"...
  • Page 17 DCS-3500 2-6 Troubleshooting "STEP 1" (Check the Battery and Charger) NOTICE If the unit is defective, it may also damage the new battery when the battery is replaced with a new one. STEP 2 Before replacing the battery, perform flow to check the unit for problems other than the battery.
  • Page 18 DCS-3500 Related Topics 2-5 Troubleshooting "STEP 0" (Error Diagnosis) (p.13) 2-7 Troubleshooting "STEP 2" (Check the Unit When Battery Failure Occurs) (p.17)
  • Page 19 DCS-3500 2-7 Troubleshooting "STEP 2" (Check the Unit When Battery Failure Occurs) Start ※1 Is there a problem with the battery terminals of the control board? Tighten the screws of the terminals, or replace the control board assembly with a new one.
  • Page 20 DCS-3500 2-8 Troubleshooting "STEP 3" (Check the Power Supply Circuit) WARNING NOTICE Perform troubleshooting in safe, clear surroundings. The If the unit is defective, it may also damage the new battery unit may run unexpectedly. when the battery is replaced with a new one.
  • Page 21 DCS-3500 Apply an electric current between terminals [3] and [6] of the power switch. The power indicator should turn on. Inspect the following terminals for a short circuit. Between terminals [2] and [3] of the power switch Between terminals [1] and [3] of the variable speed switch Between terminals [4] and [5] of the motor assembly 5-pole terminal block.
  • Page 22 DCS-3500 2-9 Troubleshooting "STEP 4" (Check Low Voltage and Over-Discharge) CAUTION NOTICE Do not pull the trigger lever when releasing the chain If the unit is defective, it may also damage the new battery brake. The saw chain may run unexpectedly.
  • Page 23 DCS-3500 Related Topics 3-6 Inspect the Battery Voltage (p.30) 3-7 Inspect for Damage from Over-Discharging (p.31) 8-5 Remove the Control Board Assembly (p.54) 2-5 Troubleshooting "STEP 0" (Error Diagnosis) (p.13) 2-6 Troubleshooting "STEP 1" (Check the Battery and Charger) (p.15)
  • Page 24 DCS-3500 2-10 Troubleshooting "STEP 5" (Check Each Sensor of Battery) WARNING NOTICE Perform troubleshooting in safe, clear surroundings. The If the unit is defective, it may also damage the new battery unit may run unexpectedly. when the battery is replaced with a new one.
  • Page 25 DCS-3500 The resistance between battery terminals [T] and [C-] and between battery terminals [T] and [D-] should be from 2.1 kΩ to 78.0 kΩ. Inspect the unit for the following: Each connector is connected securely. Each wire is connected to each connector securely.
  • Page 26 DCS-3500 2-11 Troubleshooting "STEP 6" (Check the Chain Brake Switch and Overload) WARNING CAUTION Perform troubleshooting in safe, clear surroundings. The Do not pull the trigger lever when releasing the chain unit may run unexpectedly. brake. The saw chain may run unexpectedly.
  • Page 27 DCS-3500 Inspect the unit for the following: Each connector is connected securely. Each wire is connected to each connector securely. All the wires are intact. There are no short circuits. Inspect the unit for the following problems: Sprocket clogged with saw dust or other objects...
  • Page 28 DCS-3500 2-12 Troubleshooting "STEP 7" (Check Other Failures) WARNING CAUTION Perform troubleshooting in safe, clear surroundings. The Do not pull the trigger lever when releasing the chain unit may run unexpectedly. brake. The saw chain may run unexpectedly. Flow STEP 7 (1) Start Attach the battery to the unit.
  • Page 29 DCS-3500 Flow STEP 7 (2) Go to flow STEP 0 to perform error Does the motor speed not increase or Does abnormal noise occur during is it unstable? operation? diagnosis again. Was a problem found when inspecting Clean, repair or replace the defective the unit? parts if necessary.
  • Page 30 DCS-3500 Related Topics 9-5 Remove/Attach the Variable Speed Switch (p.58) 10-5 Inspect the Variable Speed Switch (p.63) 8-5 Remove the Control Board Assembly (p.54) 8-4 Remove/Attach the Motor Assembly (p.53) 2-5 Troubleshooting "STEP 0" (Error Diagnosis) (p.13)
  • Page 31 DCS-3500 3. Inspect the Battery and Charger 3-1 Battery Components 3-3 Cautions for Using Battery and Charger CAUTION Do not open or modify the battery. Do not use a battery that is damaged or modified. Damaged or modified batteries may result in electric shock, fire, explosion or injury.
  • Page 32 DCS-3500 (Flashing in green) The battery is being charged. (Green light is on) The battery is fully charged. Remove the battery from the charger. (Flashing in red) The battery or the charger is defective or there is a bad connection between the battery and the charger.
  • Page 33 DCS-3500 3-7 Inspect for Damage from Over- Related Topics Discharging 2-7 Troubleshooting "STEP 2" (Check the Unit When Battery Failure Occurs) (p.17) 3-1 Battery Components (p.29) Prerequisites 3-2 Charger Components (p.29) The ambient temperature should be in the range of 0 to 40°C (32°F to 104°F).
  • Page 34 DCS-3500 If the resistance is outside the 2.1 kΩ to 78.0 kΩ, replace the battery with a new one. The temperature sensor is damaged. NOTICE If the unit is defective, it may also damage the new battery when the battery is replaced with a new one.
  • Page 35 DCS-3500 4. Disassemble/Assemble the Guide Bar and Saw Chain Mounting 4-1 Guide Bar and Saw Chain Mounting Components Spur sprocket Bevel gear Stud bolt Chain tensioner Washer Tensioner screw Retaining ring Sprocket guard Torx tapping bolt (M4) Hook Collar...
  • Page 36 DCS-3500 4-2 Remove the Guide Bar Nut Insert both ends of the hook in the holes of the sprocket guard. Prerequisites Tools required: - Longnose pliers Procedure Pinch the hook with longnose pliers. Remove the hook from the sprocket guard together with the nut.
  • Page 37 DCS-3500 Remove the following parts. 4-5 Remove/Attach the Spur Sprocket When reinstalling the removed parts, do so in the reverse order from that indicated below. Prerequisites Remove the sprocket guard. Procedure Pull the brake lever to the handle-side to release the chain brake.
  • Page 38 DCS-3500 NOTICE If it is hard to remove the stud bolt or broken stud is too short for tightening the 2 nuts, hold the stud bolt in a vise and turn the unit body counterclockwise or use a suitable stud remover.
  • Page 39 DCS-3500 Attach the 2 nuts to the stud bolt. Tighten the 2 nuts against each other. Turn the nut clockwise to attach the stud bolt. Related Topics 4-6 Remove the Stud Bolt (p.36) 4-1 Guide Bar and Saw Chain Mounting...
  • Page 40 DCS-3500 5. Disassemble/Assemble the Chain Brake 5-1 Chain Brake Components Torx tapping bolt (M5) Brake connector Collar Collar Brake lever Brake cover Torsion spring Torx tapping bolt (M4) Collar Compression spring Washer Brake band Torx tapping bolt (M4)
  • Page 41 DCS-3500 5-2 Remove the Chain Brake Parts Compression spring Brake connector Collar Prerequisites Remove the following parts. Brake band (1) Spur sprocket Inspect the removed parts. (2) Brake lever If the removed parts are clogged with dirt and/ Prepare eye protection and safety gloves.
  • Page 42 DCS-3500 Procedure Apply lithium based grease to the inside of the collar and the brake connector Set the assembled chain brake in the motor cover. Using a flat head screwdriver, push the compression spring into the motor Assemble the following parts.
  • Page 43 DCS-3500 Remove the Torx bolt , the washer Related Topics the collar 5-2 Remove the Chain Brake Parts (p.39) 5-1 Chain Brake Components (p.38) Remove the brake lever. 5-4 Remove/Attach the Brake Lever When reinstalling the removed parts, do so in the reverse order from that indicated below.
  • Page 44 DCS-3500 Related Topics 8-2 Remove/Attach the Cover (p.53) 5-1 Chain Brake Components (p.38)
  • Page 45 DCS-3500 6. Disassemble/Assemble the Saw Chain Lubrication System 6-1 Saw Chain Lubrication System Components Oil cap Pipe joint O-ring Worm gear Cap connector Grommet Tank vent Oil line Oil tank Auto-oiler assembly Oil strainer Oil line...
  • Page 46 DCS-3500 6-2 Remove/Attach the Oil Cap 6-3 Remove the Oil Strainer When reinstalling the removed parts, do so in the Prerequisites reverse order from that indicated below. Remove the oil cap. Procedure Procedure Remove the oil cap from the oil tank Pull out the oil strainer from the oil tank Inspect the following parts.
  • Page 47 DCS-3500 6-4 Attach the Oil Strainer Procedure Remove the worm gear. Procedure Attach the oil strainer to the oil line Return the oil strainer to the inside of the oil tank Inspect the removed parts. If any deformation, damage, or wear is found, replace the parts with new ones.
  • Page 48 DCS-3500 Procedure Procedure Apply lithium-based grease to the outer Remove the oil line and the pipe joint surface of the worm gear. from the oil line. Attach the worm gear. Remove the oil strainer from the oil line. Attach the spur sprocket.
  • Page 49 DCS-3500 6-9 Remove the Auto-Oiler Assembly Related Topics 6-2 Remove/Attach the Oil Cap (p.44) Prerequisites 6-8 Attach the Oil Line (p.47) 6-1 Saw Chain Lubrication System Components (p.43) Remove the worm gear Tools required: - Auto-oiler puller 6-8 Attach the Oil Line...
  • Page 50 DCS-3500 Remove the auto-olier assembly. Push the auto-oiler into the hole of the motor cover with the oiler installer and a plastic hammer until it bottoms. Related Topics 6-5 Remove the Worm Gear (p.45) 6-10 Attach the Auto-Oiler Assembly (p.48)
  • Page 51 DCS-3500 Related Topics 8-3 Remove/Attach the Motor Cover (p.53) 6-12 Attach the Oil Tank Vent (p.49) 6-1 Saw Chain Lubrication System Components (p.43) 6-12 Attach the Oil Tank Vent The oil tank vent prevents negative pressure from occurring in the oil tank due to the amount of oil in the oil tank decreasing.
  • Page 52 DCS-3500 7. Disassemble/Assemble the Front Handle 7-1 Front Handle Components Front handle Torx tapping bolt (M5)
  • Page 53 DCS-3500 7-2 Remove/Attach the Front Handle When reinstalling the removed parts, do so in the reverse order from that indicated below. Prerequisites Tools required: - Torx wrench (T27) Procedure Remove the 2 Torx bolts Remove the 2 Torx bolts Remove the front handle.
  • Page 54 DCS-3500 8. Disassemble/Assemble the Motor and Control Board Assembly 8-1 Motor and Control Board Assembly Components Torx bolt(M4) Cover Motor cover Control board assembly Motor assembly Torx bolt(M5) Torx tapping bolt(M4)
  • Page 55 DCS-3500 8-2 Remove/Attach the Cover Procedure Remove the 7 Torx bolts When reinstalling the removed parts, do so in the reverse order from that indicated below. Prerequisites Tools required: - Torx wrench (T27) Procedure Remove the Torx bolt Remove the 3 Torx bolts Remove the cover.
  • Page 56 DCS-3500 Procedure Procedure Disconnect the 3-pin connector of the Disconnect the 3-pin connector of the control board and the 3-pin connector control board and the 3-pin connector the motor. the motor. Disconnect the 5-pin connector of the Disconnect the 5-pin connector of the control board from the motor.
  • Page 57 DCS-3500 Connect the 3-pin connector of the Related Topics control board and the 3-pin connector 8-5 Remove the Control Board the motor. Assembly (p.54) 8-1 Motor and Control Board Assembly Connect the 5-pin connector of the Components (p.52) control board to the motor.
  • Page 58 DCS-3500 9. Disassemble/Assemble the Switch and Trigger 9-1 Switch and Trigger Components Power switch Lockout button Variable speed switch Torsion spring Trigger lever Compression spring...
  • Page 59 DCS-3500 9-2 Remove the Trigger Parts 9-3 Attach the Trigger Parts Prerequisites Procedure Attach the lockout button and the Remove the motor cover. compression spring to the motor cover Procedure Remove the following parts. Attach the torsion spring to the...
  • Page 60 DCS-3500 Lockout button Compression spring Torsion spring Trigger lever Related Topics 9-2 Remove the Trigger Parts (p.57) 9-1 Switch and Trigger Components (p.56) NOTICE 9-4 Remove/Attach the Power Switch When reattaching the power switch, make sure When reinstalling the removed parts, do so in the...
  • Page 61 DCS-3500 Remove the 4-pin connector of the wire harness from the variable speed switch. NOTICE When reattaching the power switch, make sure that the wire harness is routed between the ribs indicated by the arrows. Related Topics 8-3 Remove/Attach the Motor Cover (p.53)
  • Page 62 DCS-3500 10. Inspect the Various Parts 10-1 Inspect the Oil Line Pinch the oil line on the oil-strainer side with longnose pliers Prerequisites Remove the oil cap. Tools required: - Pressure tester - Longnose pliers (wrap the ends with tape)
  • Page 63 DCS-3500 Procedure Procedure Confirm that there is no short-circuit Check that there is no short-circuit between terminals [4] and [5] of the motor between the positive terminal screw assembly 5-pole terminal block. the negative terminal screw of the battery terminal.
  • Page 64 DCS-3500 Check that there is no short-circuit Related Topics between terminals [2] and [3] of the power 8-5 Remove the Control Board switch. Assembly (p.54) Measure the resistance between terminals [2] 8-6 Attach the Control Board Assembly (p.54) 8-1 Motor and Control Board Assembly and [3] of the power switch with a multimeter.
  • Page 65 DCS-3500 When using an LED tester (1) Connect the positive (+) wire from the coin battery to terminal [3] of the power switch. Likewise, connect the negative (-) wire to terminal [6]. (2) Check if the power indicator lights up.
  • Page 66 DCS-3500 Check that there is no short-circuit Related Topics between terminals [1] and [3] of the 9-5 Remove/Attach the Variable Speed variable speed switch. Switch (p.58) Measure the resistance between terminals [1] 9-1 Switch and Trigger Components (p.56) and [3] of the variable speed switch with a multimeter.
  • Page 67 DCS-3500 If the double sided tapes of the cleaner lid are no longer sticky, attach new double sided tapes to the cleaner lid and attach the air filter the cleaner lid Attach the cleaner lid to the motor cover and fit the 2 hooks...
  • Page 68 Copyright©2024 YAMABIKO Corporation All rights reserved.