Echo DCS-1600 Manual de usuario

DCS-1600

ECHO:

(Serial number: 24000001 and after)

(Serial number: 35000001 and after)

REVISED May 2022

Ref. No. 401-43

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

together with this manual when servicing.

We are constantly working on technical improve-

ment of our products. For this reason, technical

data, equipment and design are subject to

change without notice. All specications, illustra-

tions and directions in this manual are based on

the latest product information available at the

time of publication.

TABLE OF CONTENTS

DCS-1600 1

Page Page

1 SERVICE INFORMATION ………………… 2

1-1 Specications ………………………………… 2

1-2 Technical data ………………………………… 3

1-3 Torque limits ………………………………… 3

1-4 Special repairing materials ………………… 3

1-5 Special tool …………………………………… 3

1-6 Wiring diagram ……………………………… 4

2 TROUBLESHOOTING ……………………… 5

2-1 Error indicator ………………………………… 5

2-2 Troubleshooting chart ……………………… 6

2-3 Diagnosis of abnormal condition ………… 17

3 CHAIN BRAKE SYSTEM ………………… 18

3-1 Inspecting brake switch …………………… 19

3-2 Replacing brake lever …………………… 20

3-3 Replacing chain brake parts ……………… 22

4 SAW CHAIN LUBRICATION SYSTEM … 23

4-1 Inspecting oil cap and strainer …………… 24

4-2 Inspecting oil line ………………………… 25

4-3 Inspecting and replacing worm gear …… 26

4-4 Replacing auto-oiler ……………………… 27

4-5 Seperating motor cover and replacing oil line29

5 SWITCH AND TRIGGER ………………… 30

5-1 Inspecting power switch and variable speed

switch ……………………………………… 31

5-2 Installing switches and trigger lever……… 34

6 MOTOR AND CONTROL SYSTEM …… 36

6-1 Inspecting motor and control board ……… 37

6-2 Installing motor and control board ……… 38

7 AIR FILTER ………………………………… 39

7-1 Cleaning and replacing air lter ………… 39

8 GUIDE BAR MOUNTING SYSTEM …… 40

8-1 Replacing nut for xing guide bar ……… 40

8-2 Assembling chain tensioner ……………… 41

8-3 Inspecting sprocket ……………………… 42

8-4 Replacing guide bar stud ………………… 42

9 BATTERY AND CHARGER ……………… 43

9-1 Battery LED indicator ……………………… 44

9-2 Charger LED indicator …………………… 44

9-3 Inspecting battery ………………………… 45

10 MAINTENANCE GUIDE ………………… 46

10-1 Disassembly chart ………………………… 46

10-2 Service intervals …………………………… 46

SERVICE INFORMATION

2DCS-1600

1 SERVICE INFORMATION

1-1 Specications

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 A 42.5

Rated voltage V 50.4

Rated output kW 1.73

Li-Ion Battery Standard battery LBP-560-200 / LBP-50-250

Rated voltage V 50.4

Capacity LBP-560-200: 3.66 / 185

Ah / Wh LBP-50-250: 4.50 / 226

Weight kg(lb) 1.8 (4.0)

Battery charger Standard charger LCJQ-560 (RAPID CHARGER)

LCJU-560 (ULTRA RAPID CHARGER)

Input voltage V AC220-240

Rated output V 58.1

Guide bar / Saw chain lubrication type Automatic oil pump

Oil Tank capacity L (UK..oz.) 0.38 (13.4)

Auto oiler Type Motor driven type

Sprocket Type Spur

Number of teeth 6

Pitch 3/8

* Without guide bar and saw chain ** Without battery, guide bar and saw chain

Cuttingdevices

Guide bar Type C35S90-52SA

Called length cm 35

Gauge in 0.043

Saw chain Type OREGON 90PX

Number of drive links 52

Pitch in 3/8

Gauge in 0.043

SERVICE INFORMATION 3

DCS-1600

1-2 Technicaldata

1-3Torquelimits

Descriptions Size kgf•cm N•m lbf•in

Motor Motor assembly

(w/ Motor cover assembly)

M5 30 - 45 3 - 4.5 25 - 40

Others Cover M4 20 - 30 2 - 3 20 - 25

Stud bolt M8* 80 - 100 8 - 10 70 -87

Regular bolt, nut and screw M4 15 - 25 1.5 - 2.5 13 - 22

M5 25 - 45 2.5 - 4.5 22 - 40

*Apply thread locking sealant described in “1-4 Special repairing materials”

1-4 Specialrepairingmaterials

Material Location Remarks

Thread locking sealant Stud bolt Loctite #272 or equivalent

Grease Worm gear Lithium based grease

Chain brake (metal contact part) Molybdenum grease (approx. 1 gram)

1-5 Specialtool

Key Part Number Description Reference

1X602-000340 Torx wrench (T27) Removing and installing torx bolts

2Y089-000131 Auto-oiler puller Removing pencil type auto-oiler

391073A Auto-oiler installer Installing pencil type auto-oiler

1 2 3

Made in Germany

T27x200

4 0 1 0 5 5 7 8 6 9 7 4 5

a=5.0mm

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

Charging time min. LCJQ-560: 45(80%) / 64(100%)

LCJU-560: 22(80%) / 39(100%)

LCJQ-560: 60(80%) / 89(100%)

LCJU-560: 30(80%) / 57(100%)

Operating time/one charge* min. 32 44

*It varies according to work.

SERVICE INFORMATION

4DCS-1600

1-6Wiringdiagram

+15V

GND

Hall sensor IC-A

Hall sensor IC-B

Hall sensor IC-C

Motor drive W

Motor drive V

Motor drive U

Motor

+15V

GND

Hall sensor IC-A

Hall sensor IC-B

Hall sensor IC-C

Motor drive W

Motor drive V

Motor drive U

Blue

White

Red

Black

Yellow

White

Blue

Power supply

Identification of battery type

Sensor (Over discharge)

Sensor (Temperature)

GND

Brake signal 2

Brake signal 1

＋

D−

GND

Variable speed switch

+5V

Trigger signal

Battery

Brake switch

Control board

Variable speed switch

Power switch

GND

LED power supply (+5V)

LED (GND)

Sensor (Temperature)

Identification of battery type

Sensor (Over discharge)

Brake signal 2

Brake signal 1

Power supply

GND

Variable speed switch

+5V

Trigger signal

Switch signal 1

Switch signal 2

LED power supply (+5V)

LED (GND)

Power switch

＋

−

Black

Blue

Red

Yellow

Black

Red

Blue

Red

Black

Blue

White

Yellow

Black

White

TROUBLESHOOTING 5

DCS-1600

2 TROUBLESHOOTING

2-1 Error indicator

Power indicator LED on power switch ashes as shown when trouble occurs.(Refer to section 2-2)

LED indicator Cause How to recover

Flashing

4times per second

Unit and/or battery is/are too hot or

cold.

Warm or cool them to normal

temperature.

Chain brake is activated Release the chain brake.

Contact of power switch is defective.

(Refer to Troubleshooting STEP 5

described in Section 2-2)

Replace the power switch with new

one.

Contact or resistance of variable

speed switch is defective.

(Refer to Troubleshooting STEP 5

described in Section 2-2)

Replace the variable speed switch

with new one.

Motor sensor detects abnormality or

its defective.

(Refer to Troubleshooting STEP 5 and

STEP6 described in Section 2-2)

Repair or replace defective items as

needed.

Flashing

1 time per second

Battery capacity is too low. Charge the battery.

Battery is defective due to over-

discharging, degradation or sensor

failure.

(Refer to Troubleshooting STEP 4

described in Section 2-2)

Replace the battery with new one.

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,re,and/orseriouspersonal

injury.

LED indicator

Power switch

LED indicator

Power switch

TROUBLESHOOTING

6DCS-1600

2-2 Troubleshooting chart

Be sure to begin with “STEP0” when troubleshooting.

Start

Problem is resolved

Step1 & Step2

Step3

Yes

Step4

Yes

Step5

Yes

Step6

Step7

Yes

Troubleshooting"STEP0"

NOTE: Be sure to release chain brake.

A: Is battery fully charged?

B: Press power switch. Is LED indicator lighting or

ashing?

C: Press power switch. Is LED indicator flashing

1time per second?

D: Press power switch. Is LED indicator flashing

4time per second?

E: Press power switch and then hold trigger lever.

Is LED indicator ashing 4times per second?

F: Does unit run normally?

TROUBLESHOOTING 7

DCS-1600

2-2 Troubleshooting chart (Continued)

Troubleshooting"STEP1"~Checkingbatteryandcharger~

Start

E F

Yes

Yes No

No Yes

Yes

Step0

Step2

A: Press battery buttton to indicate charging

status.

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. *

*Be sure to check Troubleshooting “Step2”

before installing new battery. If the unit has

something wrong, the battery can be damaged

again.

D: Charge the battery.

E: Is battery fully charged?

F: Does LED indicator of charger remain red?

G: Is LED indicator of charger ashing red?

H: Does LED indicator of charger light?

J: Prepare good battery and charger and then

cross-check.

K: Battery failure?

L: Go to “Step 2” to find cause of battery failure.

After passing Step2 then replace the battery to

new one and continue to diagnosis. *

*Be sure to check Troubleshooting “Step2”

before installing new battery. If the unit has

something wrong, the battery can be damaged

again.

Is temperature of battery inside in the range of 5

to 40°C?

N: Cool or warm battery as needed.(Rechargeble

temperature of battery inside is 5 to 40°C.)

P: Are connectors of battery and charger dirty?

Q: Clean connectors of battery and charger.

R: Replace the charger with new one.

TROUBLESHOOTING

8DCS-1600

2-2 Troubleshooting chart (Continued)

Troubleshooting"STEP2"~Checkingunitincaseofbatteryfailure~

Start

Yes

Yes F

Step0

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. (Refer

to Section 6-2)

E: Is control board short-circuited between battery

connection terminal (+) and (-)? (Refer to Sec-

tion 6-1)

F: Retighten the screw(s) on battery connection

terminal or replace with new control board. (Refer

to Section 6-2)

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