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BATTERY AND CHAGER

DCS-1600

Cooling passage

Mains plug

LED indicator

Cooling passage

Terminal

Press button

LED indicator

Battery pack latch

Terminal

Battery

Charger

9 BATTERY AND CHARGER

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. By 500 times of recharges,

charge capacity falls to about 60%, but this is not trouble normally. If capacity is significantly reduced, re-

place the battery.

Summary of Contents for DCS-1600

Page 2: ...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...

Page 3: ...lacing worm gear 26 4 4 Replacing auto oiler 27 4 5 Seperating motor cover and replacing oil line 29 5 SWITCH AND TRIGGER 30 5 1 Inspecting power switch and variable speed switch 31 5 2 Installing swi...

Page 4: ...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 Guid...

Page 5: ...ar Lithium based grease Chain brake metal contact part Molybdenum grease approx 1 gram 1 5 Special tool Key Part Number Description Reference 1 X602 000340 Torx wrench T27 Removing and installing torx...

Page 6: ...Temperature GND Brake signal 2 Brake signal 1 3 2 1 S D T D GND Variable speed switch 5V Trigger signal 1 2 3 4 Battery Brake switch Control board Variable speed switch Power switch GND LED power sup...

Page 7: ...roubleshooting 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 S...

Page 8: ...Yes No No No Yes Troubleshooting STEP0 NOTE Be sure to release chain brake A Is battery fully charged B Press power switch Is LED indicator lighting or flashing C Press power switch Is LED indicator f...

Page 9: ...D Charge the battery E Is battery fully charged F Does LED indicator of charger remain red G Is LED indicator of charger flashing red H Does LED indicator of charger light J Prepare good battery and c...

Page 10: ...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...

Page 11: ...battery can be damaged again G Inspect the unit as follows 1 Each connection between terminals is secure 2 Each connection of terminal housing and lead is secure 3 Electrical current can flow through...

Page 12: ...re 3 Electrical current can flow through each lead E Repair or replace defective object s as needed F Is voltage between battery terminal and D 55V or more Refer to Section 9 4 G Fully charge the batt...

Page 13: ...3 Is LED indicator flashing or ligit ing G Go to the next step according to the numbe of continuously flashing of LED indicator 2 times Go to page12 1 5 times Go to page12 2 7 times Go to page12 3 8 t...

Page 14: ...to Section 5 1 1 Electrical current can flow between terminal 1 and 2 when pressing the switch 2 Electrical current can not flow between terminal 1 and 2 when not pressing the switch G Go to page 11...

Page 15: ...ed switch with new one Refer to Section 5 2 D Go to page 11 9 E Is there any trouble in terminals and leads of mo tor s 5 pole terminal Refer to Section 6 1 F Repair or replace defective objects as ne...

Page 16: ...ot flow between terminal 1 and 2 when not pressing brake switch E Repair or replace defective object s as needed F Inspect the unit as follows 1 Each connection between terminals is secure 2 Each conn...

Page 17: ...terminal housing and lead is secure 3 Electrical current can flow through each lead 4 There are no short curcuits E Repair or replace defective object s as needed F Inspect variable speed switch as fo...

Page 18: ...replace the object s as needed D Can variable speed switch be pushed to the end Check the position and the part itself Refer to Section 5 2 E Repair or replace the variable speed switch as needed Refe...

Page 19: ...em is resolved The data is rewrit ten when the next recordable abnormality occurs Diagnosis procedure 1 Install battery on the unit correctly 2 Pull brake lever A to release chain brake 3 Press power...

Page 20: ...M A Brake lever B Tapping bolt M4 C Washer D Collar E Tapping bolt M5 F Collar G Torsion spring H Brake switch J Tapping bolt M4 K Brake cover L Collar M Brake connector N Compression spring P Spacer...

Page 21: ...tance Electrical current can not flow between terminal 1 and 2 5 If brake switch H is defective replace control board connected to the switch H with new one NOTE Brake switch H can not be supplied sep...

Page 22: ...ng 6 Install torsion spring G to brake lever A as shown 7 Set hole of brake lever A on boss T of motor cover and install brake lever A to motor cover 8 Apply molybdenum grease on inner surface of coll...

Page 23: ...h H on motor cover as shown 13 Pass leads h3 of brake switch H through cutout of motor cover as shown 14 Be sure not to pinch leads and assemble cover S to unit NOTE Check the followings after assembl...

Page 24: ...2 4 Remove three bolts J and brake cover K 5 If blocked with dirt and or dust clean around brake parts Inspect all the brake parts for damage Replace with new part s as required Assembling 6 Apply mol...

Page 25: ...SYSTEM 23 DCS 1600 4 SAW CHAIN LUBRICATION SYSTEM A Oil cap B O ring C Cap connector D Oil tank E Oil tank vent F Oil strainer G Oil line H Grommet J Pipe joint K Oil line M Auto oiler N Worm gear G...

Page 26: ...or C if damaged 4 Pull oil strainer F from oil tank using wire hook NOTE Be careful not to puncture oil line by wire hook 5 Remove oil strainer F from oil line and clean oil strainer in suitable solve...

Page 27: ...nd oil line K 2 Connect oil line G to pressure tester 897803 30133 T 3 Remove fuel cap and pull out oil strainer from oil tank 4 Pinch oil line G with longnose pliers as shown NOTE Wrap the ends of lo...

Page 28: ...r as needed Assembling 3 Apply lithium based grease to inner and outer surface of worm gear N 4 Assemble worm gear N and drum R placing convex parts r1 of drum R in grooves n1 of worm gear N 5 Install...

Page 29: ...r puller Y089 000131 into female thread part of auto oiler M 3 Holding inner pipe u2 with a 14 mm wrench rotate outer pipe u3 counterclockwise by 17mm wrench to pull out the auto oiler dia 13mm dia 11...

Page 30: ...ler 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 bott...

Page 31: ...3 3 Remove four bolts W and front handle 4 Remove six bolts X size M4x16mm length bolt Y size M4x20mm length and three bolts Z size M5x20mm length and seperate motor cover 5 Remove oil strainer Refer...

Page 32: ...SWITCH AND TRIGGER 30 DCS 1600 5 SWITCH AND TRIGGER B A D C E F A Power switch B Variable speed switch C Trigger lever D Torsion spring E Lockout button F Compression spring...

Page 33: ...cal current can flow between terminal 1 and 2 When not pressing power switch A multime ter should indicate infinite resistance Electrical current can not flow between terminal 1 and 2 2 Inspection of...

Page 34: ...r more through it Connect positive lead of coin battery E to terminal 3 on power switch Connect nega tive lead of coin battery E to terminal 6 on power switch Power indicator LED D should light up NOT...

Page 35: ...tch B Connect the other probe to terminal 4 When pressing variable speed switch B multimeter should show that the circuit has continuity Electrical current can flow between terminal 1 and 4 When not p...

Page 36: ...ire 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 Place variable speed switch B on motor cover while passing leads...

Page 37: ...button E as shown 9 Pass lead J of wire harness between ribs of mo tor cover as shown 10 Assemble motor cover halves NOTE Be careful when assembling the covers Do not to pinch each lead by the covers...

Page 38: ...MOTOR AND CONTROL SYSTEM 36 DCS 1600 A B 6 MOTOR AND CONTROL SYSTEM A Motor B Control board...

Page 39: ...is short circuited between terminal 4 and 5 of motor s 5 pole ter minal D Connect one probe of multimeter to terminal 4 Connect the other probe to terminal 5 Multimeter should indicate infinite resis...

Page 40: ...between ribs of motor cover as shown 5 Install motor on motor cover 6 Connect 3 pole terminal G of control board and 3 pole terminal H of motor 7 Connect 5 pole terminal D of control board and 5 pole...

Page 41: ...ion with brush or compressed air If heavily blocked with dirt and or saw dust replace air filter D WARNING DANGER Wear eye protection when working with compressed air Eye damage can occur from flying...

Page 42: ...Collar K Tapping bolt M Sprocket guard N Hook P Nut 8 1 Replacing nut for fixing guide bar Disassembling 1 Pinch hook N with pliers and remove hook N and nut P together from sprocket guard M 2 Remove...

Page 43: ...et 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 Install sub assembled tensioner screw in slot of spr...

Page 44: ...ort for tightening two nuts hold defective stud in a vise and turn the chain saw body counterclock wise or use a suitable stud remover Assembling NOTE Replacement studs have a smaller self tapping thr...

Page 45: ...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 temperat...

Page 46: ...Charger LED indicator Charger LED indicator shows charging situation as follows Green flash Green ON Red flash Red ON Situation Charging Normal charging Charging complete Defective battery or charger...

Page 47: ...re The battery have been over charged due to malfunction of charger and battery Replace the battery and the charger with new ones Inspecting for damage by over discharge 1 Charge battery fully 2 Mesur...

Page 48: ...eference Intervals Before use Monthly Battery Inspect Clean Charge 9 3 Chain brake Inspect Clean Replace 3 1 3 2 3 3 Saw chain Inspect Clean Sharpen Replace Guide bar Inspect Clean Replace Air filter...

Page 49: ...MEMORANDUM 47 DCS 1600...

Page 50: ...Published by YAMABIKO Corp Tokyo Japan 1904...

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