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Efco DS 2200 S, Руководство по ремонту

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BRUSCHCUTTERS DS 2200 - DS 2400

pag. 

1

Workshop manual

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)

Overheating: obstructed cylinder fi ns, blocked air cooling 

flow (5) 
Pre-ignition, detonation: fuel with low octane level or old 

fuel,  wrong  sparkplug  thermal  grade,  defected  ignition 

system and carbon deposit (7)

Air leaks: from engine, crankshaft seals, crankcase gasket, 

impulse tube, leaning fuel mixture and make the engine 

work  over  speeding,  as  a  wrong  carburetor  adjustment 

does (3)

Oxygenated fuels or with alcohol/ethanol content: clean 

fuels are formulated with higher levels of oxygen, which can increase combustion chamber temperatures and pressure, the 

consequences are similar to a unit which has very lean setting (3, 4, 7)

Old fuel or fuel with low octane level: it does not burn properly creating an excessive pressure on internal components 

(7)

Dirty fuel filter: it stops the fuel going inside carburetor and the engine works using too much air. Carburetor inspection 

and cleaning is suggested (3)

Carbon deposit: excessive carbon deposits can build up and seize the piston. The rings can stick because of oil carbon 

allowing gases to pass the piston and cause exhaust side seizures (2)

a.
b.

c.
d.

e.

f.

g.

h.

i.

l.

m.

Содержание DS 2200 S

Страница 1: ...WORKSHOP MANUAL BRUSCHCUTTERS DS 2200 DS 2400...

Страница 2: ......

Страница 3: ...DIMENSION inch 2 13 ERGONOMICS HARNESS Optional Single harness Optional Single strap with cushion FRONT HANDLE plastic loop steel handlebar plastic loop soft touch aluminum handlebar REAR HANDLE plas...

Страница 4: ...alues 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 15 4 SERIAL NUMBER 18 5 STARTER 19 6 MUFFLER 24 7 IGNITION 26 8 CLUTCH 30 9 TRANS...

Страница 5: ...explosion caused by STATIC ELECTRIC DISCHARGE during fueling ONLYuseaclean approvedPOLYETHYLENE PLASTIC fuel container and funnel WITHOUT any metal screen or filter To avoid engine damage CAUTION Avo...

Страница 6: ...geographical areas outside the 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...

Страница 7: ...ted on CAUTION safety signs CAUTION also calls attention to safety messages in this manual Handle Fluids Safely Avoid Fires Be Prepared For Emergencies When you work around fuel do not smoke or work n...

Страница 8: ...ifications Before working on the machine Lower all equipment to the ground Stop the engine Hang a DO NOT OPERATE tag in operator station 1 2 3 Support Machine Properly and Use Proper Lifting Equipment...

Страница 9: ...and other flammable material from area Allow fumes to disperse at least 15 minutes before welding or heating Avoid Injury From Rotating Blades Keep hands and feet away while machine is running Shut of...

Страница 10: ...1700 1250 1600 1150 2000 1500 M30 675 490 850 625 1300 950 1650 1200 1850 1350 2300 1700 2150 1600 2700 2000 M33 900 675 1150 850 1750 1300 2200 1650 2500 1850 3150 2350 2900 2150 3700 2750 M36 1150 8...

Страница 11: ...00 1950 1 3 8 750 550 950 700 750 550 950 700 1700 1250 2150 1550 2700 2000 3400 2550 1 1 2 1000 725 1250 925 990 725 1250 930 2250 1650 2850 2100 3600 2650 4550 3350 DO NOT use these hand torque valu...

Страница 12: ...ite 243 Loctite 270 G Grease O Oil pag 12 BRUSCHCUTTERS DS 2200 DS 2400 Workshop manual 3 FASTENER TORQUES 39 83 0 45 39 83 0 45 35 4 0 4 7 97 0 09 35 4 0 4 22 13 0 25 22 13 0 25 70 80 0 8 159 3 1 8 1...

Страница 13: ...G Grease O Oil BRUSCHCUTTERS DS 2200 DS 2400 pag 13 Workshop manual 3 FASTENER TORQUES 39 83 0 45 39 83 0 45 35 4 0 4 7 97 0 09 35 4 0 4 22 13 0 25 22 13 0 25 70 80 0 8 159 3 1 8 12 39 0 14 12 39 0 14...

Страница 14: ...14 BRUSCHCUTTERS DS 2200 DS 2400 Workshop manual 3 FASTENER TORQUES 30 98 0 35 26 55 0 3 26 55 0 3 35 4 0 4 35 4 0 4 61 95 0 7 22 13 0 25 44 25 0 5 30 98 0 35 132 76 1 5 70 80 0 8 53 1 0 6 26 55 0 3...

Страница 15: ...Loctite 243 Loctite 270 G Grease O Oil BRUSCHCUTTERS DS 2200 DS 2400 pag 15 Workshop manual 3 FASTENER TORQUES 39 83 0 45 39 83 0 45 159 3 1 8 17 7 0 2 17 7 0 2 12 39 0 14 39 83 0 45 39 83 0 45 35 4 0...

Страница 16: ...270 G Grease O Oil pag 16 BRUSCHCUTTERS DS 2200 DS 2400 Workshop manual 3 FASTENER TORQUES 12 39 0 14 12 39 0 14 39 83 0 45 30 98 0 35 35 4 0 4 12 39 0 14 39 83 0 45 39 83 0 45 39 83 0 45 159 3 1 8 12...

Страница 17: ...O Oil BRUSCHCUTTERS DS 2200 DS 2400 pag 17 Workshop manual 3 FASTENER TORQUES 26 55 0 3 26 55 0 3 35 4 0 4 35 4 0 4 61 95 0 7 44 25 0 5 30 98 0 35 132 76 1 5 53 1 0 6 26 55 0 3 39 83 0 45 132 76 1 5...

Страница 18: ...DS 2400 Workshop manual 4 SERIAL NUMBER The serial number identifies the machine model date of production and progressive number of produced machines EXAMPLE 9 1 6 2 0 3 0 0 0 1 1 MODEL 2 YEAR 3 WEEK...

Страница 19: ...ag 19 Workshop manual 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 o...

Страница 20: ...f 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 li...

Страница 21: ...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 Use a double knot for the recoil handle...

Страница 22: ...the rope through the eyelet and wind the pulley and spring 8 turns You should have at least turn before the spring bottoms out The recoil handle should snap into its seat When reassembling pull out s...

Страница 23: ...ving 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...

Страница 24: ...BRUSCHCUTTERS DS 2200 DS 2400 Workshop manual 6 MUFFLER MUFFLER Remove the 4 screws The cover can be removed without removing the whole engine shroud Remove muffler bolts Remove 3rd point fitting scre...

Страница 25: ...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 wir...

Страница 26: ...wn 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 Check the contact spring in the plug cap to make sure it has not been pulled out of t...

Страница 27: ...DS 2400 pag 27 Workshop manual 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...

Страница 28: ...y 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 d...

Страница 29: ...nits 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 trigg...

Страница 30: ...der 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 t...

Страница 31: ...pag 31 Workshop manual 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...

Страница 32: ...kshop manual 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...

Страница 33: ...S 2200 DS 2400 pag 33 Workshop manual 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...

Страница 34: ...USCHCUTTERS DS 2200 DS 2400 Workshop manual 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...

Страница 35: ...CUTTERS DS 2200 DS 2400 pag 35 Workshop manual 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 9 10...

Страница 36: ...pag 36 BRUSCHCUTTERS DS 2200 DS 2400 Workshop manual 10 BEVEL GEAR Use the punch P N 4138347 to reassemble You also need the spacer P N 61040137 Drive the upper gear in 13 14 15...

Страница 37: ...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...

Страница 38: ...shop manual 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 alignme...

Страница 39: ...ual 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 should...

Страница 40: ...tion pin before puittting the cylinder on make sure that it is lightly oiled Compression test ApplytheEmakcompressiontester P N001000392A to cylinder Pull energetically the rope 10 times Verify that t...

Страница 41: ...seals crankcase gasket impulse tube leaning fuel mixture and make the engine work over speeding as a wrong carburetor adjustment does 3 Oxygenated fuels or with alcohol ethanol content clean fuels are...

Страница 42: ...er Primer in Primer out A B C D E Attention inspect all hoses for cracks or deterioration They need to be replaced to avoid leak issues Fuel system Make sure all filters are clean If filters are damag...

Страница 43: ...to make it as efficient as possible Very small deviations in the carburetor setting or a blocked air filter have a large effect on the running and efficiency of the engine The carburetor can come fro...

Страница 44: ...d 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 Operation of the main jet Fuel...

Страница 45: ...use pins or pricks for cleaning purposes Filter needle and valve seat The function of the needle is to allow only the necessary amount of fuel into the metering chamber When looking for faults in the...

Страница 46: ...r fixing screw remove the lever pivot needle and spring undo the pump cover fixing screw then remove the cover diaphragm and gasket IMPORTANT Diaphragms and gaskets are provided with projecting lugs t...

Страница 47: ...the spindle should turn smoothly and uniformly with no parallel movement check the fuel inlet for possible damage making certain of a secure connection with the carburetor body Setscrews Inspect the...

Страница 48: ...f adjustment necessary when working in altitude Carburetor Walbro WT 1041 The Jets have the following factory registration L 2 1 4 1 8 H 1 1 2 1 8 1 8 When following a repair or engine overhaul you ar...

Страница 49: ...3 a Switch ON and restart 3 b Ignition system defected 3 b Inspect and or replace 3 d Broken sparkplug or wrong type 3 d Replace the sparkplug 4 Fuel does not reach the carburetor the machine stops af...

Страница 50: ...ten or replace 2 c Water in the fuel 2 c Clean the carburetor and replace fuel 2 d Engine with low compression 2 d Compression test 2 e Faulty carburetor or diaphragm 2 e Check and replace ADDITIONAL...

Страница 51: ...BRUSCHCUTTERS DS 2200 DS 2400 pag 51 Workshop manual...

Страница 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...

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