Echo Power Pruner PPT-2400 Service Data

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Echo Power Pruner PPT-2400 Service Data | Manualzz

17-21C-00

PPF-2100 PPT-2100 PPT-2400 PPFD-2400

SERVICE DATA

POWER PRUNER with new gear case

PPF-2100 PPT-2100

PPT-2400 PPFD-2400

INTRODUCTION

We are constantly wor king on technical improvement of our products. For this reason, technical data, equipment and design are subject to change without notice. All specifications, illustrations and directions in this SERVICE DATA are based on the latest products infor mation available at the time of publication.

For further information to service these models, please refer to ECHO SERVICE MANUAL Ord.No.

402-18.

CONTENTS

page

1 SERVICE INFORMATION .............................. 2

1-1 Specifications ............................................ 2,3

1-2 Technical data ............................................ 4

1-3 Torque limits ............................................... 5

1-4 Special repairing materials ......................... 5

1-5 Service limits .............................................. 6

1-6 Special tools ............................................... 7

2 SERVICE PROCEDURE ................................ 8

2-1 Gear case construction .............................. 8

2-2 Checking oil line ......................................... 9

2-3 Checking oil filter and check valve .............. 9

2-4 Replacing oil line and grommet .................. 9

2-5 Removing worm gear ................................. 10

2-6 Inserting worm gear ................................... 10

2-7 Replacing bar stud ..................................... 10

2-8 Replacing drive gear and bearing .............. 11

2-9 Replacing sprocket shaft gear ..................... 11

2-10 Assembling gear case ................................. 12

Reference No.

17-21C-00

I S S U E D : 2 0 0 0 0 7

INDEX

1

1

2

SERVICE INFORMATION

PPF-2100 PPT-2100

PPT-2400 PPFD-2400

1 SERVICE INFORMATION

1-1 Specifications

Models

Dimensions Length(collapsed)

Length(fully extended) mm(in) mm(in)

Length(with extension)* mm(in)

Width mm(in)

Engine

Ignition

Height

Dry weight**

Type

Rotation

Displacement

Bore

Stroke

Compression ratio

Carburetor Type

Model

Type mm(in) kg(lb) cm

3

(in

3

) mm(in) mm(in)

Starter

Spark plug

Type

Rope diameter x length mm(in)

Fuel Type

Tank capacity

Clutch Type

Drive shaft Type cm

3

(U.S.fl.oz.)

Diameter - Length

Housing(Operation Rod) mm(in)

OD - ID mm(in)

Length mm(in)

Gear case Reduction ratio

Gear tooth

Lubrication

Guide bar / Saw chain lubrication type

Tank capacity, oil cm

3

(U.S.fl.oz.)

Sprocket Type

Number of teeth

Pitch

Guide bar Type

Called length

Gauge

Saw chain Number of drive links pitch

Gauge in cm(in) in in in

* Extension is an option.

OD: Outer Dia., ID: Inner Dia.

PPF-2100

2365 (93.1)

N/A

3288 (129.5)

230 (9.06)

221 (8.70)

5.82 (12.8)

KIORITZ, air-cooled, two-stroke, single cylinder

Counterclockwise as viewed from the output end

21.2 (1.294)

32.2 (1.268)

26.0 (1.024)

6.5

Diaphragm, horizontal-draught, with primer (purge pump)

ZAMA C1U-K52

CDI (Capacitor discharge ignition) system in a single integrated piece w/ESG

BPMR7A, RCJ-7Y, BPM7A, CJ-7Y

Automatic rewind

3.0 x 1000 (0.12 x 39.4)

Premixed two-stroke fuel (Refer to Operator's manual.)

420 (14.2)

Centrifugal, 2-shoe slide

Flexible

6.1 - 1854 (0.24 - 73.0)

25.4 - 23.6 (1.00 - 0.93)

1829 (72.0)

1.5

Spiral bevel, Spur

Lithium based grease

Automatic

225 (7.6)

Spur

6

3/8

Sprocket nose

25.4 (10)

0.043 (0.050 for Type 1E and Canada)

39

3/8

0.043 (0.050 for Type 1E and Canada)

PPF-2100 PPT-2100

PPT-2400 PPFD-2400

SERVICE INFORMATION

Models

Dimensions Length(collapsed)

Length(fully extended) mm(in) mm(in)

Length(with extension)* mm(in)

Width mm(in)

Engine

Height

Dry weight

Type

Rotation mm(in) kg(lb)

Displacement

Bore

Stroke

Compression ratio cm

3

(in

3

) mm(in) mm(in)

PPT-2100

2260 (89.0)

3410 (134.3)

5000 (196.9)

230 (9.06)

221 (8.70)

7.27 (16.0)

PPT-2400

2734 (107.6)

3884 (152.9)

5468 (215.3)

230 (9.06)

221 (8.70)

7.85 (17.3)

PPFD-2400

2320 (91.3)

N/A

3910 (153.9)

220 (8.66)

230 (9.06)

6.95 (15.3)

KIORITZ, air-cooled, two-stroke, single cylinder

Counterclockwise as viewed from the output end

21.2 (1.294)

32.2 (1.268)

23.6 (1.440)

34.0 (1.339)

26.0 (1.024)

6.5

26.0 (1.024)

6.3

Diaphragm, horizontal-draught, with primer (purge pump)

ZAMA C1U-K52 WALBRO WT424B

Carburetor Type

Model

Ignition Type

Starter

Fuel

Spark plug

Type

Rope diameter x length mm(in)

Type

Tank capacity cm

3

(U.S.fl.oz.)

Type Clutch

Drive shaft Type

Upper OD mm(in)

Length mm(in)

CDI (Capacitor discharge ignition) system in a single integrated piece w/ESG

BPMR7A, RCJ-7Y, BPM7A, CJ-7Y

Automatic rewind

3.0 x 1000 (0.12 x 39.4)

Premixed two-stroke fuel (Refer to Operator's manual.)

420 (14.2)

Centrifugal, 2-shoe slide

Aluminum extrusion

15.1 (0.59)

1588 (62.5) 2026 (79.8)

Fiberglass

15.8 (0.62)

1760 (69.3)

N/A 1543 (60.75)

Aluminum / Fiberglass

1594 (62.8)

34.6 - 32.1 (1.36 - 1.26)

2032 (80.0) 356 (14.0)

Housing

Lower

Type

Upper

Length mm(in)

Upper / Lower

OD - ID mm(in)

Length mm(in)

OD - ID mm(in)

Length mm(in)

Lower

Gear case Reduction ratio

Gear tooth

Lubrication

Guide bar / Saw chain lubrication type

Tank capacity, oil cm

3

(U.S.fl.oz.)

Sprocket Type

46.5 - 38.9 (1.83 - 1.53)

1524 (60.0)

1.5

Spiral bevel, Spur

Lithium based grease

Automatic

225 (7.6)

Spur

1491 (58.7)

Number of teeth

Pitch

Guide bar Type

Called length in

Gauge

Saw chain Number of drive links pitch

Gauge in in in in

*Extension is an option. OD: Outer Dia., ID: Inner Dia.

6

3/8

Sprocket nose

10 12

39

0.043 (0.050 for Type 1E and Canada)

44

3/8

0.043 (0.050 for Type 1E and Canada)

3

4

SERVICE INFORMATION

1-2 Technical data

Models

Engine

Idling speed rpm

Engine speed at maximum power

Clutch-in speed

Compression pressure rpm rpm

MPa(kgf/cm

2)

(psi)

Ignition system

Spark plug gap mm(in)

Minimum secondary voltage at 1000 rpm kV

Secondary coil resistance k

Pole shoe air gaps mm(in)

°BTDC Ignition timing

Carburetor Model

Type

Supplier

Venturi Size

Throttle Bore

Idle speed screw initial setting

H needle initial setting

L needle initial setting

Test Pressure, minimum

Metering lever height mm(in) mm(in) turn in turn back turn back

MPa(kgf/cm

2

)(psi) mm(in)

BTDC: Before top dead center.

H needle: High speed needle.

L needle: Idle needle.

PPF-2100 PPT-2100

PPT-2400 PPFD-2400

PPF-2100

PPT-2100

PPT-2400

PPFD-2400

2500 - 3000

7500

3700 - 4100

0.85 (8.5) (121)

2500 - 3000

7500

3700 - 4100

0.75 (7.5) (107)

0.6 - 0.7 (0.024 - 0.028)

15

1.3 - 1.8

0.3 - 0.4 (0.012 - 0.016)

( 33 ) 28 28

C1U-K52 WT424B

Diaphragm horizontal-draught

ZAMA Walbro

1 8.5 (0.335)

12.7 ( 1/2 )

3 - 4

1 3/4

1 3/4

0.05 (0.5) (7.0)

0.1 - 0.25

7.94 (0.313)

12.7 ( 1/2 )

3 - 4

3 1/4

2 1/4

0.05 (0.5) (7.0)

1.65

PPF-2100 PPT-2100

PPT-2400 PPFD-2400 SERVICE INFORMATION

1-3 Torque limits

Descriptions

Starter Pawl carrier system

Starter case

Ignition Ignition coil system

Fan cover

Spark plug

Fuel system

Size

M 8

M 4 *

M 4 *

Carburetor insulator

Carburetor

M 4 *

M14

M 5 *

M 5

Throttle wire housing nut M 6

Fuel tank M 5 *

Clutch Clutch hub

Engine Crankcase

Cylinder

Cylinder cover

M 8

M 5

M 5

M 4 *

Gear case

Muffler

Top guard

Housing

Oil tank

M 5

M 5 *

M 4 *

M 4 *

Auto-oiler

Regular bolt, nut, and screw

M 4 *

M 3

M 4

M 5

M 6

* Apply thread locking sealant. (See below.) kgf•cm

80 - 100

22 - 28

38 - 55

38 - 55

150 - 170

30 - 40

35 - 45

6 - 10

27 - 32

180 - 200

75 - 85

75 - 85

35 - 45

55 - 65

25 - 35

25 - 40

25 - 40

25 - 40

6 - 10

15 - 25

25 - 45

45 - 75

0.6 - 1.0

2.7 - 3.2

18 - 20

7.5 - 8.5

7.5 - 8.5

3.5 - 4.5

5.5 - 6.5

2.5 - 3.5

N•m

8 - 10

2.2 - 2.8

3.8 - 5.5

3.8 - 5.5

15 - 17

3 - 4

3.5 - 4.5

2.5 - 4.0

2.5 - 4.0

2.5 - 4.0

0.6 - 1.0

1.5 - 2.5

2.5 - 4.5

4.5 - 7.5

1-4 Special repairing materials

Material

Grease

Thread locking sealant

Adhesive

Liquid seal

Location

Drive shaft

Gear case

Rewind spring

Starter center post

Starter case

Ignition coil

Fan cover

Carburetor insulators

Fuel tank

Cylinder cover

Top guard

Gear case housing

Oil tank

Auto-oiler

Oil pipe grommet

Bar stud

Bearing (PPFD-2400 shaft)

Gear case

Loctite #222, ThreeBond #1342, or equivalent in•lbf

70 - 90

19 - 24

33 - 48

33 - 48

130 - 150

25 - 35

30 - 40

5-9

23 - 28

160 - 175

65 - 75

65 - 75

30 - 40

50 - 55

22 - 30

29 - 46

29 - 46

29 - 46

5 - 9

13 - 22

22 - 40

40 - 65

Remarks

Lithium based grease or ECHO LUBE TM

Loctite #242 or equivalent

Loctite #424 or equivalent

Loctite #609 or equivalent

Loctite #593, DOW #732 or equivalent

5

6

1-5 Service limits

A B

SERVICE INFORMATION

C

PPF-2100 PPT-2100

PPT-2400 PPFD-2400

D

5K193

E

5K228

F

5K229

G

5K230

H

5K231

K

5K016

L

5K042 5K194

5K171

Description

A Cylinder bore

B Piston outer diameter

C Piston pin bore

D Piston ring groove

EPiston ring side clearance

F Piston pin outer diameter

G Piston ring width

H Piston ring end gap

K Crankshaft runout

L Clutch drum bore

5K071

1

2

3

4

5

0

6

5

10

7

8

9

10

11

Min.

Max.

Max.

Max.

Min.

Min.

Max.

Max.

Max.

mm (in)

PPF-2100 PPT-2100 PPT-2400 PPFD-2400

When plating is worn and aluminum can be seen

32.10 (1.264)

8.030 (0.3161)

33.90 (1.335)

1.6

(0.063)

0.1

(0.004)

7.98 (0.3142)

1.45 (0.057)

0.5

(0.02)

0.05 (0.002)

51.5

(2.03)

PPF-2100 PPT-2100

PPT-2400 PPFD-2400

1-6 Special tools

1 2

SERVICE INFORMATION

3

4 : a = 4 mm

5 : a = 3 mm

7 a

7 8 9

6

10 11 12 13

14 15 16 17

Key Part Number Description

1 Tachometer

2 363018-00310 Washer

Used for:

Measuring engine speed

Installing crankcase oil seal of starter side

3 433019-12330 Flange nut Removing magneto rotor (flywheel) Use key No.18 together

4 895610-79920 L-hex wrench (4 mm) Removing and installing hex. socket bolts (M5)

5 895612-79920 L-hex wrench (3 mm) Removing and installing hex. socket bolts (M4)

6 897701-06030 Bearing wedge Removing ball bearings on crankshaft

7 897701-14732 Bearing tool

8 897702-30131 Piston pin tool

9 897705-11520 Bearing tool

10 897708-19835 Worm remover

11 897712-04630 2-pin wrench

12 897714-24330 Oil seal tool

13 897726-09130 Oil seal tool

14 897800-79931 Spark tester

Removing and installing crankcase ball bearings

Removing and installing piston pin (Use 8 mm dia. adapter.)

Removing and installing con-rod small end needle bearing

Removing and installing worm for auto-oiler

Removing and installing pawl carrier

Installing crankcase oil seals

Removing clutch drum and installing drive gear ball bearing

Checking ignition system

15 897803-30130 Pressure tester Checking carburetor and crankcase leakages

16 897835-16131 Pressure connector Checking crankcase and cylinder leakages

17 900100-08008 Bolt Removing magneto rotor (flywheel) Use key No.3 together

8

SERVICE PROCEDURE

PPF-2100 PPT-2100

PPT-2400 PPFD-2400

2. SERVICE PROCEDURE

Refer to SERVICE DATA of PPF-2100/2110, PPT-2100/2400 and PPFD-2400 (Ref. No. 17-21B-00) for servicing drive shaft.

Refer to SERVICE MANUAL of CS-3000/3050/3400/3450 or CS-4200/4400 for servicing auto-oiler assembly.

2-1 Gear case construction

(A)

(N)

(T)

(P)

(Q)

(R)

(S)

(O)

(M)

(H)

(L)

(K)

(H)

(J)

(G)

(B)

(E)

(C)

(D)

(C)

(I)

(H)

(G)

(F)

(A) Nut for stud bolt

(B) E-ring

(C) Washer

(D) Sprocket

(E) Bar stud bolt

(F) Shaft connector

(Except PPF-2100)

(G) Retaining ring

(H) Ball bearing

(I) Drive gear

(J) Worm gear

(K) Sprocket shaft

(L) Bevel gear

(M) Check valve

(N) Oil tank

(O) Oil tank cap

(P) Oil strainer

(Q) Oil pipe grommet

(R) Inlet oil line

(S) Auto-oiler assembly

(T) Outlet oil line

PPF-2100 PPT-2100

PPT-2400 PPFD-2400

2-2 Checking oil line

(B)

(A)

SERVICE PROCEDURE

9

1. Disconnect oil line from the auto-oiler and remove oil tank from the gear case.

2. Connect pressure tester #897803-30130 to the oil line (A) using appropriate connector pipe (B)

(recommended outer dia. : 4 - 5 mm).

3. Apply pressure approximately 0.01 MPa

(0.1 kgf/cm

2

) (1.5 psi). Pressure should not drop.

If the pressure drops, leakage may be occurring at oil cap, oil cap O-ring, oil tank, oil line, grommet, or oil tank check valve. Check them and replace defective part(s).

2-3 Checking oil filter and check valve

(C)

(D)

(A)

(B)

1. Pry out oil pipe grommet (A), and pull out oil line and oil filter (B).

2. Wash oil filter in suitable clean solvent or replace the filter with a new one if damaged.

3. Remove oil tank check valve (C), and clean it.

4. Check if the valve lips (D) are hardened or left opened. Replace as required.

5. Insert oil tank check valve until flush with oil tank.

2-4 Replacing oil line and grommet

(A)

1. Remove defective oil line and the grommet.

2. Insert new oil line to the grommet as shown.

(A): 50 mm (2 in)

NOTE: Apply an adhesive (Loctite #424 or equivalent) at the grommet.

3. Connect oil filter to oil line.

10

2-5 Removing worm gear

(A)

(B)

(C)

SERVICE PROCEDURE

PPF-2100 PPT-2100

PPT-2400 PPFD-2400

1. Remove E-ring, washer, sprocket, another washer, then auto-oiler.

2. Screw worm remover #897708-19835 (A) on to the worm.

3. Insert handle (B) in the tool.

4. Screw hex socket bolt (C) in the center of the handle until the bolt touches the center of sprocket shaft end.

5. Tighten the bolt with wrench holding handle (B) until the worm comes off.

2-6 Inserting worm gear

(A)

NOTE: Do not reuse removed worm gear. Bore of the used worm gear may be enlarged and the worm gear may slip on sprocket shaft.

1. Screw worm gear into the worm remover (A).

2. Apply oil to the tapered side of worm gear.

3. Tap on to sprocket shaft until the worm gear bottoms.

2-7 Replacing bar stud

9

0

6 e t it c o

L

1. Install two nuts on defective stud and tighten them against each other.

2. Turn nut counterclockwise to remove stud.

If it is hard to remove stud, hold defective stud in a vise and tur n the gear case body counter clockwise, or use a suitable stud remover.

3. Install two nuts to new stud and secure the nuts against each other.

NOTE: Apply small amount of adhesive

(Loctite #609 or equivalent) to the stud.

4. Tur n nut clockwise to install stud until it bottoms.

PPF-2100 PPT-2100

PPT-2400 PPFD-2400

2-8 Replacing drive gear and bearing

SERVICE PROCEDURE

(C)

(D)

(B)

11

(A)

1. Separate gear case and take out gear sets.

2. Remove retaining ring (A).

3. Set the bearing cage on a vise or equivalent.

4. Push out drive gear (B).

NOTE: Removed bearing may never be reused since the cages are distorted.

5. Push in new bearing(s) using oil seal tool (C)

#897726-09130.

For PPT-2100/2400 and PPFD-2400: If shaft connector (D) hit bottom inside of oil seal tool, remove shaft connector and try again.

If not using oil seal tool, set bearing on a vise supporting inner race and push in drive gear.

6. Install retaining ring.

NOTE: When replacing drive gear, always replace bearings as a set.

2-9 Replacing sprocket shaft gear

(A)

(C)

(B)

1. Remove retaining ring (A) using plier.

2. Remove bearings on both sides by hand.

3. Hold bevel gear by hand as shown and tap on the sprocket shaft to separate bevel gear from sprocket shaft.

4. Install bevel gear (B) by hand on to sprocket shaft aligning double D-slot (C) on the shaft and gear.

5. Install bearing on to sprocket shaft and press together with bevel gear.

6. Install sprocket side bearing and secure with retaining ring.

12

2-10 Assembling gear case

SERVICE PROCEDURE n e n ala co

0%

Se

Sili

10

100

%

S ilico n e

S eal an t

PPF-2100 PPT-2100

PPT-2400 PPFD-2400

1. Clean sealing channels thoroughly on upper and lower case housings.

2. Apply thin bead of black 100% silicon rubber sealant (DOW #732, Loctite #593 or equivalent) into channels.

NOTE: Make sure to apply sealant on to channels cut in bearing support area on both halves of gear housings.

3. Install gear sets.

4. Apply 17 g (6 oz) of lithium based grease to gears and gear housings.

se ea

Gr

(C)

(B)

5. Install four 3 mm hex socket bolts, tightening to torque specification of 2.5 - 4.0 N•m (25 - 40 kgf•cm) (29 - 46 in•lbs).

6. Install worm gear onto sprocket shaft. (Refer to

2-6 Inserting worm gear.)

(A)

7. Connect outlet oil line (A) to auto-oiler.

8. Apply small amount of lithium based grease to worm gear and install auto-oiler with outlet oil line.

9. Secure auto-oiler with two hex socket bolts applying sealant (Loctite #242 or equivalent).

10. Install oil tank and route inlet oil line (B) through gear case and connect the oil line to autooiler.

11. Install washer, sprocket, another washer and

E-ring (C).

NOTE: Bevel of E-ring must face washer as shown.

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