Echo HCAS-2200 Mounting instructions

HCAS-2200

15-21D-01 1

INTRODUCTION

We are constantly working on technical

improvement of our products. For this reason,

technical data, equipment and design are

subject to change without notice. All

specifications and directions in this SERVICE

DATA are based on the latest products

information available at the time of

publication.

CONTENTS

page

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

1-1 Specification .................................................. 2

1-2 Technical data ................................................ 3

1-3 Torque limits ............................................... 4

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

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

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

2 EMISSION ADJUSTMENT GUIDE ............... 7

2-1 General adjusting rules .............................. 7

2-2 Presetting idle adjust screw, L mixture needle

and H mixture needle ........................................ 7

2-3 Adjusting carburettor .................................. 8

Reference No. 15-21D-01

REVISED: 200606

INDEX

ISSUED: 200603

SERVICE INFORMATION

2HCAS-2200

1 SERVICE INFORMATION

1-1 Specifications

Model HCAS-2200

Dimensions Length mm(in) 1695 (66.7)

Width mm(in) 250 (9.8)

Height mm(in) 234 (9.3)

Dry weight kg(lb) 6.4 (14.0)

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

Rotation Counterclockwise as viewed from the output end

Displacement cm3(in3) 21.2 (1.29)

Bore mm(in) 32.2 (1.27)

Stroke mm(in) 26.0 (1.02)

Compression ratio 5.9

Carburetor Type Rotary type : Diaphragm, horizontal-draught, with purge bulb

Model ZAMA RB-K75

Ignition Type CDI (Capacitor discharge ignition) system

Slope advance ignition system

combined with electronic speed governor

Spark plug BPMR8Y

Exhaust Muffler type Spark arrestor muffler

Starter Type Automatic rewind

Rope diameter x length mm(in) 3.0 x 1000 (3.0 x 39.5)

Fuel Type Premixed two-stroke fuel

Mixture ratio 50 : 1 (2%)

Gasoline Minimum 89 octane

Two-stroke engine oil ISO-L-EGD (ISO/CD13738), JASO FC

Tank capacity L (U.S.fl.oz.) 0.45 (15.2)

Clutch Type Centrifugal, 2-shoe pivot

Handle Type Front Loop type with hand guard

Rear Rubber grip with throttle trigger

Drive shaft Type Flexible

Inner shaft : Diameter mm(in) 6.15 (0.24)

Inner shaft : Length mm(in) 864 (34.0)

Housing OD - ID - L mm(in) 25.0 - 22.0 (0.98 - 0.86)

(Main pipe) Length mm(in) 844 (33.2)

Gear case Reduction ratio 3.95

Gear tooth Spiral bevel gear

Lubrication Lithium based grease or ECHO LUBETM

Cutter Type Double reciprocating, double edge blade

Length mm(in) 450 (18)

Pitch mm(in) 35.0 (1.38)

Height mm(in) 21.0 (0.83)

Thickness mm(in) 2.5 (0.098)

OD: Outer diameter.

ID: Inner diameter.

SERVICE INFORMATION 3

HCAS-2200

1-2 Technical data

Engine

Idling speed r/min 2700 - 3200

Wide open throttle speed r/min 9500 - 11500

Clutch engagement speed r/min 3700 - 4300

Compression pressure MPa (kgf/cm2) (psi) 0.72 (7.3) (104)

Ignition system

Spark plug gap mm(in) 0.6 - 0.7 (0.024 - 0.028)

Primary coil resistance Ω300 - 400

Minimum secondary voltage at 1500 r/min kV 15.0

Secondary coil resistance kΩ2.4 - 3.2

Pole shoe air gaps mm(in) 0.30 - 0.40 (0.012 - 0.016)

Ignition timing at 1000 r/min °BTDC 19.0

at 8500 r/min °BTDC 42.0

at 11500 r/min °BTDC 14.0

Carburettor

Venturi Size mm(in) 9.0 (0.354)

Throttle Bore mm(in) 10.5 (0.413)

Idle adjust screw initial setting turn in* 2 1/2

L mixture needle initial setting turn back 2

H mixture needle initial setting turn back 2

Test Pressure, minimum MPa (kgf/cm2) (psi) 0.05 (0.5) (7.0)

Metering lever height mm(in) 0.1 - 0.25 (0.004-0.01) lower than diaphragm seat

BTDC: Before top dead center.

* Set idle adjust screw to contact throttle plate before initial setting.

SERVICE INFORMATION

4HCAS-2200

1-3 Torque limits

Descriptions Size kgf•cm N•M in•lbf

Starter

system M 4* 45 - 55 4.5 - 5.5 40 - 48

Starter case

Ignition Ignition coil M 4* 45 - 55 4.5 - 5.5 40 - 48

system Ignition switch M 4 30 - 40 3 - 4 26 - 35

Fan cover M 4 30 - 40 3 - 4 26 - 35

Spark plug M 14 150 - 170 15 - 17 130 - 150

Fuel Carburettor M 5 26 - 37 2.6 - 3.7 22 - 32

system Intake insulator M 5 26 - 37 2.6 - 3.7 22 - 32

Fuel tank M 5 26 - 37 2.6 - 3.7 22 - 32

Clutch Clutch hub M 8 180 - 220 18 - 22 160 - 200

Engine Crankcase M 5** 70 - 110 7 - 11 60 - 95

Cylinder M 5** 70 - 110 7 - 11 60 - 95

Cylinder cover M 4* 22 - 32 2.2 - 3.2 20 - 28

Muffler M 5* 90 - 110 9 - 11 80 - 95

Regular bolt, nut, M 3 6 -10 0.6 - 1.0 5 - 9

and screw M 4 15 -25 1.5 - 2.5 13 - 22

M 5 25 -45 2.5 - 4.5 22 - 40

M 6 45 -75 4.5 - 7.5 40 - 65

M 8 110 -150 11 - 15 95 - 130

*Apply thread locking sealant. (See below)

** The torque differences among bolts should not exceed 20 kgf•cm (2N•m, 17in•lbf) on one cylinder or crankcase.

1-4 Special repairing materials

Material Location Remarks

Grease Drive shaft

Gear case Lithium based grease or ECHO LUBETM

Rewind spring

Starter center post

Oil seal inner lips

Thread locking Starter case Loctite #222, ThreeBond #1342 or equivalent

sealant Cylinder cover (Starter side)

Ignition coil Loctite #675 or equivalent

Muffler

SERVICE INFORMATION 5

HCAS-2200

Description mm (in)

Cylinder bore When plating is worn and aluminum can be seen

Piston outer diameter Min. 32.10 (1.264)

Piston pin bore Max. 8.030 (0.3161)

Piston ring groove Max. 1.6 (0.063)

Piston ring side clearance Max. 0.1 (0.004)

Piston pin outer diameter Min. 7.970 (0.3138)

Piston ring width Min. 1.45 (0.057)

Piston ring end gap Max. 0.5 (0.02)

Con-rod small end bore Max. 12.000 (0.4724)

Crankshaft runout Max. 0.05 (0.002)

Clutch drum bore Max. 51.5 (2.03)

1-5 Service limits

5K016

5K263 5K264 5K265

5K266 5K017

5K219

5K171

12345678910 11

5K071A

5K267

5K286

SERVICE INFORMATION

6HCAS-2200

5.3

120

140

160

180

100

91020

Key Part Number Description Used for:

1 897801-33330 Tachometer PET-1000 Measuring engine speed

2 363018-00310 Washer Installing crankcase oil seal of starter side

3 895610-79920 L-hex wrench (4 mm) Removing and installing hex. socket bolts (M5)

4 897603-23030 PTO shaft puller Removing driven (PTO) shaft

5 897701-06030 Bearing wedge Removing ball bearings on crankshaft

6 897701-14732 Bearing tool Removing and installing crankcase ball bearings

7 897701-06030 Puller Removing drive gear assembly

8 897705-11520 Bearing tool removing and installing con-rod small end needle bearing

9 897712-04630 2-pin wrench Removing and installing pawl carrier

10 897726-16431 Oil seal tool Installing crankcase oil seals

11 897726-09130 Oil seal tool Removing clutch drum and installing clutch drum ball bearing

12 990511-30023 Spark tester Checking ignition system

13 897803-30133 Pressure tester Checking carburetor and crankcase leakages

14 91009 Retaining ring pliers Removing and installing retaining ring

15 900100-08008 Bolt Removing magneto rotor (flywheel)

16 433019-12330 Flange nut Removing magneto rotor (flywheel)

17 91007 Compression gauge Measuring cylinder compression

18 91020 Limiter plug tool Removal and installing limiter plug

1-6 Special tools

912

SERVICE INFORMATION 7

HCAS-2200

2 EMISSION ADJUSTMENT GUIDE

2-1 General adjusting rules

A. Before starting the unit for adjustment, check the following items.

1. The correct spark plug must be clean and properly gapped.

2. The air filter element must be clean and properly installed.

3. The muffler exhaust port must be clear of carbon.

4. The fuel lines, tank vent and fuel filter are in good condition and clear of debris.

5. The fuel is fresh ( > 89 octane : RON) and properly mixed at 50 : 1 with “ISO L-EGD”or “JASO FC”2-

stroke oil.

6. The gear case assembly with blade set adjusted clearance properly must be installed for proper engine

B. Start and run engine for 2 minutes alternating engine speed between WOT and idle every 5 seconds.

Adjust idle adjust screw to 2900 +/- 200 r/min. If engine does not run correctly after this adjustment, proceed

to the next step (2-2).

IMPORTANT : After adjusting carburettor according to the steps 2-2 and 2-3, the limiter plug(s) must be

installed on Idle and H mixture needle(s) hole(s) to comply with Emission Directive.

2-2 Presetting idle adjust screw, idle mixture needle and H mixture needle

1. Remove plugs from idle mixture needle hole (A)

and H mixture needle hole (B) using limiter plug tool

(1) Put limiter plug tool (C) on limiter plug in needle hole.

(2) Screw limiter plug tool anticlockwise 2 turns into limiter

plug.

(3) Pull out limiter plug tool with the limiter plug from

needle hole.

NOTE : When plug is damaged and left in the hole,

use needle or pin-shaped tool to scrape.

2. Turn idle mixture needle (D) and H mixture needle

(G) clockwise until lightly seated. And then turn out

both needles following turns.

Idle mixture needle : 2 H mixture needle : 2

3. Turn idle adjust screw (E) anticlockwise until its

tip just touches throttle plate (F). Then turn it in

clockwise 2 1/2 turns.

(G)

(E)

(F) (D)

(A)

(B)

SERVICE INFORMATION

8HCAS-2200

2-3 Adjusting carburettor

1. Start engine and warm it up alternating engine

speed between WOT and idle every 5 seconds for

1 minute.

2. Adjust idle mixture needle and obtain maximum

idle speed with 2.5 mm blade small screw driver.

3. Set idle speed to 3,500 r/min by turning idle adjust

screw.

4. Turn idle mixture needle anticlockwise to reduce

idle speed 500 to 750 r/min in the range of 2,750 to

3,000 r/min.

NOTE : Engine speed must be allowed to stabilize

a minimum of 20 seconds after each adjustment of

L mixture needle to assure accurate tachometer

readings.

5. Adjust H mixture needle and obtain maximum

WOT engine speed.

6. Turn H mixture needle anticlockwise to reduce

WOT engine speed 100 r/min.

7. Restart engine again and make sure engine runs

in the range of 2,700 to 3,200 r/min at idling and the

range of 9,500 to 11,500 r/min at WOT.Also make it

sure cutting device would not move at engine idle

speed and suitable acceleration.

8. After adjusting carburettor, insert and secure new

plug(s) (F) P005-001270 deep in the needle holes

per the Emission regulation using limiter plug tool (E).

NOTE : Initial carburettor setting (idle adjust screw,

idle and H mixture needles) shown on page 3 and 7

is to start the engine after restoration or carburettor

change. Idle adjust screw, idle and H needles turn

for designated engine revolution through procedures

indicated here may vary. As long as idle and WOT

engine speed is set in given range, variance would

be ignorable.

(F)

(E)

(F)

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