Echo Power Pruner PPF-2100 Mounting instructions

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,
illustrations and directions in this S RVIC DATA
are based on the latest products information
available at the time of publication.
For further information to service these models,
please refer to CHO S RVIC MANUAL Ord.No.
402-18.
POWER PRUNER
with new gear case
PPF-2100 PPT-2100
PPT-2400 PPFD-2400
Reference No. 17-21C-00
ISSUED: 200007
SERVICE D T
1
17-21C-00
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
2-10Assembling gear case.................................12
PPF-2100 PPT-2100 PPT-2400 PPFD-2400
INDEX

1 SERVICE INFORMATION
1-1 Specificatio s
Models PPF-2100
Dimensions Length(collapsed) mm(in) 2365 (93.1)
Length(fully extended) mm(in) N/A
Length(with extension)* mm(in) 3288 (129.5)
Width mm(in) 230 (9.06)
Height mm(in) 221 (8.70)
Dry weight** kg(lb) 5.82 (12.8)
ngine Type KIORITZ, air-cooled, two-stroke, single cylinder
Rotation Counterclockwise as viewed from the output end
Displacement cm3(in3) 21.2 (1.294)
Bore mm(in) 32.2 (1.268)
Stroke mm(in) 26.0 (1.024)
Compression ratio 6.5
Carburetor Type Diaphragm, horizontal-draught, with primer (purge pump)
Model ZAMA C1U-K52
Ignition Type CDI (Capacitor discharge ignition) system
in a single integrated piece w/ SG
Spark plug BPMR7A, RCJ-7Y, BPM7A, CJ-7Y
Starter Type Automatic rewind
Rope diameter x length mm(in) 3.0 x 1000 (0.12 x 39.4)
Fuel Type Premixed two-stroke fuel (Refer to Operator's manual.)
Tank capacity cm3(U.S.fl.oz.) 420 (14.2)
Clutch Type Centrifugal, 2-shoe slide
Drive shaft Type Flexible
Diameter - Length mm(in) 6.1 - 1854 (0.24 - 73.0)
Housing(Operation Rod) OD - ID mm(in) 25.4 - 23.6 (1.00 - 0.93)
Length mm(in) 1829 (72.0)
Gear case Reduction ratio 1.5
Gear tooth Spiral bevel, Spur
Lubrication Lithium based grease
Guide bar / Saw chain lubrication type Automatic
Tank capacity, oil cm3(U.S.fl.oz.) 225 (7.6)
Sprocket Type Spur
Number of teeth 6
Pitch in 3/8
Guide bar Type Sprocket nose
Called length cm(in) 25.4 (10)
Gauge in 0.043 (0.050 for Type 1 and Canada)
Saw chain Number of drive links 39
pitch in 3/8
Gauge in 0.043 (0.050 for Type 1 and Canada)
2SERVICE INFORMATION PPF-2100 PPT-2100
PPT-2400 PPFD-2400
* xtension is an option.
OD: Outer Dia., ID: Inner Dia.

3
SERVICE INFORMATION
PPF-2100 PPT-2100
PPT-2400 PPFD-2400
Models PPT-2100 PPT-2400 PPFD-2400
Dimensions Length(collapsed) mm(in) 2260(89.0) 2734(107.6) 2320(91.3)
Length(fully extended) mm(in) 3410(134.3) 3884(152.9) N/A
Length(with extension)* mm(in) 5000(196.9) 5468(215.3) 3910(153.9)
Width mm(in) 230(9.06) 230(9.06) 220(8.66)
Height mm(in) 221(8.70) 221(8.70) 230(9.06)
Dry weight kg(lb) 7.27(16.0) 7.85(17.3) 6.95(15.3)
ngine Type KIORITZ, air-cooled, two-stroke, single cylinder
Rotation Counterclockwise as viewed from the output end
Displacement cm3(in3) 21.2 (1.294) 23.6 (1.440)
Bore mm(in) 32.2 (1.268) 34.0 (1.339)
Stroke mm(in) 26.0 (1.024) 26.0 (1.024)
Compression ratio 6.5 6.3
Carburetor Type Diaphragm, horizontal-draught, with primer (purge pump)
Model ZAMA C1U-K52 WALBRO WT424B
Ignition Type CDI (Capacitor discharge ignition) system
in a single integrated piece w/ SG
Spark plug BPMR7A, RCJ-7Y, BPM7A, CJ-7Y
Starter Type Automatic rewind
Rope diameter x length mm(in) 3.0 x 1000 (0.12 x 39.4)
Fuel Type Premixed two-stroke fuel (Refer to Operator's manual.)
Tank capacity cm3(U.S.fl.oz.) 420 (14.2)
Clutch Type Centrifugal, 2-shoe slide
Drive shaft Type Aluminum extrusion Fiberglass
Upper OD mm(in) 15.1 (0.59) 15.8 (0.62)
Length mm(in) 1588 (62.5) 2026 (79.8) 1760 (69.3)
Lower Length mm(in) 1543 (60.75) N/A
Housing Type Upper / Lower Aluminum / Fiberglass
Upper OD - ID mm(in) 34.6 - 32.1 (1.36 - 1.26)
Length mm(in) 1594 (62.8) 2032 (80.0) 356 (14.0)
Lower OD - ID mm(in) 46.5 - 38.9 (1.83 - 1.53)
Length mm(in) 1524 (60.0) 1491 (58.7)
Gear case Reduction ratio 1.5
Gear tooth Spiral bevel, Spur
Lubrication Lithium based grease
Guide bar / Saw chain lubrication type Automatic
Tank capacity, oil cm3(U.S.fl.oz.) 225 (7.6)
Sprocket Type Spur
Number of teeth 6
Pitch in 3/8
Guide bar Type Sprocket nose
Called length in 10 12
Gauge in 0.043 (0.050 for Type 1 and Canada)
Saw chain Number of drive links 39 44
pitch in 3/8
Gauge in 0.043 (0.050 for Type 1 and Canada)
* xtension is an option. OD: Outer Dia., ID: Inner Dia.

1-2 Tech ical data
Models PPF-2100 PPT-2400
PPT-2100 PPFD-2400
ngine
Idling speed rpm 2500 - 3000 2500 - 3000
ngine speed at maximum power rpm 7500 7500
Clutch-in speed rpm 3700 - 4100 3700 - 4100
Compression pressure MPa(kgf/cm2)(psi) 0.85 (8.5) (121) 0.75 (7.5) (107)
Ignition system
Spark plug gap mm(in) 0.6 - 0.7 (0.024 - 0.028)
Minimum secondary voltage
at 1000 rpm kV 15
Secondary coil resistance kΩ1.3 - 1.8
Pole shoe air gaps mm(in) 0.3 - 0.4 (0.012 - 0.016)
Ignition timing °BTDC ( 33 ) 28 28
Carburetor Model C1U-K52 WT424B
Type Diaphragm horizontal-draught
Supplier ZAMA Walbro
Venturi Size mm(in) 18.5 (0.335) 7.94 (0.313)
Throttle Bore mm(in) 12.7 ( 1/2 ) 12.7 ( 1/2 )
Idle speed screw initial setting
turn in 3 - 4 3 - 4
H needle initial setting turn back 1 3/4 3 1/4
L needle initial setting turn back 1 3/4 2 1/4
Test Pressure, minimum MPa(kgf/cm
2
)(psi)
0.05 (0.5) (7.0) 0.05 (0.5) (7.0)
Metering lever height mm(in) 0.1 - 0.25 1.65
BTDC: Before top dead center.
4PPF-2100 PPT-2100
PPT-2400 PPFD-2400
SERVICE INFORMATION
H needle: High speed needle.
L needle: Idle needle.

5
SERVICE INFORMATION
PPF-2100 PPT-2100
PPT-2400 PPFD-2400
Material Location Remarks
Grease Drive shaft
Gear case Lithium based grease or CHO LUB TM
Rewind spring
Starter center post
Thread locking sealant Starter case
Ignition coil
Fan cover
Carburetor insulators Loctite #222, ThreeBond #1342, or equivalent
Fuel tank
Cylinder cover
Top guard
Gear case housing
Oil tank Loctite #242 or equivalent
Auto-oiler
Adhesive Oil pipe grommet Loctite #424 or equivalent
Bar stud Loctite #609 or equivalent
Bearing (PPFD-2400 shaft)
Liquid seal Gear case Loctite #593, DOW #732 or equivalent
1-4 Special repairi g materials
1-3 Torque limits
Descriptions Size kgf•cm N•m in•lbf
Starter Pawl carrier M 8 80- 100 8-10 70-90
system Starter case M 4* 22- 28 2.2-2.8 19-24
Ignition Ignition coil M 4 * 38-55 3.8-5.5 33-48
system Fan cover M 4 * 38-55 3.8-5.5 33-48
Spark plug M14 150-170 15-17 130-150
Fuel Carburetor insulator M 5* 30-40 3-4 25-35
system Carburetor M 5 35-45 3.5-4.5 30-40
Throttle wire housing nut M 6 6-10 0.6-1.0 5-9
Fuel tank M 5* 27- 32 2.7-3.2 23-28
Clutch Clutch hub M 8 180-200 18-20 160-175
ngine Crankcase M 5 75-85 7.5-8.5 65-75
Cylinder M 5 75-85 7.5-8.5 65-75
Cylinder cover M 4* 35-45 3.5-4.5 30-40
Muffler M 5 55-65 5.5-6.5 50-55
Top guard M 5* 25-35 2.5-3.5 22-30
Gear Housing M 4* 25-40 2.5-4.0 29-46
case Oil tank M 4* 25-40 2.5-4.0 29-46
Auto-oiler M 4* 25-40 2.5-4.0 29-46
Regular bolt, nut, and screw M 3 6-10 0.6-1.0 5-9
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
* Apply thread locking sealant. (See below.)

1-5 Service limits
0
5
10
12345678910 11
5K193
5K016 5K042 5K194
5K071
5K171
5K228 5K229 5K230
5K231
ABCD
EFGH
KL
6PPF-2100 PPT-2100
PPT-2400 PPFD-2400
SERVICE INFORMATION
mm (in)
Description PPF-2100 PPT-2100 PPT-2400 PPFD-2400
A Cylinder bore When plating is worn and aluminum can be seen
B Piston outer diameter Min. 32.10 (1.264) 33.90 (1.335)
C Piston pin bore Max. 8.030 (0.3161)
D Piston ring groove Max. 1.6 (0.063)
Piston ring side clearance Max. 0.1 (0.004)
F Piston pin outer diameter Min. 7.98 (0.3142)
G Piston ring width Min. 1.45 (0.057)
H Piston ring end gap Max. 0.5 (0.02)
K Crankshaft runout Max. 0.05 (0.002)
L Clutch drum bore Max. 51.5 (2.03)

1-6 Special tools
a
1
7
11
15
2
8
12
16
34:a=4mm
5:a=3mm
9
13
17
6
10
14
7
SERVICE INFORMATION
PPF-2100 PPT-2100
PPT-2400 PPFD-2400
Key Part Number Description Used for:
1 Tachometer Measuring engine speed
2 363018-00310 Washer 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 Removing and installing crankcase ball bearings
8 897702-30131 Piston pin tool Removing and installing piston pin (Use 8 mm dia. adapter.)
9 897705-11520 Bearing tool Removing and installing con-rod small end needle bearing
10 897708-19835 Worm remover Removing and installing worm for auto-oiler
11 897712-04630 2-pin wrench Removing and installing pawl carrier
12 897714-24330 Oil seal tool Installing crankcase oil seals
13 897726-09130 Oil seal tool Removing clutch drum and installing drive gear ball bearing
14 897800-79931 Spark tester 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

8PPF-2100 PPT-2100
PPT-2400 PPFD-2400
SERVICE PROCEDURE
( )
(F)
(G)
(G)
(K)
(L)
(M)
(N)
(O)
(P)(Q)(R)
(S)
(T)
(A)
(B)
(C)
(C)(D)
(I) (H)
(H)
(H)
(J)
(A) Nut for stud bolt
(B) -ring
(C) Washer
(D) Sprocket
( ) Bar stud bolt
(F) Shaft connector
( xcept 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
2. SERVICE PROCEDURE
Refer to SERVICE DATA of PPF-2100/2110, PPT-2100/2400 a d PPFD-2400 (Ref. No. 17-21B-00) for
servici g drive shaft.
Refer to SERVICE MANUAL of CS-3000/3050/3400/3450 or CS-4200/4400 for servici g auto-oiler
assembly.
2-1 Gear case co structio

2-2 Checki g oil li e
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/cm2) (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 Checki g oil filter a d check valve
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 Replaci g oil li e a d grommet
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.
9
PPF-2100 PPT-2100
PPT-2400 PPFD-2400 SERVICE PROCEDURE
(A)
(B)
(A)
(A)
(B)
(C)
(D)

10 SERVICE PROCEDURE PPF-2100 PPT-2100
PPT-2400 PPFD-2400
(A)
(B)
(C)
(A)
L
o
c
t
i
t
e
6
0
9
2-5 Removi g worm gear
1. Remove -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 I serti g worm gear
NOTE: Do ot reuse removed worm gear. Bore
of the used worm gear may be e larged a d
the worm gear may slip o 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 Replaci g bar stud
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 turn 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 amou t of adhesive
(Loctite #609 or equivale t) to the stud.
4. Turn nut clockwise to install stud until it
bottoms.

11
SERVICE PROCEDURE
PPF-2100 PPT-2100
PPT-2400 PPFD-2400
2-8 Replaci g drive gear a d beari g
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 beari g may ever be reused
si ce 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: Whe replaci g drive gear, always
replace beari gs as a set.
2-9 Replaci g sprocket shaft gear
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.
(A)
(B)
(C)
(D)
(A)
(C)
(B)

12 SERVICE PROCEDURE PPF-2100 PPT-2100
PPT-2400 PPFD-2400
2-10 Assembli g gear case
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 seala t o to
cha els cut i beari g support area o both
halves of gear housi gs.
3. Install gear sets.
4. Apply 17 g (6 oz) of lithium based grease to
gears and gear housings.
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.)
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 auto-
oiler.
11. Install washer, sprocket, another washer and
-ring (C).
NOTE: Bevel of E-ri g must face washer as
show .
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(A)
(B)
(C)