husqwm271_hwen1997_1018855-26

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  • 8/3/2019 husqwm271_hwen1997_1018855-26

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    101 88 55-26

    Workshop Manual

    Husqvarna Chain Saws

    English1

    Thisworkshopmanualappliestotheengineassemblyinthefollowingsaws:

    MODELS 28

    1XP/288XP

    36/41

    61/268/272XP

    26

    8K/272K

    31

    20XP

    39

    4XP

    27

    2S

    51/55

    40/45

    42/242XP/246

    254XP/257/262XP

    2English

    LISTOFCO

    NTENTS

    Introduction..........

    ...........................3

    Safetyregulations

    ...........................5

    TechnicalData.................................6

    Tools......................

    .........................14

    Servicedata..........

    .........................20

    Troubleshooting...........................40

    Safetyequipment..........................42

    Starter.............................................57

    Electricalsystem...........................61

    Centrifugalclutch..........................67

    Lubricationsystem

    .......................70

    Carburettor............

    .........................83

    Airfilter........................................101

    Tankunit................

    .......................103

    Anti-vibrationsystem..................106

    Pistoncylinder.............................108

    Crankcaseandcrankshaft..........114

    English3

    INTROD

    UCTION

    Asproductioncontinues,changeswillbeintro-

    ducedsuccessivelytothechainsaw.Ifatany

    timethesechangesinfluenceserviceand/or

    spares,specialserviceannouncementswillbe

    sentout,whichmeansthatthismanualwillcease

    tobecurrentwithtime.Inordertoavoidprob-

    lems,themanualshouldalwaysbereadtogether

    withallserviceannouncementsthatapplytothe

    specificmodelofchainsaw.

    Layout

    Thedescriptivesectionsinthisworkshopmanual

    aresetoutinanumberofflowdiagrams.When

    carryingoutrepairsonaspecificchainsaw,

    followthesignsthatapplytothesawinquestion.

    Diagramsarenotnumberedastheyarelinkedto

    theactualtext,eitherbylinesorbybeinginthe

    samebox.

    Positionaldirectivestocomponentsinsidethe

    diagramsaredesignatedwithA,B,etc.andstart

    fromAagainineachnewsection.

    General

    Updates

    AlwaysuseHusqvarnaoriginal:

    Spareparts

    Servicetools

    Accessories

    Forspecificproceduresspecialtoolsarere-

    quired.Inthisworkshopmanual,alltheservice

    toolsrequiredarelisted.Useofthetoolsis

    describedinappropriatesections.

    Tools

    Thisworkshopmanualprovidesadetailedde-

    scriptionofproceduresfortroubleshooting,repair

    andtestingofthechainsaws.Safetyprecautions

    thatshouldbetakenduringrepairarealso

    described.

    Thisworkshopmanualappliestotheengine

    assemblyinthefollowingchainsaws:

    3640

    4142

    45515561

    242XP

    246254XP

    257262XP

    268

    272XP

    268K

    272K

    272S

    281XP

    288XP

    394XP

    3120XP

    Safety

    Note!

    Thesectiondealingwithsafetyshouldbe

    readandunderstoodbyallwhocarryout

    repairorserviceworkonthechainsaw.

    Targetgroup

    Therearewarningsymbolsonthechainsaw.Ifa

    warningsymbolhasbeendamagedorismissing,

    itmustbereplacedimmediatelyinorderto

    maximisesafetywhenthesawisinuse.

    Thisworkshopmanualiswrittenforpersonnel

    thatareassumedtohavegeneralknowledgeof

    serviceandrepairofsmallengines.

    Theworkshopmanualshouldbereadandunder-

    stoodbyallpersonnelcarryingoutserviceand

    repairworkonthechainsaw.Themanualisalso

    suitableforuseinthetrainingofnewemployees.

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    4English

    INTRODUCTION

    Disma

    ntlingandreassemblyoftheentire

    chainsaw

    When

    theentirechainsawistobedismantled

    andreassembled,proceedasfollows:

    1.Refertopage57,whichdealswiththe

    St

    arterandcarryouttheinstructions

    un

    dertheheadingDismantling.

    2.W

    orkforwardsthroughthemanualand

    ca

    rryoutDismantlinginstructionsinthe

    or

    derthatthesectionsoccur.

    3.ReturntotheStarteronpage58and

    followtheinstructionsunderCleaning

    an

    dInspection.

    4.W

    orkforwardthroughthemanualand

    ca

    rryoutCleaningandInspectioninthe

    or

    derthatthesectionsoccur.

    5.Orderorcollectalltherequiredspare

    pa

    rtsfromthesparepartsstores.

    6.In

    ordertoAssemblethechainsaw,

    pr

    oceedasfollows:

    Refertopages117-120whichdealswith

    theCrankcaseandcarryouttheinstruc-

    tio

    nsunderAssembly.

    Refertopages111-112whichdealswith

    thePistonandCylinderandcarryout

    theinstructionsunderAssembly.

    Refertopages107whichdealswiththe

    Anti-vibrationsystemandcarryoutthe

    instructionsunderAssembly.

    Refertopage105whichdealswiththe

    Ta

    nkunitandcarryouttheinstructions

    un

    derAssembly.

    Contin

    uetoworkbackwardsthroughthe

    manua

    landcarryoutAssemblyinstructions

    asthe

    sectionsoccur.

    Inorde

    rtoimproveunderstanding,some

    sectionsbeginwithaDescriptionofthe

    relevantsub-assembly.

    Use

    Thisworkshopmanualcanbeusedintwodifferent

    ways:

    Repairofaspecificsub-assembly

    Dismantlingandreassemblyoftheentirechain

    saw

    Repairofaspecificsub-assembly

    Whenaspecificsub-assemblyonthechainsawis

    toberepaired,proceedasfollows:

    1.

    Refertothepagereferringtotherelevantsub-

    assembly.

    2.

    Carryoutthesteps:Dismantling

    Cleaningandinspection

    Reassembly

    English5

    SAFETYREGUL

    ATIONS

    GeneralInstructions

    Sp

    ecialinstructions

    WARNING!

    Thewarningtextindicatesarisk

    ofpersonalinjuryifinstructions

    arenotfollowed.

    NOTE!

    Thewarningtextindicatesariskof

    damagetoequipmentifinstructions

    arenotfollowed.

    Thechainsawistypeapprovedwith

    regardtosafetyaccordingtoapplicable

    legalrequirementswhenfittedwiththe

    cuttingequipmentspecifiedinthe

    Operator'sManual.Equippingthesawwith

    otherequipmentoraccessoriesandspare

    partsnotapprovedbyHusqvarnacan

    resultinnoncompliancewiththesesafety

    requirementsandliabilityforpersons

    carryingoutsuchmodifications.

    Thefuelusedinthechainsawposesthe

    followinghazards:

    1.Thefluidanditsfumesarepoisonous.

    2.Cancauseeyeandskinirritation.

    3.Cancausebreathingdifficulties

    4.Ishighlyinflammable.

    Thebar,chainandclutchcover(chain

    brake)mustbeassembledbeforethe

    chainsawisstarted,otherwisetheclutch

    maycomeloosecausingpersonalinjury.

    Wearearmuffswhentestingthechain

    saw.

    Donotusethesawuntilithasbeen

    adjustedsothatthechaindoesnotrotate

    whenidling.

    Bearinmindthefirerisk.Thesaw

    can

    producesparksthatcancauseafirehazard..

    Aftertesting,donottouchthe

    silenceruntilithascooled.Risk

    ofburns.Thisespeciallyappliesif

    thesaw

    isfittedwithacatalyticconverter.

    Thecoatingonandinthecatalyticelement

    ishazardoustotouch.Useprotectivegloves

    whenworkingonthecatalyticconverter.

    Inadequatechainlubricationcanresultin

    thechainbreaking,whichcancause

    seriousorfatalinjury.

    Makesurethatthestarterrecoil

    springdoesnotflyoutandcause

    personalinjury.Releasethespring

    tensionbeforethecordpulleyisremoved.

    Whenremovingthepressure

    springforthechainbrake,ensure

    thatthebrakeisinthe'on'

    positionwhichreducesthespring

    tension,otherwisethespringcanflyout

    causingpersonalinjury.

    Afterrepair,thechainbrakemustbe

    checkedinaccordancewiththe

    instructionsonpage47.

    Whenreplacingthecrankshaftbearings

    notethatthecrankcasehalvesarehot.

    Useprotectivegloves.

    Whenusingcompressedair,theairjet

    shouldneverbepointedtowardsthebody.

    Aircanbeforcedintothebloodstream,

    whichcancausefatality.

    Workshopswherechainsawsareserviced

    mustbeequippedwithsafetyequipment

    assetoutinlocaldirectives.

    Nooneshouldrepairachainsawwithout

    firsthavingreadandunderstoodthe

    contentsofthisworkshopmanual.

    Thefollowingwarningtextsaretobefound

    inthismanualincertainplaces.The

    warningtextsoccurbeforetheprocedure

    towhichtheyrefer.

    1

    !

    6English

    Displacement

    Bore

    Stroke

    Max.powerat

    Sparkpluggap

    Ignitionsystem

    Airgap

    Carburettor

    cm3

    mm

    mm

    r/min

    mm/inches

    mm/inches

    TECHNICA

    LDATA

    36

    36

    38.0

    32.0

    9000

    40

    40

    40.0

    32.0

    9000

    41

    40

    40.0

    32.0

    9000

    42

    42

    42.0

    30.0

    9300

    45

    44

    42.0

    32.0

    9000

    51

    51

    45.0

    32.0

    9000

    36

    0.5/.02

    PHELON

    0.3/.012

    WALBROWT239

    40

    0.5/.02

    PHELON

    0.3/.012

    ZAMAC1Q-EL1

    41

    0.5/.02

    PHELON

    0.3/.012

    WALBROWT239

    42

    0.5/.02

    SEMAM7

    0.3/.012

    WALBROHDA98

    45

    0.5/.02

    PHELON

    0.3/.012

    ZAMAC1Q-EL1

    51

    0.5/.02

    ELECTROLUXET

    0.3/.012

    WALBROWT170

    36

    33-46/13-18

    17.3/9000rpm

    .325-3/8

    1.3/.050

    40

    33-46/13-18

    17.4/8500rpm

    .325

    1.3/.050

    41

    33-46/13-18

    17.3/9000rpm

    .325-3/8

    1.3/.050

    42

    28-46/11-18

    17.9/9300rpm

    .325

    1.5/.058/1.3/.0501)

    45

    33-46/13-18

    17.4/8500rpm

    .325

    1.3/.050

    51

    33-51/13-20

    17.4/9000rpm

    .325-3/8

    1.5/.058/1.3/.0501)

    1) FromMay1996

    Barlength

    Chainspeed

    Chainpitch

    Drivelinkgauge

    cm/inches

    m/s

    inches

    mm/inches E

    nglish7

    Fueltankvolume

    Oilpum

    pcapacity

    Oiltankvolume

    Automaticoilpump

    Litres

    cm3/minat8.500rpm

    Litres

    r/min

    r/min

    r/min

    Champion

    TECHNIC

    ALDATA

    36

    3000

    450

    0

    13000

    RCJ7Y

    40

    2500

    360

    0

    12500

    RCJ7Y

    41

    3000

    450

    0

    13000

    RCJ7Y

    42

    2700

    380

    0

    14500

    RCJ7Y

    45

    2500

    360

    0

    12500

    RCJ7Y

    51

    2500

    370

    0

    12500

    RCJ7Y

    36

    0.4

    7

    0.2

    Yes

    40

    0.5

    8

    0.25

    Yes

    41

    0.4

    7

    0.2

    Yes

    42

    0.5

    3-7

    0.27

    Yes

    45

    0.5

    8

    0.25

    Yes

    51

    0.6

    10

    0.3

    Yes

    36

    4.6

    5.3

    (13")

    No

    40

    4.7

    5.4

    (13")

    No

    41

    4.6

    5.3

    (13")

    No

    42

    4.7

    5.5

    (13")

    No

    45

    4.7

    5.4

    (13")

    No

    51

    5.2

    6.2

    (15")

    No

    Weightwithoutbarandchain

    Weightwithbarandchain

    Handleheater

    kg

    kg/lbs

    Watt/r/min

    Idlingspeed

    Engagem

    entspeed

    Max.speed

    Sparkplug

  • 8/3/2019 husqwm271_hwen1997_1018855-26

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    8English

    Displacement

    Bore

    Stroke

    Max.powerat

    Barlength

    Chainspeed

    Chainpitch

    Drivelinkgauge

    Sparkpluggap

    Ignitionsystem

    Airgap

    Carburettor

    cm3

    mm

    mm

    r/min

    mm/inches

    mm/inches

    cm/inches

    m/s

    inches

    mm/inches

    TECHNICALDATA

    55

    53

    46.0

    32.0

    9000

    61

    62

    48.0

    34.0

    8300

    242XP

    42

    42.0

    30.0

    9900

    246

    46

    44.0

    30.0

    9000

    254XP

    54

    45.0

    34.0

    9300

    257

    57

    46.0

    34.0

    9000

    55

    0.5/.02

    ELECTROLUXET

    0.3/.012

    WALBROWT170

    61

    0.5/.02

    ELECTROLUXET

    0.3/.012

    TILLOTSONHS254

    242XP

    0.5/.02

    SEMAM7

    0.3/.012

    WALBROHDA98

    246

    0.5/.02

    SEMAM7

    0.3/.012

    WALBROHDA98

    254XP

    0.5/.02

    ELECTROLUXET

    0.3/.012

    WALBROHDA35B

    257

    0.5/.02

    ELECTROLUXET

    0.3/.012

    WALBROHDA120

    55

    38-51/15-20

    17.4/9000rpm

    .325-3/8

    1.5/.058/1.3/.0501)

    61

    38-51/15-20

    18.4/8300rpm

    3/8

    1.5/.058

    242XP

    28-46/11-18

    19.1/9900rpm

    .325

    1.5/.058/1.3/.0501)

    246

    28-46/11-18

    17.3/9000rpm

    .325

    1.5/.058/1.3/.0501)

    254XP

    33-51/13-20

    17.3/9300rpm

    .325-3/8

    1.5/.058

    257

    33-51/13-20

    17.3/9000rpm

    .325-3/8

    1.5/.058

    1) FromMay1996

    English9

    Idlingspeed

    Engagementspeed

    Max.speed

    Sparkplug

    Fueltankvolume

    Oilpumpcapacity

    Oiltankvolume

    Automaticoilpump

    Weightwithoutbarandchain

    Weightwithb

    arandchain

    Handleheater

    Litres

    cm3/minat8.500rpm

    Litres

    r/min

    r/min

    r/min

    Champion

    kg

    kg/lbs

    Watt/r/min

    TECHNICALDATA

    55

    2500

    3700

    12500

    RCJ7Y

    61

    2500

    3700

    12000

    RCJ7Y

    242XP

    2700

    3900

    15500

    RCJ7Y

    246

    2700

    3900

    15000

    RCJ7Y

    254XP

    2700

    3700

    13800

    RCJ7Y

    257

    2700

    3700

    13500

    RCJ7Y

    55

    0.6

    10

    0.3

    Yes

    61

    0.75

    4/8/12/17

    0.45

    Yes

    242XP

    0.5

    3-7

    0.27

    Yes

    246

    0.5

    3-7

    0.27

    Yes

    254XP

    0.6

    3-10

    0.3

    Yes

    257

    0.6

    3-10

    0.3

    Yes

    55

    5.2

    6.2(15")

    No

    61

    6.1

    7.1(15")

    No

    242XP

    4.7

    5.5(13")

    65/10.000

    246

    4.7

    5.5(13")

    No

    254XP

    5.4

    6.3(13")

    65/10000

    257

    5.6

    6.6(13")

    65/10000

    10English

    Displacemennt

    Bore

    Stroke

    Max.powerat

    Barlength

    Chainspeed

    Chainpitch

    Drivelinkgauge

    Sparkpluggap

    Ignitionsystem

    Airgap

    Carburettor

    cm3

    mm

    mm

    r/min

    mm/inches

    mm/inches

    cm/inches

    m/s

    inches

    mm/inches

    TECHNICA

    LDATA

    262XP

    62

    48.0

    34.0

    9600

    268

    67

    50.0

    34.0

    9000

    272XP

    72

    52.0

    34.0

    9300

    268K

    67

    50.0

    34.0

    9000

    272K

    72

    52.0

    34.0

    9300

    272S

    72

    52.0

    34.0

    9300

    262XP

    0.5/.02

    ELECTROLUXET

    0.3/.012

    WALBROHDA120

    268

    0.5/.02

    ELECTROLUXET

    0.3/.012

    TILLOTSONHS260

    272XP

    0.5/.02

    ELECTROLUXET

    0.3/.012

    TILLOTSONHS260

    268K

    0.5/.02

    ELECTROLUXET

    0.3/.012

    TILLOTSONHS255

    272K

    0.5/.02

    ELECTROLUXET

    0.3/.012

    TILLOTSONHS255

    272S

    0.5/.02

    ELECTROLUXET

    0.3/.012

    TILLOTSONHS255

    262XP

    33-51/13-20

    18.5/9600rpm

    .325-3/8

    1.5/.058

    268

    38-51/15-20

    18.4/9000rpm

    3/8

    1.5/.058

    272XP

    38-51/15-20

    20.0/9300rpm

    3/8

    1.5/.058

    268K

    -

    -

    -

    -

    272K

    -

    -

    -

    -

    272S

    -

    -

    -

    -

    English11

    Idlingspeed

    Engagement

    speed

    Max.speed

    Sparkplug

    Fueltankvolume

    Oilpumpc

    apacity

    Oiltankvolume

    Automaticoilpump

    Weightwithoutchainandbar

    Weig

    htwithchainandbar

    Handleheater

    Litres

    cm3/minat8

    .500rpm

    Litres

    r/min

    r/min

    r/min

    Champion

    kg

    kg

    /lbs

    Watt/r/min

    TECHNIC

    ALDATA

    262XP

    2700

    340

    0

    13500

    RCJ7Y

    268

    2500

    350

    0

    12500

    RCJ7Y

    272XP

    2500

    350

    0

    13500

    RCJ7Y

    268K

    2500

    350

    0

    10000

    RCJ7Y

    272K

    2500

    350

    0

    10000

    RCJ7Y

    272S

    2500

    350

    0

    10000

    RCJ7Y

    262XP

    0.6

    6.5-13.5

    0.3

    Yes

    268

    0.75

    4/9/13/17

    0.45

    Yes

    272XP

    0.75

    5/9/14/19

    0.45

    Yes

    268K

    0.75

    -

    -

    -

    272K

    0.75

    -

    -

    -

    272S

    0.75

    -

    -

    -

    262XP

    5.8

    6.8

    (13")

    65/10000

    268

    6.2

    7.2

    (15")

    65/10000

    272XP

    6.3

    7.3

    (15")

    65/10000

    268K

    9.5

    -

    -

    272K

    9.6

    -

    -

    272S

    21.0(includingcarriage)

    -

    -

  • 8/3/2019 husqwm271_hwen1997_1018855-26

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    12English

    Displacement

    Bore

    Stroke

    Max.powerat

    Barlength

    Chainspeed

    Chainpitch

    Drivelinkgauge

    Sparkpluggap

    Ignitionsystem

    Airgap

    Carburettor

    cm3

    mm

    mm

    r/min

    mm/inches

    mm/inches

    cm/inches

    m/s

    inches

    mm/inches

    TECHNICALDATA

    281XP

    81

    52.0

    38.0

    9000

    288XP

    87

    54.0

    38.0

    9300

    394XP

    94

    56.0

    38.0

    8800

    3120XP

    119

    60.0

    42.0

    9000

    281XP

    0.5/.02

    SEMAM7

    0.3/.012

    TILLOTSONHS228

    288XP

    0.5/.02

    SEMAM7

    0.3/.012

    TILLOTSONHS228

    394XP

    0.5/.02

    SEMAM44

    0.3/.012

    WALBROWJ39

    3120XP

    0.5/.02

    SEMAM37

    0.3/.012

    WALBROWG6

    281XP

    38-71/15-28

    20.0/9000rpm

    3/8

    1.5/.058

    288XP

    38-71/15-28

    20.7/9300rpm

    3/8

    1.5/.058

    394XP

    46-91/18-36

    19.6/8800rpm

    3/8-.404

    1.5/.058-1.6/.063

    3120XP

    60-107/24-42

    20.1/9000rpm

    .404

    1.6/.063 En

    glish13

    Idlingspeed

    Engagementspee

    d

    Max.speed

    Sparkplug

    Fueltankvolume

    Oilpumpcapac

    ity

    Oiltankvolume

    Automaticoilpump

    Weightwithoutbarandchain

    Weightwithbarchain

    Handleheater

    Litres

    cm3/minat8.500rpm

    Litres

    r/min

    r/min

    r/min

    Champion

    kg

    kg/lbs

    Watt/r/min

    TECHNICAL

    DATA

    281XP

    2500

    3200

    12500

    RCJ6Y

    288XP

    2500

    3200

    12500

    RCJ6Y

    394XP

    2500

    3400

    12500

    RCJ6Y

    3120XP

    2500

    3300

    11500-12500

    RCJ7Y

    281XP

    0.9

    9/12/15/18

    0.5

    Yes

    288XP

    0.9

    9/12/15/18

    0.5

    Yes

    394XP

    0.9

    14-21

    0.5

    Yes

    3120XP

    1.25

    8-51

    0.7

    Yes

    281XP

    7.5

    8.7(18")

    56/7200

    288XP

    7.5

    8.7(18")

    56/7200

    394XP

    7.9

    9.2(18")

    65/10000

    3120XP

    10.4

    12.3(28")

    No

    14English

    5025057-013/16"

    5025016-016mm

    5025064-015mm

    5025018-014mm

    5025019-013mm

    5025022-018mm

    5025023-0110mm

    5027113-01

    5025134-02(0,3mm)

    5025083-01

    5025102-01

    5027114-01

    compl5025070-01

    5025037-01

    5027009-01

    502

    5088-015mm

    502

    5087-014mm

    502

    5086-013mm

    502

    5006-01

    5049826-01

    (36,41,40,45)

    Toolsforallchainsaws

    TOOLS

    5025191-01(0,5mm)

    English15

    4mm

    8mm

    5025033-01

    3mm;4mm;5mm

    8mm;10mm

    5052679-12

    40>9101116

    45>9251168

    50>9250856

    5025194-01

    5049090-01

    5025161-01

    (51,55)

    5025030-09

    5025079-01(55)

    40>9101116

    45>9251168

    5049029-02

    5025403-01

    (40,45,55)

    5025046-01

    (55)

    compl5025038-01

    5025033-01

    5025194-01

    5300311-36

    5300311-12

    5025100-02

    Toolsforsaws36and41

    Toolsforsaws40,45,51and55

    TOOLS

    5025099-01

    (55)

    5025026-01

    (55)

    5053818-17

    (40.45)

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    16English

    3mm;4mm

    8mm

    5025033-01

    compl5025031-01

    5027003-01

    5025161-01

    5049090-01

    5025082-01

    5025030-07

    5025132-01

    5025150-01

    5025100-02

    5025072-01

    5025071-01

    5025045-01

    5025046-01

    compl5025038-01

    *com

    pl50251

    49-02

    3m

    m;4mm

    8m

    m

    5025033-01

    5025072-01

    502507

    1-01

    5025045-01

    5025046-01

    compl5025038-01

    5049090-01

    5025161-01

    5025079-01

    5025030-10

    Toolsforsaws42,242and246

    Toolsforsaws254,257and262

    TOOLS

    *compl5025149-02 5

    025149-01*

    *5025154-01

    5025026-01*

    5025099-01

    5025149-01*

    *5025154-01

    5025099-01

    5025026-01*

    English17

    3mm;4mm;3/16"

    8mm

    5027136-01(4mm)

    5025033-01

    compl5025031-01

    5027003-01

    5025161-01

    5049090-01

    5025047-01

    5025048-01

    5025045-01

    5025046-01

    compl5025038-01

    5025020-01

    3mm;4mm;3/16"

    8mm

    5027136-01(4mm)

    5025033-01

    5025082-01

    5025066-02

    502

    5047-01

    5025081-01

    compl5025038-01

    5025161-01

    5049090-01

    5025053-01

    5025052-01

    5025030-04

    5025030-08

    5025169-01

    (268)

    5025066-02

    5025067-01

    5025100-02

    5025046-01

    TOOLS

    Toolsforsaws61,268and272

    Toolsforsaws281and288

    5025026-01*

    5025149-01*

    *5025154-01

    5025026-01*

    5025149-01*

    *5025154-01

    *compl5025149-02

    *com

    pl5025149-02

    18English

    3mm;4mm;5mm;3/16"

    8mm;10mm

    5025033-01

    5025082-01

    5025066-02

    5025201-01(394)

    5027138-01(3120)

    compl5025038-01

    5049090-0

    1

    5025052-01

    5025030-08

    5025204-01

    (394)

    5027140-01

    (3120)

    5027139-01(394)

    TOO

    LS

    Toolsforsaws394and3120

    *compl5025149-02

    5025149-01*

    *5025154-01

    5025026-01*

    English19

    Ordernumber

    Designation

    5025006-01

    Pliers

    5025016-01

    Allenkey

    5025018-01

    Allenkey

    5025019-01

    Allenkey

    5025020-01

    Assemblytool

    5025022-01

    Socket

    5025023-01

    Socket

    5025026-01

    Puller

    5025030-04

    Assemblytool

    5025030-08

    Assemblytool

    5025030-09

    Assemblytool

    5025030-10

    Assemblytool

    5025031-01

    Puller

    5025033-01

    Pistonstop

    5025037-01

    Vacuumgauge

    5025038-01

    Pressuregauge

    5025045-01

    Extendedsocket

    5025046-01

    Extendedsocket

    5025047-01

    Coverplate

    5025048-01

    Coverplate

    5025052-01

    Assemblysocket

    5025057-01

    Allenkey

    5025064-01

    Allenkey

    5025066-02

    U-key

    5025067-01

    U-key

    5025070-01

    Assemblytool,piston

    5025071-01

    Coverplate

    5025072-01

    Coverplate

    5025079-01

    Assemblymandrel

    5025081-01

    Coverplate

    5025082-01

    Assemblymandrel

    5025083-01

    Hook,tankvalve

    5025086-01

    Allenkey

    5025087-01

    Allenkey

    5025088-01

    Allenkey

    5025099-01

    Pullersleeve

    5025100-02

    U-key

    5025102-01

    Assemblyfixture

    5025132-01

    Assemblysleeve

    5025134-02

    Feelergauge

    5025149-01

    Puller

    5025149-02

    Puller

    5025150-01

    Socket

    5025154-01

    Boltset

    5025161-01

    Dismantlingtool,crankcase

    5025169-01

    Assemblymandrel

    5025169-01

    Feelergauges

    5025194-01

    Assemblymandrel

    5025201-01

    Coverplate

    5025204-01

    Spacer

    5025403-01

    Spacer

    5027009-01

    Pumpblower

    5027113-01

    Testsparkplug

    5027114-01

    Tachometer

    5027136-01

    Allenkey

    5027138-01

    Coverplate

    5027139-01

    Coverplate

    5027140-01

    Spacer

    5049029-02

    Coverplate

    5049090-01

    Puller

    5049826-01

    Siliconerubber

    5052679-12

    Assemblymandrel

    5053818-17

    Puller

    Listoftools

    TOOLS Or

    dernumber

    Designation

  • 8/3/2019 husqwm271_hwen1997_1018855-26

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    20English

    Saws36and

    41

    SERVICEDATA

    L

    L

    I

    G

    G

    G

    G

    5

    10

    15

    4

    6

    Characterkey

    Numbersbycomponentsthatarebolted

    refertothetighteningtorqueinNm.

    L

    =Lubricateusingtwo-strokeoil.

    I

    =Lubricateusingsawchainoil.

    G

    =Lubricateusinggrease.

    =Lockingfluid(Loctite).

    English21

    SERVICED

    ATA

    L

    G

    15

    4

    6

    4

    3

    28

    4

    22English

    Saws42,242and246

    SERVICE

    DATA

    L

    L

    I

    G

    G

    G

    G

    515

    4

    8

    3

    G

    242

    42246

    10

    5

    42246

    242

    7-8

    8-10

    4-5

    Characterkey

    Numbersbycomponentsthatarebolted

    refertothetighteningtorqueinNm.

    L

    =Lubricateusingtwo-strokeoil.

    I

    =Lubricateusingsawchainoil.

    G

    =Lubricateusinggrease.

    =Lockingfluid(Loctite).

    English23

    SERVIC

    EDATA

    L

    G

    L

    20

    4

    2

    4

    28

    2

    9

    32

    9

    6

    2

    2

    13

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    24English

    Saws40and

    45

    SERVICEDATA

    L

    L

    I

    G

    G

    G

    G

    3-4

    2-3

    25-35

    7-8

    2-3

    2-3

    2-3

    10-12

    Characterkey

    Numbersbycomponentsthatarebolted

    refertothetighteningtorqueinNm.

    L

    =Lubricateusingtwo-strokeoil.

    I

    =Lubricateusingsawchainoil.

    G

    =Lubricateusinggrease.

    =Lockingfluid(Loctite).

    English25

    SERVICED

    ATA

    L

    G

    3-4

    2-3

    2-3

    25-30

    2-3

    2-32

    -3

    2-3

    8-10

    2-3

    2-3

    3-4

    20

    2-3

    26English

    Saws51

    and55

    SERVICE

    DATA

    L

    L

    I

    GG

    G

    G

    G

    4-5 1

    5

    6-8

    7-8

    30-40

    3-4

    3-4

    8-10

    3-4

    1,5-2

    Characterkey

    Numbersbycomponentsthatarebolted

    refertothetighteningtorqueinNm.

    L

    =Lubricateusingtwo-strokeoil.

    I

    =Lubricateusingsawchainoil.

    G

    =Lubricateusinggrease.

    =Lockingfluid(Loctite).

    English27

    SERVIC

    EDATA

    L

    G

    15

    25

    12-14

    8-10

    3-4

    3-4

    3-4

    3-5

    3-4

    3-4

    1-2

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    28English

    Saws254and

    257

    254

    257

    SERVICEDATA

    L

    L

    I

    G

    G

    G

    G

    G

    5

    8

    15

    45

    10

    10

    5

    35

    3

    5

    3

    Characterkey

    Numbersbycomponentsthatarebolted

    refertothetighteningtorqueinNm.

    L

    =Lubricateusingtwo-strokeoil.

    I

    =Lubricateusingsawchainoil.

    G

    =Lubricateusinggrease.

    =Lockingfluid(Loctite).

    English29

    254

    SERVICED

    ATA

    L

    G

    5

    3

    2

    28

    4

    10

    20

    4

    13

    4

    9

    3

    5

    30English

    Saw262

    SERVICE

    DATA

    L

    L

    I

    G

    G

    G

    G

    G

    5

    8

    15

    46

    10

    35

    4

    4

    3

    4

    Characterkey

    Numbersbycomponentsthatarebolted

    refertothetighteningtorqueinNm.

    L

    =Lubricateusingtwo-strokeoil.

    I

    =Lubricateusingsawchainoil.

    G

    =Lubricateusinggrease.

    =Lockingfluid(Loctite).

    English31

    SERVIC

    EDATA

    L

    G

    2

    2

    28

    4

    9

    20

    4

    5

    13

    4

    4

    5

    3

    95

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    32English

    Saws61,268and272

    268272

    61

    SERVICEDATA

    L

    L

    I

    G G

    G

    G

    G

    5

    8

    15

    610

    5

    10

    2

    35

    6

    6

    35

    1

    4

    3

    Characterkey

    Numbersbycomponentsthatare

    boltedrefertothetighteningtorqueinNm.

    L

    =Lubricateusingtwo-strokeoil.

    I

    =Lubricateusingsawchainoil.

    G

    =Lubricateusinggrease.

    =Lockingfluid(Loctite).

    English33

    272

    268272

    61

    SERVICED

    ATA

    L

    G

    3

    428

    4

    10

    15

    4

    3

    3

    5

    14

    6

    4

    6

    11

    3

    1

    3

    9

    3

    34English

    Saws281

    and288

    SERVICE

    DATA

    L

    I

    G

    G

    G

    G

    G

    5

    8

    15

    6

    13

    5

    4

    35

    6

    L

    Characterkey

    Numbersbycomponentsthatarebolted

    refertothetighteningtorqueinNm.

    L

    =Lubricateusingtwo-strokeoil.

    I

    =Lubricateusingsawchainoil.

    G

    =Lubricateusinggrease.

    =Lockingfluid(Loctite).

    English35

    SERVICEDATA

    L

    G6

    4

    35

    11

    20

    7

    7

    3

    17

    3

    4

    77

    6

    4

    3

    19

  • 8/3/2019 husqwm271_hwen1997_1018855-26

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    36English

    Saw394

    L

    I

    GG

    G

    G

    G

    5 15

    2-4

    10-12

    6-8

    7-9

    SERVICEDATA

    L

    Characterkey

    Numbersbycomponentsthatare

    boltedrefertothetighteningtorque

    inNm.

    =Lockingfluid(Loctite).

    L

    =Lubricateusingtwo-strokeoil.

    I

    =Lubricateusingsawchainoil.

    G

    =Lubricateusinggrease.

    English37

    SERVICED

    ATA

    G

    L

    30-40

    10-12

    5-6

    6

    2-3

    4-5

    3-5

    3-5

    5-6

    20-22,5

    12-14

    L

    38English

    Saw3120

    SERVICE

    DATA

    L

    I

    G

    G

    G

    G

    L

    G

    5

    8

    15

    5

    12

    5

    38

    7

    8

    5

    7

    5

    1

    3

    4

    Characterkey

    Numbersbycomponentsthatarebolted

    refertothetighteningtorqueinNm.

    L

    =Lubricateusingtwo-strokeoil.

    I

    =Lubricateusingsawchainoil.

    G

    =Lubricateusinggrease.

    =Lockingfluid(Loctite).

    English39

    SERVIC

    EDATA

    L

    G

    L

    5

    4

    40

    12

    20

    4

    12

    17

    10

    8

    9

    4

    6

    5

    57

    3

    3

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    40English

    Wornneedlevalve/needle

    Leakingcontroldiaphragm/

    coverplate

    Controlsystemsticking

    Wornthrottlelever

    Faultydiffuserjet

    Fuelfilterblocked

    Fuellineblocked

    Leakingmanifold

    Loosecarburettormounting

    Wornthrottlevalveshaft

    Loosethrottlevalvescrew

    Wornthrottlevalve

    Controlsystemsticking

    Leakinthrottlesystem(airor

    fuel)

    Controldiaphragmcentreknob

    isworn

    Holeindiaphragm

    Leakingcontroldiaphragm/

    coverplate

    Crankcaseleaking

    Fuellineblocked

    Controlsystemsettoohigh

    Controlsystemsticking

    Controlsystem(airorfuel)

    Leakingcontroldiaphragm/

    coverplate

    Faultydiffuserjet

    Crankcaseleaking

    Controlsystemsettoohigh

    Controlsystemsticking

    Controlsystemdamaged

    Wornneedlevalve

    Leakingcontroldiaphragm/

    coverplate

    Controlsystemincorrectly

    assembled

    AdjustL-screw

    Airfilterblocked

    Chokenotworkingcorrectly

    Wornchokeshaft

    Wornchokeplate

    Fuelfilterblocked

    Fuellineblocked

    Pistonringseized

    Blockedimpulsechannel

    Looseorfaultyfuelpipe

    Holeindiaphragm

    Wornneedlevalve/needle

    Controlsystemsticking

    Controlsystemsettoohigh

    Leakincontrolsystem(airor

    fuel)

    Loosecoveroncarburettor

    pumpside

    Wornneedlevalve

    Controlsystemsettoohigh

    Controlsystemsticking

    Difficultstarting

    Carburettor

    leakingfuel

    Floodingwhen

    theengineisnot

    running

    Faultsthatcandeveloponthechainsaware

    dividedintofourgroupsasfollows.Ineachcat-

    egory,possiblemalfunctionsareshownontheleft,

    withalistofpossiblefaultsontheright.Themost

    probablefaultisgivenfirstandsoon.

    Idling(lowrpm)

    Willnotidle

    Idlingtoorich

    AdjustL-screw

    Leakingmanifold(intermediate)

    Loosecarburettormounting

    Looseorfaultyfuelpipe

    Fuelfilterblocked

    Fuellineblocked

    Fueltankbreatherblocked

    Throttleshaftandleverstiff

    Throttlecablesticking

    Defectivethrottlereturnspring

    Bentthrottlelevershaftstop

    Faultydiffuserjet

    AdjustL-screw

    Wornneedlevalve/needle

    Controlsystemsettoohigh

    Wornthrottlelever

    Leakingcontroldiaphragm/

    coverplate

    Controlsystemsticking

    Idlesw

    henL-screw

    closed

    Idlinguneven

    L-screwrequires

    consta

    ntadjustment

    Toomuchfuelatidling

    Troubleshootingschematic

    TROUBLESHOO

    TING

    Starting

    Idling

    (lowrpm)(cont.)

    English41

    AdjustH-screw

    Blockedairfilter

    Blockedfueltankbreather

    Blockedfuelfilter

    Fuellineblocked

    Looseordamagedfuelline

    Impulsechannelleaking

    Impulsechannelblocked

    Loosecoveroncarburettor

    pumpside

    Faultypumpdiaphragm

    Leakingmanifold

    Loosecarburettormounting

    Controlsystemsettoolow

    Controlsystemdamaged

    Controlsystemincorrectly

    assembled

    Leakingcontroldiaphragm/cover

    Controlsystems

    ticking

    Blockedsilencer

    AdjustH-screw

    Blockedfueltankbreather

    Blockedfuelfilter

    Impulsechannelleaking

    Impulsechannelblocked

    Loosecoveroncarburettor

    pumpside

    Faultypumpdiaphragm

    Blockedairfilter

    Controlsystems

    ticking

    Leakinthrottlesystem(airor

    fuel)

    Controlsystemincorrectly

    assembled

    Loosediaphragm

    Holeindiaphragm

    Leakingcontroldiaphragm/cover

    Blockedfueltankbreather

    Blockedfuelfilter

    Fuellineblocked

    Looseordamagedfuelline

    Impulsechannelleaking

    Impulsechannelblocked

    Loosecoveroncarburettor

    pumpside

    Faultypumpdiaphragm

    Leakingmanifold

    Loosecarburettormounting

    bolts

    Controlsystemsettoolow

    Leakinthrottlesystem(airor

    fuel)

    Controlsystemincorrectly

    assembled

    Loosediaphragm

    Holeindiaphragm

    Leakingcontroldiaphragm/cover

    Willnotrunatfull

    throttle

    Lowpower

    Willnot

    four-stroke

    Highrpm

    Accelerationandretardation

    Do

    esnotaccelerate

    Mo

    torstallswhen

    throttlereleased

    Ov

    errichaccelera-

    tion

    AdjustL-screw

    AdjustH-screw

    Blockedairfilter

    Blockedfueltankbreather

    Blockedfuelfilter

    Fuellineblocked

    Looseordamagedfuelline

    Impulsechannelblocked

    Loosecoveroncarburettor

    pumpside

    Faultypumpdiaphragm

    Leakingmanifold

    Loosecarburettormounting

    Throttlesettoolow

    Controlsystemincorrectly

    assembled

    Controlsystemsticking

    Faultydiffuserjet

    Blockedsilencer

    AdjustL-screw

    AdjustH-screw

    Faultypumpdiaphragm

    Controlsystemsettoohigh

    Controlsystemsticking

    Faultydiffuserjet

    AdjustL-screw

    AdjustH-screw

    Blockedairfilter

    Faultypumpdiaphragm

    Faultydiffuserjet

    Troubleshootingmethods

    In

    additiontofaultsgivenintheaboveschematic,

    tro

    ubleshootingcanbecarriedoutonaspecific

    co

    mponentorsub-systemofthechainsaw.The

    differenttestingproceduresaredescribedin

    respectivesectionsandareasfollows:

    1.

    Pressuretestingthecarburettor.

    Seepage100.

    2.

    Pressuretestingthecrankcaseandcylinder.

    Seepage114.

    3.

    Pressuretestingthedecompressionvalve.

    Seepage114.

    4.

    Checkingtheoperationofthechainbrake.

    Seepage47.

    TROUBLESHO

    OTING

    42English

    Chainbrake

    3120continuesonnextpage.

    Placetheclutchcoverinavicewiththejaws

    positionedasshownbelowandreleasethe

    tubularpinB.

    CarefullyknockoutthetubularpinB.

    Allsawsexcept3120

    3

    120

    !WARNING!

    Iftheclutchcoverslidesoutof

    thevice'sgripthespringcanfly

    outwithimmenseforceresulting

    inpersonalinjury!

    Wearprotectiveglasses!

    Dismantling

    Loosenthescrewonthehandguardand

    screwback2turns.

    Gentlyhitthescrewsothatthethreadedpart

    ofthebushingcanberemoved.

    Dismantletheotherpartofthebushingby

    meansofapunch.

    RemovethecylindricalpinA.

    Slidethehandguardforwardssothatthe

    brakeisactuated.

    Dismantletheclutchcoverandclean.See

    theoperatinginstructions.

    Removethecoveronthechainbrakespring.

    Thecoverhas4or5screws.

    Continuesonnextpage.

    SAFETYEQ

    UIPMENT

    B

    A

    !WARNING!

    Ifthebrakeisnot'on',thespring

    canflyoutresultinginpersonal

    injury.

    Wearprotectiveglasses!

    English43

    3120

    Slideupthebackedgeofthe

    springwithascrewdriver.

    Useapunchtoknockoutthepinholdingthe

    kneelink.

    Carefullyunscrewthevicesothatthepres-

    surerodandtheratchetmoveoutofthe

    clutchcover.

    Dismantlethepressurerodfromthebrake

    band.

    Allsawsexcept3120

    Removethescrewthatholdsthefixedendof

    theband.

    40,42,45,51,

    242,246,55,254,

    257,262and394

    36,41,61,268,

    272,281and288

    Knockouttheband'sfixedendusinga

    punchthroughtheholeintheclutchcover

    andremovethelooseparts.

    Liftuptheband'sfixedendusingascrew-

    driverandremovethelooseparts.

    SAFETYE

    QUIPMENT

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    44English

    CleaningandInspection

    Cleanandinspectallparts.

    Thethicknessofthebrakebandmustnotbe

    under0.8mmatanypoint.

    Assembly

    Fittheband'sfixedendintopositiononthe

    clutchcover.

    Allsawsexcept3120

    3120

    Continuesonnextpage.

    3120continuesonnextpage.

    Fitthescrewthatholdstheband'sfixedend.

    Greasethekneelinkandknockinthetubular

    pinthatholdsthekneelink.

    SAFETYEQUIPMENT

    Min.0.8mm

    English45

    Allsawsexcept3120

    3120

    Slidethespringoverthekneelink'sstudand

    pressdowntheoppositeendofthespringinto

    itsrecess.

    Fitthecoveroverthespring.

    Fitthespringandscrewontothepressure

    rodonthebrakeband.

    Note!Plasticsleeve.

    Bottom

    thescrew

    ontothepressurerod

    threadandbackoff4-5turns.

    Greaseandfittheratchet.Settheunitina

    vice,positionedinthejawsasshownbelow.

    !WARNING!

    Iftheclutchcoverslidesoutof

    thevice'sgripthespringcanfly

    outwithimmenseforceresulting

    inpersonalinjury!

    3120continuesonnextpage.

    Continuesonnextpage.

    SAFETYEQUIPMENT

    46English

    Allsawsexcept3120

    Carefullytightentheviceuntiltheholeforthe

    tubularpinandtheratchetalign.

    Carefullyknockinthepin.

    Fitthehandguard,thetwobushingsandthe

    screw.

    Fitthecylindricalpin.

    Pullbackthehandguardsothatthebrakeis

    notactuated.

    SAFETYEQ

    UIPMENT

    Checkthechainbrakeasdescribedonthe

    nextpage.

    3120

    English47

    Barlength,L

    Height,H

    15-20inches

    50cm

    21-28inches

    70cm

    29-32inches

    80cm

    L

    H

    Theengineshouldnotberunning

    duringthetest.

    Testthatthechainbrakecomesonas

    follows:

    !WARNING!

    Afterrepair,thechainbrake

    mustbecheckedassetoutin

    thefollowinginstructions.

    Checkingbrakeoperation

    Holdthechainsawaboveafirmsurface.

    Thedistancebetweenthebarandthe

    surfaceareshowninthetablebelow.

    SAFETYEQUIPMENT

    Releasethefronthandleandletthechain

    sawrotatearoundtherearhandle.

    Whenthebarnosehitsthesurfacethe

    chainbrakeshouldtrip.

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    48English

    Chaincatcher

    Description

    Thechaincatcherisintentedtocatchthe

    chainifitshouldbreak.

    Thechaincatcherhasadifferentdesignand

    issecureddifferentlyonthechainsaws

    describedinthismanual.

    Thefollowingdesignsareused:

    Aluminiumangle.

    Plasticangle.

    Fixedroller.

    Rotatingroller.

    Thefollowingsecuringmethodsareused:

    Usingscrewsonthecrankcase.

    Usingscrewsonthespike.

    Usingnutsonthespike.

    Replacing

    Dismantlethechainandbar.Seetheoper-

    atinginstructions

    Reassemblethechainandbar.Seethe

    operatinginstructions

    Checkthechaincatcherandreplaceifbro-

    kenorbadlydamaged.

    Thetighteningtorqueisstatedintheservice

    data

    SAFETYEQUIPMENT

    English49

    Muffler W

    ARNING!

    Donottouchthemuffleruntilit

    hascooled.Riskofburns!

    Dismantling

    !

    SAFETYEQUIPMENT

    BC A

    Ifthesawisequippedwithmufflermounting

    (A),unscrewthisfrom

    thecrankcaseand

    muffler.

    Unscrewthemufflerfromthecylinder

    (M5orM6bolts,M5orM6nuts).

    Removethemuffler,gasketandcoolingplate

    (B)ifthesawissoequipped.

    Ifthesawisequippedwithasparkarrester

    (C),removethis.

    Saws36and41

    Saw242Cat

    Dismantlethemuffler

    asshowninthefigure

    totheright.

    Dismantlethemufflerasshown

    inthefiguretotheright.

    !

    A

    1

    WARNING!

    Thecoatingonandinthecatalytic

    converterelement(A)ishazardous

    toyourhealthiftouched.Wear

    protectivegloveswhenworkingon

    acatalyticconverter

    50English

    SAFETYEQ

    UIPMENT

    CleaningandInspection

    Cleanallpartsandcheckthefollowing:

    Thatthemufflerandmufflermountingsare

    notcrackedorotherwisedamaged.

    ThatthegasketsareOK.

    Assembly

    Cleanallcontactsurfaces.

    Othersaws

    Ifthesawisequippedwithasparkarrester

    (C),fitthis.

    Saws36and

    41

    Fitthecoolingplate(B)if

    fitted,gasketandmuffleron

    thecylinder.

    Othersaws

    242Cat

    Assemblethemufflerandfittothe

    cylinder.Tighteningtorque,seepage

    20.

    ! D E F

    B C A

    Se

    e"Servicedata"regardingtighteningtorques.

    1.

    Securethemuffleronthecylinderusingthetwo

    bolts(D).

    2.

    Assemblethemufflercomponentsusingthefour

    bolts(E).

    3.

    Securethemufflertothecrankcaseusingthetwo

    bolts(F)andLoctite.

    Onlyspeciallytreatedboltsmaybeusedon

    thecatalyticconverter(hightemperature).

    Seesparepartscatalogue.

    1

    Tightenallboltsusingthetightening

    torquesetoutinthe"Servicedata".

    WARNING!

    Thecoatingonandinthecatalytic

    converterelement(A)ishazardous

    toyourhealthiftouched.Wear

    protectivegloveswhenworkingon

    acatalyticconverter

    WARNING!

    Thecoatingonandinthecata-

    lyticconverterelement(A)is

    hazardoustoyourhealthif

    touched.Wearprotectivegloves

    whenworkingonacatalytic

    converter

    !

    English51

    Stopswitch

    Dismantling

    Removetheearthscrew(A)andcable(B).

    Presstheswitch'ssecuringtabs(C)towards

    eachotherandpushouttheswitch.

    CleaningandInspection

    Cleantheswitchandcheckitsresistanceas

    follows:

    Connectanohmmeterasshowninthefig.

    Theresistanceshouldbe:

    Inthestopposition

    lessthan0.1ohm.

    Intherunposition

    morethan1000ohm.

    Assembly

    Fittheearthscrew(A)andcable(B).

    Note!Onsomemodelstheearthcableshould

    beconnectedtotheearthscrew.

    SAFETYE

    QUIPMENT

    B

    CA

    Presstheswitchintothesocketonthetankunit.

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    52English

    Throttlelock

    Removethetankunitfromtheengine

    assembly.Seepage103.

    !

    WARNING!

    Thefuelusedinthechainsaw

    posesthefollowinghazards:

    1.

    Theliquidanditsvapours

    are

    poisonous.

    2.

    Cancauseskinirritation.

    3.

    Ishighlyinflammable.

    Dismantlethethrottlelockpin(A)

    usingapunch.

    Dismantling

    A

    SAFETYEQUIP

    MENT

    Turnthethrottlelockas

    showninthefigure,andlift

    itoutwiththespringfrom

    thecut-outinthehandle.

    Saw394

    Slidethethrottlelockand

    removeitforwardsas

    showninthefigure.

    Saws61

    ,268,268K,

    272XP,2

    72K,272S,

    281XP,288XPand

    394.

    Saws61,268,272XP,2

    72K,

    272S,281XPand288

    XP.

    Continuesonnextpage.

    Carefullypriseupthelock

    fromtheslotandremove.

    Saws36,41,42,55,

    242XP,246,51,

    254XP,257

    and

    262XP.

    Othersaws.

    Saws40,45.

    Seecontinuationonnextpage.

    Saw3120.

    Seecontinuationonnext

    page.

    English53

    Dismantlethethrottlepin(B)byusinga

    punch.

    Dismantlethethrottle.Onsaw394,also

    removethethrottlecable.

    B

    Removethethreescrewsinthesideofthe

    handleaswellasthescrew

    holdingthe

    springunderthehandle.

    Liftoutthethrottlelockandthethrottle.

    Saw3120

    Removethethreepinswithapunch.

    Pressthethrottlelockdownandmove

    itandthetriggerforwardsuntilthe

    backedgeofthelockappears.

    Liftoutthetriggerlock.

    Removethespringswhereappropriate.

    Saws36,41,42,55,242XP,246,51,254XP,

    257and262XP.

    Removetherubberelement(A).Slideout

    thethrottlepin(B)andliftoutthethrottlearm

    andspring.

    A

    B

    A

    SAFETYEQUIPMENT

    Saws61,268,268K,272XP,272K,272S,

    281XP,288XPand394.

    Saws40and45

    Liftoutthethrottlewithcablefrom

    thefront.

    54English

    Cleaningandinspection

    Cleanallparts.

    Checkthatthesprings,wherefitted,are

    OKandhavethecorrecttension.

    Checkthatthelock'sactivation

    mechanismisnotworn.Forexamplesof

    theactivationmechanism,seethefigure.

    SAFETYEQ

    UIPMENT

    Onthosesawsfittedwithathrottlecable,check

    thatthecableandleverareOKandrunfreely.

    English55

    Assembly

    SAFETYE

    QUIPMENT

    Fitspringsinap

    propriatecases.

    !

    Othersaws.

    Saws36,40,41,45,42,

    242XP,246,51,55,

    254XP,257and262XP.

    Onsaw394,fitthecable

    tothetrigger.Insertthem

    intothehandlefromthe

    front.

    Fitthecab

    letothetrigger

    andinstall

    thethrottlelock

    andtrigger.

    Fitthetriggerwiththecable

    fromthefront.

    Fitthepin(B)andspring

    (whenused).

    Fittheside

    ofthehandle

    usingthreescrewsonthe

    sideandoneunderneath,

    whichhold

    sthespring.

    Fitthespringandslidethe

    throttlelockforwardsfrom

    abovesothatitsrearedge

    canbeslidinundertheedge

    ofthehandle.

    Allsawsexcept40and4

    5continueonthenextpage.

    Saws61,268,268

    K,

    272XP,272K,272

    S,

    281XP

    and

    288X

    P.

    Seenextpage.

    Saws36,41,42,242XP,

    246,51,55,254XP,257,

    262XPand394.

    B

    WARNING!

    Thefuelusedinthechainsaw

    posesthefollowinghazards:

    1.

    Theliquidanditsvapours

    are

    poisonous.

    2.

    Cancauseskinirritation.

    3.

    Ishighlyinflammable.

    Saws40,45.

    Saw3120.

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    56English

    SAFETYEQUIPMENT

    Saw3120.

    Fitthethreepinsthathold

    thecablebracket,throttle

    lockandtrigger.

    Saws61,268,268K

    ,

    272XP,272K,272S

    ,

    281XPand288XP.

    Fitthethrottlelockand

    spring.Onsaw394,twist

    asshowninthefigure

    whenfitting.

    Fitthethrottlearmand

    spring.Fitthepinand

    the

    tworubberdampers.

    Saws36,41,42,242XP,

    246,51,55,254XP,257,

    262XPand394.

    Fitthethrottlelockfro

    mthe

    front.

    Fitthethrottlelockpin.

    Fitthetankunit.Seepage1

    05.

    English57

    Dismantling

    Dismantlethestarter

    Seetheoperatinginstructions.

    Pulloutthecord20-30cmandinsertitinto

    thecut-outinthestarterpulleyrim.

    Somesawshaveseverallongcut-outs.

    Rotatethestarterpulleyanticlockwiseuntil

    thespring-tensiononthestarterpulleyceases.

    Dismantlethestarterpulley'scentreboltand

    washer.

    ! Ifthestarterhasacordguide(A),remove

    this

    Liftoutthestarterpulleycarefully.

    Ifthecordistobereplaced,cutitoffandpull

    outthebitsfromthehandleandstarterpulley

    usingapairoflongnosedpliers.

    !WARNING!

    Ensurethatthespringdoesnot

    flyoutandcausepersonalinjury!

    Wearprotectiveglasses!

    Ifthespringistobereplaced,removetheold

    springfrom

    thestarterpulley.Somesaws

    haveaprotectiveplateoverthespring.

    STARTE

    R

    WARNING!

    Ifthespringtensionisreleased

    whenliftingthestarterpulley,the

    springcanflyoutandcauseper-

    sonalinjury!

    Wearprotectiveglasses!

    A

    58English

    CleaningandInspection

    !WARNING!

    Ensurethatthespringdoesnot

    flyoutandcausepersonalinjury!

    Cleanallpartsandcheckthefollowing:

    Thestartercord.

    Thedogsinthestarterpulley.

    ThatthepawlsontheflywheelareOK,and

    springbacktowardsthecentreandmovefreely.

    STAR

    TER

    Changingtheferrule

    Removethepartsoftheoldferrule.

    Fitthenewferruleinthestarterhousing.

    Useawrench,spacer(A)andball(B).

    Splayouttheferruleontheinsideas

    showninthefigure.

    B AEnglish59

    Assembly

    !WARNING!

    Ensurethatthespringdoesnot

    flyoutandcausepersonalinjury!

    Ifanewspringistobefitted,positioninits

    security/holdersothattheeyeisoverthe

    studinthestartercover.

    Slideinthespringandremovethesecurity/

    holder.

    Ifanewcordistobefitted,putthefreeendintheholeonthestarterpulley.Griptheendusinglong

    nosedpliersandpullthecordthrough.

    36and41.

    Screwthecordtothestarter

    pulley.

    Secureth

    ecordonthe

    starterpulley.

    Knotthecordonthestarter

    pulley.

    61,268,27

    2,281and288.

    42,242,246,51,55,254,

    257,262,394and3120.

    Continues

    onnextpage.

    STA

    RTER

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    60English

    Ifthestarterunithasacoverplate(B)over

    thespring,fittheplate.

    Fitthestarterpulley.Rotatebackandforth

    untilthestarterpulleycatchesinthespring.

    Fitthestarterpulleywasherandboltand

    tightentheboltto4Nm.

    Ifthestarterhasacordguide(A),fitthis.

    Pulloutthecordthroughtheholeinthecover

    andfitthehandle,securewithadoubleknot.

    Pulloutthecord20-30cmandinsertitinto

    thecut-outonthestarterpulleyrim.Some

    sawshaveseverallongcut-outs.

    Rotatethestarterpulleyclockwiseuntilthe

    cordiscorrectlytensioned.

    A.Pulloutthecordcompletelyandholdthe

    pulleywithyourthumb.

    B.Inthispositionitshouldbepossibletoturn

    thestarterpulleyafurther1/2-3/4turn.

    Fitthestarteronthecrankcase.Tightenthe

    boltsto4Nm.

    STARTER B

    Greasethereturnspringandstarterpulley

    bearing.

    Checkthecordtension

    A

    English61

    Ignitionsystem

    ELECTRICALSYSTEM

    Dismantling

    Saws36and41.

    Loosentheflywheelnutandunscrewit1

    turn

    Tapthenutquicklywithahammersothat

    theflywheelcomesloose

    Removethenutandflywheel.

    Othersaws,seenextpage.

    Loosenthecablethatrunstothestop

    switchfromtheignitionmodule.

    Releasethecablesfromtheguiderailand

    removetheguiderail.

    Intheeventofafaultintheignitionsystem

    theignitionmoduleshouldbecheckedbefore

    dismantlingtheignitionsystem.

    Checktheignitionmoduleasfollows:

    Connecttestsparkplug5027113-01tothe

    HTleadandclampthetestsparkplugtothe

    cylinder.

    Turntheengineoverusingthestarter.

    Ifthetestsparkplugsparkstheignition

    moduleisOK.

    Removethecylindercoverandthestarterunit.

    Removethesparkplugandfitthepistonstop.

    62English

    Unscrewthetwopawlsandsprings

    locatedontheflywheel.

    Loosentheflywheelnutandundountilit

    alignswiththeendoftheshaft.

    Allsawsexcept36and41.

    Fitpuller5025149-02andloosenthe

    flywheel.

    Removethepuller,nutandflywheel.

    Continuationallsaws

    Removetheignitioncoil.

    ELECTRICA

    LSYSTEM

    Thegeneratorcanbeunscrewedifthesawis

    fittedwithahandleheatingsystem.

    Removeallpartssothatthecablecanbe

    released.Seeapplicablesections.

    English63

    CleaningandInspection

    Assembly

    Fitthegeneratorifthesawisfittedwith

    handleheating.

    Tightentheboltsto4Nmandlockusing

    Loctite.

    Fitthecabletotheactualcontactonthe

    saw.Adjustthelengthofthecableby

    knottingit.

    Replacetheflywheelwasherandnut.

    Tighteningtorque,see"Servicedata".

    Removethepistonstop.

    Fittheignitionmodule

    withouttighteningthe

    screws.

    Turntheflywheelsothatits

    magnetisbesidethe

    ignitionmodule.

    ELECTRIC

    ALSYSTEM

    Cleanallparts,especiallytheflywheeland

    shafttaper.

    Checkthattheflywheelisnotcrackedor

    damagedinanyotherway.

    Placetheflywheelonthecrankshaft.Rotate

    gentlyuntiltheflywheel'skeymatesinthe

    keywayontheshaft

    Continue

    assemblyon

    nextpage.

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    64English

    ELECTRICALSY

    STEM

    Insertfeelergauge5025134-02

    (0.3mm)betweentheignitionmodule

    andtheflywheel'smagnet.

    Pushtheignitionmoduletowardsthe

    flywheelandtightentheboltsto4Nm.

    Fittheguiderail,insertthecablesandfit

    thecabletotheignitionmodule.

    Stopswitch

    Thestopswitchisdescribedinthesection

    "Safetyequipment".Seepage51.

    Saws42,242,246,281and288.

    Othersaw

    s.

    PushtheHTcablethroughthesparkplug

    coverandfitthecontactspringusingthe

    pliers.

    Slidethesparkplugcoveroverthecontact

    spring.

    Fittheignitioncoil,whichislocatednextto

    thecarburettorandconnectthecables.

    Fitthestarterandcylindercover.

    Fitthestarterandcylindercover.

    MakeaholeintheHTcableusingpliers

    5025006-01.

    Fittingthesparkplugcover

    English65

    ELECTRICALSYSTEM

    Handleheating

    Somesawsareequippedwithanelectric

    handleheating.Thisconsistsofthefollowing

    parts:

    Generator.

    Powerswitch.

    Heaterloopinthetankunit.

    Handleloopwithheaterloop.

    (Oneortwoloops).

    Description

    Theabovecomponentsareconnectedin

    series,whichmeansthatifthereisafaultin

    one,allcomponentsstopworking.

    Thewiringdiagramisshowninthefigureto

    theright.Theorderofcomponentscanvary

    fromsawtosaw.

    A1

    B

    C

    D

    E

    A2

    Troubleshootingcantakeplacewithmost

    componentsconnectedtothesaw.An

    ohmmeterisrequiredfortroubleshooting.

    Beforetroubleshootingindividual

    componentsremovethepowerswitchand

    disconnectoneoftheswitch'scables.

    Removeothercomponentsasnecessary.

    E.g.thecylindercover.Seetheoperating

    instructions.

    Troubleshootingindividualcomponents,see

    nextpage.

    Measurementpoints:

    A1andA2Earth.E.g.thecylinder

    A1-B

    Measurementofthegenerator

    B-C

    Measurementofthehandleloop

    C-D

    Measurementoftheheaterloops

    intherearhandle

    D-A2

    Measurementofthepowerswitch

    Troubleshooting

    66English

    ELECTRICA

    LSYSTEM

    Checkingthegenerator

    Connecttheohmmetertothecylinder

    (pointA1)andpointB.Theohmmeter

    shouldread0.9-1.3ohm.

    Replaceageneratorthathashigheror

    lowervalues.

    ConnecttheohmmetertopointsBandC.

    Theohmmetershouldread3-4ohm.

    Replacethehandleloopthathasahigher

    value.

    ConnecttheohmmetertopointsCandD.

    Theohmmetershouldread0.7-2.5ohm.

    Replaceaheatloopsthathashigher

    values.

    Checkthehandleloop

    Checkingtheheatloopsintherearhandles

    A1

    B

    B

    C

    Connecttheohmmeteracrosstheswitch.

    Theohmmetershouldreadmorethan

    1000ohmwiththeswitchinposition"0".

    Theohmmetershouldread,atthehighest,

    0.1ohmw

    iththeswitchinposition"1".

    Checkingthepowerswitch

    D

    C

    English67

    Dismantling

    Removethebarandchain.Seetheoperat-

    inginstructions.

    On268K

    and272K,removethecutting

    attachment.Seetheoperatinginstructions.

    On272S,removethegrinderattachment.

    Seetheoperatinginstructions.

    Useaspannerandremovetheclutch.On

    saws36and41usetheservicetoolno.530

    0311-12.

    Note!Left-handthread.

    Sawswiththree

    coilsprings.

    Removethe

    springbyfirst

    liftingashoe

    usingasuitable

    spacer(A).

    Then

    remo

    ve

    the

    clutch

    shoes.

    Removethespringsusinga

    screwdriver.

    Then

    removetheclutch

    shoes.

    Sawswithone

    longspring.

    Priseoutthespringheels

    usingascrewdriver.Remove

    thespringsfrom

    theother

    sideusingcirclippliers.Then

    removetheclutchshoes.

    CENTRIFUGALCLUTCH

    A

    Removethesparkplugandinsertthepiston

    stop.

    SawswiththreeC-springs.

    Removetheclutch

    drumandneedlebearing.

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    68English

    CleaningandInspection

    ThatmeasurementAisnotbelow1mm.

    Checkthatthereisnoplay

    betweenthe

    clutchshoeandclutchhub

    Checkforwearonthechainsprocket.

    Checktheconditionoftheneedlebearing

    andthebearingsurfaceonth

    ecrankshaft.

    Thattheclutchdrum

    friction

    surfaceand

    bearingsurfaceareundamag

    ed.

    ThatmeasurementBisnotunder1mm.

    Cleanallpartsandinspectthefollowing:

    CENTRIFUGALC

    LUTCH

    B

    A

    Clutchshoes

    withchamfers.

    Clutch

    shoes

    withoutchamfers.

    English69

    Assembly

    Greasetheneedlebearing(C)andfitonto

    thecrankshaft.Thenfittheclutchdrum.

    NOTE!Thebearingcanalsobegreased

    laterthroughtheholeonthecrankshaft.

    Fitthechainandbar.Seetheoperatinginstruc-

    tions.On268Kand272K,fitthecuttingattach-

    ment.

    Seetheoperatinginstructions.

    Topreventimbalanceallclutchshoesshould

    bereplacedatthesametime.

    Usingaspannersecuretheclutchcentre.

    Onsaws36and41useservicetoolno.

    5300311-12.

    Note!Left-handthread.

    Sawswiththree

    coilsprings.

    Sawswithone

    longspring.

    Sawswithth

    reeC-springs.

    Locatetheclutchshoeson

    thehubandfitthesprings

    withthehelpofpliers.

    Locatetheclutchshoesonthe

    hub.Liftashoeusingasuit-

    ablespacer(A)andfitthe

    spring.

    Locatetheclutchshoesonthe

    hubandfitthespringswiththe

    helpofcirclippliers.

    CENTRIFUGAL

    CLUTCH

    C

    A

    Removethepistonstopandfitthespark

    plug.

    NOTE!Theclutch

    springsshouldnotbe

    openedoutmorethan

    necessary.Riskof

    deformation.

    70English

    LUBRICATIO

    NSYSTEM

    Dismantling

    Saws36,40,41,45,51and55.Seepage72

    Othersaws.

    Removethepumpdriveandwasher.

    Undothethreebolts(A)andremovethe

    oilpump.Somepumpshavetobe

    removedbyusingextractorscrews.M5

    screwsshouldbeinsertedintothe2

    threadedholesinthepumpbodyand

    tightenedequallytoliftthepumpand

    thrustwasher.Otherpumpshaveacut-out

    (C)forascrewdrivertopriseoffthepump.

    Bothtypesareshownbelow.

    Saws42,242XP,246,254XP,262XPand257.

    Saws61,268,272XP.Seenextpage.

    Saws281XPand288XP.Seenextpage.

    Saw394.Seepage72.

    Dismantletheoilpumpasfollows:

    1.Unscrewscrew(A)andremovelocking

    clip(B).

    2.Undoscrew(C).

    3.Leveroutthepumppiston(D)and

    plasticplug(E)usingascrewdriver.

    4.Removetheseal(F).

    C

    F

    B A

    D

    E

    Dismantlethefollowingparts:

    S

    tarter.Seetheoperatinginstructions

    Centrifugalclutch.Seepage67.

    Saw3

    120.Seepage72

    A B C

    English71

    LUBRICAT

    IONSYSTEM

    Saws61,268,272XP.

    Dismantletheoilpumpasfollows:

    1.Removethelockwasher(A),washer,

    springandadjusterscrew(B).

    2.Removethelockinglacquerandundo

    screw(C).

    3.Knocktheedgeofthepumphousing

    againstapieceofwoodsothatthe

    pumppiston(D)slidesoutofthe

    housing.

    4.Removethepinion(E)withwashers

    andsprings.

    5.Removethepin(F).

    6.Removetheseal(G).

    7.IfnecessaryremovetheO-ring(H).

    A H

    F B G

    E

    C

    D

    F A

    D E

    C

    B

    Saws281XPand288XP.

    Dismantletheoilpumpasfollows:

    1.Undotheadjusterscrew(A).

    2.Removetheplug(B)withpumppiston

    (C)andspringwithwashers.

    3.DismantletheO-ring(D).Replaceif

    necessary.

    4.Ifnecessary,replacetheseal(E).

    5.Ifnecessary,replacetheO-ring(F).

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    72English

    Saw394.

    Dismantletheoilpumpasfollows:

    1.Dismantlethescrew(A)sothatthe

    springandlatchpin(B)canbe

    removed.

    2.Leveroutthepumppiston(C)withthe

    plasticplug(D)usingascrewdriver.

    3.Removetheseal(E).

    A

    BC

    D

    E

    Saw3120.

    Undothethreeboltsthathold

    theoilpumpandliftupthepump

    bythecut-outfortheadjuster

    screw.Liftoffthepumpand

    loosenthewireformanualoil

    supply.

    Dismantletheoilpumpasfollows:

    1.Undo

    thescrews(A)andremovethepartsas

    show

    ninthefigurebelow.

    2.Undo

    screw(B).NOTE!Left-handthread.

    B

    A

    LUBRICATIONS

    YSTEM

    English73

    Saws36,40,41,45,51and55.

    Dismantlethechainguideplatesasshown

    inrespectivediagramsbelow.

    36/41

    40/45

    51/55

    Saws36,40,41and45.

    Undothetwoboltsandliftoffthepump

    andtheupperseal.

    LUBRICATION

    SYSTEM

    Saws51and55.

    Liftoffthepumpandtheupperseal.

    Takethepumpapartasshowninth

    eexplodedviewon

    thenextpage.

    74English

    LUBRICATIO

    NSYSTEM

    36/41

    40/45

    50/51

    A.

    Lowerseal.

    B.

    Pumpcylinder.

    C.

    Upperseal.

    D.

    Chainguideplate.

    E.

    Pumphousing.

    F.

    Pumppiston.

    G.Wormgear.

    C

    B

    A

    D

    E

    F

    G

    D

    E

    F

    G

    C

    B

    A

    A

    B

    C

    E

    F

    G

    English75

    LUBRICAT

    IONSYSTEM

    Dismantlingtheoilpump's

    wormgear

    Onsomesawsthewormgearfortheoil

    pumpispressedonthecrankshaft.

    Removethewormgearbyusingthe

    servicetoolforthesawinquestion.See

    "Tools".

    Firstscrewthetoolontotheentireworm

    gear

    Turnthescrewuntilthewormgearis

    removed.

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    76English

    LUBRICATIONS

    YSTEM

    CleaningandInspection

    Cleanallpartsandcheckthefollowing

    whenappropriatetothesawinquestion.

    Thatthetaperontheadjusterscrew

    showsnosignsofwear.

    Thatthepumppiston'seccentricfacedoes

    notshowsignsofwear.

    Theoilpipeisnotblockedandthefilter

    screenisclean.

    Thatallsealsareundamaged.

    Thatthewormgearontheoilpumpdrive

    isundamaged.

    Thatthepumppiston'spiniongearisundamaged.

    English77

    Assemblingtheoilpump

    LUBRICATION

    SYSTEM

    Fittheoilpumpasfollows:

    1.ApplySAE30oiltoallmovingparts.

    2.Insertthepumppiston(D)with

    washersandspring.

    3.Pressinthepumppistonalittlemore

    andscrewintheadjusterscrew(C).

    4.Inserttheplasticplug(E).

    5.Refitscrew(A)andlockingclip(B).

    6.Fittheseal(F).

    C

    F

    B A

    D

    E

    Saws42,242XP,246,254XP,262XPand257.

    Saws61,268,272XP.

    A H

    F B G

    E

    C

    D

    I

    Seecontinuation,page80.

    Seecontinuation,page80.

    Assemblingthewormgear

    Onthosesawswheretheoilpumpworm

    gearispressedonthecrankshaft.

    Screwthewormgearintothedismantling

    toolandpressthewormgearontothe

    crankshaftuntilitbottomsagainstthe

    collar.

    Fittheoilpumpasfollows:

    1.ApplySAE30oiltoallmovingparts.

    2.Fittheseal(G)ifnecessary.

    3.Pressinpin(F).

    4.Locatethepinion(E)withwashersand

    spring.

    5.Insertthepumppiston(D)throughthe

    pinion,springandwashersinthepump

    housing.

    6.Fitscrew(C).Thescrewshouldbe

    lockedusingLoctiteorlockinglacquer.

    7.Fittheadjusterscrew(I)withwashers,

    springandlockingclip(A).

    8.FittheO-ring(H).

    78English

    LUBRICATIO

    NSYSTEM

    F A

    D E

    C

    B

    Saws281XPand288XP.

    Fittheoilpumpasfollows:

    1.ApplySAE30oiltoallmovingparts

    2.Fittheseal(E)ifnecessary.

    3.Fittheplug(B)andspringwithwashers

    onthepumppiston(C)andfittheunit

    inthepumphousing.

    4.Fittheadjusterscrew(A)inthepump

    housing,andthroughtheholeinplug

    (B).

    5.FittheO-rings(D)and(F).

    Saw394.

    Fittheoilpumpasfollows:

    1.ApplySAE30oiltoallmovingparts.

    2.Fitthepumppiston(C)withwashers

    andspringinthepumphousing.

    3.Fitthelatchpin(B),pressinthepump

    piston(C)alittlemoreandfitthe

    adjusterscrew(A).

    4.Fittheseal(E).

    5.Fittheplug(D).

    A

    BC

    D

    E

    Seecontinuation,page80.

    Seecontinua

    tion,page80.

    English79

    LUBRICAT

    IONSYSTEM

    Saw3120.

    Fittheoilpumpasfollows:

    1.ApplySAE30oiltoallmovingparts

    2.Fittheseal(C).

    3.Fitthepumppiston(D)withspring.

    Pressinthepistonandholditin

    positionwithascrewdriverfromthe

    pumphousing'sinsideinslot(E).

    4.Fitscrew(B)sothatitispositioned

    approx.oneturnfromthebottom.

    NOTE!Left-handthread

    B

    A

    5.Fitleverarm(F).

    6.Fitunits(B-F-G)withspring(H)and

    screwinpositionusingscrews(A)and

    latch(J).

    7.Removethescrewdriver.

    8.FitanewO-rings(K)and(L).

    C

    KF

    D

    E

    H

    G

    J

    Fitthewireformanualoilsupply.

    Seecontinuationonnextpage.

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    80English

    LUBRICATIONS

    YSTEM

    Saws42,61,242,246,254,257,262,268,272,281,288,394and3120.

    1.Lubricatethepiniongearwithgrease.

    2.Fittheoilpumponthesawby

    tighteningthethreebolts.

    3.Ifthetaperedsleevehasbeenused,

    removeit.

    4.Fitthecentrifugalclutch.

    Seepage69.

    5.Fitthebarandchain.

    6.Adjusttheoilpumpforthecorrectoilflow.

    Seetheoperatinginstructions.

    Saws61,268,272,281and288

    Usethetaperedsleevewhich

    isplacedontheshaftwhen

    fittingtheoilpump.Otherwise

    thesealswillbedamaged.

    English81

    Saws36,40,41and45,see

    continuationonthenextpage.

    Saws51and55,seecontinuation

    onthenextpage.

    36/41

    40/45

    50/51

    A.

    Lowerseal.

    B.

    Pumpcylinder.

    C.

    Upperseal.

    D.

    Chainguideplate.

    E.

    Pumphousing.

    F.

    Pumppiston.

    G.

    Wormgear

    C

    B

    A

    D

    E

    F

    G

    D

    E

    F

    G

    C

    B

    A

    A

    B

    C

    E

    F

    G

    LUBRICATION

    SYSTEM

    Fittheoilpumpasfollows:

    1.ApplySAE30oiltoallmovingparts.

    2.Fitthewormgear(G)onthe

    crankshaft,ifnecessary

    3.Fitthepumppiston(F)inthepump

    cylinder(B).

    4.Fillthepumprecesswithgrease.

    5.Fittheunitinthepumphousing(E).

    Ensurethepumpcylinder'scut-out

    alignsinthepumphousing.

    6.Fitthelowerseal(A)onthecrankcase.

    Saws36,40,41,45,51and55.

    82English

    Fitthechainguideplatesaccordingto

    respectivediagramsbelow.

    36/41

    40/45

    51/55

    Fittheoilpumpinthecrankcase,tighten

    thetwoboltsandfittheupperseal.

    Fittheoilpumpinthecrankcaseandfit

    theupperseal.

    LUBRICATIO

    NSYSTEM

    Saws36,40,41and45.

    Saws51and55.

    Fitthebarandchain.

    English83

    CARBURETTOR

    Description

    Thediagramsinthisdescriptiondonot

    correspondwiththecarburettorfittedon

    thechainsaws.Theyserveonlytoshow

    theprinciplesofdesignandoperation.

    Design

    BCA

    Themeteringunit(A)containsthejetsand

    fuelcontrolfunctions.Itisherethecorrect

    amountoffuelforthegivenenginespeed

    andpowerismetered.

    Themixingventuri(B)housesthechoke,

    throttlevalveanddiffuserjets.Hereairis

    mixedwiththefueltogiveafuel/air

    mixturethatcanbeignitedbytheignition

    spark.

    Thecarburettorconsistsofthreesub-systems:

    Meteringunit,A.

    Mixingventuri,B.

    Pumpunit,C.

    Inthepumpunit(C),fuelispumpedfromthe

    fueltanktothemeteringunit.Onesideofthe

    pumpdiaphragmisconnectedtothecrankcase

    andpulsesintimewiththepressurechangesin

    thecrankcase.Theothersideofthediaphragm

    pumpsthefuel.

    WARNING!

    Thefuelusedinthechainsawposes

    thefollowinghazards:

    1.Theliquidanditsvapoursare

    poisonous.

    2.Cancauseskinirritation.

    3.Ishighlyinflammable.

    !

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    84English

    Operation

    Thecarburettoroperatesdifferentlyinthe

    followingmodes:

    Coldstart

    Idling

    Partthrottle

    Fullthrottle

    D

    E

    F

    G

    H

    G

    H

    F

    G

    E

    F

    G

    Intheidlingmode(H)thethrottlevalveis

    closed.Airissuckedinthroughan

    apertureinthethrottlevalveandasmall

    amountoffuelissuppliedthroughthe

    diffuserjet(G).

    Inthepartthrottlemodethethrottlevalve

    (H)ispartiallyopen.Fuelissupplied

    throughthediffuserjets(FandG).

    Inthefullthrottlemodebothvalvesare

    openandfuelissuppliedthroughallthree

    diffuserjets(E,FandG).

    CARBURETT

    OR

    Inthecoldstartmodethechokevalve(D)

    isfullyclosed.Thisincreasesthevacuum

    inthecarburettorandfueliseasiertosuck

    fromallthediffuserjets(E,FandG).The

    throttlevalve(H)ispartlyopen.

    English85

    CARBURETTOR

    ! Seethecarburettorinquestiononthenext

    fourpagesandtheinstructionsbelow.

    Plugs

    Whencleaningthecarburettortheplugs

    mustberemoved.Removeasfollows:

    1.Drillaholeintheplug.

    2.Insertascrewdriverorpunchinthehole

    andpriseuptheplug.

    Semifixedjet/fixedjet

    Somecarburettorshaveanextrajet(semi

    fixedjet).Thejetisofbrassandislocated

    inthemeteringunitandisusedtogivea

    fuelsupplement.Onaverage10%ofthe

    fuelpassesthroughthejet.

    Belowornexttothejetisascreenwhich

    needstobecleaned.

    Dismantlethejetand/orscreeninoneof

    thefollowingways:

    1.Knocktheunitintotheventuriusinga

    punchandtaketheunitapart.(some

    Tillotsonmodels).

    2.Dismantlethelockwasheroverthejet

    andliftoffthejetandscreen.

    Dismantleallpartsnecessaryandremove

    thecarburettorfromthesaw.Onsome

    modelsthecylinderneedstobeloosened

    andliftedtobeabletoremovethe

    carburettor.

    WARNING!

    Thefuelusedinthechainsaw

    posesthefollowinghazards:

    1.Theliquidanditsvapoursare

    poisonous.

    2.Cancauseskinirritation.

    3.Ishighlyinflammable.

    Dismantling

    86English

    TillotsonHS255B

    AB

    H

    E F G

    I J C

    H

    K

    1.Removethecover(A)overthemetering

    unitandcarefullyremovethecontrol

    diaphragm(B)withthegasket.

    2.Undothescrew(H)andtakeout

    theneedlevalve(C)withlever

    arm,shaftandspring.

    3.Removethecover(E)overthepumpunit

    andcarefullyremovethegasket(F)and

    thepumpdiaphragm(G).

    4.Usinganeedleorthelikecarefully

    removethefuelscreen(D).

    5.Unscrewthehighandlowspeedjet

    screws.

    6.Removetheplugs(J).Seepage85.

    7.Ifnecessaryremovethethrottleand

    chokevalvesaswellastheshafts,lever

    armsandsprings.

    8.Removethespeedgovernor(I).(Only

    272K,268Kand272S).

    9.Removethesemifixedjet(K).Seepage85.

    AB

    H

    E F G

    J CD

    D

    CARBUR

    ETTOR

    1.Removethecover(A)overthemetering

    unitandcarefullyremovethecontrol

    diaphragm(B)withthegasket.

    2.Undothescrew(H)andtakeout

    theneedlevalve(C)withleverarm,

    shaftandspring.

    3.Removethecover(E)overthepumpunit

    andcarefullyremovethegasket(F)and

    thepumpdiaphragm(G).

    4.Usinganeedleorthelikecarefullyremove

    thefuelscreen(D).

    5.Unscrewthehighandlowspeedjet

    screws.

    6.Removetheplugs(J).

    Seepage85.

    7.Ifnecessaryremovethethrottleandchoke

    valvesaswellastheshafts,leverarms

    andsprings.

    TillotsonHS228B

    English87

    WalbroHDAandHD

    D G F E

    A B H C J

    1.Removethecover(A)overthemetering

    unitandcarefullyremovethecontrol

    diaphragm(B)withthegasket.

    2.Undothescrew(H)andtakeoutthe

    needlevalve(C)withleverarm,shaftand

    spring.

    3.Removethecover(E)overthepump

    unitandcarefullyremovethegasket(F)

    andthepumpdiaphragm(G).

    4.Usinganeedleorthelikecarefullyremove

    thefuelscreen(D).

    5.Unscrewthehighandlowspeedjet

    screws.

    6.Removetheplug(J).Seepage85.

    7.Ifnecessaryremovethethrottleandchoke

    valvesaswellastheshafts,leverarmsand

    springs.

    TillotsonHS260A

    AB

    H

    E F G

    J C

    H

    K

    1.Removethecover(A)overthemetering

    unitandcarefullyremovethecontrol

    diaphragm(B)withthegasket.

    2.Undothescrew(H)andtakeoutthe

    needlevalve(C)withleverarm,shaftand

    spring.

    3.Removethecover(E)overthepumpunit

    andcarefullyremovethegasket(F)and

    thepumpdiaphragm(G).

    4.Usinganeedleorthelikecarefullyremove

    thefuelscreen(D).

    5.Unscrewthehighandlowspeedjet

    screws.

    6.Removetheplugs(J).Seepage85.

    7.Ifnecessaryremovethethrottleandchoke

    valvesaswellastheshafts,leverarms

    andsprings.

    8.Removethesemifixedjet(K).Seepage85.

    D

    CARBURETTOR

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    88English

    CARBURETT

    OR

    WalbroWG

    1.Removethecover(A)overthemetering

    unitandcarefullyremovethecontrol

    diaphragm(B)withthegasket.

    2.Undothescrew(H)andtakeoutthe

    needlevalve(C)withleverarm,shaftand

    spring.

    3.Removethecover(E)overthepumpunit

    andcarefullyremovethegasket(F)and

    thepumpdiaphragm(G).

    4.Usinganeedleorthelikecarefullyremove

    thefuelscreen(D).

    5.Unscrewthelowspeedjetscrews.

    6.Removetheplugs(J).Seepage85.

    7.Ifnecessaryremovethethrottleandchoke

    valvesaswellastheshafts,leverarms

    andsprings.

    8.Removethesemifixedjet(K).Seepage85.

    WalbroWJ

    AB

    H

    E F G

    J C

    K

    1.Removethecover(A)overthemetering

    unitandcarefullyremovethecontrol

    diaphragm(B)withthegasket.

    2.Undothescrew(H)andtakeoutthe

    needlevalve(C)withleverarm,shaftand

    spring.

    3.Removethecover(E)overthepumpunit

    andcarefullyremovethegasket(F)and

    thepumpdiaphragm(G).

    4.Usinganeedleorthelikecarefullyremove

    thefuelscreen(D).

    5.Unscrewthehighandlowspeedjet

    screws.

    6.Removetheplug(J).Seepage85.

    7.Ifnecessaryremovethethrottleandchoke

    valvesaswellastheshafts,leverarms

    andsprings.

    8.Removethesemifixedjet(K).Seepage85.

    D

    D G F E

    A B H C K J

    English89

    WalbroWT

    E F G

    C J B

    H

    K

    A

    ZAMAC1Q-EL1

    1.Removethecover(A)overthemetering

    unitandcarefullyremovethecontrol

    diaphragm(B)withthegasket.

    2.Undothescrew(H)andtakeoutthe

    needlevalve(C)withleverarm,shaftand

    spring.

    3.Removethecover(E)overthepumpunit

    andcarefullyremovethegasket(F)and

    thepumpdiaphragm(G).

    4.Usinganeedleorthelikecarefullyremove

    thefuelscreen(D).

    5.Unscrewthehighandlowspeedjet

    screws.

    6.Ifnecessaryremovethethrottleand

    chokevalvesaswellastheshafts,lever

    armsandsprings.

    1.Removethecover(A)overthemetering

    unitandcarefullyremovethecontrol

    diaphragm(B)withthegasket.

    2.Undothescrew(H)andtakeoutthe

    needlevalve(C)withleverarm,shaft

    andspring.

    3.Removethecover(E)overthepump

    unitandcarefullyremovethegasket(F)

    andthepumpdiaphragm(G).

    4.Usinganeedleorthelikecarefullyremove

    thefuelscreen(D).

    5.Unscrewthehighandlowspeedjet

    screws.

    6.Removetheplug(J).Seepage85.

    7.Ifnecessaryremovethethrottleandchoke

    valvesaswellastheshafts,leverarms

    andsprings.

    8.Removethesemifixedjetwithdiffuser

    jet(K).Seepage85.

    CARBURETTOR

    D

    A B H

    C D G F EK

    90English

    CARBURETTOR

    CleaningandInspection

    Usecompressedairtodrythepetrolonthe

    components.Directtheairthroughall

    channelsinthecarburettorhousingand

    ensurethattheyarenotblocked.

    Refertothecarburettordiagramin

    questiononthepreviouspagesandcheck

    thefollowing:

    1.Thatthegasketandpumpandcontrol

    diaphragmsareundamaged.

    2.Thatthereisnoplayonthethrottleand

    chokevalveshafts.

    3.Thattheneedlevalveanditsleverare

    notworn.

    4.Thatthefuelscreenisundamaged

    5.Thatthetipsofthehighandlowspeed

    jetscrewsarenotdamaged.

    6.OnTillotsonHS255B,thatthespeed

    governor(I)isclean.

    7.Thattheairintakemanifold

    isnotcracked.

    WARNING!

    Thefuelusedinthechainsaw

    posesthefollowinghazards:

    1.Theliquidanditsvapoursare

    poisonous.

    2.Cancauseskinirritation.

    3.Ishighlyinflammable.

    Cleanallcomponentsinpetrol.Wear

    glovesorskinprotectioncream.

    WARNING!

    Neverdirectthecompressedair

    jettowardsthebody.Aircanbe

    forcedintothebloodstreamand

    cancausefatality.

    !

    !

    English91

    Plugs

    Whencleaningthecarburettortheplugs

    mustberemoved.

    Reassembleasfollows:

    1.Placetheplugintheholewiththe

    convexsidefacingupwards.

    2.Expandtheplugbyusingapunchon

    thetopside.

    Semifixedjet/fixedjet

    Somecarburettorshaveanextrajet(semi

    fixedjet).Thejetisofbrassandislocated

    inthemeteringunitandisusedtogivea

    fuelsupplement.Onaverage10%ofthe

    fuelpassesthroughthejet.

    Belowornexttothejetisascreenwhich

    needstobecleaned.

    Reassemblethejetand/orscreeninone

    ofthefollowingways:

    1.Puttogethertheunitandfititinthe

    carburettorbymeansofapunch(Some

    Tillotsonmodels).

    2.Fitthejetwithscreenandlockwasher.

    CARBURETTOR

    Assembly

    Refertothecarburettorinquestiononthe

    nexteightpages.Apressuretest,see

    page100,shouldbecarriedoutafter

    assemblingandbeforethecarburettoris

    refittedtothesaw.

    !WARNING!

    Thefuelusedinthechainsaw

    posesthefollowinghazards:

    1.Thefluidanditsvapoursare

    poisonous.

    2.Cancauseskinirritation.

    3.Ishighlyinflammable.

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    92English

    CARBURETT

    OR

    1.Ifthethrottleandchokevalves,shafts,

    leverarmsandspringshavebeen

    dismantledthesemustbereassembled.

    Lubricatetheshaftbearingsusinga

    lightoil.

    2.Fittheplugs(J).Seepage91.

    3.Fitthehighandlowjetscrewsand

    springs.NOTE!Donottightenthe

    screwsagainsttheseats.Thiscan

    damagetheseatsandneedletips.

    4.Fitthefuelscreen(D)byusingthe

    handleofasmallscrewdriver.

    5.Fitthepumpdiaphragm(G),gasket

    (F)andcover(E)onthepumpunit.

    6.Fittheneedlevalve(C)withleverarm,

    shaftandspringandtightenscrew(H).

    7.Check,usingorarulerorthelike,that

    theleverarmislevelwiththechamber

    floor.Seethefiguretothelowerright.

    Theleverarmcanbebentifnecessary

    toachievethecorrectsettings.

    8.Fitthecontroldiaphragm(B)with

    gasketandcover(A)onthemetering

    unit.

    9.Carryoutapressuretest.

    Seepage100.

    TillotsonHS228B

    Maintainahighlevelofcleanlinesswhen

    reassemblingthecarburettor.Evensmall

    particlesofdirtcancauseoperating

    problems.

    AB

    H

    E F G

    J CD

    English93

    TillotsonHS255B

    1.Ifthethrottleandchokevalves,shafts,

    leverarmsandspringshavebeen

    dismantledthesemustbereassembled.

    Lubricatetheshaftbearingsusingalight

    oil.

    2.Fittheplugs(J).Seepage91.

    3.Fitthesemifixedjet(K).Seepage91.

    4.Fitthehighandlowjetscrewsandsprings.

    NOTE!Donottightenthescrewsagainst

    theseats.Thiscandamagetheseatsand

    needletips.

    5.Fitthefuelscreen(D)byusingthehandle

    ofasmallscrewdriver.

    6.Fitthepumpdiaphragm(G),gasket

    (F)andcover(E)onthepumpunit.

    7.Fittheneedlevalve(C)withleverarm,

    shaftandspringandtightenscrew(H).

    8.Check,usingorarulerorthelike,thatthe

    leverarmislevelwiththechamberfloor.

    Seethefiguretothelowerright.Thelever

    armcanbebentifnecessarytoachieve

    thecorrectsettings.

    9.Fitthespeedgovernor(I).Lockwith

    Loctiteorlockinglacquer.(Onlyappliesto

    272K,268Kand272S).

    10.Fitthecontroldiaphragm(B)withgasket

    andcover(A)onthemeteringunit.

    11.Carryoutapressuretest.

    Seepage100.

    Maintainahighlevelofcleanlinesswhen

    reassemblingthecarburettor.Evensmall

    particlesofdirtcancauseoperatingprob-

    lems.

    CARBURETTOR

    AB

    H

    E F G

    I J C

    H

    K

    D

    94English

    TillotsonHS260A

    1.Ifthethrottleandchokevalves,shafts,

    leverarmsandspringshavebeen

    dismantledthesemustbereassembled.

    Lubricatetheshaftbearingsusingalight

    oil.

    2.Fittheplugs(J).Seepage91.

    3.Fitthesemifixedjet(K).Seepage91.

    4.Fitthehighandlowjetscrewsand

    springs.NOTE!Donottightenthescrews

    againsttheseats.Thiscandamagethe

    seatsandneedletips.

    5.Fitthefuelscreen(D)byusingthehandle

    ofasmallscrewdriver.

    6.Fitthepumpdiaphragm(G),gasket

    (F)andcover(E)onthepumpunit.

    7.Fittheneedlevalve(C)withleverarm,

    shaftandspringandtightenscrew(H).

    8.Check,usingorarulerorthelike,thatthe

    leverarmislevelwiththechamberfloor.

    Seethefiguretothelowerright.Thelever

    armcanbebentifnecessarytoachieve

    thecorrectsettings.

    9.Fitthecontroldiaphragm(B)withgasket

    andcover(A)onthemeteringunit.

    10.Carryoutapressuretest.Seepage100.

    Maintainahighlevelofcleanlinesswhen

    reassemblingthecarburettor.Evensmall

    particlesofdirtcancauseoperating

    problems.

    CARBURETTOR

    AB

    H

    E F G

    J C

    H

    K

    D

    English95

    1.Ifthethrottleandchokevalves,shafts,

    leverarmsandspringshavebeen

    dismantledthesemustbereassembled.

    Lubricatetheshaftbearingsusinga

    lightoil.

    2.Fittheplugs(J).Seepage91.

    3.Fitthehighandlowjetscrewsandsprings.

    NOTE!Donottightenthescrewsagainst

    theseats.Thiscandamagetheseatsand

    needletips.

    4.Fitthefuelscreen(D)byusingthehandle

    ofasmallscrewdriver.

    5.Fitthepumpdiaphragm(G),gasket

    (F)andcover(E)onthepumpunit.

    6.Fittheneedlevalve(C)withleverarm,

    shaftandspringandtightenscrew(H).

    7.Check,usingorarulerorthelike,thatthe

    leverarmislevelwiththechamberfloor.

    Seethefiguretothelowerright.Thelever

    armcanbebentifnecessarytoachieve

    thecorrectsettings.

    8.Fitthecontroldiaphragm(B)withgasket

    andcover(A)onthemeteringunit.

    9.Carryoutapressuretest.Seepage100.

    Maintainahighlevelofcleanlinesswhen

    reassemblingthecarburettor.Evensmall

    particlesofdirtcancauseoperatingprob-

    lems.

    CARBURETTOR

    WalbroHDAochHD

    D G F E

    A B H C J

  • 8/3/2019 husqwm271_hwen1997_1018855-26

    25/32

    96English

    1.Ifthethrottleandchokevalves,shafts,lever

    armsandspringshavebeendismantled

    thesemustbereassembled.Lubricatethe

    shaftbearingsusingalightoil.

    2.Fittheplugs(J).Seepage91.

    3.Fitthesemifixedjet(K).Seepage91.

    4.Fitthehighandlowjetscrewsandsprings.

    NOTE!Donottightenthescrewsagainst

    theseats.Thiscandamagetheseatsand

    needletips.

    5.Fitthefuelscreen(D)byusingthehandle

    ofasmallscrewdriver.

    6.Fitthepumpdiaphragm(G),gasket

    (F)andcover(E)onthepumpunit.

    7.Fittheneedlevalve(C)withleverarm,shaft

    andspringandtightenscrew(H).

    8.Check,usingorarulerorthelike,thatthe

    leverarmislevelwiththechamberfloor.

    Seethefiguretothelowerright.Thelever

    armcanbebentifnecessarytoachievethe

    correctsettings.

    9.Fitthecontroldiaphragm(B)withgasket

    andcover(A)onthemeteringunit.

    10.Carryoutapressuretest.Seepage100.

    Maintainahighlevelofcleanlinesswhen

    reassemblingthecarburettor.Evensmall

    particlesofdirtcancauseoperatingprob-

    lems.

    CARBURETTOR

    WalbroWJ

    AB

    H

    E F G

    J C

    K

    D

    English97

    WalbroWG

    Maintainahighlevelofcleanlinesswhen

    reassemblingthecarburettor.Evensmall

    particlesofdirtcancauseoperatingprob-

    lems.

    CARBURETTOR

    D G F E

    A B H C K J

    1.Ifthethrottleandchokevalves,shafts,

    leverarmsandspringshavebeen

    dismantledthesemustbereassembled.

    Lubricatetheshaftbearingsusingalightoil.

    2.Fittheplugs(J).Seepage91.

    3.Fitthefixedjet(K).Seepage91.

    4.Fitthehighandlowjetscrewsandsprings.

    NOTE!Donottightenthescrewsagainst

    theseats.Thiscandamagetheseatsand

    needletips.

    5.Fitthefuelscreen(D)byusingthehandle

    ofasmallscrewdriver.

    6.Fitthepumpdiaphragm(G),gasket

    (F)andcover(E)onthepumpunit.

    7.Fittheneedlevalve(C)withleverarm,shaft

    andspringandtightenscrew(H).

    8.Check,usingorarulerorthelike,thatthe

    leverarmislevelwiththechamberfloor.

    Seethefiguretothelowerright.Thelever

    armcanbebentifnecessarytoachievethe

    correctsettings.

    9.Fitthecontroldiaphragm(B)withgasket

    andcover(A)onthemeteringunit.

    10.Carryoutapressuretest.Seepage

    100.

    98English

    WalbroWT

    1.Ifthethrottleandchokevalves,shafts,

    leverarmsandspringshavebeen

    dismantledthesemustbereassembled.

    Lubricatetheshaftbearingsusingalightoil.

    2.Fittheplugs(J).Seepage91.

    3.Fitthesemifixedjet(K).Seepage91.

    4.Fitthehighandlowjetscrewsandsprings.

    NOTE!Donottightenthescrewsagainst

    theseats.Thiscandamagetheseatsand

    needletips.

    5.Fitthefuelscreen(D)byusingthehandleof

    asmallscre