husqwm271_hwen1997_1018855-26
TRANSCRIPT
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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
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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)
-
-
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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
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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
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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
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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