Husqvarna Chain Saws Workshop Manual 101 88 55-26 Eng, front 1 96-09-13, 10.
LIST OF CONTENTS Introduction ..................................... 3 Safety regulations ........................... 5 Technical Data ................................. 6 Tools ............................................... 14 Service data ................................... 20 Trouble shooting ........................... 40 Safety equipment .......................... 42 Starter ............................................. 57 Electrical system ........................... 61 Centrifugal clutch ............
INTRODUCTION General Updates This workshop manual provides a detailed description of procedures for trouble shooting, repair and testing of the chain saws. Safety precautions that should be taken during repair are also described. As production continues, changes will be introduced successively to the chain saw. If at any time these changes influence service and/or spares, special service announcements will be sent out, which means that this manual will cease to be current with time.
INTRODUCTION Use Dismantling and reassembly of the entire This workshop manual can be used in two different ways: • • Repair of a specific sub-assembly Dismantling and reassembly of the entire chain saw chain saw When the entire chain saw is to be dismantled and reassembled, proceed as follows: 1. Refer to page 57, which deals with the Starter and carry out the instructions under the heading Dismantling. 2.
SAFETY REGULATIONS General Instructions Workshops where chain saws are serviced must be equipped with safety equipment as set out in local directives. No one should repair a chain saw without first having read and understood the contents of this workshop manual. The following warning texts are to be found in this manual in certain places. The warning texts occur before the procedure to which they refer. Special instructions The fuel used in the chain saw poses the following hazards: 1.
TECHNICAL DATA Displacement cm3 Bore mm Stroke mm Max. power at r/min 36 40 41 36 40 40 38.0 40.0 40.0 32.0 32.0 32.0 9000 9000 9000 42 45 51 42 44 51 42.0 42.0 45.0 30.0 32.0 32.0 9300 9000 9000 Spark plug gap Ignition system mm/inches Air gap Carburettor mm/inches 36 40 41 0.5/ .02 0.5/ .02 0.5/ .02 PHELON PHELON PHELON 0.3/ .012 0.3/ .012 0.3/ .012 WALBRO WT 239 ZAMA C1Q-EL1 WALBRO WT 239 42 45 51 0.5/ .02 0.5/ .02 0.5/ .02 SEM AM 7 PHELON ELECTROLUX ET 0.3/ .012 0.3/ .012 0.
TECHNICAL DATA Idling speed r/min Engagement speed r/min Max. speed r/min Spark plug Champion 36 40 41 3000 2500 3000 4500 3600 4500 13000 12500 13000 RCJ 7 Y RCJ 7 Y RCJ 7 Y 42 45 51 2700 2500 2500 3800 3600 3700 14500 12500 12500 RCJ 7 Y RCJ 7 Y RCJ 7 Y Fuel tank volume Litres Oil pump capacity cm /min at 8.500 rpm 3 Oil tank volume Litres Automatic oil pump 36 40 41 0.4 0.5 0.4 7 8 7 0.2 0.25 0.2 Yes Yes Yes 42 45 51 0.5 0.5 0.6 3-7 8 10 0.27 0.25 0.
TECHNICAL DATA Displacement cm3 Bore mm Stroke mm Max. power at r/min 55 61 242XP 53 62 42 46.0 48.0 42.0 32.0 34.0 30.0 9000 8300 9900 246 254XP 257 46 54 57 44.0 45.0 46.0 30.0 34.0 34.0 9000 9300 9000 Spark plug gap Ignition system mm/inches Air gap Carburettor mm/inches 55 61 242XP 0.5/ .02 0.5/ .02 0.5/ .02 ELECTROLUX ET ELECTROLUX ET SEM AM 7 0.3/ .012 0.3/ .012 0.3/ .012 WALBRO WT 170 TILLOTSON HS 254 WALBRO HDA 98 246 254XP 257 0.5/ .02 0.5/ .02 0.5/ .
TECHNICAL DATA Idling speed r/min Engagement speed r/min Max. speed r/min Spark plug Champion 55 61 242XP 2500 2500 2700 3700 3700 3900 12500 12000 15500 RCJ 7 Y RCJ 7 Y RCJ 7 Y 246 254XP 257 2700 2700 2700 3900 3700 3700 15000 13800 13500 RCJ 7 Y RCJ 7 Y RCJ 7 Y Fuel tank volume Litres Oil pump capacity cm3/min at 8.500 rpm Oil tank volume Litres Automatic oil pump 55 61 242XP 0.6 0.75 0.5 10 4/8/12/17 3-7 0.3 0.45 0.27 Yes Yes Yes 246 254XP 257 0.5 0.6 0.6 3-7 3-10 3-10 0.27 0.
TECHNICAL DATA Displacemennt cm3 Bore mm Stroke mm 262XP 268 272XP 62 67 72 48.0 50.0 52.0 34.0 34.0 34.0 9600 9000 9300 268K 272K 272S 67 72 72 50.0 52.0 52.0 34.0 34.0 34.0 9000 9300 9300 Spark plug gap Ignition system mm/inches Air gap Carburettor mm/inches 262XP 268 272XP 0.5/ .02 0.5/ .02 0.5/ .02 ELECTROLUX ET ELECTROLUX ET ELECTROLUX ET 0.3/ .012 0.3/ .012 0.3/ .012 WALBRO HDA 120 TILLOTSON HS 260 TILLOTSON HS 260 268K 272K 272S 0.5/ .02 0.5/ .02 0.5/ .
TECHNICAL DATA Idling speed r/min Engagement speed r/min Max. speed r/min Spark plug Champion 262XP 268 272XP 2700 2500 2500 3400 3500 3500 13500 12500 13500 RCJ 7 Y RCJ 7 Y RCJ 7 Y 268K 272K 272S 2500 2500 2500 3500 3500 3500 10000 10000 10000 RCJ 7 Y RCJ 7 Y RCJ 7 Y Fuel tank volume Litres Oil pump capacity cm3/min at 8.500 rpm 262XP 268 272XP 0.6 0.75 0.75 6.5-13.5 4/9/13/17 5/9/14/19 268K 272K 272S 0.75 0.75 0.75 - Weight without chain and bar kg Oil tank volume Litres 0.3 0.
TECHNICAL DATA Displacement cm3 Bore mm Stroke mm Max. power at r/min 281XP 288XP 81 87 52.0 54.0 38.0 38.0 9000 9300 394XP 3120XP 94 119 56.0 60.0 38.0 42.0 8800 9000 Spark plug gap Ignition system mm/inches Air gap mm/inches 281XP 288XP 0.5/ .02 0.5/ .02 SEM AM 7 SEM AM 7 0.3/ .012 0.3/ .012 TILLOTSON HS 228 TILLOTSON HS 228 394XP 3120XP 0.5/ .02 0.5/ .02 SEM AM 44 SEM AM 37 0.3/ .012 0.3/ .
TECHNICAL DATA Idling speed r/min Engagement speed r/min Max. speed r/min Spark plug Champion 281XP 288XP 2500 2500 3200 3200 12500 12500 RCJ 6 Y RCJ 6 Y 394XP 3120XP 2500 2500 3400 3300 12500 11500-12500 RCJ 6 Y RCJ 7 Y Oil pump capacity cm3/min at 8.500 rpm Oil tank volume Litres Automatic oil pump 9/12/15/18 9/12/15/18 0.5 0.5 Yes Yes 0.5 0.7 Yes Yes Fuel tank volume Litres 281XP 288XP 0.9 0.9 394XP 3120XP 0.9 1.
TOOLS Tools for all chain saws 502 50 57-01 3/16" 502 50 16-01 6 mm 502 50 64-01 5 mm 502 50 18-01 4 mm 502 50 19-01 3 mm 502 50 22-01 8 mm 502 50 23-01 10 mm 502 50 88-01 5 mm 502 50 87-01 4 mm 502 50 86-01 3 mm 502 71 13-01 504 98 26-01 (36, 41, 40, 45) 502 50 06-01 502 51 34-02 (0,3 mm) 502 51 91-01 (0,5 mm) 502 50 83-01 502 50 37-01 502 70 09-01 compl 502 50 70-01 502 51 02-01 502 71 14-01 14 – English Eng, p 2-39 14 96-09-13, 09.
TOOLS Tools for saws 36 and 41 Tools for saws 40, 45, 51 and 55 3 mm; 4 mm; 5 mm 4 mm 8 mm; 10 mm 8 mm 502 50 33-01 502 50 33-01 505 26 79-12 40 > 910 1116 45 > 925 1168 50 > 925 0856 502 51 94-01 530 03 11-12 530 03 11-36 502 50 99-01 (55) 502 51 94-01 502 50 26-01 (55) 505 38 18-17 (40.
TOOLS Tools for saws 42, 242 and 246 Tools for saws 254, 257 and 262 3 mm; 4 mm 3 mm; 4 mm 8 mm 8 mm 502 50 33-01 502 50 33-01 *compl 502 51 49-02 *compl 502 51 49-02 502 51 49-01* 502 51 49-01* *502 51 54-01 *502 51 54-01 502 50 26-01* 502 50 26-01* 502 50 99-01 502 50 99-01 502 70 03-01 compl 502 50 31-01 502 51 61-01 504 90 90-01 502 51 61-01 504 90 90-01 502 50 82-01 502 50 30-07 502 51 32-01 502 51 50-01 502 50 79-01 502 50 30-10 502 51 00-02 compl 502 50 38-01 compl 502 50 38-01
TOOLS Tools for saws 61, 268 and 272 3 mm; 4 mm; 3/16" Tools for saws 281 and 288 3 mm; 4 mm; 3/16" 8 mm 502 71 36-01 (4 mm) 8 mm 502 71 36-01 (4 mm) 502 50 33-01 502 50 33-01 *compl 502 51 49-02 *compl 502 51 49-02 502 51 49-01* 502 51 49-01* *502 51 54-01 *502 51 54-01 502 50 26-01* 502 50 26-01* 502 70 03-01 compl 502 50 31-01 504 90 90-01 502 51 61-01 502 51 61-01 504 90 90-01 502 50 82-01 502 51 69-01 (268) 502 50 30-04 502 50 30-08 502 50 53-01 502 50 52-01 502 50 66-02 502 5
TOOLS Tools for saws 394 and 3120 3 mm; 4 mm; 5 mm; 3/16" 8 mm; 10 mm 502 50 33-01 *compl 502 51 49-02 502 51 49-01* *502 51 54-01 502 50 26-01* 504 90 90-01 502 50 82-01 502 50 52-01 502 50 30-08 502 50 66-02 compl 502 50 38-01 502 52 04-01 (394) 502 71 40-01 (3120) 502 52 01-01 (394) 502 71 38-01 (3120) 502 71 39-01 (394) 18 – English Eng, p 2-39 18 96-09-13, 09.
TOOLS List of tools Order number Designation Order number 502 50 06-01 502 50 16-01 502 50 18-01 502 50 19-01 502 50 20-01 Pliers Allen key Allen key Allen key Assembly tool 502 51 49-01 502 51 49-02 502 51 50-01 502 51 54-01 502 51 61-01 Puller Puller Socket Bolt set Dismantling tool, crankcase 502 50 22-01 502 50 23-01 502 50 26-01 502 50 30-04 502 50 30-08 Socket Socket Puller Assembly tool Assembly tool 502 51 69-01 502 51 69-01 502 51 94-01 502 52 01-01 502 52 04-01 Assembly mandrel Feeler ga
SERVICE DATA Saws 36 and 41 ● 5 6 10 15 ● ▲ 4 ● ■ ▲ ● Character key Numbers by components that are bolted refer to the tightening torque in Nm. ▲ = Lubricate using two-stroke oil. ■ = Lubricate using saw chain oil. ● = Lubricate using grease. = Locking fluid (Loctite). 20 – English Eng, p 2-39 20 96-09-13, 09.
SERVICE DATA 6 15 ▲ 4 4 ● 4 28 3 English – Eng, p 2-39 21 96-09-13, 09.
SERVICE DATA Saws 42, 242 and 246 ● 5 8-10 7-8 242 4-5 42 246 15 5 10 ● 242 ▲ 4 ▲ ■ ● 42 246 8 Character key 3 Numbers by components that are bolted refer to the tightening torque in Nm. ▲ = Lubricate using two-stroke oil. ■ = Lubricate using saw chain oil. ● = Lubricate using grease. = Locking fluid (Loctite). ● ● 22 – English Eng, p 2-39 22 96-09-13, 09.
SERVICE DATA 2 3 20 9 13 ▲ ▲ 2 2 ● 2 4 4 28 6 9 2 English – Eng, p 2-39 23 96-09-13, 09.
SERVICE DATA Saws 40 and 45 ● 3-4 2-3 7-8 25-35 ■ ● 2-3 ▲ ● ▲ ● 2-3 Character key 2-3 Numbers by components that are bolted refer to the tightening torque in Nm. ▲ = Lubricate using two-stroke oil. ■ = Lubricate using saw chain oil. ● = Lubricate using grease. = Locking fluid (Loctite). 10-12 24 – English Eng, p 2-39 24 96-09-13, 09.
SERVICE DATA 2-3 3-4 2-3 2-3 20 2-3 ▲ 2-3 2-3 8-10 2-3 ● 3-4 2-3 25-30 2-3 English – Eng, p 2-39 25 96-09-13, 09.
SERVICE DATA ● Saws 51 and 55 4-5 7-8 15 30-40 6-8 ■ ▲ ▲ ● 3-4 ● 3-4 1,5-2 8-10 Character key 3-4 ● Numbers by components that are bolted refer to the tightening torque in Nm. ▲ = Lubricate using two-stroke oil. ■ = Lubricate using saw chain oil. ● = Lubricate using grease. = Locking fluid (Loctite). ● 26 – English Eng, p 2-39 26 96-09-13, 09.
SERVICE DATA 3-4 3-4 3-4 15 8-10 12-14 ▲ 3-5 ● 1-2 25 3-4 3-4 Eng, p 2-39 27 96-09-13, 09.
SERVICE DATA ● Saws 254 and 257 254 5 10 5 257 5 10 15 35 4 ■ ▲ ▲ ● 8 ● Character key ● 3 ● Numbers by components that are bolted refer to the tightening torque in Nm. 5 ▲ = Lubricate using two-stroke oil. ■ = Lubricate using saw chain oil. ● = Lubricate using grease. = Locking fluid (Loctite). 3 28 – English Eng, p 2-39 28 96-09-13, 09.
SERVICE DATA 3 4 20 10 13 ▲ 5 4 254 ● 2 3 4 9 28 5 English – Eng, p 2-39 29 96-09-13, 09.
SERVICE DATA Saw 262 ● 5 4 6 10 15 4 35 ■ ▲ ▲ ● 8 ● ● Character key 4 ● Numbers by components that are bolted refer to the tightening torque in Nm. 4 ▲ = Lubricate using two-stroke oil. ■ = Lubricate using saw chain oil. ● = Lubricate using grease. = Locking fluid (Loctite). 3 30 – English Eng, p 2-39 30 96-09-13, 09.
SERVICE DATA 2 4 9 20 13 ▲ 5 5 4 4 ● 2 3 4 9 28 5 English – Eng, p 2-39 31 96-09-13, 09.
SERVICE DATA ● Saws 61, 268 and 272 2 5 10 6 6 10 15 6 35 61 35 ▲ 5 ● ■ ▲ 268 272 ● 1 4 8 Character key ● Numbers by components that are bolted refer to the tightening torque in Nm. ▲ = Lubricate using two-stroke oil. ■ = Lubricate using saw chain oil. ● = Lubricate using grease. = Locking fluid (Loctite). 3 ● 32 – English Eng, p 2-39 32 96-09-13, 09.
SERVICE DATA 3 1 3 61 1 3 1 15 3 10 268 272 14 ▲ 5 4 6 6 4 ● 272 3 4 3 28 4 9 English – Eng, p 2-39 33 96-09-13, 09.
SERVICE DATA Saws 281 and 288 ● 5 13 4 6 15 ■ ▲ 35 ▲ 5 ● ● 8 Character key ● Numbers by components that are bolted refer to the tightening torque in Nm. ▲ = Lubricate using two-stroke oil. ■ = Lubricate using saw chain oil. ● = Lubricate using grease. = Locking fluid (Loctite). ● 34 – English Eng, p 2-39 6 34 96-09-13, 09.
SERVICE DATA 4 3 6 20 11 17 ▲ 7 7 1 7 3 6 ● 4 4 3 35 7 9 English – Eng, p 2-39 35 96-09-13, 09.
SERVICE DATA ● Saw 394 5 10-12 15 6-8 ● ▲ 2-4 ■ ● ▲ 7-9 ● Character key Numbers by components that are bolted refer to the tightening torque in Nm. ▲ = Lubricate using two-stroke oil. ■ = Lubricate using saw chain oil. ● = Lubricate using grease. = Locking fluid (Loctite). ● 36 – English Eng, p 2-39 36 96-09-13, 09.
SERVICE DATA 5-6 20-22,5 10-12 ▲ 3-5 12-14 6 ▲ 3-5 5-6 ● 4-5 30-40 2-3 English – Eng, p 2-39 37 96-09-13, 09.
SERVICE DATA Saw 3120 ● 5 4 12 15 5 38 ▲ ■ ▲ 5 ● 3 1 ● 8 7 ● 5 5 7 Character key Numbers by components that are bolted refer to the tightening torque in Nm. 8 ▲ = Lubricate using two-stroke oil. ■ = Lubricate using saw chain oil. ● = Lubricate using grease. = Locking fluid (Loctite). ● 38 – English Eng, p 2-39 38 96-09-13, 09.
SERVICE DATA 3 5 7 17 5 20 12 10 ▲ 12 8 ▲ 5 6 3 ● 4 40 4 9 4 English – Eng, p 2-39 39 96-09-13, 09.
TROUBLE SHOOTING Trouble shooting schematic Faults that can develop on the chain saw are divided into four groups as follows. In each category, possible malfunctions are shown on the left, with a list of possible faults on the right. The most probable fault is given first and so on. Idling (low rpm) (cont.
TROUBLE SHOOTING Acceleration and retardation High rpm Will not run at full throttle Adjust H-screw Blocked air filter Blocked fuel tankbreather Blocked fuel filter Fuel line blocked Loose or damaged fuel line Impulse channel leaking Impulse channel blocked Loose cover on carburettor pump side Faulty pump diaphragm Leaking manifold Loose carburettor mounting Control system set too low Control system damaged Control system incorrectly assembled Leaking control diaphragm/cover Control system sticking Blocke
SAFETY EQUIPMENT Chain brake A Dismantling Dismantle the clutch cover and clean. See the operating instructions. Slide the hand guard forwards so that the brake is actuated. Loosen the screw on the hand guard and screw back 2 turns. Gently hit the screw so that the threaded part of the bushing can be removed. Dismantle the other part of the bushing by means of a punch. Remove the cylindrical pin A. All saws except 3120 Remove the cover on the chain brake spring. The cover has 4 or 5 screws.
SAFETY EQUIPMENT 3120 All saws except 3120 Slide up the back edge of the spring with a screwdriver. Carefully unscrew the vice so that the pressure rod and the ratchet move out of the clutch cover. Dismantle the pressure rod from the brake band. Use a punch to knock out the pin holding the knee link. Remove the screw that holds the fixed end of the band.
SAFETY EQUIPMENT Cleaning and Inspection Clean and inspect all parts. The thickness of the brake band must not be under 0.8 mm at any point. Min. 0.8 mm Assembly Fit the band's fixed end into position on the clutch cover. All saws except 3120 3120 Grease the knee link and knock in the tubular pin that holds the knee link. Fit the screw that holds the band's fixed end. Continues on next page. 3120 continues on next page. 44 – English Eng, p 40-82 44 96-09-13, 10.
SAFETY EQUIPMENT All saws except 3120 Slide the spring over the knee link's stud and press down the opposite end of the spring into its recess. Fit the cover over the spring. 3120 Fit the spring and screw onto the pressure rod on the brake band. Note! Plastic sleeve. Bottom the screw onto the pressure rod thread and back off 4-5 turns. ! WARNING! If the clutch cover slides out of the vice's grip the spring can fly out with immense force resulting in personal injury! Grease and fit the ratchet.
SAFETY EQUIPMENT All saws except 3120 3120 Carefully tighten the vice until the hole for the tubular pin and the ratchet align. Fit the hand guard, the two bushings and the screw. Carefully knock in the pin. Fit the cylindrical pin. Pull back the hand guard so that the brake is not actuated. Check the chain brake as described on the next page. 46 – English Eng, p 40-82 46 96-09-13, 10.
SAFETY EQUIPMENT Checking brake operation ! WARNING! After repair, the chain brake must be checked as set out in the following instructions. The engine should not be running during the test. Test that the chain brake comes on as follows: Hold the chain saw above a firm surface. The distance between the bar and the surface are shown in the table below.
SAFETY EQUIPMENT Chain catcher Description The chain catcher is intented to catch the chain if it should break. The chain catcher has a different design and is secured differently on the chain saws described in this manual. The following designs are used: • Aluminium angle. • Plastic angle. • Fixed roller. • Rotating roller. The following securing methods are used: • Using screws on the crankcase. • Using screws on the spike. • Using nuts on the spike. Replacing Dismantle the chain and bar.
SAFETY EQUIPMENT Muffler Dismantling ! B WARNING! Do not touch the muffler until it has cooled. Risk of burns! C If the saw is equipped with muffler mounting (A), unscrew this from the crankcase and muffler. A Unscrew the muffler from the cylinder (M5 or M6 bolts, M5 or M6 nuts). Remove the muffler, gasket and cooling plate (B) if the saw is so equipped. If the saw is equipped with a spark arrester (C), remove this.
SAFETY EQUIPMENT Cleaning and Inspection ! WARNING! The coating on and in the catalytic converter element (A) is hazardous to your health if touched. Wear protective gloves when working on a catalytic converter Clean all parts and check the following: • That the muffler and muffler mountings are not cracked or otherwise damaged. • That the gaskets are OK. Assembly Clean all contact surfaces. Assemble the muffler and fit to the cylinder. Tightening torque, see page 20.
SAFETY EQUIPMENT Stop switch A Dismantling Remove the earth screw (A) and cable (B). Press the switch's securing tabs (C) towards each other and push out the switch. B C Cleaning and Inspection Clean the switch and check its resistance as follows: Connect an ohm meter as shown in the fig. The resistance should be: In the stop position less than 0.1 ohm. In the run position more than 1000 ohm. Assembly Press the switch into the socket on the tank unit. Fit the earth screw (A) and cable (B).
SAFETY EQUIPMENT Throttle lock Dismantling Saws 40, 45. Other saws. ! WARNING! The fuel used in the chain saw poses the following hazards: 1. The liquid and its vapours are poisonous. 2. Can cause skin irritation. 3. Is highly inflammable. See continuation on next page. Remove the tank unit from the engine assembly. See page 103. Dismantle the throttle lock pin (A) using a punch. A Saw 394 Turn the throttle lock as shown in the figure, and lift it out with the spring from the cut-out in the handle.
SAFETY EQUIPMENT Saws 61, 268, 268K, 272XP, 272K, 272S, 281XP, 288XP and 394. Dismantle the throttle pin (B) by using a punch. B Saws 36, 41, 42, 55, 242XP, 246, 51, 254XP, 257 and 262XP. Remove the rubber element (A). Slide out the throttle pin (B) and lift out the throttle arm and spring. B A A Saw 3120 Dismantle the throttle. On saw 394, also remove the throttle cable. Remove the three pins with a punch.
SAFETY EQUIPMENT Cleaning and inspection Clean all parts. Check that the lock's activation mechanism is not worn. For examples of the activation mechanism, see the figure. Check that the springs, where fitted, are OK and have the correct tension. On those saws fitted with a throttle cable, check that the cable and lever are OK and run freely. 54 – English Eng, p 40-82 54 96-09-13, 10.
SAFETY EQUIPMENT Assembly Saws 36, 40, 41, 45, 42, 242XP, 246, 51, 55, 254XP, 257 and 262XP. Other saws. ! WARNING! The fuel used in the chain saw poses the following hazards: 1. The liquid and its vapours are poisonous. 2. Can cause skin irritation. 3. Is highly inflammable. Fit springs in appropriate cases. Saws 36, 41, 42, 242XP, 246, 51, 55, 254XP, 257, 262XP and 394. Saws 61, 268, 268K, 272XP, 272K, 272S, 281XP and 288XP. See next page. Saws 40, 45. Saw 3120.
SAFETY EQUIPMENT Saws 36, 41, 42, 242XP, 246, 51, 55, 254XP, 257, 262XP and 394. Saws 61, 268, 268K, 272XP, 272K, 272S, 281XP and 288XP. Saw 3120. Fit the throttle lock and spring. On saw 394, twist as shown in the figure when fitting. Fit the throttle arm and spring. Fit the pin and the two rubber dampers. Fit the three pins that hold the cable bracket, throttle lock and trigger. Fit the throttle lock from the front. Fit the throttle lock pin. Fit the tank unit. See page 105.
STARTER Dismantling Dismantle the starter See the operating instructions. Pull out the cord 20-30 cm andinsert it into the cut-out in the starter pulley rim. Some saws have several long cut-outs. Rotate the starter pulley anticlockwise until the spring-tension on the starter pulley ceases. Dismantle the starter pulley's centre bolt and washer.
STARTER Cleaning and Inspection ! WARNING! Ensure that the spring does not fly out and cause personal injury! Clean all parts and check the following: The starter cord. The dogs in the starter pulley. That the pawls on the flywheel are OK, and spring back towards the centre and move freely. Changing the ferrule Remove the parts of the old ferrule. Fit the new ferrule in the starter housing. B A Use a wrench, spacer (A) and ball (B). Splay out the ferrule on the inside as shown in the figure.
STARTER Assembly ! WARNING! Ensure that the spring does not fly out and cause personal injury! If a new spring is to be fitted, position in its security/holder so that the eye is over the stud in the starter cover. Slide in the spring and remove the security/ holder. If a new cord is to be fitted, put the free end in the hole on the starter pulley. Grip the end using long nosed pliers and pull the cord through. 36 and 41. 61, 268, 272, 281 and 288. 42, 242, 246, 51, 55, 254, 257,262, 394 and 3120.
STARTER Grease the return spring and starter pulley bearing. If the starter unit has a cover plate (B) over the spring, fit the plate. B Fit the starter pulley. Rotate back and forth until the starter pulley catches in the spring. Fit the starter pulley washer and bolt and tighten the bolt to 4 Nm. If the starter has a cord guide (A), fit this. Pull out the cord through the hole in the cover and fit the handle, secure with a double knot.
ELECTRICAL SYSTEM Ignition system In the event of a fault in the ignition system the ignition module should be checked before dismantling the ignition system. Check the ignition module as follows: • Connect test spark plug 502 71 13-01 to the HT lead and clamp the test spark plug to the cylinder. • Turn the engine over using the starter. • If the test spark plug sparks the ignition module is OK. Dismantling Remove the cylinder cover and the starter unit. Remove the spark plug and fit the piston stop.
ELECTRICAL SYSTEM All saws except 36 and 41. Unscrew the two pawls and springs located on the flywheel. Fit puller 502 51 49-02 and loosen the flywheel. Remove the puller, nut and flywheel. Loosen the flywheel nut and undo until it aligns with the end of the shaft. Continuation all saws Remove the ignition coil. The generator can be unscrewed if the saw is fitted with a handle heating system. Remove all parts so that the cable can be released. See applicable sections.
ELECTRICAL SYSTEM Cleaning and Inspection Clean all parts, especially the flywheel and shaft taper. Check that the flywheel is not cracked or damaged in any other way. Assembly Fit the generator if the saw is fitted with handle heating. Tighten the bolts to 4 Nm and lock using Loctite. Fit the cable to the actual contact on the saw. Adjust the length of the cable by knotting it. Place the flywheel on the crankshaft.
ELECTRICAL SYSTEM • Insert feeler gauge 502 51 34-02 (0.3 mm) between the ignition module and the flywheel's magnet. • Push the ignition module towards the flywheel and tighten the bolts to 4 Nm. Fit the guide rail, insert the cables and fit the cable to the ignition module. Saws 42, 242, 246, 281 and 288. Fit the ignition coil, which is located next to the carburettor and connect the cables. Fit the starter and cylinder cover. Other saws. Fit the starter and cylinder cover.
ELECTRICAL SYSTEM Handle heating Description Some saws are equipped with an electric handle heating. This consists of the following parts: • Generator. • Power switch. • Heater loop in the tank unit. • Handle loop with heater loop. (One or two loops). B The above components are connected in series, which means that if there is a fault in one, all components stop working. The wiring diagram is shown in the figure to the right. The order of components can vary from saw to saw.
ELECTRICAL SYSTEM Checking the generator Check the handle loop Connect the ohm meter to the cylinder (point A1) and point B. The ohm meter should read 0.9-1.3 ohm. Replace a generator that has higher or lower values. Connect the ohm meter to points B and C. The ohm meter should read 3-4 ohm. Replace the handle loop that has a higher value. B B C A1 Checking the heat loops in the rear handles Connect the ohm meter to points C and D. The ohm meter should read 0.7-2.5 ohm.
CENTRIFUGAL CLUTCH Dismantling Remove the bar and chain. See the operating instructions. On 268K and 272K, remove the cutting attachment. See the operating instructions. On 272S, remove the grinder attachment. See the operating instructions. Remove the spark plug and insert the piston stop. Use a spanner and remove the clutch. On saws 36 and 41 use the service tool no. 530 03 11-12. Note! Left-hand thread. Saws with three coil springs. Saws with one long spring. Remove the springs using a screwdriver.
CENTRIFUGAL CLUTCH Cleaning and Inspection Clean all parts and inspect the following: Clutch shoes without chamfers. That measurement A is not below 1 mm. Clutch shoes with chamfers. That measurement B is not under 1 mm. A B Check that there is no play between the clutch shoe and clutch hub Check for wear on the chain sprocket. Check the condition of the needle bearing and the bearing surface on the crankshaft. That the clutch drum friction surface and bearing surface are undamaged.
CENTRIFUGAL CLUTCH Assembly Grease the needle bearing (C) and fit onto the crankshaft. Then fit the clutch drum. NOTE! The bearing can also be greased later through the hole on the crankshaft. C To prevent imbalance all clutch shoes should be replaced at the same time. Saws with three coil springs. Saws with one long spring. Locate the clutch shoes on the hub and fit the springs with the help of pliers. NOTE! The clutch springs should not be opened out more than necessary. Risk of deformation.
LUBRICATION SYSTEM Dismantling Dismantle the following parts: Saws 36, 40, 41, 45, 51 and 55. See page 72 • Starter. See the operating instructions • Centrifugal clutch. See page 67. Saw 3120. See page 72 Other saws. Remove the pump drive and washer. Saws 61, 268, 272XP. See next page. Saws 281XP and 288 XP. See next page. Undo the three bolts (A) and remove the oil pump. Some pumps have to be removed by using extractor screws.
LUBRICATION SYSTEM Saws 61, 268, 272XP. E Dismantle the oil pump as follows: C D F 1. Remove the lock washer (A), washer, spring and adjuster screw (B). 2. Remove the locking lacquer and undo screw (C). 3. Knock the edge of the pump housing against a piece of wood so that the pump piston (D) slides out of the housing. 4. Remove the pinion (E) with washers and springs. 5. Remove the pin (F). 6. Remove the seal (G). 7. If necessary remove the O-ring (H). B G A H Saws 281XP and 288 XP.
LUBRICATION SYSTEM Saw 394. Dismantle the oil pump as follows: C 1. Dismantle the screw (A) so that the spring and latch pin (B) can be removed. 2. Lever out the pump piston (C) with the plastic plug (D) using a screwdriver. 3. Remove the seal (E). B D E A Saw 3120. Dismantle the oil pump as follows: 1. Undo the screws (A) and remove the parts as shown in the figure below. 2. Undo screw (B). NOTE! Left-hand thread.
LUBRICATION SYSTEM Saws 36, 40, 41, 45, 51 and 55. Dismantle the chain guide plates as shown in respective diagrams below. 36/41 Saws 36, 40, 41 and 45. Undo the two bolts and lift off the pump and the upper seal. 40/45 51/55 Saws 51 and 55. Lift off the pump and the upper seal. Take the pump apart as shown in the exploded view on the next page. English – Eng, p 40-82 73 96-09-13, 10.
LUBRICATION SYSTEM D E F G E F G B C C B A A 40/45 36/41 D C B E F G A. B. C. D. E. F. G. A 50/51 74 – English Eng, p 40-82 74 96-09-13, 10.31 Lower seal. Pump cylinder. Upper seal. Chain guide plate. Pump housing. Pump piston. Worm gear.
LUBRICATION SYSTEM Dismantling the oil pump's worm gear On some saws the worm gear for the oil pump is pressed on the crankshaft. Remove the worm gear by using the service tool for the saw in question. See "Tools". First screw the tool onto the entire worm gear Turn the screw until the worm gear is removed. English – Eng, p 40-82 75 96-09-13, 10.
LUBRICATION SYSTEM Cleaning and Inspection Clean all parts and check the following when appropriate to the saw in question. That the taper on the adjuster screw shows no signs of wear. That the pump piston's eccentric face does not show signs of wear. That the pump piston's pinion gear is undamaged. That the worm gear on the oil pump drive is undamaged. That all seals are undamaged. The oil pipe is not blocked and the filter screen is clean. 76 – English Eng, p 40-82 76 96-09-13, 10.
LUBRICATION SYSTEM Assembling the worm gear Screw the worm gear into the dismantling tool and press the worm gear onto the crankshaft until it bottoms against the collar. On those saws where the oil pump worm gear is pressed on the crankshaft. Assembling the oil pump Saws 42, 242XP, 246, 254XP, 262XP and 257. Fit the oil pump as follows: 1. Apply SAE 30 oil to all moving parts. 2. Insert the pump piston (D) with washers and spring. 3.
LUBRICATION SYSTEM Saws 281XP and 288 XP. Fit the oil pump as follows: C 1. Apply SAE 30 oil to all moving parts 2. Fit the seal (E) if necessary. 3. Fit the plug (B) and spring with washers on the pump piston (C) and fit the unit in the pump housing. 4. Fit the adjuster screw (A) in the pump housing, and through the hole in plug (B). 5. Fit the O-rings (D) and (F). F A D E Saw 394. See continuation, page 80. Fit the oil pump as follows: C 1. Apply SAE 30 oil to all moving parts. 2.
LUBRICATION SYSTEM Saw 3120. Fit the oil pump as follows: 1. Apply SAE 30 oil to all moving parts 2. Fit the seal (C). 3. Fit the pump piston (D) with spring. Press in the piston and hold it in position with a screwdriver from the pump housing's inside in slot (E). 4. Fit screw (B) so that it is positioned approx. one turn from the bottom. NOTE! Left-hand thread 5. Fit lever arm (F). 6. Fit units (B-F-G) with spring (H) and screw in position using screws (A) and latch (J). 7. Remove the screwdriver. 8.
LUBRICATION SYSTEM Saws 42, 61, 242, 246, 254, 257, 262, 268, 272, 281, 288, 394 and 3120. Saws 61, 268, 272, 281 and 288 Use the tapered sleeve which is placed on the shaft when fitting the oil pump. Otherwise the seals will be damaged. 1. Lubricate the pinion gear with grease. 2. Fit the oil pump on the saw by tightening the three bolts. 3. If the tapered sleeve has been used, remove it. 4. Fit the centrifugal clutch. See page 69. 5. Fit the bar and chain. 6.
LUBRICATION SYSTEM Saws 36, 40, 41, 45, 51 and 55. Fit the oil pump as follows: A. B. C. D. E. F. G. 1. Apply SAE 30 oil to all moving parts. 2. Fit the worm gear (G) on the crankshaft, if necessary 3. Fit the pump piston (F) in the pump cylinder (B). 4. Fill the pump recess with grease. 5. Fit the unit in the pump housing (E). Ensure the pump cylinder's cut-out aligns in the pump housing. 6. Fit the lower seal (A) on the crankcase. D E F G Lower seal. Pump cylinder. Upper seal. Chain guide plate.
LUBRICATION SYSTEM Saws 36, 40, 41 and 45. Saws 51 and 55. Fit the oil pump in the crankcase and fit the upper seal. Fit the oil pump in the crankcase, tighten the two bolts and fit the upper seal. Fit the chain guide plates according to respective diagrams below. 36/41 40/45 51/55 Fit the bar and chain. 82 – English Eng, p 40-82 82 96-09-13, 10.
CARBURETTOR Description The diagrams in this description do not correspond with the carburettor fitted on the chain saws. They serve only to show the principles of design and operation. ! WARNING! The fuel used in the chain saw poses the following hazards: 1. The liquid and its vapours are poisonous. 2. Can cause skin irritation. 3. Is highly inflammable. Design The carburettor consists of three sub-systems: • Metering unit, A. • Mixing venturi, B. • Pump unit, C.
CARBURETTOR Operation The carburettor operates differently in the following modes: • Cold start • Idling • Part throttle • Full throttle In the cold start mode the choke valve (D) is fully closed. This increases the vacuum in the carburettor and fuel is easier to suck from all the diffuser jets (E, F and G). The throttle valve (H) is partly open. D E F G In the idling mode (H) the throttle valve is closed.
CARBURETTOR Dismantling ! WARNING! The fuel used in the chain saw poses the following hazards: 1. The liquid and its vapours are poisonous. 2. Can cause skin irritation. 3. Is highly inflammable. Dismantle all parts necessary and remove the carburettor from the saw. On some models the cylinder needs to be loosened and lifted to be able to remove the carburettor. See the carburettor in question on the next four pages and the instructions below.
CARBURETTOR Tillotson HS 228 B E 1. Remove the cover (A) over the metering unit and carefully remove the control diaphragm (B) with the gasket. F G 2. Undo the screw (H) and take out the needle valve (C) with lever arm, shaft and spring. D 3. Remove the cover (E) over the pump unit and carefully remove the gasket (F) and the pump diaphragm (G). J 4. Using a needle or the like carefully remove the fuel screen (D). C 5. Unscrew the high and low speed jet screws. H B 6. Remove the plugs (J).
CARBURETTOR Tillotson HS 260 A E 1. Remove the cover (A) over the metering unit and carefully remove the control diaphragm (B) with the gasket. F G 2. Undo the screw (H) and take out the needle valve (C) with lever arm, shaft and spring. D 3. Remove the cover (E) over the pump unit and carefully remove the gasket (F) and the pump diaphragm (G). J H 4. Using a needle or the like carefully remove the fuel screen (D). C 5. Unscrew the high and low speed jet screws. 6. Remove the plugs (J). See page 85.
CARBURETTOR Walbro WJ E 1. Remove the cover (A) over the metering unit and carefully remove the control diaphragm (B) with the gasket. 2. Undo the screw (H) and take out the needle valve (C) with lever arm, shaft and spring. 3. Remove the cover (E) over the pump unit and carefully remove the gasket (F) and the pump diaphragm (G). 4. Using a needle or the like carefully remove the fuel screen (D). F G D J C K 5. Unscrew the high and low speed jet screws. 6. Remove the plug (J). See page 85. 7.
CARBURETTOR Walbro WT E 1. Remove the cover (A) over the metering unit and carefully remove the control diaphragm (B) with the gasket. 2. Undo the screw (H) and take out the needle valve (C) with lever arm, shaft and spring. F D G 3. Remove the cover (E) over the pump unit and carefully remove the gasket (F) and the pump diaphragm (G). 4. Using a needle or the like carefully remove the fuel screen (D). C J 5. Unscrew the high and low speed jet screws. 6. Remove the plug (J). See page 85. 7.
CARBURETTOR Cleaning and Inspection ! WARNING! The fuel used in the chain saw poses the following hazards: 1. The liquid and its vapours are poisonous. 2. Can cause skin irritation. 3. Is highly inflammable. Clean all components in petrol. Wear gloves or skin protection cream. ! WARNING! Never direct the compressed air jet towards the body. Air can be forced into the blood stream and can cause fatality. Use compressed air to dry the petrol on the components.
CARBURETTOR Assembly Refer to the carburettor in question on the next eight pages. A pressure test, see page 100, should be carried out after assembling and before the carburettor is refitted to the saw. ! WARNING! The fuel used in the chain saw poses the following hazards: 1. The fluid and its vapours are poisonous. 2. Can cause skin irritation. 3. Is highly inflammable. ”Semi fixed jet”/”fixed jet” Plugs When cleaning the carburettor the plugs must be removed. Reassemble as follows: 1.
CARBURETTOR Tillotson HS 228 B E Maintain a high level of cleanliness when reassembling the carburettor. Even small particles of dirt can cause operating problems. 1. If the throttle and choke valves, shafts, lever arms and springs have been dismantled these must be reassembled. Lubricate the shaft bearings using a light oil. F G D 2. Fit the plugs (J). See page 91. 3. Fit the high and low jet screws and springs. NOTE! Do not tighten the screws against the seats.
CARBURETTOR Tillotson HS 255 B D Maintain a high level of cleanliness when reassembling the carburettor. Even small particles of dirt can cause operating problems. 1. If the throttle and choke valves, shafts, lever arms and springs have been dismantled these must be reassembled. Lubricate the shaft bearings using a light oil. 2. Fit the plugs (J). See page 91. F G I J H 3. Fit the ”semi fixed jet” (K). See page 91. 4. Fit the high and low jet screws and springs.
CARBURETTOR Tillotson HS 260 A E Maintain a high level of cleanliness when reassembling the carburettor. Even small particles of dirt can cause operating problems. 1. If the throttle and choke valves, shafts, lever arms and springs have been dismantled these must be reassembled. Lubricate the shaft bearings using a light oil. 2. Fit the plugs (J). See page 91. F G D J H 3. Fit the ”semi fixed jet” (K). See page 91. 4. Fit the high and low jet screws and springs.
CARBURETTOR Walbro HDA och HD A B Maintain a high level of cleanliness when reassembling the carburettor. Even small particles of dirt can cause operating problems. H C 1. If the throttle and choke valves, shafts, lever arms and springs have been dismantled these must be reassembled. Lubricate the shaft bearings using a light oil. J 2. Fit the plugs (J). See page 91. 3. Fit the high and low jet screws and springs. NOTE! Do not tighten the screws against the seats.
CARBURETTOR Walbro WJ E F Maintain a high level of cleanliness when reassembling the carburettor. Even small particles of dirt can cause operating problems. 1. If the throttle and choke valves, shafts, lever arms and springs have been dismantled these must be reassembled. Lubricate the shaft bearings using a light oil. G D J 2. Fit the plugs (J). See page 91. 3. Fit the ”semi fixed jet” (K). See page 91. 4. Fit the high and low jet screws and springs. NOTE! Do not tighten the screws against the seats.
CARBURETTOR Walbro WG A B Maintain a high level of cleanliness when reassembling the carburettor. Even small particles of dirt can cause operating problems. H C 1. If the throttle and choke valves, shafts, lever arms and springs have been dismantled these must be reassembled. Lubricate the shaft bearings using a light oil. K J 2. Fit the plugs (J). See page 91. 3. Fit the ”fixed jet” (K). See page 91. 4. Fit the high and low jet screws and springs. NOTE! Do not tighten the screws against the seats.
CARBURETTOR Walbro WT E Maintain a high level of cleanliness when reassembling the carburettor. Even small particles of dirt can cause operating problems. F D G 1. If the throttle and choke valves, shafts, lever arms and springs have been dismantled these must be reassembled. Lubricate the shaft bearings using a light oil. C 2. Fit the plugs (J). See page 91. J 3. Fit the ”semi fixed jet” (K). See page 91. 4. Fit the high and low jet screws and springs. NOTE! Do not tighten the screws against the seats.
CARBURETTOR ZAMA C1Q-EL1 Maintain a high level of cleanliness when reassembling the carburettor. Even small particles of dirt can cause operating problems. A B 1. If the throttle and choke valves, shafts, lever arms and springs have been dismantled these must be reassembled. Lubricate the shaft bearings using a light oil. 2. Fit the high and low jet screws and springs. NOTE! Do not tighten the screws against the seats. This can damage the seats and needle tips. 3.
CARBURETTOR Pressure testing Pressure testing should be carried out with the carburettor fully assembled. Testing should always be carried out after the carburettor has been repaired, but a test can also be made for trouble shooting before dismantling. ! WARNING! The fuel used in the chain saw poses the following hazards: 1. The liquid and its vapours are poisonous. 2. Can cause skin irritation. 3. Is highly inflammable. Make the test as follows: 1.
AIR FILTER Replace the chain saw’s air filter at the intervals stated in respective operating instructions. It is extremely important that the air filter units on power cutters 268K, 272K and stump grinder 272S are maintained correctly. The air filter units on these models have therefore been included in this workshop manual. 268K, 272K and 272S A The air filter system consists of: 1. Prefilter. 2. Main filter.
AIR FILTER Main filter The main filter is a paper filter and is accessible under the cover (B). This filter should be replaced/cleaned when the saw’s power decreases or after 1-2 weeks. The filter is cleaned either by shaking or carefully blowing clean with compressed air. Note. The filter must not be washed. B 102 – English Eng, p 83-124 102 96-09-13, 11.
TANK UNIT Dismantling Empty the tank and dismantle the cylinder cover as well as the bar and chain. ! WARNING! The fuel used in the chain saw poses the following hazards: 1. The liquid and its vapours are poisonous. 2. Can cause skin irritation. 3. Is highly inflammable. Loosen the fuel pipe and disconnect the throttle cable if fitted. The figures on the next page illustrate all types of mountings between the tank unit and the engine sub-assembly marked by letters.
TANK UNIT A B C D E L K J I F H Saw Bolts placed at 36 40 41 A, D, F, K Has no tank unit A, D, F, K 257 262XP 268 A, D, F, L A, D, F, L A, C, D, F, G, K 42 45 51 A, D (under a cover) F, G, L Has no tank unit A, D, F, L (all under covers) 268K 272XP 272K A, C, D, F, G, K A, C, D, F, G, K A, C, D, F, G, K 55 61 242XP A, D, F, L (all under covers) A, C, D, F, G, K A, D (under a cover) F, G, L 272S 281XP 288XP A, C, D, F, G, K A, C, D, F, G, K A, C, D, F, G, K 246 254XP A, D (under a cover) F
TANK UNIT Assembly If a new fuel pipe is to be fitted proceed as follows: 1. Measure the length of the old hose outside of the tank unit, note the length. 2. Oil half of the hose lightly and thread the oiled part into the fuel tank from the outside. 3. Twist the hose so that it takes on the same angle to the carburettor and let the hose protrude as much as the old hose did. 4. Pull the hose through the filler hole using tool 502 50 83-01, cut off the bevelled end and fit the fuel filter.
ANTI-VIBRATION SYSTEM Description The anti-vibration system reduces the vibrations which pass from the engine and cutting equipment to the handles. The anti-vibration system consists either of rubber elements or coil springs. The system’s movement limitation consists of side absorbers and/or stop screws. Dismantling The tank unit must be removed from the engine sub-assembly to access the anti-vibration system. See the previous pages. Saw 394 Release the catch on the plastic key.
ANTI-VIBRATION SYSTEM Assembly Fit the rubber stop with the help of a wire or the like. Fitting the anti-vibration system’s side absorber. Fitting the anti-vibration system’s damper element. Tightening torques, see the ”Service data” for respective saws. Saw 394 Slide in the spring and its holder. Saws 40, 45 and 3120 Other saws Fit the rubber element using the tools shown in the figure below. Fit the spring element using an allen key as shown in the figure below.
PISTON AND CYLINDER Dismantling Dismantle the following parts: • Cylinder cover. See operating instructions. • Spark plug. See operating instructions. • Carburettor. • Muffler. Saws 36, 40, 41 and 45. Other saws Dismantle the insulation plate between the cylinder and the carburettor and the intake manifold. On saw 394, disconnect the anti-vibration spring (A) from the cylinder. On all chain saws, undo the four cylinder bolts (B).
PISTON AND CYLINDER Cleaning and Inspection Clean all parts, scrape off any gasket residue remove carbon deposits from the following areas: 1. The piston crown. 2. The top of the cylinder bore. 3. The cylinder exhaust port. 4. The decompression valve channel. Check the following: 1. That the cylinder’s surface coating is not worn, especially the upper part of the cylinder. 2. That the cylinder is free of score marks. 3. That the piston is free of score marks. See ”Faults and causes” on the next page.
PISTON AND CYLINDER On saws 40 and 45, check the rubber sealing on the shaft seat. Change the shaft seat, if necessary. Faults and causes Score marks on the piston. 1. Incorrect carburettor setting max. speed too high 2. Too low octane fuel. 3. Too little or incorrect oil in the fuel. Carbon build-up 1. Incorrect carburettor setting max. speed too low. 2. Too much or incorrect oil in the fuel. Piston ring breakage 1. Excessive engine speed 2. Piston ring worn out. 3. Oversized piston ring groove.
PISTON AND CYLINDER Assembly NOTE! Ensure that no dirt or other foreign particles fall into the crankcase. Oil the needle bearing and fit it into the connecting rod little end. Refit the piston with the arrow facing the exhaust port. Slide in the gudgeon pin and fit the circlip. Other saws Saws 36, 40, 41 and 45 Fit a new cylinder gasket Oil the piston and piston ring. Compress the piston ring either by hand or by using tool 502 50 70-01. Carefully fit the cylinder.
PISTON AND CYLINDER Other saws Saws 36, 40, 41 and 45. Fit the four bolts under the crankcase. Tightening torque, see ”Service data”. Saws 36 and 41. Saws 40 and 45. Fit the four cylinder bolts (B). On saw 394, connect the anti-vibration spring (A) to the cylinder. The bolts are tightened using a 4 mm allen key (smaller saws) or 3/16” allen key (larger saws). Fit the tank unit. B A Fit the ignition coil and its cables.
PISTON AND CYLINDER Pressure testing Decompression valve Test the decompression valve as follows. 1. Connect the tool 502 50 38-01 to the decompression valve 2. Pump up the pressure to 80 kPa (0.8 bar). 3. Wait 30 seconds. 4. The pressure should not drop below 60 kPa (0.6 bar). Crankcase and cylinder The following parts must be removed to pressure test the crankcase and cylinder: • Carburettor. • Muffler. Carry out the test as follows: 1.
CRANKCASE AND CRANKSHAFT This section deals with the following: • Crankcase and crankshaft (describes how the whole assembly is dismantled and assembled). • Bar bolts (only describes replacing the bar bolts). See page 121. • Seals. Describes changing the seals without splitting the crankcase. See page 122. Dismantling Before the crankcase can be split the following must be removed: A. Chain and bar. See operating instructions. B. Starter. See page 57. C. Electrical system. See page 61.
CRANKCASE AND CRANKSHAFT Press out the crankshaft by using tool 502 51 61-01. If necessary remove the crankshaft bearing from the crankcase. Proceed as follows: ! WARNING! The crankcase halves can be hot. Risk of burns. Wear protective gloves. Remove all rubber and plastic components from the crankcase halves. Saws 36 and 41. Saws 40 and 45. Split the shaft support and dismantle the halves. Heat the crankcase half in question to 200°C.
CRANKCASE AND CRANKSHAFT Cleaning and Inspection NOTE! Ensure no dirt or foreign particles enter the bearings, if fitted in the crankcase halves. Clean all parts and scrape of any gasket residue from the mating surfaces of the crankcase halves. Check the following: That the big end bearing does not have any radial play. Axial play is acceptable. That the big end bearing does not have any score marks or discoloration on the sides. That the little end bearing surfaces are not scored or discoloured.
CRANKCASE AND CRANKSHAFT Assembly Saws 36 and 41. Saws 40 and 45. Other saws See page 120. Fit the bearing and seals on the crankshaft. Grease the seals. Continue assembly as described on page 111. ! WARNING! The crankcase halves can be hot. Risk of burns. Wear protective gloves. If the bearing needs to be fitted proceed as follows: A. Heat the crankcase half in question to 200°C. B. Wear protective gloves, take out the crankcase half and press in the bearing.
CRANKCASE AND CRANKSHAFT Saw 40 and 45. See page 120. Grease and fit a new crankcase gasket (A). Check that the guide pin (B) is in position and fit the other crankcase half. Other saws. NOTE! Ensure that the connecting rod does not jam against the crankcase when the crankcase and crankshaft are assembled. Using the assembly tool for the chain saw in question assemble the crankshaft in the clutch side’s crankcase half. Some saws have a sharp edge on the crankshaft which can damage the seal.
CRANKCASE AND CRANKSHAFT Other saws. Saw 40 and 45. See next page. Fit the crankcase bolts. Tighten crosswise with the torque set out in the ”Service data”. Tighten the bolts closest to the crankshaft first. NOTE! Ensure excess gasket material does not fall into the crankcase. Cut off excess gasket at the level of the cylinder seating plane. On saw 394, fit the floor of the carburettor chamber using the four bolts. A B Fit the following parts A. B. C. Chain and bar. See operating instructions.
CRANKCASE AND CRANKSHAFT Saws 40 and 45. NOTE! Ensure that dirt and foreign particles do not enter the bearing. Fit the bearing on the crankshaft by using the assembly tool. See ”Tools”. Check the shaft seat’s sealing (A). Fit the shaft seat over the bearing and join the shaft seat at (B). A B Continue assembly as described on page 111. 120 – English Eng, p 83-124 120 96-09-13, 11.
CRANKCASE AND CRANKSHAFT Bar bolts When changing the bar bolts on all saws except 40 and 45 proceed as follows: 1. Drain the chain oil. 2. Knock through the old bar bolt so that it falls in the oil tank. 3. Remove the bolt from the oil tank. 4. Attach a steel wire to the end of the new bar bolts, thread the wire through the oil tank and out through the bolt hole in the crankcase. 5. Pull the steel wire until the bolt comes out through its hole. 6.
CRANKCASE AND CRANKSHAFT Changing the seals This section describes how to change the seals without splitting the crankcase. Dismantling Before dismantling the seals remove the following parts: On the starter side: • Starter • Flywheel • Generator (if fitted) On the clutch side: • Chain and bar • Oil pump Seals fitted in the crankcase Use the dismantling tool for the saw in question and remove the seal as follows: 1. Screw the tool into the seal’s rubber part. 2.
CRANKCASE AND CRANKSHAFT Assembly Seal assembly in the oil pump B C 1. Place the oil pump on a sleeve (A) with an inner diameter greater than the seal’s outer diameter. 2. Fit the seal (B) using the assembly punch so that the surfaces (C), are level. A Seal assembly in the plastic flange 1. Place the plastic flange on a flat and firm surface. 2. Fit the seal using the assembly punch until it bottoms on the flange shoulder.
CRANKCASE AND CRANKSHAFT Assembly positions starter side Measurement A should be as in the table below for resp. saws (Under the crankcase plane). 61, 268 272 281, 288 A 4-4.5 mm 2 mm 3.5 mm Measurement B should be as in the table below for resp. saws (Under the crankcase plane). 42, 242, 246 394 3120 B 1 mm 5 mm 0-0.5 mm 51, 55 1 mm above the crankcase plane 1 mm Assembly position on the clutch side Measurement C should be as in the table below for resp. saws (Under the crankcase plane).
