Husqvarna 965030298 manual

101 88 55-26 W orkshop Manual Husqvar na Chain Saws Eng, front 96-09-13, 10.38 1[...]

2 – English LIST OF CONTENTS Introduction ..................................... 3 Safety regulations ........................... 5 T echnical Data ................................. 6 T ools ............................................... 14 Service data ................................... 20 T rouble shooting ........................... 40 Safety[...]

English – 3 INTRODUCTION As production continues, changes will be intro- duced 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. In order to avoid prob- lems, the manual should always be read[...]

4 – English INTRODUCTION Dismantling and reassembly of the entire 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. Work forwards through the manual and carry out Dismantling instructions i[...]

English – 5 SAFETY REGULA TIONS General Instructions Special instructions WARNING! The warning text indicates a risk of personal injury if instructions are not followed. NOTE! The warning text indicates a risk of damage to equipment if instructions are not followed. The chain saw is type approved with regard to safety according to applicable lega[...]

6 – English Displacement Bore Stroke Max. power at Spark plug gap Ignition system Air gap Carburettor cm 3 mm mm r/min mm/inches mm/inches TECHNICAL DA T A 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 W ALBRO WT 239 40 0.5/ .02 PHELON 0.3[...]

English – 7 Fuel tank volume Oil pump capacity Oil tank volume Automatic oil pump Litres cm 3 /min at 8.500 rpm Litres r/min r/min r/min Champion TECHNICAL DA T A 36 3000 4500 13000 RCJ 7 Y 40 2500 3600 12500 RCJ 7 Y 41 3000 4500 13000 RCJ 7 Y 42 2700 3800 14500 RCJ 7 Y 45 2500 3600 12500 RCJ 7 Y 51 2500 3700 12500 RCJ 7 Y 36 0.4 7 0.2 Y es 40 0.[...]

8 – English Displacement Bore Stroke Max. power at Bar length Chain speed Chain pitch Drive link gauge Spark plug gap Ignition system Air gap Carburettor cm 3 mm mm r/min mm/inches mm/inches cm/inches m/s inches mm/inches TECHNICAL DA T A 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 93[...]

English – 9 Idling speed Engagement speed Max. speed Spark plug Fuel tank volume Oil pump capacity Oil tank volume Automatic oil pump Weight without bar and chain Weight with bar and chain Handle heater Litres cm 3 /min at 8.500 rpm Litres r/min r/min r/min Champion kg kg/lbs W att/ r/min TECHNICAL DA T A 55 2500 3700 12500 RCJ 7 Y 61 2500 3700 1[...]

10 – English Displacemennt Bore Stroke Max. power at Bar length Chain speed Chain pitch Drive link gauge Spark plug gap Ignition system Air gap Carburettor cm 3 mm mm r/min mm/inches mm/inches cm/inches m/s inches mm/inches TECHNICAL DA T A 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 3[...]

English – 11 Idling speed Engagement speed Max. speed Spark plug Fuel tank volume Oil pump capacity Oil tank volume Automatic oil pump Weight without chain and bar Weight with chain and bar Handle heater Litres cm 3 /min at 8.500 rpm Litres r/min r/min r/min Champion kg kg/lbs W att/ r/min TECHNICAL DA T A 262XP 2700 3400 13500 RCJ 7 Y 268 2500 3[...]

12 – English Displacement Bore Stroke Max. power at Bar length Chain speed Chain pitch Drive link gauge Spark plug gap Ignition system Air gap Carburettor cm 3 mm mm r/min mm/inches mm/inches cm/inches m/s inches mm/inches TECHNICAL DA T A 281XP 81 52.0 38.0 9000 288XP 87 54.0 38.0 9300 394XP 94 56.0 38.0 8800 3120XP 1 19 60.0 42.0 9000 281XP 0.5[...]

English – 13 Idling speed Engagement speed Max. speed Spark plug Fuel tank volume Oil pump capacity Oil tank volume Automatic oil pump Weight without bar and chain Weight with bar chain Handle heater Litres cm 3 /min at 8.500 rpm Litres r/min r/min r/min Champion kg kg/lbs W att/ r/min TECHNICAL DA T A 281XP 2500 3200 12500 RCJ 6 Y 288XP 2500 320[...]

14 – English 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 71 13-01 502 51 34-02 (0,3 mm) 502 50 83-01 502 51 02-01 502 71 14-01 compl 502 50 70-01 502 50 37-01 502 70 09-01 502 50 88-01 5 mm 502 50 87-01 4 mm 502 50 86-01 3 mm 502 50 06-01 504 98 26-01 (36[...]

English – 15 4 mm 8 mm 502 50 33-01 3 mm; 4 mm; 5 mm 8 mm; 10 mm 505 26 79-12 40 > 910 1 1 16 45 > 925 1 168 50 > 925 0856 502 51 94-01 504 90 90-01 502 51 61-01 (51, 55) 502 50 30-09 502 50 79-01 (55) 40 > 910 1 1 16 45 > 925 1 168 504 90 29-02 502 54 03-01 (40, 45, 55) 502 50 46-01 (55) compl 502 50 38-01 502 50 33-01 502 51 94-0[...]

16 – English 3 mm; 4 mm 8 mm 502 50 33-01 compl 502 50 31-01 502 70 03-01 502 51 61-01 504 90 90-01 502 50 82-01 502 50 30-07 502 51 32-01 502 51 50-01 502 51 00-02 502 50 72-01 502 50 71-01 502 50 45-01 502 50 46-01 compl 502 50 38-01 *compl 502 51 49-02 3 mm; 4 mm 8 mm 502 50 33-01 502 50 72-01 502 50 71-01 502 50 45-01 502 50 46-01 compl 502 5[...]

English – 17 3 mm; 4 mm; 3/16" 8 mm 502 71 36-01 (4 mm) 502 50 33-01 compl 502 50 31-01 502 70 03-01 502 51 61-01 504 90 90-01 502 50 47-01 502 50 48-01 502 50 45-01 502 50 46-01 compl 502 50 38-01 502 50 20-01 3 mm; 4 mm; 3/16" 8 mm 502 71 36-01 (4 mm) 502 50 33-01 502 50 82-01 502 50 66-02 502 50 47-01 502 50 81-01 compl 502 50 38-01 [...]

18 – English 3 mm; 4 mm; 5 mm; 3/16" 8 mm; 10 mm 502 50 33-01 502 50 82-01 502 50 66-02 502 52 01-01 (394) 502 71 38-01 (3120) compl 502 50 38-01 504 90 90-01 502 50 52-01 502 50 30-08 502 52 04-01 (394) 502 71 40-01 (3120) 502 71 39-01 (394) T OOLS T ools for saws 394 and 3120 *compl 502 51 49-02 502 51 49-01* *502 51 54-01 502 50 26-01* En[...]

English – 19 Order number Designation 502 50 06-01 Pliers 502 50 16-01 Allen key 502 50 18-01 Allen key 502 50 19-01 Allen key 502 50 20-01 Assembly tool 502 50 22-01 Socket 502 50 23-01 Socket 502 50 26-01 Puller 502 50 30-04 Assembly tool 502 50 30-08 Assembly tool 502 50 30-09 Assembly tool 502 50 30-10 Assembly tool 502 50 31-01 Puller 502 50[...]

20 – English Saws 36 and 41 SER VICE DA T A ▲ ▲ ■ ● ● ● ● 5 10 15 4 6 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). Eng, p 2-39 96-09-13, 09.48 20[...]

English – 21 SER VICE DA T A ▲ ● 15 4 6 4 3 28 4 Eng, p 2-39 96-09-13, 09.48 21[...]

22 – English Saws 42, 242 and 246 SER VICE DA T A ▲ ▲ ■ ● ● ● ● 5 15 4 8 3 ● 242 42 246 10 5 42 246 242 7-8 8-10 4-5 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 (Loc[...]

English – 23 SER VICE DA T A ▲ ● ▲ 20 4 2 4 28 2 9 3 2 9 6 2 2 13 Eng, p 2-39 96-09-13, 09.49 23[...]

24 – English Saws 40 and 45 SER VICE DA T A ▲ ▲ ■ ● ● ● ● 3-4 2-3 25-35 7-8 2-3 2-3 2-3 10-12 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). Eng, p 2-39 96-09-[...]

English – 25 SER VICE DA T A ▲ ● 3-4 2-3 2-3 25-30 2-3 2-3 2-3 2-3 8-10 2-3 2-3 3-4 20 2-3 Eng, p 2-39 96-09-13, 09.49 25[...]

26 – English Saws 51 and 55 SER VICE DA T A ▲ ▲ ■ ● ● ● ● ● 4-5 15 6-8 7-8 30-40 3-4 3-4 8-10 3-4 1,5-2 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). Eng, p[...]

English – 27 SER VICE DA T A ▲ ● 15 25 12-14 8-10 3-4 3-4 3-4 3-5 3-4 3-4 1-2 Eng, p 2-39 96-09-13, 09.50 27[...]

28 – English Saws 254 and 257 254 257 SER VICE DA T A ▲ ▲ ■ ● ● ● ● ● 5 8 15 4 5 10 10 5 35 3 5 3 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). Eng, p 2-39 [...]

English – 29 254 SER VICE DA T A ▲ ● 5 3 2 28 4 10 20 4 13 4 9 3 5 Eng, p 2-39 96-09-13, 09.54 29[...]

30 – English Saw 262 SER VICE DA T A ▲ ▲ ■ ● ● ● ● ● 5 8 15 4 6 10 35 4 4 3 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). Eng, p 2-39 96-09-13, 09.54 30[...]

English – 31 SER VICE DA T A ▲ ● 2 2 28 4 9 20 4 5 13 4 4 5 3 9 5 Eng, p 2-39 96-09-13, 09.54 31[...]

32 – English Saws 61, 268 and 272 268 272 61 SER VICE DA T A ▲ ▲ ■ ● ● ● ● ● 5 8 15 6 10 5 10 2 35 6 6 35 1 4 3 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)[...]

English – 33 272 268 272 61 SER VICE DA T A ▲ ● 3 4 28 4 10 15 4 3 3 5 14 6 4 6 1 1 3 1 3 9 3 Eng, p 2-39 96-09-13, 09.56 33[...]

34 – English Saws 281 and 288 SER VICE DA T A ▲ ■ ● ● ● ● ● 5 8 15 6 13 5 4 35 6 ▲ 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). Eng, p 2-39 96-09-13, 09.56[...]

English – 35 SER VICE DA T A ▲ ● 6 4 35 11 20 7 7 3 17 3 4 7 7 6 4 3 1 9 Eng, p 2-39 96-09-13, 09.57 35[...]

36 – English Saw 394 ▲ ■ ● ● ● ● ● 5 15 2-4 10-12 6-8 7-9 SER VICE DA T A ▲ Character key Numbers by components that are bolted refer to the tightening torque in Nm. = Locking fluid (Loctite). ▲ = Lubricate using two-stroke oil. ■ = Lubricate using saw chain oil. ● = Lubricate using grease. Eng, p 2-39 96-09-13, 09.57 36[...]

English – 37 SER VICE DA T A ● ▲ 30-40 10-12 5-6 6 2-3 4-5 3-5 3-5 5-6 20-22,5 12-14 ▲ Eng, p 2-39 96-09-13, 09.57 37[...]

38 – English Saw 3120 SER VICE DA T A ▲ ■ ● ● ● ● ▲ ● 5 8 15 5 12 5 38 7 8 5 7 5 1 3 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). Eng, p 2-39 96-09-13, 0[...]

English – 39 SER VICE DA T A ▲ ● ▲ 5 4 40 12 20 4 12 17 10 8 9 4 6 5 5 7 3 3 Eng, p 2-39 96-09-13, 09.58 39[...]

40 – English Worn needle valve/needle Leaking control diaphragm/ cover plate Control system sticking Worn throttle lever Faulty diffuser jet Fuel filter blocked Fuel line blocked Leaking manifold Loose carburettor mounting Worn throttle valve shaft Loose throttle valve screw Worn throttle valve Control system sticking Leak in throttle system (air[...]

English – 41 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 s[...]

42 – English Chain brake 3120 continues on next page. Place the clutch cover in a vice with the jaws positioned as shown below and release the tubular pin B. Carefully knock out the tubular pin B. All saws except 3120 3120 ! WARNING! If the clutch cover slides out of the vice's grip the spring can fly out with immense force resulting in pers[...]

English – 43 3120 Slide up the back edge of the spring with a screwdriver . Use a punch to knock out the pin holding the knee link. Carefully unscrew the vice so that the pres- sure rod and the ratchet move out of the clutch cover . Dismantle the pressure rod from the brake band. All saws except 3120 Remove the screw that holds the fixed end of t[...]

44 – English Cleaning and Inspection Clean and inspect all parts. The thickness of the brake band must not be under 0.8 mm at any point. Assembly Fit the band's fixed end into position on the clutch cover . All saws except 3120 3120 Continues on next page. 3120 continues on next page. Fit the screw that holds the band's fixed end. Greas[...]

English – 45 All saws except 3120 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. 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. Grease an[...]

46 – English All saws except 3120 Carefully tighten the vice until the hole for the tubular pin and the ratchet align. Carefully knock in the pin. Fit the hand guard, the two bushings and the screw . Fit the cylindrical pin. Pull back the hand guard so that the brake is not actuated. SAFETY EQUIPMENT Check the chain brake as described on the next[...]

English – 47 Bar length, L Height, H 15-20 inches 50 cm 21-28 inches 70 cm 29-32 inches 80 cm L H The engine should not be running during the test. T est that the chain brake comes on as follows: ! WARNING! After repair, the chain brake must be checked as set out in the following instructions. Checking brake operation Hold the chain saw above a f[...]

48 – English 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 s[...]

English – 49 Muffler WARNING! Do not touch the muffler until it has cooled. Risk of burns! Dismantling ! SAFETY EQUIPMENT B C A If the saw is equipped with muffler mounting (A), unscrew this from the crankcase and muffler . Unscrew the muffler from the cylinder (M5 or M6 bolts, M5 or M6 nuts). Remove the muffler , gasket and cooling plate (B) if [...]

50 – English SAFETY EQUIPMENT Cleaning and Inspection Clean all parts and check the following: • That the muffler and muf fler mountings are not cracked or otherwise damaged. • That the gaskets are OK. Assembly Clean all contact surfaces. Other saws If the saw is equipped with a spark arrester (C), fit this. Saws 36 and 41 Fit the cooling pla[...]

English – 51 Stop switch Dismantling Remove the earth screw (A) and cable (B). Press the switch's securing tabs (C) towards each other and push out the switch. 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 oh[...]

52 – English Throttle lock Remove the tank unit from the engine assembly . See page 103. ! 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 the throttle lock pin (A) using a punch. Dismantling A SAFETY EQUIPMENT T urn[...]

English – 53 Dismantle the throttle pin (B) by using a punch. Dismantle the throttle. On saw 394, also remove the throttle cable. B Remove the three screws in the side of the handle as well as the screw holding the spring under the handle. Lift out the throttle lock and the throttle. Saw 3120 Remove the three pins with a punch. Press the throttle[...]

54 – English Cleaning and inspection Clean all parts. Check that the springs, where fitted, are OK and have the correct tension. Check that the lock's activation mechanism is not worn. For examples of the activation mechanism, see the figure. SAFETY EQUIPMENT On those saws fitted with a throttle cable, check that the cable and lever are OK a[...]

English – 55 Assembly SAFETY EQUIPMENT Fit springs in appropriate cases. ! Other saws. Saws 36, 40, 41, 45, 42, 242XP , 246, 51, 55, 254XP , 257 and 262XP . On saw 394, fit the cable to the trigger . Insert them into the handle from the front. Fit the cable to the trigger and install the throttle lock and trigger . Fit the trigger with the cable [...]

56 – English SAFETY EQUIPMENT Saw 3120. Fit the three pins that hold the cable bracket, throttle lock and trigger . Saws 61, 268, 268K, 272XP , 272K, 272S, 281XP and 288XP . 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. Saws 36, 41,[...]

English – 57 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 [...]

58 – English 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 . ST ARTER Changing the ferrule Remove the parts of[...]

English – 59 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 starte[...]

60 – English If the starter unit has a cover plate (B) over the spring, fit the plate. 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 an[...]

English – 61 Ignition system ELECTRICAL SYSTEM Dismantling Saws 36 and 41. • Loosen the flywheel nut and unscrew it 1 turn • T ap the nut quickly with a hammer so that the flywheel comes loose • Remove the nut and flywheel. Other saws, see next page. Loosen the cable that runs to the stop switch from the ignition module. Release the cables [...]

62 – English Unscrew the two pawls and springs located on the flywheel. Loosen the flywheel nut and undo until it aligns with the end of the shaft. All saws except 36 and 41. Fit puller 502 51 49-02 and loosen the flywheel. Remove the puller , nut and flywheel. Continuation all saws Remove the ignition coil. ELECTRICAL SYSTEM The generator can be[...]

English – 63 Cleaning and Inspection Assembly Fit the generator if the saw is fitted with handle heating. T ighten 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. • Replace the flywheel washer and nut. T ightening torque, see "Service data". • [...]

64 – English 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. Stop switch The stop switch is described in the se[...]

English – 65 ELECTRICAL SYSTEM Handle heating 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). Description The above components are connected in series, which means that if there is[...]

66 – English ELECTRICAL SYSTEM Checking the generator 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. Connect the ohm[...]

English – 67 Dismantling Remove the bar and chain. See the operat- ing instructions. On 268K and 272K, remove the cutting attachment. See the operating instructions. On 272S, remove the grinder attachment. See the operating instructions. Use a spanner and remove the clutch. On saws 36 and 41 use the service tool no. 530 03 1 1-12. Note! Left-hand[...]

68 – English Cleaning and Inspection That measurement A is not below 1 mm. 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. That measu[...]

English – 69 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. Fit the chain and bar . See the operating instruc- tions. On 268K and 272K, fit the cutting attach- ment. See the operating instructions. T o prevent imbalance a[...]

70 – English LUBRICA TION SYSTEM Dismantling Saws 36, 40, 41, 45, 51 and 55. See page 72 Other saws. Remove the pump drive and washer . Undo the three bolts (A) and remove the oil pump. Some pumps have to be removed by using extractor screws. M5 screws should be inserted into the 2 threaded holes in the pump body and tightened equally to lift the[...]

English – 71 LUBRICA TION SYSTEM Saws 61, 268, 272XP . Dismantle the oil pump as follows: 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[...]

72 – English Saw 394. Dismantle the oil pump as follows: 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). A B CD E Saw 3120. Undo the three bolts that hold the oil pump and lift up the pump by the cut-out for the[...]

English – 73 Saws 36, 40, 41, 45, 51 and 55. Dismantle the chain guide plates as shown in respective diagrams below . 36/41 40/45 51/55 Saws 36, 40, 41 and 45. Undo the two bolts and lift off the pump and the upper seal. LUBRICA TION SYSTEM Saws 51 and 55. Lift off the pump and the upper seal. T ake the pump apart as shown in the exploded view on[...]

74 – English LUBRICA TION SYSTEM 36/41 40/45 50/51 A. Lower seal. B. Pump cylinder . C. Upper seal. D. Chain guide plate. E. Pump housing. F . Pump piston. G. Worm gear . CB A D E F G D E F G CB A A B C E F G Eng, p 40-82 96-09-13, 10.31 74[...]

English – 75 LUBRICA TION 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 "T ools". First screw the tool onto the entire worm gear T urn the screw until the worm gear is removed. Eng, p 4[...]

76 – English LUBRICA TION 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 . The oil pipe is not blocked and the filter screen is clean. That all seals [...]

English – 77 Assembling the oil pump LUBRICA TION SYSTEM 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. Press in the pump piston a little more and screw in the adjuster screw (C). 4. Insert the plastic plug (E). 5. Refit screw (A) and locking clip (B). 6. Fit the sea[...]

78 – English LUBRICA TION SYSTEM F A D E CB Saws 281XP and 288 XP . Fit the oil pump as follows: 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[...]

English – 79 LUBRICA TION 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[...]

80 – English LUBRICA TION SYSTEM Saws 42, 61, 242, 246, 254, 257, 262, 268, 272, 281, 288, 394 and 3120. 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. Adjust the oil [...]

English – 81 Saws 36, 40, 41 and 45, see continuation on the next page. Saws 51 and 55, see continuation on the next page. 36/41 40/45 50/51 A. Lower seal. B. Pump cylinder . C. Upper seal. D. Chain guide plate. E. Pump housing. F . Pump piston. G. Worm gear CB A D E F G D E F G CB A A B C E F G LUBRICA TION SYSTEM Fit the oil pump as follows: 1.[...]

82 – English Fit the chain guide plates according to respective diagrams below . 36/41 40/45 51/55 Fit the oil pump in the crankcase, tighten the two bolts and fit the upper seal. Fit the oil pump in the crankcase and fit the upper seal. LUBRICA TION SYSTEM Saws 36, 40, 41 and 45. Saws 51 and 55. Fit the bar and chain. Eng, p 40-82 96-09-13, 10.3[...]

English – 83 CARBURETT OR 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. Design B C A The metering unit (A) contains the jets and fuel control functions. It is here the correct amount of fuel for the given engine speed an[...]

84 – English Operation The carburettor operates differently in the following modes: • Cold start • Idling • Part throttle • Full throttle DE F G HG HF G EF G In the idling mode (H) the throttle valve is closed. Air is sucked in through an aperture in the throttle valve and a small amount of fuel is supplied through the diffuser jet (G). I[...]

English – 85 CARBURETT OR ! See the carburettor in question on the next four pages and the instructions below . Plugs When cleaning the carburettor the plugs must be removed. Remove as follows: 1. Drill a hole in the plug. 2. Insert a screwdriver or punch in the hole and prise up the plug. ”Semi fixed jet”/”fixed jet” Some carburettors ha[...]

86 – English T illotson HS 255 B A B H E F G I J C H K 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 [...]

English – 87 W albro HDA and HD D G F E A B H C J 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 diaph[...]

88 – English CARBURETT OR W albro WG 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. [...]

English – 89 W albro WT E F G C J BH K A ZAMA C1Q-EL1 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 d[...]

90 – English CARBURETT OR Cleaning and Inspection Use compressed air to dry the petrol on the components. Direct the air through all channels in the carburettor housing and ensure that they are not blocked. Refer to the carburettor diagram in question on the previous pages and check the following: 1. That the gasket and pump and control diaphragm[...]

English – 91 Plugs When cleaning the carburettor the plugs must be removed. Reassemble as follows: 1. Place the plug in the hole with the convex side facing upwards. 2. Expand the plug by using a punch on the top side. ”Semi fixed jet”/”fixed jet” Some carburettors have an extra jet (semi fixed jet). The jet is of brass and is located in [...]

92 – English CARBURETT OR 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. 3. Fit the high and low jet screws and springs. NOTE! Do not tighten the screws against the seats. This can damage the seat[...]

English – 93 T illotson HS 255 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 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 tight[...]

94 – English Tillotson HS 260 A 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. 3. Fit the ”semi fixed jet” (K). See page 91. 4. Fit the high and low jet screws and springs. NOTE! Do not tighte[...]

English – 95 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. 3. 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 [...]

96 – English 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. 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 agains[...]

English – 97 W albro WG Maintain a high level of cleanliness when reassembling the carburettor . Even small particles of dirt can cause operating prob- lems. CARBURETT OR D G F E A B H C K J 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 ligh[...]

98 – English W albro WT 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. 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 sc[...]

English – 99 ZAMA C1Q-EL1 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. Fit the fuel [...]

100 – English CARBURETT OR Pressure testing Refitting onto chain saw Fit the carburettor to the chain saw and refit any other parts removed. For tightening torques, see the ”Service data” for the saw in question. Carburettor adjustment. See the operating instructions for the saw in question. Make the test as follows: 1. Set the high and low s[...]

English – 101 AIR FIL TER The air filter system consists of: 1. Prefilter . 2. Main filter . Prefilter A Replace the chain saw’s air filter at the intervals stated in respective operating in- structions. It is extremely important that the air filter units on power cutters 268K, 272K and stump grinder 272S are maintained correctly . The air filt[...]

102 – English AIR FIL TER 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 de- creases 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 Eng, p 83-124 9[...]

English – 103 If the fuel pipe needs to be replaced, meas- ure its length outside of the tank unit and make a note of the length. This information is needed when fitting a new pipe. T ANK UNIT 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.[...]

104 – English T ANK UNIT 36 40 41 42 45 51 55 61 242XP 246 254XP 257 262XP 268 268K 272XP 272K 272S 281XP 288XP 394XP 3120XP Saw Bolts placed at A, D, F , K Has no tank unit A, D, F , K A, D (under a cover) F , G, L Has no tank unit A, D, F , L (all under covers) A, D, F , L (all under covers) A, C, D, F , G, K A, D (under a cover) F , G, L A, D [...]

English – 105 T ANK UNIT Assembly If a new fuel pipe is to be fitted proceed as follows: 1. Measure the length of the old hose out- side 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. T wist the hose so that it takes on the same angle to the carburettor and let [...]

106 – English ANTI-VIBRA TION SYSTEM Dismantling Description The anti-vibration system reduces the vibra- tions 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. Remove the [...]

English – 107 ANTI-VIBRA TION SYSTEM Assembly Fitting the anti-vibration system’s side absorber . Fit the rubber element using the tools shown in the figure below . Saw 394 Other saws Slide in the spring and its holder . Fit the spring element using an allen key as shown in the figure below . Fit the rubber stop with the help of a wire or the l[...]

108 – English Dismantling PIST ON AND CYLINDER 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. Saws 36 and 4[...]

English – 109 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. Cleaning and Inspection PIST ON AND CYLINDER Check the following: 1. That the cylinder’s surface coating is not worn[...]

110 – English Faults and causes Score marks on the piston. 1. Incorrect carburettor setting max. speed too high 2. T oo low octane fuel. 3. T oo little or incorrect oil in the fuel. PIST ON AND CYLINDER Piston ring breakage 1. Excessive engine speed 2. Piston ring worn out. 3. Oversized piston ring groove. Carbon build-up 1. Incorrect carburettor[...]

English – 111 Assembly PIST ON AND CYLINDER 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. NOTE! Ensure that no dirt or other foreign particles fall into the crankcase. Apply silicone rubber 504 98 26-01 to the lower crank[...]

112 – English PIST ON AND CYLINDER Other saws Fit the four bolts under the crankcase. T ightening torque, see ”Service data”. 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). BA Fit the intake m[...]

English – 113 Pressure testing The following parts must be removed to pressure test the crankcase and cylinder: • Carburettor . • Muffler . PIST ON AND CYLINDER Carry out the test as follows: 1. Fit the cover plates (service tool) on the intake manifold and exhaust port. 2. Connect tool 502 50 38-01 to the cover plate on the intake manifold. [...]

114 – English CRANKCASE AND CRANKSHAFT Before the crankcase can be split the follow- ing must be removed: A. Chain and bar . See operating instructions. B. Starter . See page 57. C. Electrical system. See page 61. NOTE! Ensure that no dirt or foreign particles enter the bearings. On saw 394, remove the carburettor chamber floor (A) and air jet (B[...]

English – 115 Press out the crankshaft by using tool 502 51 61-01. ! WARNING! The crankcase halves can be hot. Risk of burns. Wear protec- tive gloves. If necessary remove the crankshaft bearing from the crankcase. Proceed as follows: If necessary remove the following parts: A. Chain tension screw B. Bar bolts C. Spike Remove the bearing from the[...]

116 – English 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 b[...]

English – 117 Assembly CRANKCASE AND CRANKSHAFT Other saws NOTE! Ensure that dirt and foreign particles do not enter the bearing. 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. C. Let the crankcase half cool be[...]

118 – English Other saws. 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 crank- shaft which can damage the seal. The as- sembly sleeve should be used when working on these saws. See ”T ools”. NOTE! Place the oil tank’ s vent hose in the [...]

English – 119 NOTE! Ensure excess gasket material does not fall into the crankcase. Other saws. Fit the crankcase bolts. T ighten crosswise with the torque set out in the ”Service data”. T ighten the bolts closest to the crankshaft first. Cut off excess gasket at the level of the cylinder seating plane. On saw 394, fit the floor of the carbur[...]

120 – English NOTE! Ensure that dirt and foreign particles do not enter the bearing. Fit the bearing on the crankshaft by using the assembly tool. See ”T ools”. A B Continue assembly as described on page 1 1 1. CRANKCASE AND CRANKSHAFT Saws 40 and 45. Check the shaft seat’s sealing (A). Fit the shaft seat over the bearing and join the shaft[...]

English – 121 Bar bolts CRANKCASE AND CRANKSHAFT 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[...]

122 – English CRANKCASE AND CRANKSHAFT Changing the seals 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[...]

English – 123 CRANKCASE AND CRANKSHAFT Assembly BC 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 . Seal assembly in the crankcase Some saws have a sharp edge on the crank- shaft which can damage the seal. The as- sembly[...]

124 – English A Assembly positions starter side 1 mm Assembly position on the clutch side 254, 257, 262 1.5 mm above the crankcase plane. B CRANKCASE AND CRANKSHAFT C 1.5 mm Measurement A should be as in the table below for resp. saws (Under the crankcase plane). 61, 268 4-4.5 mm 272 2 mm 281, 288 3.5 mm Measurement B should be as in the table be[...]