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Humminbird 150 Fish Finder User Manual

Contents

1. p FD Measurement points A1 and A2 Earth E g the cylinder A1 B Measurement of the generator B C Measurement of the handle loop Before trouble shooting individual C D Measurementofthe heater loops components remove the power switch and in the rear handle disconnect one of the switch s cables D A2 Measurement ofthe power switch Remove other components as necessary E g the cylinder cover See the operating instructions vies Trouble shooting individual components see next page English 65 ELECTRICAL SYSTEM Checking the generator Check the handle loop Connect the ohm meter to the cylinder Connect the ohm meter to points B and C point A1 and point B The ohm meter The ohm meter should read 3 4 ohm should read 0 9 1 3 ohm Replace the handle loop that has a higher Replace a generator that has higher or value lower values Checking the heat loops in the rear handles Checking the power switch Connect the ohm meter to points C and D Connect the ohm meter across the switch The ohm meter should read 0 7 2 5 ohm The ohm meter should read more than Replace a heat loops that has higher 1000 ohm with the switch in position O values The ohm meter should read at the highest 0 1 ohm with the switch in position 1 1 I J 66 English CENTRIFUGAL CLUTCH Dismantling Remove the bar and chain See the operat ing instructions On 268K and 272K remove the cutting
2. Seecontinuation on next page English 117 CRANKCASE AND CRANKSHAFT Saw 40 and 45 See page 120 Grease and fit a new crankcase gasket A Checkthatthe guide pin B is in position and fit the other crankcase half NOTE Continuing to pull with the assembly tool after the gasket is clamped will damage the crankshaft Using the assembly tool for the chain saw in question fit the two crankcase halves Pull until the gasket is clamped between the two crankcase halves See continuation on next page 118 English 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 crank shaft which can damage the seal The as sembly sleeve should be used when working on these saws See Tools NOTE Place the oil tank s vent hose in the pocket above the tank cap in the equivalent crankcase half p CRANKCASE AND CRANKSHAFT Saw 40 and 45 See next page 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 Fit the following parts A Chain and bar See operating instructions B Starter See page 59 C Electrical
3. Remove the plug J See page 85 If necessary remove the throttle and choke valves as well as the shafts lever arms and springs Remove the semi fixed jet K See page 85 Walbro WG 1 Remove the cover A over the metering unit and carefully remove the control diaphragm B with the gasket Undo the screw H and take out the needle valve C with lever arm shaft and spring e Remove the cover E over the pump unit and carefully remove the gasket F and the pump diaphragm G Using a needle or the like carefully remove the fuel screen D Unscrew the low speed jet screws Remove the plugs J See page 85 If necessary remove the throttle and choke valves as well as the shafts lever arms and springs Remove the semi fixed jet K See page 85 88 English CARBURETTOR Walbro WT 1 Remove the cover A over the metering unit and carefully remove the control diaphragm B with the gasket Undo the screw H and take out the needle valve C with lever arm shaft and spring Remove the cover E over the pump unit and carefully remove the gasket F and the pump diaphragm Using a needle or the like carefully remove the fuel screen D Unscrew the high and low speed jet Screws Remove the plug J See page 85 If necessary remove the throttle and choke valves as well as the shafts lever arms and springs Remove the
4. Fit the oil pump as follows 1 Apply SAE 30 oil to all moving parts 2 Fit the pump piston C with washers and spring in the pump housing Fitthe latch pin B press in the pump piston C a little more and fit the adjuster screw A Fit the seal E Fit the plug D See continuation page 80 78 English LUBRICATION SYSTEM Saw 3120 Fit the oil pump as follows Apply SAE 30 oil to all moving parts Fit lever arm F Fit the seal C Fit units B F G with spring and Fitthe pump piston D with spring screw in position using screws A and Press in the piston and hold it in latch J position with a screwdriver from the Remove the screwdriver pump housing s inside in slot E Fita new O rings K and L Fit screw B so that it is positioned approx one turn from the bottom NOTE Left hand thread Fit the wire for manual oil supply See continuation on next page English 79 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 Lubricate the pinion gear with grease Fit the oil pump on the saw by tightening the three bolts If the tapered sleeve has been used remove it Fit the centrifugal clutch See page 69 Fit the bar and chain Adjust the
5. Carefully knock in the pin Fit the cylindrical pin Pull back the hand guard so that the brake is Check the chain brake as described on the not actuated next page 46 English 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 J Bar length L Height H 15 20 inches 50 cm 21 28 inches 70 cm 29 32 inches 80 cm Release the front handle and let the chain saw rotate around the rear handle When the bar nose hits the surface the chain brake should trip English 47 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 See the oper ating instructions Check the chain catcher and replace if bro ken or badly damaged The ti
6. aa g y I i o compl 502 50 31 01 502 51 61 01 504 90 90 01 2 SE EON 502 51 61 01 Nr P 504 90 90 01 T vw A 502508201 My E 2 502 50 30 07 7 4 eL m D er Le p 502 51 32 01 502 51 50 01 S e I caw 502 50 79 01 r Nr A 502 50 30 10 502 51 00 02 compl 502 50 38 01 CC compl 502 50 38 01 e d d 502 50 72 01 502 50 45 01 502 50 72 01 502 50 46 01 502 50 46 01 502 50 71 01 502 50 71 01 16 English TOOLS Tools for saws 61 268 and 272 Tools for saws 281 and 288 3 mm 4 mm 3 16 3 mm 4 mm 3 16 Q 8 mm 502 71 36 01 4 mm Q 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 54 01 compl 502 50 31 01 502 51 61 01 504 90 90 01 504 90 90 01 N gt N NA LT 4 s Nun sa E 7 f 502516901 se 502 50 82 01 x WE wow 268 N CS J Ge 502 50 30 04 r Sr TY 502 50 30 08 502 50 53 01 502 50 52 01 502 50 66 02 502 50 67 01 502 51 00 02 502 50 66 02 amp compl 502 50 38 01 compl 502 50 38 01 amp d b x 502 50 47 01 902304501 562 50 47 01 j A 502 50 46 01 Ss NE QZ Ne 502 50 46 01 502 50 48 01 502 50 81 01 502 50 20 01 English 1 7 TOOLS Tools for saws 394 and 3120 3 mm 4 mm 5 mm 3 16 Q 8 mm 10 mm 502 50 33 0
7. Worn choke plate Fuel filter blocked Fuel line blocked Piston ring seized Blocked impulse channel Loose or faulty fuel pipe Hole in diaphragm Worn needle valve needle Control system sticking Control system set too high Leak in control system air or fuel Loose cover on carburettor pump side Worn needle valve Control system set too high Control system sticking Idling low rpm Will not idle Idling too rich AO English Adjust L screw Leaking manifold intermediate Loose carburettor mounting Loose or faulty fuel pipe Fuel filter blocked Fuel line blocked Fuel tank breather blocked Throttle shaft and lever stiff Throttle cable sticking Defective throttle return spring Bent throttle lever shaft stop Faulty diffuser jet Adjust L screw Worn needle valve needle Control system set too high Worn throttle lever Leaking control diaphragm cover plate Control system sticking Idling low rpm cont Idles when L screw closed ldling uneven L screw requires constant adjustment Too much fuel at idling 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 or fuel Control diaphragm centre knob
8. 3 Pressure testing the decompression valve See page 114 4 Checking the operation of the chain brake See page 47 English 41 SAFETY EQUIPMENT Chain brake 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 Remove the cover onthe chain brake spring an cover slides out of The cover has 4 or 5 screws the vice s grip the spring can fly out with immense force resulting in personal injury Wear protective glasses 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 WARNING If the brake is not on the spring can fly out resulting in personal injury Wear protective glasses Continues on next page 3120 continues on next page 42 English SAFETY EQUIPMENT V Slide up the back edge of the spring with a screwdriver Use a punch to knock out the pin holding the knee link 40 42 45 51 242 246 55 254 257 262 and 394 Lift up the band s fixed end using a screw driver and remove the loose parts Carefully unscrew the vice so that the pres sure rod and the ratchet
9. Feeler gauge TOOLS Order number 502 51 49 01 502 51 49 02 502 51 50 01 502 51 54 01 502 51 61 01 502 51 69 01 502 51 69 01 502 51 94 01 502 52 01 01 502 52 04 01 502 54 03 01 502 70 09 01 502 71 13 01 502 71 14 01 502 71 36 01 502 71 38 01 502 71 39 01 502 71 40 01 504 90 29 02 504 90 90 01 504 98 26 01 505 26 79 12 505 38 18 17 Designation Puller Puller Socket Bolt set Dismantling tool crankcase Assembly mandrel Feeler gauges Assembly mandrel Cover plate Spacer Spacer Pump blower Test spark plug Tachometer Allen key Cover plate Cover plate Spacer Cover plate Puller Silicone rubber Assembly mandrel Puller English 19 SERVICE DATA Saws 36 and 41 2222 gt Character key Numbers by components that are bolted X mE refer to the tightening torque in Nm qu NS A Lubricate using two stroke oil A B Lubricate using saw chain oil nv Lubricate using grease Locking fluid Loctite 20 English SERVICE DATA English 2 1 SERVICE DATA Saws 42 242 and 246 Eg Character key 3 Numbers by components that are bolted refer to the tightening torque in Nm A Lubricate using two stroke oil B Lubricate using saw chain oil Lubricate using grease T Locking fluid Loctite 22 English SERVICE DATA English 23 SERVICE DATA Saws 40 and 45 Character key Numbers by compon
10. attachment See the operating instructions On 2725 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 V v 4 Prise out the spring heels using ascrewdriver Remove Remove the springs using a Remove the spring by first the springs from the other screwdriver lifting a shoe using a suitable side using circlip pliers Then Then remove the clutch spacer A remove the clutch shoes shoes Then remove the clutch Remove the clutch drum and needle bearing English 67 CENTRIFUGAL CLUTCH Cleaning and Inspection Clean all parts and inspect the following Clutch shoes Clutch shoes without chamfers with chamfers That measurement B is not under 1 mm That measurement A is not below 1 mm A 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 68 English 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 Topreventimbalance all clutch shoes
11. is worn Hole in diaphragm Leaking control diaphragm cover plate Crankcase leaking Fuel line blocked Control system set too high Control system sticking Control system air or fuel Leaking control diaphragm cover plate Faulty diffuser jet Crankcase leaking Control system sticking Control system damaged Worn needle valve Leaking control diaphragm cover plate Control system incorrectly assembled High rpm Will not run at full throttle Low power Will not four stroke TROUBLE SHOOTING 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 Blocked silencer Adjust H screw Blocked fuel tankbreather Blocked fuel filter Impulse channel leaking Impulse channel blocked Loose cover on carburettor pump side Faulty pump diaphragm Blocked air filter Control system sticking Leak in throttle system air or fuel Control system incorrectly assembled Loose diaphragm Hole in diaphragm Leaking control diaphragm cover Blocked fuel tank breather Blocked fuel filter Fuel line blocked Loose or damaged fuel line Impulse ch
12. English SERVICE DATA English 33 SERVICE DATA Saws 281 288 Character key Numbers by components that are bolted refer to the tightening torque in Nm A Lubricate using two stroke oil B Lubricate using saw chain oil Lubricate using grease Locking fluid Loctite 34 English SERVICE DATA English 35 SERVICE DATA Saw 394 Character key Numbers by components that are bolted refer to the tightening torque in Nm A Lubricate using two stroke oil B Lubricate using saw chain oil Lubricate using grease T Locking fluid Loctite 36 English SERVICE DATA English 37 SERVICE DATA Saw 3120 Character key Numbers by components that are bolted refer to the tightening torque in Nm A Lubricate using two stroke oil B Lubricate using saw chain oil Lubricate using grease Locking fluid Loctite 38 English SERVICE DATA English 39 Trouble shooting schematic TROUBLE SHOOTING Faults that can develop on the chain saw are divided into four groups as follows In each cat egory 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 Starting Difficult starting Carburettor leaking fuel Flooding when the engine is not running Adjust L screw Air filter blocked Choke not working correctly Worn choke shaft
13. 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 Fit the cover plates service tool on the intake manifold and exhaust port Connect tool 502 50 38 01 to the cover plate on the intake manifold The decompression valve should be closed Plug the opening to the impulse channel Pump up the pressure to 80 kPa 0 8 bar Wait 30 seconds The pressure should not drop below 60 kPa 0 6 bar Leakage can occur from the decompression valve and the crankshaft seals Fit the following Carburettor Muffler English 113 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 follow Centrifugal clutch See page 67 ing must be removed Oil pump See page 70 Chain and bar Carburettor See operating instructions Muffler See page 49 Starter See page 57 Piston and cylinder See page 108 Electrical system See page 61 Tank unit See page 103 NOTE Ensure that no dirt or foreign particles enter the bearing
14. 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 Fit the plugs J See page 91 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 Fit the fuel screen D by using the handle of a small screwdriver Fitthe pump diaphragm gasket F and cover E on the pump unit Fit the needle valve C with lever arm shaft and spring and tighten screw H Check using or a ruler or the like that the lever arm is level with the chamber floor See the figure to the lower right The lever arm can be bent if necessary to achieve the correct settings Fit the control diaphragm B with gasket and cover on the metering unit Carry out a pressure test See page 100 92 English CARBURETTOR Tillotson HS 255 B Maintain a high level of cleanliness when reassembling the carburettor Even small particles of dirt can cause operating prob lems 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 Fit the plugs J See page 91 Fit the semi fixed jet
15. move out of the clutch cover Dismantle the pressure rod from the brake Remove the screw that holds the fixed end of the band Knock out the band s fixed end using a punch through the hole in the clutch cover and remove the loose parts English 43 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 Assembly Fit the band s fixed end into position on the clutch cover Greasethe knee link and knock in the tubular pin that holds the knee link Continues on next page 44 English 3120 continues on next page SAFETY EQUIPMENT All saws except 3120 Slide the spring over the knee link s stud and Fit the spring and screw onto the pressure press down the opposite end ofthe spring into rod on the brake band its recess Note Plastic sleeve Bottom the screw onto the pressure rod thread and back off 4 5 turns WARNING Fit the cover over the spring 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 Set the unit in a vice positioned in the jaws as shown below 3120 continues on next page English 45 SAFETY EQUIPMENT All saws except 3120 Carefully tighten the vice until the hole forthe tubular pin and the ratchet align Fitthe hand guard the two bushings and the Screw
16. pump and loosen the wire for manual oil supply 72 English LUBRICATION SYSTEM Saws 36 40 41 45 51 and 55 Dismantle the chain guide plates as shown in respective diagrams below Saws 51 and 55 Undo the two bolts and lift off the pump Lift off the pump and the upper seal and the upper seal Take the pump apart as shown in the exploded view on the next page English 73 LUBRICATION SYSTEM Lower seal Pump cylinder Upper seal Chain guide plate Pump housing Pump piston Worm gear 74 English 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 75 LUBRICATION SYSTEM Cleaning and Inspection Clean all parts and check the following when appropriate to the saw in question b a 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 LUBRICATION SYSTEM Assemblin
17. remove locking clip B Undo screw C Lever out the pump piston D and plastic plug E using a screwdriver Remove the seal F 70 English LUBRICATION SYSTEM Saws 61 268 272XP Dismantle the oil pump as follows Remove the lock washer A washer spring and adjuster screw B Remove the locking lacquer and undo screw C Knock the edge of the pump housing against a piece of wood so that the pump piston D slides out of the housing Remove the pinion E with washers and springs Remove the pin F Remove the seal G If necessary remove the O ring H Dismantle the oil pump as follows Undo the adjuster screw A Remove the plug B with pump piston C and spring with washers Dismantle the O ring D Replace if necessary If necessary replace the seal E If necessary replace the O ring F English 71 LUBRICATION SYSTEM Saw 394 Dismantle the oil pump as follows Dismantle the screw A so that the spring and latch pin B can be removed Lever out the pump piston C with the plastic plug D using a screwdriver Remove the seal E shown in the figure below 2 Undo screw B NOTE Left hand thread Saw 3120 Dismantle the oil pump as follows IT 1 Undo the screws A and remove the parts as Undo the three bolts that hold the oil pump and lift up the pump by the cut out for the adjuster screw Lift off the
18. semi fixed jet with diffuser jet K See page 85 ZAMA C1Q EL1 Remove the cover A over the metering unit and carefully remove the control diaphragm B with the gasket Undo the screw H and take out the needle valve C with lever arm shaft and spring Remove the cover E over the pump unit and carefully remove the gasket F and the pump diaphragm G Using a needle or the like carefully remove the fuel screen D Unscrew the high and low speed jet Screws If necessary remove the throttle and choke valves as well as the shafts lever arms and springs English 89 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 directthe compressedair 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 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 diaphragms are undamaged That there is no play on the throttle and choke valve shafts That the needle v
19. settings Fit the control diaphragm B with gasket and cover on the metering unit Carry out a pressure test See page 100 English 95 CARBURETTOR Walbro WJ Maintain a high level of cleanliness when reassembling the carburettor Even small particles of dirt can cause operating prob lems 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 Fitthe plugs J See page 91 Fitthe semi fixed jet K See page 91 Fitthe high and low jet screws and springs NOTE Do not tighten the screws against the seats This can damage the seats and needle tips Fit the fuel screen D by using the handle of a small screwdriver Fitthe pump diaphragm gasket F and cover E on the pump unit Fit the needle valve C with lever arm shaft and spring and tighten screw H Check using or a ruler or the like that the lever arm is level with the chamber floor See the figure to the lower right The lever arm can be bent if necessary to achieve the correct settings Fit the control diaphragm B with gasket and cover A on the metering unit 10 Carry out a pressure test See page 100 96 English CARBURETTOR Walbro WG Maintain a high level of cleanliness when reassembling the carburettor Even small particles of dirt can cause operating prob lems 1 If the th
20. should be replaced at the same time NOTE The clutch springs should not be d out more than Saws with three Saws with one m opene d Saws with three C springs deformation Locate the clutch shoes on Locate the clutch shoes on the Locate the clutch shoes onthe the hub and fit the springs hub Lift a shoe using a suit hub and fit the springs with the with the help of pliers able spacer A and fit the help of circlip pliers Soe ec nie CY Using a spanner secure the clutch centre On saws 36 and 41 use service tool no 530 03 11 12 Note Left hand thread Fit the chain and bar See the operating instruc Puta the piston stop and fit the spark tions On 268K and 272K fit the cutting attach plug ment See the operating instructions English 69 LUBRICATION SYSTEM Dismantling Dismantle the following parts Starter See the operating instructions Centrifugal clutch See page 67 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 pump and thrust washer Other pumps have a cut out C for a screwdriver to prise off the pump Both types are shown below Saw 394 See page 72 Saws 42 242XP 246 254XP 262XP and 257 Dismantle the oil pump as follows Unscrew screw A and
21. through all three diffuser jets E F and G 84 English 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 Semi fixed jet fixed jet Some carburettors have an extra jet semi fixed jet The jet is of brass and is located in the metering unit and is used to give a fuel supplement On average 10 of the fuel passes through the jet Below or next to the jet is a screen which needs to be cleaned 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 Dismantle the jet and or screen in one of the following ways 1 Knock the unit into the venturi using a punch and take the unit apart some Tillotson models 2 Dismantle the lock washer over the jet and lift off the jet and screen English 85 CARBURETTOR Tillotson HS 228 B 1 Remove the cover A over the metering unit and carefully remove the control diaphragm B with the gasket Undo the screw H and take o
22. 1 compl 502 51 49 02 502 51 49 01 504 90 90 01 502 50 82 01 amp 502 50 52 01 X P A Y Se 502 50 30 08 502 50 66 02 compl 502 50 38 01 502 52 04 01 502 52 01 01 394 394 502 71 38 01 3120 502 71 40 01 3120 CGS NV 502 71 39 01 394 18 English List of tools Order number 502 50 06 01 502 50 16 01 502 50 18 01 502 50 19 01 502 50 20 01 502 50 22 01 502 50 23 01 502 50 26 01 502 50 30 04 502 50 30 08 502 50 30 09 502 50 30 10 502 50 31 01 502 50 33 01 502 50 37 01 502 50 38 01 502 50 45 01 502 50 46 01 502 50 47 01 502 50 48 01 502 50 52 01 502 50 57 01 502 50 64 01 502 50 66 02 502 50 67 01 502 50 70 01 502 50 71 01 502 50 72 01 502 50 79 01 502 50 81 01 502 50 82 01 502 50 83 01 502 50 86 01 502 50 87 01 502 50 88 01 502 50 99 01 502 51 00 02 502 51 02 01 502 51 32 01 502 51 34 02 Designation Pliers Allen key Allen key Allen key Assembly tool Socket Socket Puller Assembly tool Assembly tool Assembly tool Assembly tool Puller Piston stop Vacuum gauge Pressure gauge Extended socket Extended socket Cover plate Cover plate Assembly socket Allen key Allen key U key U key Assembly tool piston Cover plate Cover plate Assembly mandrel Cover plate Assembly mandrel Hook tank valve Allen key Allen key Allen key Puller sleeve U key Assembly fixture Assembly sleeve
23. 2 WALBRO WT 170 0 3 012 TILLOTSON HS 254 0 3 012 WALBRO HDA 98 0 3 012 WALBRO HDA 98 0 3 012 WALBRO HDA 35B 0 3 012 WALBRO HDA 120 C Chain pitch Drive link gauge inches mm inches 325 3 8 1 5 058 1 3 050 3 8 1 5 058 325 1 5 058 1 3 050 325 1 5 058 1 3 050 7 325 3 8 1 5 058 325 3 8 1 5 058 From May 1996 55 242XP 246 254 257 Idling speed r min 2500 2500 2700 2700 2700 2700 Fuel tank volume Litres 0 6 0 75 0 5 0 5 0 6 0 6 kg TECHNICAL DATA ED u Engagement speed Max speed Spark plug r min r min Champion 3700 12500 RCJ 7 Y 3700 12000 RCJ 7 Y 3900 15500 RCJ 7 Y 3900 15000 RCJ 7 Y 3700 13800 RCJ 7 Y 3700 13500 RCJ 7 Y Oil pump capacity Oil tank volume Automatic oil pump cm min at 8 500 rpm 10 4 82 17 3 7 Weight without bar and chain Weight with bar and chain kg Ibs x Litres 0 3 Yes 0 45 Yes 0 27 Yes 0 27 Yes 0 3 Yes 0 3 Yes Handle heater Watt r min No No 65 10 000 No 65 10000 65 10000 English 9 262XP 268 272XP 268K 272K 2728 262XP 268 272XP 268K 272K 2728 262XP 268 272XP 268K 272K 2728 10 English Displacemennt Bore cm mm 62 48 0 67 50 0 72 52 0 67 50 0 72 52 0 72 52 0 Spark plug gap Ignition system mm inches 0 5 02 ELECTROLUX ET 0 5 02 ELECTROLUX ET 0 5 02 ELECTROLUX ET 0 5 02 ELECTROLUX ET 0 5 02 ELECTROLUX E
24. 288XP 0 5 02 394XP 0 5 02 3120XP 0 5 02 Bar length cm inches 281XP 38 71 15 28 288XP 38 71 15 28 94 46 91 18 36 3120XP 60 107 24 42 12 English TECHNICAL DATA Bore 52 0 54 0 56 0 60 0 Ignition system SEM AM 7 SEM AM 7 SEM AM 44 SEM AM 37 Chain speed m s 20 0 9000 rpm 20 7 9300 rpm 19 6 8800 rpm 20 1 9000 rpm Stroke mm 38 0 38 0 38 0 42 0 US Air gap mm inches 0 3 012 0 3 012 0 3 012 0 3 012 Chain pitch inches 3 8 3 8 3 8 404 404 Max power at r min 9000 9300 8800 9000 Carburettor TILLOTSON HS 228 TILLOTSON HS 228 WALBRO WJ 39 WALBRO WG 6 Drive link gauge mm inches 1 5 058 1 6 063 1 6 063 TECHNICAL DATA m Idling speed Engagement speed Max speed Spark plug r min r min r min Champion 281XP 2500 3200 12500 RCJ 6 Y 288XP 2500 3200 12500 RCJ 6 Y 394XP 2500 3400 12500 RCJ 6 Y 3120XP 2500 3300 11500 12500 RCJ 7 Y re Fuel tank volume Oil pump capacity Oil tank volume Automatic oil pump Litres cm min at 8 500 rpm Litres 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 Weight without bar and chain Weight with bar chain Handle heater kg kg lbs Watt r min 281 XP 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 English 13 TOOLS Tools for al
25. DER Dismantling Dismantle the following parts Cylinder cover See operating instructions Carburettor Spark plug See operating instructions Muffler Dismantle the insulation plate between the On saw 394 disconnect the anti vibration cylinder and the carburettor and the intake spring A from the cylinder manifold On all chain saws undo the four cylinder bolts B The bolts are removed using a 4 mm allen key smaller saws or 3 16 allen key larger saws Remove the cables to the ignition coil Remove the ignition coil NOTE Ensure that no dirt or other foreign particles fall into the crankcase Immediately cover the crankcase opening crankshaft and crankshaft bearing with a paper or cloth Remove one of the circlips on the piston push out the gudgeon pin and remove the piston ET wi Remove the needle bearing from the little end of the connecting rod Remove the decompression valve if fitted 108 English 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 That the cylinder is free of score marks That the piston is free of score marks See Faults and
26. Husqvarna Chain Saws Workshop Manual 101 88 55 26 2 English LIST OF CONTENTS Introduction 3 Safety regulations 5 Technical Data 6 I 14 Service data 20 Trouble shooting 40 Safety equipment 42 57 Electrical system 61 Centrifugal clutch 67 Lubrication system 70 Carburettor 22 2 83 Air filter oreet reine 101 103 Anti vibration system 106 Piston cylinder 108 Crankcase and crankshaft 114 INTRODUCTION General This workshop manual provides a detailed de scription of procedures for trouble shooting repair and testing of the chain saws Safety precautions that should be taken during repair are also described This workshop manual applies to the engine assembly in the following chain saws 36 257 40 262XP 268 41 42 272XP 268K 45 272K 51 2728 55 61 281XP 288XP 242XP 246 394XP 254XP 3120XP Safety Note The section dealing with safety should be read and understood by all who carry out repair or service work on the chain saw There are warning symbols on the chain saw If a warning symbol has been damaged or is missing it must be replaced immediately
27. Remove the springs where appropriate English 53 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 SAFETY EQUIPMENT Assembly Saws 36 40 41 45 42 242XP 246 51 55 WARNING The fuel used in the chain saw poses the following hazards Other saws gt 254XP 257 and 262XP 1 The liquid and its vapours are poisonous 2 cause skin irritation 3 Is highly inflammable Fit springs in appropriate cases Saws 61 268 268K 272XP 272K 2728 Saw 3120 281XP and 288XP See next page Saws 36 41 42 242XP Saws 40 45 246 51 55 254XP 257 262XP and 394 On saw 394 fit the cable to the trigger Insert them into the handle from the Fit the pin B and spring when used Fit the cable to the trigger and install the throttle lock and trigger Fit the side of the handle using three screws on the side and one underneath which holds the spring Fitthe trigger with the cable from the front Fit the spring and slide the throttle lock forwards from above so that its rear edge canbeslidin underthe edge of the handle All saws except 40 and 45 c
28. See page 91 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 Fit the fuel screen D by using the handle of a small screwdriver Fit the pump diaphragm gasket F and cover E on the pump unit Fit the needle valve C with lever arm shaft and spring and tighten screw H Check using or a ruler or the like that the lever arm is level with the chamber floor See the figure to the lower right The lever arm can be bent if necessary to achieve the correct settings Fit the speed governor I Lock with Loctite or locking lacquer Only applies to 272K 268K and 2725 10 Fit the control diaphragm B with gasket and cover on the metering unit 11 Carry out a pressure test See page 100 English 93 CARBURETTOR Tillotson HS 260 A 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 Fitthe plugs J See page 91 Fitthe semi fixed jet K See page 91 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 Fit the fuel screen D by using the handle of a s
29. T 0 5 02 ELECTROLUX ET Bar length Chain speed cm inches m s 33 51 13 20 18 5 9600 rpm 38 51 15 20 18 4 9000 rpm 38 51 15 20 20 0 9300 rpm TECHNICAL DATA 34 0 US Air gap mm inches 0 3 012 0 3 012 0 3 012 0 3 012 0 3 012 0 3 012 Chain pitch inches 325 3 8 3 8 3 8 Max power at r min 9600 9000 9300 9000 9300 9300 Carburettor WALBRO HDA 120 TILLOTSON HS 260 TILLOTSON HS 260 TILLOTSON HS 255 TILLOTSON HS 255 TILLOTSON HS 255 Drive link gauge mm inches TECHNICAL DATA T rpm V m Idling speed Engagement speed Max speed Spark plug r min r min r min Champion 262XP 2700 3400 13500 RCJ 7 Y 268 2500 3500 12500 RCJ 7 Y 272XP 2500 3500 13500 RCJ 7 Y 268K 2500 3500 10000 RCJ 7 Y 272K 2500 3500 10000 RCJ 7 Y 2728 2500 3500 10000 RCJ 7 Y Fuel tank volume Oil pump capacity Oil tank volume Automatic oil pump Litres cm min at 8 500 rpm Litres 262XP 0 6 6 5 13 5 0 3 Yes 268 0 75 4 91 3 17 0 45 Yes 272XP 0 75 5 9 14 19 0 45 Yes 268K 0 75 272K 0 75 2725 0 75 Weight without chain and bar Weight with chain andbar Handle heater kg kg lbs Watt r min 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 3 272S 21 0 including carriage English 1 1 Displacement cm 281XP 81 288XP 87 394XP 94 3120XP 119 Spark plug gap mm inches 281 XP 0 5 02
30. able on the previous page Tightening torques see the service data for the saw in question Connect the fuel pipe and the throttle cable to the carburettor Fit the cylinder cover and the chain and bar English 105 ANTI VIBRATION SYSTEM 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 Dismantling The tank unit must be removed from the engine sub assembly to access the anti vibration system See the previous pages V Saw 394 Saws 40 45 and 3120 Remove the rubber element using re spective tools as shown in the figure below Release the catch on the plastic key Remove the spring element using an allen key as shown below 106 English 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 Saws 40 45 and 3120 Slide in the spring and its holder 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 English 107 PISTON AND CYLIN
31. alve and its lever are not worn That the fuel screen is undamaged That the tips of the high and low speed jet screws are not damaged On Tillotson HS 255 B that the speed governor 1 is clean That the air intake manifold is not cracked 90 English 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 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 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 Some carburettors have an extra jet semi fixed jet The jet is of brass and is located in the metering unit and is used to give a fuel supplement On average 10 of the fuel passes through the jet Below or next to the jet is a screen which needs to be cleaned Reassemble the jet and or screen in one of the following ways 1 Put together the unit and fit it in the carburettor by means of a punch Some Tillotson models Fit the jet with screen and lock washer English 91 CARBURETTOR Tillotson HS 228 B Maintain a
32. an damage the seats and needle tips Fit the fuel screen D by using the handle of a small screwdriver Fitthe pump diaphragm gasket F and cover E on the pump unit Fit the needle valve C with lever arm shaft and spring and tighten screw H Check using or a ruler or the like that the lever arm is level with the chamber floor See the figure to the lower right The lever arm can be bent if necessary to achieve the correct settings Fit the control diaphragm B with gasket and cover A on the metering unit 10 Carry out a pressure test See page 100 98 English CARBURETTOR ZAMA C1Q EL1 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 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 Fit the fuel screen D by using the handle of a small screwdriver Fitthe pump diaphragm gasket F and cover E on the pump unit Fit the needle valve C with lever arm shaft and spring and tighten screw H Check using or a ruler or the like that the lever arm is level with the chamber floor See the figure to the lower right The lever ar
33. annel leaking Impulse channel blocked Loose cover on carburettor pump side Faulty pump diaphragm Leaking manifold Loose carburettor mounting bolts Control system set too low Leak in throttle system air or fuel Control system incorrectly assembled Loose diaphragm Hole in diaphragm Leaking control diaphragm cover Acceleration and retardation Does not accelerate Adjust L screw Adjust H screw Blocked air filter Blocked fuel tankbreather Blocked fuel filter Fuel line blocked Loose or damaged fuel line Impulse channel blocked Loose cover on carburettor pump side Faulty pump diaphragm Leaking manifold Loose carburettor mounting Throttle set too low Control system incorrectly assembled Control system sticking Faulty diffuser jet Blocked silencer Motor stalls when throttle released Adjust L screw Adjust H screw Faulty pump diaphragm Control system set too high Control system sticking Faulty diffuser jet Over rich accelera Adjust L screw tion Adjust H screw Blocked air filter Faulty pump diaphragm Faulty diffuser jet Trouble shooting methods In addition to faults given in the above schematic trouble shooting can be carried out on a specific component or sub system of the chain saw The different testing procedures are described in respective sections and are as follows 1 Pressure testing the carburettor See page 100 2 Pressure testing the crankcase and cylinder See page 114
34. asket 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 That the crankshaft bearings do not show signs of play have an abnormal noise level and rotate smoothly That the sealing surfaces on the crankcase seals are not worn and that the rubber has not hardened That the crankcase is not cracked 116 English CRANKCASE AND CRANKSHAFT Assembly Saws 36 and 41 Saws 40 and 45 See page 120 Fit the bearing and seals on the crankshaft WARNING Grease the seals Thecrankcase halves can be hot Continue assembly as described on Risk of burns Wear protective page 111 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 m crankcase half and press in the bearing E Ensure that dirt and foreign particles do not enter the bearing C Let the crankcase half cool before continuing work If new seals need to be fitted in the crankcase grease the sealing surfaces and knock in the seals using respective punchs see Service tools The seals can also be fitted when the crankcase is in position Assembly position See pages 123 and 124
35. be washed 102 English TANK UNIT Dismantling Empty the tank and dismantle the cylinder cover as well as the bar and chain 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 If heated handles are fitted remove the con nections The cable to the switch cannot be removed before the tank unit and the engine sub assembly are separated Cleaning and Inspection Clean all parts and check the following That the fuel pipe is undamaged That the tank unit is not cracked That the throttle cable runs freely That the AV system is undamaged For AV system see page 107 That the tank breather is not blocked or leaks That the fuel cap does not leak That the fuel pipe bushing seals That the fuel filter is not blocked 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 The mountings applying to the chain saw in question is evident from the table on the next page NOTE Take care that the fuel pipe and throttle cable are not damaged Dismantle the bolts as shown in the figures and the table on the next page and lift off the tank unit from the engine sub assembly If the fuel pipe needs to be replaced meas ure its le
36. causes on the next page Small scratches can be polished off using fine emery paper That the piston ring is not stuck into its groove Max 1 mm Measure the piston ring wear by placing it in the bottom of the cylinder bore and measuring the gap and which should not exceed 1 mm That the needle bearing is undamaged That the intake manifold is undamaged Pressure 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 English 109 PISTON AND CYLINDER Onsaws 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 110 English 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 an
37. cept 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 62 English 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 Rotate gently until the flywheel s key mates in the keyway on the shaft Replace the flywheel washer and nut Tightening torque see Service data Remove the piston stop Fit the ignition module without tightening the Screws Turn the flywheel so that its magnet is beside the ignition module Continue assembly on next page English 63 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 tig
38. d fit the circlip Other saws Fit a new cylinder gasket Saws 36 40 41 and 45 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 Apply silicone rubber 504 98 26 01 to the lower crank casehalf s contactsurfaces Check that the seals fit in their grooves correctly Tighten the crankcase halves Tightening torque refer to Service data Seecontinuation on next page English 1 1 1 PISTON AND CYLINDER Fit the four bolts under the crankcase Tightening torque see Service data Fit the four cylinder bolts B Onsaw 394 connectthe anti vibration spring A to the cylinder The bolts are tightened using 4 mm allen key smaller saws or 3 16 allen key larger saws Fitthe intake manifold andthe insulation wall between the cylinder and carburettor Fit the following parts Cylinder cover See operating instructions Carburettor Spark plug See operating instructions Muffler If a new piston or cylinder has been fitted the saw must be run in for 3 4 hours with the carburettor set to the basic settings See the operating instructions for the saw in question 112 English 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
39. e designated with A B etc and start from A again in each new section English 3 INTRODUCTION Use This workshop manual can be used in two different ways e Repair of a specific sub assembly e Dismantling and reassembly of the entire chain Saw Repair of a specific sub assembly When a specific sub assembly on the chain saw is to be repaired proceed as follows 1 Refer to the page referring to the relevant sub assembly 2 Carry out the steps Dismantling Cleaning and inspection Reassembly 4 English 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 Work forwards through the manual and carry out Dismantling instructions in the order that the sections occur Return to the Starter on page 58 and follow the instructions under Cleaning and Inspection Work forward through the manual and carry out Cleaning and Inspection in the order that the sections occur Order or collect all the required spare parts from the spare parts stores In order to Assemble the chain saw proceed as follows Refer to pages 117 120 which deals with the Crankcase and carry out the instruc tions under Assembly Refer to pages 111 112 which deals with the Piston and Cylinder and carry out the instructions under A
40. ents that are bolted refer to the tightening torque in Nm A Lubricate using two stroke oil B Lubricate using saw chain oil Lubricate using grease Locking fluid Loctite 24 English SERVICE DATA English 25 SERVICE DATA Saws 51 and 55 Character key Numbers by components that are bolted refer to the tightening torque in Nm A Lubricate using two stroke oil B Lubricate using saw chain oil Lubricate using grease T Locking fluid Loctite 26 English SERVICE DATA English 27 SERVICE DATA Saws 254 257 Character key Numbers by components that are bolted refer to the tightening torque in Nm A Lubricate using two stroke oil B Lubricate using saw chain oil Lubricate using grease Locking fluid Loctite 28 English SERVICE DATA English 29 SERVICE DATA Character key Numbers by components that are bolted refer to the tightening torque in Nm A Lubricate using two stroke oil B Lubricate using saw chain oil Lubricate using grease Locking fluid Loctite 30 English SERVICE DATA English 3 1 SERVICE DATA e Saws 61 268 and 272 Character key Numbers by components that are bolted refer to the tightening torque in Nm A Lubricate using two stroke oil B Lubricate using saw chain oil Lubricate using grease Locking fluid Loctite 32
41. g the worm gear On those saws where the oil pump worm Screw the worm gear into the dismantling gear is pressed on the crankshaft tool and press the worm gear onto the crankshaft until it bottoms against the Assembling the oil pump Saws 42 242XP 246 254XP 262XP and 257 Fit the oil pump as follows Apply SAE 30 oil to all moving parts 2 Insert the pump piston D with washers and spring Press in the pump piston a little more and screw in the adjuster screw C Insert the plastic plug E Refit screw A and locking clip B Fit the seal F Fit the oil pump as follows Apply SAE 30 oil to all moving parts Fit the seal if necessary Press in pin F Locate the pinion E with washers and spring Insert the pump piston D through the pinion spring and washers in the pump housing Fit screw C The screw should be locked using Loctite or locking lacquer Fit the adjuster screw 1 with washers spring and locking clip A Fit the O ring See continuation page 80 English 77 LUBRICATION SYSTEM Saws 281XP and 288 XP Fit the oil pump as follows 1 Apply SAE 30 oil to all moving parts 2 Fitthe 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 Fit the adjuster screw A in the pump housing and through the hole in plug B Fit the O rings D and F
42. ghtening torque is stated in the service data Reassemble the chain and bar See the operating instructions 48 English SAFETY EQUIPMENT Muffler Dismantling WARNING Do not touch the muffler until it has cooled Risk of burns 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 the saw is so equipped If the saw is equipped with a spark arrester C remove this Saw 242 Cat Dismantle the muffler as shown in the figure to the right 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 Dismantle the muffler as shown in the figure to the right English 49 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 Assembly Clean all contact surfaces Saws 36 and 41 If the saw is equipped with a spark arrester fit this Fit the cooling plate B if fitted gasket and muffler on the cylinder Clean all parts and check the following Thatthe muffler and muffler mountings are not cracked or otherwise damaged That the gaskets are OK Asse
43. he gasket F and the pump diaphragm G Using a needle or the like carefully remove the fuel screen D Unscrew the high and low speed jet Screws Remove the plugs J See page 85 If necessary remove the throttle and choke valves as well as the shafts lever arms and springs Remove the semi fixed jet K See page 85 Walbro HDA and HD Remove the cover A over the metering unit and carefully remove the control diaphragm B with the gasket Undo the screw H and take out the needle valve C with lever arm shaft and spring Remove the cover E over the pump unit and carefully remove the gasket F a and the pump diaphragm G S ato a Using a needle or the like carefully remove the fuel screen D Unscrew the high and low speed jet Screws Remove the plug J See page 85 If necessary remove the throttle and choke valves as well as the shafts lever arms and springs English 87 CARBURETTOR Walbro WJ Remove the cover A over the metering unit and carefully remove the control diaphragm B with the gasket Undo the screw H and take out the needle valve C with lever arm shaft and spring Remove the cover E over the pump unit and carefully remove the gasket F and the pump diaphragm G Using a needle or the like carefully remove the fuel screen D Unscrew the high and low speed jet Screws
44. hten 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 Fit the starter and cylinder cover the carburettor and connect the cables Fit the starter and cylinder cover Fitting the spark plug cover Make a hole in the HT cable using pliers 502 50 06 01 Push the HT cable through the spark plug cover and fit the contact spring using the pliers Slide the spark plug cover over the contact spring Stop switch The stop switch is described in the section Safety equipment See page 51 64 English ELECTRICAL SYSTEM Handle heating Description Some saws are equipped with an electric handle heating This consists ofthe following parts Generator Power switch Heater loop in the tank unit Handle loop with heater loop One or two loops 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 fsossassesnnus Trouble shooting _ la Au Trouble shooting can take place with most components connected to the saw An ohm meter is required for trouble shooting 9
45. in order to maximise safety when the saw is in use Target group This workshop manual is written for personnel that are assumed to have general knowledge of service and repair of small engines The workshop manual should be read and under stood by all personnel carrying out service and repair work on the chain saw The manual is also suitable for use in the training of new employees Updates 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 together with all service announcements that apply to the specific model of chain saw Tools For specific procedures special tools are re quired In this workshop manual all the service tools required are listed Use of the tools is described in appropriate sections Always use Husqvarna original Spare parts e Service tools e Accessories Layout The descriptive sections in this workshop manual are set out in a number of flow diagrams When carrying out repairs on a specific chain saw follow the signs that apply to the saw in question Diagrams are not numbered as they are linked to the actual text either by lines or by being in the same box Positional directives to components inside the diagrams ar
46. ir 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 2725 are maintained correctly The air filter units on these models have there fore been included in this workshop manual 268K 272K and 272S The air filter system consists of 1 Prefilter 2 Main filter Prefilter The prefilter is an oiled foam filter which is easily accessible under the filter cover A In dusty conditions this filter should be checked replaced after every second refuelling The filter should be cleaned and oiled regu larly to obtain maximum filtration efficiency Cleaning Dismantle the filter Wash the filter in warm soapy water After cleaning rinse the filter thoroughly in clean water Squeeze and let the filter dry NOTE Compressed air at a high pressure can damage the foam Oiling Oil the filter carefully It is extremely impor tant that the entire filter is saturated with oil Use HUSQVARNA oil no 503 4773 01 The bottle holds 0 11 which is sufficient for three applications English 101 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 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
47. ith chain oil English 121 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 Pull the seal from the crankcase by turning the handle Seals fitted on the oil pump or plastic flange Press out the seal using a suitable tool 122 English CRANKCASE AND CRANKSHAFT Assembly Seal assembly in the oil pump 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 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 sleeve should be used when working on these saws See Tools 1 Fit the seal using the assembly mandrel 2 The seal should be fitted using the measurements for each saw a
48. l 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 013mm a Qu 502 50 88 01 5 mm 502 50 87 01 4 mm 502 50 86 01 mm 502 50 06 01 502 51 34 02 0 3 mm 502 51 91 01 0 5 mm 502 50 37 01 N 502 70 09 01 E compl 502 50 70 01 502 71 14 01 14 English 502 50 22 01 8 mm 502 50 23 01 10 mm J 504 98 26 01 86 41 40 45 Ss ia 502 50 83 01 fr n B j 502 51 02 01 TOOLS Tools for saws 36 and 41 3 mm 4 mm 5 mm Q 8 mm 10 mm 502 50 33 01 502 51 94 01 530 03 11 12 530 03 11 36 502 51 00 02 Tools for saws 40 45 51 and 55 502 50 33 01 er 505 26 79 12 gt 40 910 1116 45 gt 925 1168 50 gt 925 0856 502 51 94 01 50 99 01 7 50 26 01 G 505 38 18 17 55 40 45 502 51 61 01 51 55 504 90 90 01 ON Fo A hi 502 50 30 09 40 gt 910 1116 45 gt 925 1168 502 50 79 01 55 compl 502 50 38 01 gt Q 502 54 03 01 40 45 55 A 502 50 46 01 55 504 90 29 02 English 15 TOOLS Tools for saws 42 242 and 246 Tools for saws 254 257 and 262 502 50 33 01 x 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 ea 4 DENT e D 502 50 99 01 502 70 03 01
49. m can be bent if necessary to achieve the correct settings Fit the control diaphragm B with gasket and cover A on the metering unit Carry out a pressure test See page 100 English 99 CARBURETTOR Pressure testing WARNING The fuel used in the chain saw Pressure testing should be carried out with the poses the following hazards carburettor fully assembled Testing should 1 en its vapours are always be carried out after the carburettor has Can causes Hn init tlon been repaired but a test can also be made for 3 Is highly inflammable trouble shooting before dismantling Make the test as follows 1 Setthe high and low speed jet screws one turn open from the bottom Connect pressure tester 502 50 38 01 to the carburettor s fuel intake Lower the carburettor into a beaker of water Pump up the pressure to 50 kPa 0 5 bar and clamp the pump tube with the spring clip There should be no leakage If a leakage occurs refer to the table below Diffuser jets Needle valve Leakage on the Pump diaphragm pulse tube Ventilation hole Control diaphragm above the metering unit Refitting onto chain saw Fit the carburettor to the chain saw and refit any other parts removed Carburettor adjustment See the operating For tightening torques see the Service instructions for the saw in question data for the saw in question 100 English AIR FILTER Replace the chain saw s a
50. mall screwdriver Fitthe pump diaphragm gasket F and cover E on the pump unit Fit the needle valve C with lever arm shaft and spring and tighten screw H Check using or a ruler or the like that the lever arm is level with the chamber floor See the figure to the lower right The lever arm can be bent if necessary to achieve the correct settings Fit the control diaphragm B with gasket and cover A on the metering unit 10 Carry out a pressure test See page 100 94 English CARBURETTOR Walbro HDA och HD Maintain a high level of cleanliness when reassembling the carburettor Even small particles of dirt can cause operating prob lems 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 Fit the plugs J See page 91 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 Fit the fuel screen D by using the handle of a small screwdriver Fitthe pump diaphragm gasket F and cover E on the pump unit Fit the needle valve C with lever arm shaft and spring and tighten screw H Check using or a ruler or the like that the lever arm is level with the chamber floor See the figure to the lower right The lever arm can be bent if necessary to achieve the correct
51. mble the muffler and fit to the cylinder Tightening torque see page 20 WARNING The coating on and in the cata lytic converter element A is hazardous to your health if touched Wear protective gloves when working on a catalytic converter Only specially treated bolts may be used on the catalytic converter high temperature See spare parts catalogue See Service data regarding tightening torques 1 Secure the muffler on the cylinder using the two bolts D Tighten all bolts using the tightening 2 Assemble the muffler components using the four torque set out in the Service data bolts E 3 Secure the muffler to the crankcase using the two B bolts F and Loctite 50 English SAFETY EQUIPMENT 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 ohm In the run position morethan 1000 ohm Assembly Press the switch into the socket on the tank unit Fit the earth screw A and cable B Note On some models the earth cable should be connected to the earth screw English 51 SAFETY EQUIPMENT Throttle lock Dismantling WARNING The fuel used in the chain saw Other saws poses the following ha
52. n 4500 3600 4500 3800 3600 3700 mu Max speed r min 13000 12500 13000 14500 12500 12500 Fuel tank volume Litres 0 5 0 4 0 5 0 5 0 6 Oil pump capacity cm min at 8 500 rpm 7 8 7 3 7 Weight without bar and chain Weight with bar and chain kg kg lbs 5 3 13 5 4 13 5 3 13 5 5 13 5 4 13 6 2 15 Spark plug Champion RCJ 7 Y RCJ 7 Y RCJ 7 Y RCJ 7 Y RCJ 7 Y RCJ 7 Y Oil tank volume Automatic oil pump Litres 0 2 0 25 0 2 0 27 0 25 0 3 Handle heater Watt r min No No No No No No Yes Yes Yes Yes Yes Yes English 7 55 242XP 246 254 257 55 242XP 246 254 257 55 242XP 246 254 257 8 English Displacement cm 53 62 42 46 54 57 Spark plug gap mm inches 0 5 02 0 5 02 0 5 02 0 5 02 0 5 02 0 5 02 Bar length cm inches 38 51 15 20 38 51 15 20 28 46 11 18 28 46 11 18 33 51 13 20 33 51 13 20 TECHNICAL DATA Bore mm 46 0 48 0 42 0 44 0 45 0 46 0 Ignition system ELECTROLUX ET ELECTROLUX ET SEM AM 7 SEM AM 7 ELECTROLUX ET ELECTROLUX ET Chain speed m s 17 4 9000 rpm 18 4 8300 rpm 19 1 9900 rpm 17 3 9000 rpm 17 3 9300 rpm 17 3 9000 rpm Stroke Max power at mm r min 32 0 9000 34 0 8300 30 0 9900 30 0 9000 34 0 9300 34 0 9000 o S Air gap Carburettor mm inches 0 3 01
53. ngth outside of the tank unit and make a note ofthe length This information is needed when fitting a new pipe English 103 TANK UNIT Bolts placed at Saw Ge SS x A D F L all under covers A D under a cover F G L 254 A D F L Has no tank unit Has no tank unit Bolts placed at A D F K A D F K N 246 Saw 104 English TANK UNIT Assembly If a new fuel pipe is to be fitted proceed as 3 Twist the hose so that it takes on the same follows angle to the carburettor and let the hose 1 Measure the length of the old hose out protrude as much as the old hose did side of the tank unit note the length 4 Pull the hose through the filler hole using 2 Oil half of the hose lightly and thread the tool 502 50 83 01 cut off the bevelled end oiled part into the fuel tank from the outside and fit the fuel filter Fit the throttle and lock NOTE Ensure that the fuel pipe and throttle cable are not damaged Fit the engine sub assembly to the tank unit and at the same time insert the fuel pipe in the bottom of the carburettor space If the saw has a throttle cable insert this into The figures on the previous page illustrate all the carburettor space too types of mountings between the tank unit and the engine sub assembly marked by letters The mountings applying to the chain saw in question is evident from the table on the next page Fit the bolts as set out in the t
54. nkshaft bearings note that the crankcase halves are hot Use protective gloves When using compressed air the air jet should never be pointed towards the body Air can be forced into the blood stream which can cause fatality English 5 36 41 42 51 36 41 42 51 6 English Displacement cm 36 40 40 42 44 51 Spark plug gap mm inches 0 5 02 0 5 02 0 5 02 0 5 02 0 5 02 0 5 02 Bar length cm inches 33 46 13 18 33 46 13 18 33 46 13 18 28 46 11 18 33 46 13 18 33 51 13 20 TECHNICAL DATA Bore 38 0 40 0 40 0 42 0 42 0 45 0 Ignition system PHELON PHELON PHELON SEM AM 7 PHELON ELECTROLUX ET Chain speed m s 17 3 9000 rpm 17 4 8500 rpm 17 3 9000 rpm 17 9 9300 rpm 17 4 8500 rpm 17 4 9000 rpm 30 0 S Air gap mm inches 0 3 012 0 3 012 0 3 012 0 3 012 0 3 012 0 3 012 Chain pitch inches 325 3 8 325 325 3 8 325 325 325 3 8 r min 9000 9000 9000 9300 9000 9000 Carburettor WALBRO WT 239 ZAMA C1Q EL1 WALBRO WT 239 WALBRO HDA 98 ZAMA C1Q EL1 WALBRO WT 170 Drive link gauge mm inches 1 3 050 1 3 050 1 3 050 1 5 058 1 3 050 1 3 050 1 5 058 1 3 050 From May 1996 36 41 42 51 T rpm Idling speed r min 3000 2500 3000 2700 2500 2500 TECHNICAL DATA Engagement speed r mi
55. oil pump for the correct oil flow See the operating instructions 80 English LUBRICATION SYSTEM Saws 36 40 41 45 51 and 55 Fit the oil pump as follows Apply SAE 30 oil to all moving parts Lower seal 2 Fit the worm gear on the Pump oylinder crankshaft if necessary Upper seal Fit the pump piston F in the pump Chain guide plate cylinder B Pump housing Fill the pump recess with grease Pump piston Fit the unit in the pump housing E Worm gear Ensure the pump cylinder s cut out aligns in the pump housing Fit the lower seal A on the crankcase Saws 36 40 41 and 45 see Saws 51 and 55 see continuation continuation on the next page on the next page English 81 LUBRICATION SYSTEM Saws 36 40 41 and 45 Saws 51 and 55 Fit the oil pump in the crankcase tighten Fit the oil pump in the crankcase and fit the two bolts and fit the upper seal the upper seal Fit the chain guide plates according to respective diagrams below Fit the bar and chain 82 English 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 Design The carburettor consists of three sub systems Metering unit A Mixing venturi B Pump unit C The metering unit A contains the jets and fuel control functions It is he
56. ons The fuel used in the chain saw poses the following hazards 1 The fluid and its fumes are poisonous 2 Can cause eye and skin irritation 3 Can cause breathing difficulties 4 ls highly inflammable The bar chain and clutch cover chain brake must be assembled before the chain saw is started otherwise the clutch may come loose causing personal injury Wear ear muffs when testing the chain Saw Do not use the saw until it has been adjusted so that the chain does not rotate when idling Bear in mind the fire risk The saw can produce sparks that can cause a fire hazard After testing do not touch the silencer until it has cooled Risk of burns This especially applies if the saw is fitted with a catalytic converter The coating on and in the catalytic element is hazardous to touch Use protective gloves when working on the catalytic converter Inadequate chain lubrication can result in the chain breaking which can cause serious or fatal injury Make sure that the starter recoil L zt spring does not fly out and cause personal injury Release the spring tension before the cord pulley is removed When removing the pressure spring for the chain brake ensure that the brake is in the on position which reduces the spring tension otherwise the spring can fly out causing personal injury After repair the chain brake must be checked in accordance with the instructions on page 47 When replacing the cra
57. ontinue on the next page English 55 Saws 36 41 42 242XP 246 51 55 254XP 257 262XP and 394 Fit the throttle lock and spring On saw 394 twist as shown in the figure when fitting SAFETY EQUIPMENT Saws 61 268 268K 272XP 272K 2728 281XP and 288XP Fit the throttle arm and spring Fit the pin and the two rubber dampers Saw 3120 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 56 English STARTER Dismantling 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 WARNING If the spring tension is released when lifting the starter pulley the spring can fly out and cause per sonal injury Wear protective glasses If the starter has a cord guide A remove this If the cord is to be replaced cut it off and pull out the bits from the handle and starter pulley using a pair of long nosed pliers WARNING Ensure that the spring does not fly out and cause personal injury Wear protective glasses If the spring is to be replaced remove the old spring from the starter pulley Some saws have a protective plate over the spring English 57 STARTER Cleaning and Inspection Clean all parts and check the following WARNING The starter cord Ensure that the sp
58. r and fit the handle secure with a double knot Pull out the cord 20 30 cm and insert it into the cut out on the starter pulley rim Some saws have several long cut outs Rotate the starter pulley clockwise until the cord is correctly tensioned Check the cord tension A Pull out the cord completely and hold the pulley with your thumb B In this position it should be possible to turn the starter pulley a further 1 2 3 4 turn Fit the starter on the crankcase Tighten the bolts to 4 Nm 60 English 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 Switch from the ignition module Saws 36 and 41 Loosen the cable that runs to the stop Release the cables from the guide rail and remove the guide rail Loosen the flywheel nut and unscrew it 1 turn Tap the nut quickly with a hammer so that the flywheel comes loose Remove the nut and flywheel Other saws see next page English 61 ELECTRICAL SYSTEM All saws ex
59. re the correct amount of fuel for the given engine speed and power is metered The mixing venturi B houses the choke throttle valve and diffuser jets Here air is mixed with the fuel to give a fuel air mixture that can be ignited by the ignition spark In the pump unit C fuel is pumped from the fuel tank to the metering unit One side of the pump diaphragm is connected to the crankcase and pulses in time with the pressure changes in the crankcase The other side of the diaphragm pumps the fuel WARNING Thefuel used inthe chain saw poses the following hazards 1 The liquid and its vapours are poisonous 2 Can cause skin irritation 3 Is highly inflammable English 83 CARBURETTOR Operation The carburettor operates differently in the following modes Cold start Idling Partthrottle 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 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 In the part throttle mode the throttle valve H is partially open Fuel is supplied through the diffuser jets F and G In the full throttle mode both valves are open and fuel is supplied
60. ring does not fly outand cause personal injury The dogs in the starter pulley That the pawls on the flywheel are OK and spring backtowards the centre and move freely Changing the ferrule Remove the parts of the old ferrule Fit the new ferrule in the starter housing Use a wrench spacer A and ball B Splay out the ferrule on the inside as shown in the figure 58 English STARTER Assembly WARNING Ensure that the spring does not fly outand 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 42 242 246 51 55 254 36 and 41 61 268 272 281 and 288 257 262 394 and 3120 Screw the cord to the starter Secure the cord on the Knot the cord on the starter starter pulley Continues on next page English 59 STARTER Grease the return spring and starter pulley bearing 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 Pullout the cord through the hole in the cove
61. rottle and choke valves shafts lever arms and springs have been dismantled these must be reassembled Lubricate the shaft bearings using a light oil Fit the plugs J See page 91 Fit the fixed jet See page 91 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 Fit the fuel screen D by using the handle of a small screwdriver Fit the pump diaphragm gasket F and cover E on the pump unit Fit the needle valve C with lever arm shaft and spring and tighten screw H Check using or a ruler or the like that the lever arm is level with the chamber floor See the figure to the lower right The lever arm can be bent if necessary to achieve the correct settings Fit the control diaphragm B with gasket and cover A on the metering unit 10 Carry out a pressure test See page 100 English 97 CARBURETTOR Walbro WT 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 Fitthe plugs J See page 91 Fitthe semi fixed jet K See page 91 Fitthe high and low jet screws and springs NOTE Do not tighten the screws against the seats This c
62. s On saw 394 remove the carburettor chamber floor A and air jet B Undo the bolts holding the crankcase to gether The bolts are on the clutch side Note the location of the bolts that are of a different length Split the crankcase using tool 502 51 61 01 See continuation on next page 114 English 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 protec tive gloves Remove all rubber and plastic components from the crankcase halves Heat the crankcase half in question to 200 C Wear protective gloves and knock the crankcase half gently inside face down on Split the shaft support and a wooden bench or the like and the dismantle the halves bearing will drop out Fit the new bearing into the crankcase half while it is still hot If the crankshaft bearing still remains on the crankshaft when dismantling remove it using puller 502 90 90 01 Remove the bearing from the crankshaft using puller 502 90 90 01 If necessary remove the following parts A Chain tension screw B Bar bolts C Spike English 115 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 g
63. s shown in the instructions on the next page After fitting the seal assemble On the starter side Starter Flywheel Generator if fitted On the clutch side Chain and bar Oil pump English 123 CRANKCASE AND CRANKSHAFT Assembly positions starter side Measurement A should be as in the table below for resp saws Under the crankcase plane 4 4 5 mm Measurement B should be as in the table below for resp saws Under the crankcase plane 42 242 246 1mm 394 5 mm 3120 0 0 5 mm 1 mm above the crankcase plane Assembly position on the clutch side Measurement C should be as in the table below for resp saws Under the crankcase plane 51 55 1mm 394 0 5 mm 254 257 262 1 5 mm above the crankcase plane 124 English
64. ssembly Refer to pages 107 which deals with the Anti vibration system and carry out the instructions under Assembly Refer to page 105 which deals with the Tank unit and carry out the instructions under Assembly Continue to work backwards through the manual and carry out Assembly instructions as the sections occur In order to improve understanding some sections begin with a Description of the relevant sub assembly 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 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 legal requirements when fitted with the cutting equipment specified in the Operator s Manual Equipping the saw with other equipment or accessories and spare parts not approved by Husqvarna can result in non compliance with these safety requirements and liability for persons carrying out such modifications Special instructi
65. system See page 63 Fit the crankcase bolts Tighten crosswise with the torque set out inthe Service data Tighten the bolts closest to the crankshaft first Centrifugal clutch See page 69 Oil pump See page 77 Carburettor Muffler See page 49 Piston and cylinder See page 111 Tank unit See page 105 If a crankshaft has been fitted the saw must be run in for 3 4 hours with the carburettor set to the basic settings See the operating instructions English 119 CRANKCASE AND CRANKSHAFT Saws 40 and 45 NOTE Ensure that dirt and foreign particles do not enter the bearing Check the shaft seat s sealing A Fit the shaft seat over the bearing and join the shaft seat at B Continue assembly as described on page 111 120 English CRANKCASE AND CRANKSHAFT Bar bolts When changing the bar bolts on all saws except 40 and 45 proceed as follows Drain the chain oil Knock through the old bar bolt so that it falls in the oil tank Remove the bolt from the oil tank 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 Pull the steel wire until the bolt comes out through its hole Check that the bolt s square shoulder is aligned with its recess in the crankcase Turn the bolt if necessary Pull through the bolt with its nut and spacer between the nut and crankcase Refill w
66. ut the needle valve C with lever arm shaft and spring Remove the cover E over the pump unit and carefully remove the gasket F and the pump diaphragm G Using a needle or the like carefully remove the fuel screen D Unscrew the high and low speed jet Screws Remove the plugs J See page 85 If necessary remove the throttle and choke valves as well as the shafts lever arms and springs Tillotson HS 255 B 1 Remove the cover A over the metering unit and carefully remove the control diaphragm B with the gasket Undo the screw H and take out the needle valve C with lever arm shaft and spring Remove the cover E over the pump unit and carefully remove the gasket F and the pump diaphragm G Using a needle or the like carefully remove the fuel screen D Unscrew the high and low speed jet Screws Remove the plugs J See page 85 If necessary remove the throttle and choke valves as well as the shafts lever arms and springs Remove the speed governor 1 Only 272K 268K and 2725 Remove the semi fixed jet K See page 85 86 English CARBURETTOR Tillotson HS 260 A 1 Remove the cover A over the metering unit and carefully remove the control diaphragm B with the gasket Undo the screw H and take out the needle valve C with lever arm shaft and spring Remove the cover E over the pump unit and carefully remove t
67. zards 1 The liquid and its vapours are poisonous 2 cause skin irritation 3 Is highly inflammable Remove the tank unit from the engine assembly See page 103 Dismantle the throttle lock pin A Saws 61 268 268K Saw 3120 using a punch 272XP 272K 2728 See continuation on next 281XP 288XP and page 394 Saws 40 45 See continuation on next page Saws 36 41 42 55 242XP 246 51 Saw 394 254XP 257 and 262XP Turn the throttle lock as Slide the throttle lock and Carefully prise up the lock shown in the figure and lift remove it forwards as from the slot and remove it out with the spring from shown in the figure the cut out in the handle Continues on next page 52 English SAFETY EQUIPMENT Saws 61 268 268K 272XP 272K 2728 281XP 288XP and 394 Dismantle the throttle pin B by using a Dismantle the throttle On saw 394 also remove the throttle cable Saws 40 and 45 Remove the three screws in the side of the handle as well as the screw holding the spring under the handle 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 Saw 3120 Remove the three pins with a punch Pressthe throttle lock down and move it and the trigger forwards until the back edge of the lock appears Lift out the throttle with cable from the front

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