Page 2 - LIST OF CONTENTS
2 – English LIST OF CONTENTS Introduction ..................................... 3Safety regulations ........................... 5Technical Data ................................. 6Tools ............................................... 14Service data ................................... 20Trouble shooti...
Page 3 - INTRODUCTION
English – 3 INTRODUCTION As production continues, changes will be intro-duced successively to the chain saw. If at anytime these changes influence service and/orspares, special service announcements will besent out, which means that this manual will ceaseto be current with time. In order to avoid pr...
Page 4 - Use
4 – English INTRODUCTION Dismantling and reassembly of the entire chain saw When the entire chain saw is to be dismantledand reassembled, proceed as follows: 1. Refer to page 57, which deals with theStarter and carry out the instructionsunder the heading Dismantling. 2. Work forwards through the man...
Page 5 - SAFETY REGULATIONS; General Instructions
English – 5 SAFETY REGULATIONS General Instructions Special instructions WARNING!The warning text indicates a riskof personal injury if instructionsare not followed. NOTE!The warning text indicates a risk ofdamage to equipment if instructionsare not followed. The chain saw is type approved withregar...
Page 6 - TECHNICAL DATA
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 DATA 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...
Page 14 - Tools for all chain saws; TOOLS
14 – English 502 50 57-01 3/16"502 50 16-01 6 mm502 50 64-01 5 mm502 50 18-01 4 mm502 50 19-01 3 mm 502 50 22-01 8 mm502 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 mm502 50 87-01 4 mm502 50 ...
Page 19 - List of tools
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 5...
Page 20 - SERVICE DATA; Character key
20 – English Saws 36 and 41 SERVICE DATA ▲ ▲ ■ ● ● ● ● 5 10 15 4 6 Character key Numbers by components that are boltedrefer 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-...
Page 40 - Trouble shooting schematic; Starting
40 – English Worn needle valve/needleLeaking control diaphragm/cover plateControl system stickingWorn throttle leverFaulty diffuser jet Fuel filter blockedFuel line blockedLeaking manifoldLoose carburettor mountingWorn throttle valve shaftLoose throttle valve screwWorn throttle valveControl system s...
Page 41 - High rpm; Trouble shooting methods
English – 41 Adjust H-screwBlocked air filterBlocked fuel tankbreatherBlocked fuel filterFuel line blockedLoose or damaged fuel lineImpulse channel leakingImpulse channel blockedLoose cover on carburettorpump sideFaulty pump diaphragmLeaking manifoldLoose carburettor mountingControl system set too l...
Page 42 - Chain brake; Dismantling; SAFETY EQUIPMENT
42 – English Chain brake 3120 continues on next page. Place the clutch cover in a vice with the jawspositioned as shown below and release thetubular pin B.Carefully knock out the tubular pin B. All saws except 3120 3120 ! WARNING!If the clutch cover slides out ofthe vice's grip the spring can flyout...
Page 44 - Cleaning and Inspection
44 – English Cleaning and Inspection Clean and inspect all parts.The thickness of the brake band must not beunder 0.8 mm at any point. Assembly Fit the band's fixed end into position on theclutch cover. All saws except 3120 3120 Continues on next page. 3120 continues on next page. Fit the screw that...
Page 47 - Checking brake operation
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 runningduring the test.Test that the chain brake comes on asfollows: ! WARNING!After repair, the chain brakemust be checked as set out inthe following instructions. Checking bra...
Page 48 - Chain catcher; Description
48 – English Chain catcher Description The chain catcher is intented to catch thechain if it should break.The chain catcher has a different design andis secured differently on the chain sawsdescribed in this manual. The following designs are used:• Aluminium angle.• Plastic angle.• Fixed roller.• Ro...
Page 49 - Muffler
English – 49 Muffler WARNING!Do not touch the muffler until ithas cooled. Risk of burns! Dismantling ! SAFETY EQUIPMENT B C A If the saw is equipped with muffler mounting(A), unscrew this from the crankcase andmuffler. Unscrew the muffler from the cylinder(M5 or M6 bolts, M5 or M6 nuts). Remove the ...
Page 51 - Stop switch; Assembly
English – 51 Stop switch Dismantling Remove the earth screw (A) and cable (B). Press the switch's securing tabs (C) towardseach other and push out the switch. Cleaning and Inspection Clean the switch and check its resistance asfollows: Connect an ohm meter as shown in the fig.The resistance should b...
Page 52 - Throttle lock
52 – English Throttle lock Remove the tank unit from the engineassembly. See page 103. ! WARNING!The fuel used in the chain sawposes the following hazards:1. The liquid and its vapoursare poisonous. 2. Can cause skin irritation. 3. Is highly inflammable. Dismantle the throttle lock pin (A)using a pu...
Page 54 - Cleaning and inspection
54 – English Cleaning and inspection Clean all parts. Check that the springs, where fitted, areOK and have the correct tension. Check that the lock's activationmechanism is not worn. For examples ofthe activation mechanism, see the figure. SAFETY EQUIPMENT On those saws fitted with a throttle cable,...
Page 57 - STARTER
English – 57 Dismantling Dismantle the starterSee the operating instructions. Pull out the cord 20-30 cm andinsert it intothe cut-out in the starter pulley rim.Some saws have several long cut-outs. Rotate the starter pulley anticlockwise untilthe spring-tension on the starter pulley ceases. Dismantl...
Page 58 - Changing the ferrule
58 – English Cleaning and Inspection ! WARNING!Ensure that the spring does notfly 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, andspring back towards the centre and move freely. STARTE...
Page 61 - Ignition system
English – 61 Ignition system ELECTRICAL SYSTEM Dismantling Saws 36 and 41. • 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. Loosen the cable that runs to the stopswitch from ...
Page 62 - ELECTRICAL SYSTEM
62 – English Unscrew the two pawls and springslocated on the flywheel. Loosen the flywheel nut and undo until italigns with the end of the shaft. All saws except 36 and 41. Fit puller 502 51 49-02 and loosen theflywheel. Remove the puller, nut and flywheel. Continuation all saws Remove the ignition ...
Page 64 - Fitting the spark plug cover
64 – English ELECTRICAL SYSTEM • Insert feeler gauge 502 51 34-02 (0.3 mm) between the ignition moduleand 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 fitthe cable to the ignition module. Stop switch T...
Page 65 - Trouble shooting
English – 65 ELECTRICAL SYSTEM Handle heating Some saws are equipped with an electrichandle heating. This consists of the followingparts: • Generator.• Power switch.• Heater loop in the tank unit.• Handle loop with heater loop. (One or two loops). Description The above components are connected inser...
Page 67 - CENTRIFUGAL CLUTCH
English – 67 Dismantling Remove the bar and chain. See the operat-ing instructions.On 268K and 272K, remove the cuttingattachment. See the operating instructions.On 272S, remove the grinder attachment.See the operating instructions. Use a spanner and remove the clutch. Onsaws 36 and 41 use the servi...
Page 70 - LUBRICATION SYSTEM
70 – English LUBRICATION 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 theoil pump. Some pumps have to beremoved by using extractor screws. M5screws should be inserted into the 2threaded holes in the p...
Page 77 - Assembling the oil pump; Assembling the worm gear
English – 77 Assembling the oil pump LUBRICATION 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 s...
Page 83 - CARBURETTOR
English – 83 CARBURETTOR Description The diagrams in this description do notcorrespond with the carburettor fitted onthe chain saws. They serve only to showthe principles of design and operation. Design B C A The metering unit (A) contains the jets andfuel control functions. It is here the correctam...
Page 87 - Walbro HDA and HD
English – 87 Walbro HDA and HD D G F E A B HC J 1. Remove the cover (A) over the metering unit and carefully remove the controldiaphragm (B) with the gasket. 2. Undo the screw (H) and take out the needle valve (C) with lever arm, shaft andspring. 3. Remove the cover (E) over the pump unit and carefu...
Page 88 - Walbro WG; Walbro WJ
88 – English CARBURETTOR Walbro WG 1. Remove the cover (A) over the metering unit and carefully remove the controldiaphragm (B) with the gasket. 2. Undo the screw (H) and take out the needle valve (C) with lever arm, shaft andspring. 3. Remove the cover (E) over the pump unit and carefully remove th...
Page 89 - Walbro WT
English – 89 Walbro WT E F G C J B H K A ZAMA C1Q-EL1 1. Remove the cover (A) over the metering unit and carefully remove the controldiaphragm (B) with the gasket. 2. Undo the screw (H) and take out the needle valve (C) with lever arm, shaft andspring. 3. Remove the cover (E) over the pump unit and ...
Page 95 - Walbro HDA och HD
English – 95 1. If the throttle and choke valves, shafts, lever arms and springs have beendismantled these must be reassembled.Lubricate the shaft bearings using alight 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 againstthe ...
Page 100 - Pressure testing
100 – English CARBURETTOR Pressure testing Refitting onto chain saw Fit the carburettor to the chain saw andrefit any other parts removed.For tightening torques, see the ”Servicedata” for the saw in question. Carburettor adjustment. See the operatinginstructions for the saw in question. Make the tes...
Page 101 - AIR FILTER
English – 101 AIR FILTER The air filter system consists of: 1. Prefilter.2. Main filter. Prefilter A Replace the chain saw’s air filter at theintervals stated in respective operating in-structions. It is extremely important that the air filterunits on power cutters 268K, 272K and stumpgrinder 272S a...
Page 103 - TANK UNIT
English – 103 If the fuel pipe needs to be replaced, meas-ure its length outside of the tank unit andmake a note of the length. This information isneeded when fitting a new pipe. TANK UNIT Dismantling WARNING!The fuel used in the chain sawposes the following hazards:1. The liquid and its vapours are...
Page 104 - Saw Bolts placed at
104 – English TANK UNIT 364041 424551 5561242XP 246254XP 257262XP268 268K272XP272K 272S281XP288XP 394XP3120XP Saw Bolts placed at A, D, F, KHas no tank unitA, D, F, K A, D (under a cover) F, G, LHas no tank unitA, D, F, L (all under covers) A, D, F, L (all under covers)A, C, D, F, G, KA, D (under a ...
Page 106 - ANTI-VIBRATION SYSTEM
106 – English ANTI-VIBRATION SYSTEM Dismantling Description The anti-vibration system reduces the vibra-tions which pass from the engine and cuttingequipment to the handles. The anti-vibrationsystem consists either of rubber elements orcoil springs.The system’s movement limitation consistsof side ab...
Page 108 - PISTON AND CYLINDER
108 – English Dismantling PISTON 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 thecylinder and the carburettor and t...
Page 110 - Faults and causes
110 – English 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. PISTON AND CYLINDER Piston ring breakage 1. Excessive engine speed 2. Piston ring worn out. 3. Oversized piston ring gro...
Page 114 - CRANKCASE AND CRANKSHAFT
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 particlesenter the bearings. On saw 394, remove the ca...
Page 121 - Bar bolts
English – 121 Bar bolts CRANKCASE AND CRANKSHAFT When changing the bar bolts on all sawsexcept 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 ...
Page 122 - Changing the seals
122 – English CRANKCASE AND CRANKSHAFT Changing the seals Dismantling Before dismantling the seals remove thefollowing 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...
