Boss BPTYR2500 Instruction Manual

BPTYR2500

34 Yarraman Place

Virginia, QLD, 4014

Ph: 03 8726 1471

Email: [e-mail]

Web: www.bosspowertools.com.au

INSTRUCTION MANUAL

PETROL

TOP HANDLE CHAINSAW 25.4cc

WARNING!

Read all safety warnings and all instructions and retain this manual for future reference.
Failure to follow the warnings and instructions may result in fire and/or serious injury.

EXPLANATION OF SYMBOLSAND SAFETY WARNINGS

Contents

1. For Safe Operation..................................................................3

2. Explanation of Symbols on the Machine............................. 5

3. Installing Guide Bar and Saw Chain...................................... 6

4. Fuel and Chain Oil.................................................................. 7

5. Operating the Engine..............................................................8

6. Sawing.....................................................................................11

7. Maintenance............................................................................14

8. Maintenance of Saw Chain and Guide Bar.............................20

9. Troubleshooting Guide..........................................................23

10. Specifications.......................................................................24

Read operator's instruction
book before operating this
machine.

Wear head, eye and ear
protection.

Use the chain saw
With two hands.

Warning Danger of
kickback.

Read, understand and
follow all warnin

g

s.

1Forsafe operation

1.Never operate a chain saw when you are fatigued,ill,or upset,or

under the influence of medication that may make you drowsy,or if
you are under the influence of alcohol or drugs.

2.Use safety footwear,snug fitting clothing and eye,hearing and
head protection devices.

3.Always use caution when handling fuel .Wipe up all spills and
then move the chain saw at least 3 m from the fueling point before
starting the engine.
3a.Eliminate all sources of sparks or flame (i.e.smoking,open
flames, or work that can cause sparks)in the areas where fuel is
mixed,Poured,or stored.
3b.Do not smoke while handling fuel or while operating the chain
saw.

4.Do not allow other persons to be near the chain saw when
starting or cutting .Keep bystanders
and animals out of the work area.Children,pets and bystanders
should be a minimum of 10 m
away when you start or operate the chain saw.

5.Never start cutting until you have a clear work area,secure footing
and a planned retreat path from the falling tree.

6.Always hold the chain saw firmly with both hands when the
engine is running .Use a firm grip with thumb and fingers
encircling the chain saw handles.

7.Keep all parts of your body away from the saw chain when
the engine is running.

8.Before you start the engine. make sure the saw chain is not
contacting anything.

9.Always carry the chain saw with the engine stopped, the guide
bar and saw chain to the rear. and the muffler away from your body.

10. Always inspect the chain saw before each use for worn. loose,

or damaged parts. Never operate a chain saw that is damaged,
improperly adjusted. or is not completely and securely assembled
be sure that the saw chain stops moving when the throttle control
trigger is released.

11. All chain saw service. other than the items listed in the Owner's
Manual, should be performed by competent chain saw service
personnel(E.g. if improper tools are used to remove the flywheel, or
if an improper tool is used to hold the flywheel in order to remove
the clutch. structural damage to the flywheel could occur which
could subsequently cause the flywheel to disintegrate).

12. Always shut off the engine before setting it down.

13. Use extreme caution when cutting small size brush and
saplings because slender material may catch the saw chain and be
whipped toward you or pull you off balance.

14. When cutting a limb that is under tension. be alert for spring
back so that you will not be struck When the tension in the wood
fibers is released.

15. Never cut in high wind. Bad weather, when visibility is poor or in
very high or low temperatures Always check the tree for dead
branches which could fail during the felling operation.
.

16. Keep the handles dry. clean and free of oil or fuel mixture
.

17. Operate the chain saw only in well ventilated areas Never start
or run the engine inside a closed room or building. Exhaust fumes
contain dangerous carbon monoxide.

18. Do not operate the chain saw in a tree unless specially trained
to do so.

19 .Guard against kickback. Kick-back is the upward motion of the
guide bar which occurs when the saw chain at the nose of the guide
bar contacts an object.Kickback can lead to dangerous loss of
control of the chain saw.

20. When transporting your chain saw. make sure the appropriate
guide bar scabbard is in place.

KICKBACK SAFETY PRECAUTIONS FOR CHAIN SAW USERS

WARNING
Kickback may occur when the nose or tip of the guide bar touches an
object. or when the wood closes in and pinches the saw chain in the
cut. Tip contact in some cases may cause a lightning fast reverse
reaction.kicking the guide bar up and back towards the
operator .Pinching the saw chain along the top of the guide bar may
push the guide bar rapidly back towards the operator Either of these
reactions may cause you to lose control of the saw. which could result
in serious personal injury.
Do not rely exclusively on the safety devices built into your saw. As a
chain saw user you should take several steps to keep cutting jobs free
from accident or injury.
(1) With a basic understanding of kickback you can reduce or
eliminate the element of surprise. Sudden surprise contributes to
accidents.

(2) Keep a good grip on the saw with both hands. the right hand on the
rear handle, and the left hand on the front handle. when the engine is
running, Use a firm grip with thumbs and fingers encircling the chain
saw handles. A firm grip will help you reduce kick-back and maintain
control of the saw.

(3) Make certain that the area in which you are acting is free from
obstructions. Do not let the nose of the guide bar contact a log. branch,
or any other obstructions which could be hit while you are operating
the saw.

(4) Cut at high engine speeds.

(5) Do not overreach or cut above shoulder height.

(6) Follow the manufacturers sharpening and maintenance
instructions for the saw chain.

(7) Only use replacement bars and chains specified by the
manufacturer or the equivalent.

2 Explanation of Symbols on the Machine

For safe operation and maintenance, symbols are carved in relief
on the machine.

According to these indications. please be careful not to make any
mistake.

The port to refuel "MIX GASOLINE"
Position:Fuelcap

The port to top up chain oil
Position: Oil cap

Setting the switch to the 'O' position, the engine stops
immediately.
Position: Front at the top of the rear handle.

Starting the engine If you pull out the choke knob (at the back
right of the rear handle) to the point of the arrow. you can set the
starting mode
as follows:

First-stage position-starting mode when the engine is warm.
Second-stage position-starting mode when the engine is cold.

Position: Upper-right of the air cleaner cover

The screw under the 'H' stamp is The High-speed adjustment
screw.
The screw under the 'L' stamp is The Slow-speed adjustment
screw.
The screw at the left of the 'T' stamp is the Idle adjustment screw.
Position: Left side of the rear handle

Shows the directions that the chain brake is released (white
arrow) and activated (black arrow)
Position: Front of the chain cover

if you turn the rod by screwdriver follow the arrow to the "MAX"
position,the chain oil flow more. and if you turn to the "MIN"
Position: Bottom of the power unit

3. Installing Guide Bar and Saw Chain

A standard saw unit package contains the items as illustrated

Bar protector

(op

tional

)

Power

unit

Guide

bar

Saw chain

Open the box and install the guide bar and the saw chain on the power unit as
follows:

The saw chain has very sharp edges.Use thick protective gloves for satety

1. Pull the guard towards the front handle to check that the chain
brake is not engaged.

2. Loosen the nuts and remove the chain cover.

3. Fix the hanger on the rear of power unit by screw.

4.Mount the guide bar then fit the saw chain around the bar and sprocket.

Note:Pay attention to the correct direction of the saw chain.

5.Fit the chain tensioner nut into the lower hole of the guide bar, then
install the chain cover,andFasten the mounting nut to finger tightness.

Plug wrench

Screwdriver for
Carburetoradjustment

Hole

Ch

ain tensioner nut

Chain cover

Moving direction

When installing the chain cover ,be sure to fit the hook completely at the
rear end of the cover.

6. While holding up the tip of the bar: adjust the chain tension by
turning the tensioner screw until the tie straps just touch the bottom
side of the bar rail.

7. Tighten the nuts securely with the bar tip held up (11.8 -

14.7N.m/120 -150kg.cm). Then check the chain for smooth rotation
and proper tension while moving it by hand. if necessary. readjust with
the chain cover loose.

8. Tighten the tensioner screw.

A new chain will expand its length in the beginning of use.Check and readjust the
tension frequently as a loose chain can easily derail or cause rapid wear of itself
and the Guide bar.

4.Fuel and Chain Oil

FUEL

WARNING
Gasoline is very flammable. Avoid smoking or bringing any flame or
sparks near fuel. Make sure to stop the engine and allow it cool before
refueling the unit. Select outdoor bare ground for fueling and move at
least 3 m (10 ft) away from the fueling point before starting the engine.

Do not use BIA or TCW (2-stroke water-cooling type) mixed oil.

RECOMMENDED MIXING RATIO GASOLINE 25 : OIL 1

1: Exhaust emission are controlled by the fund a mental engine parameters and
components (eq.,carburetion. ignition timing and port timing)with.out addition of any
major hardware or the introduction of an inert material during combustion.
2: These engines are certified to operate on unleaded gasoline.
3: Make sure to use gasoline with a minimum octane number of 89RON
(USA/Canada: 87AL).
4: if you use a gasoline of a lower octane value than prescribed, there is a danger
that the engine temperature may rise and an engine problem such as piston seizing
may consequently occur.
5: Unleaded gasoline is recommended to reduce the contamination of the air for the
sake of your health and the environment .
6: Poor quality gasoline's or oils may damage sealing rings . fuel lines or fuel tank of
the engine.

HOW TO MIX FUEL

Pay attention to agitation.

1 Measure out the quantities of gasoline and oil to be mixed.
2 Put some of the gasoline into a dean. approved fuel container.
3 Pour in all of the oil and agitate well.
4 Pour in the rest of gasoline and agitate again for at least one minute. As some
oils may be difficult to agitate depending on oil ingredients, sufficient agitation is
necessary for the engine to last long . Be careful that . if the agitation is insufficient.
there is an increased danger of early piston seizing due to abnormally lean mixture
5 Put a clear indication on the outside of the container to avoid mixing up with
gasoline or other containers.
6 Indicate the contents on outside of container for easy Identification.

FUELING THE UNIT

1. Untwist and remove the fuel cap. Rest the cap on a dustless place.

2. Put fuel into the fuel tank to 80% of the full capacity.

3. Fasten the fuel cap securely and wipe up any fuel spillage around the unit.

WARNING

1. Select bare ground for fueling.

2. Move at least 10 feet (3 meters) away from the fueling point before Starting the
engine.

3. Stop the engine before refueling the unit .At that time.be sure to sufficiently
agitate the mixed gasoline in the container.

FOR YOUR ENGINE LIFE, AVOID:

1. FUEL WITH NO OIL(RAW GASOLINE) - It will cause severe damage to the
internal engine parts very quickly.

2. GASOHOL - it can cause deterioration of rubber and or plastic parts and
disruption of engine lubrication.

3. OIL FOR 4-CYCLE ENGINE USE - it can cause spark plug fouling. exhaust
port blocking. or piston ring sticking .
4 Mixed fuels which have been left unused for a period of one month or more may
clog the carburetor and result in the engine failing to operate properly.
5 In the case of storing the product for a long period of time. clean the fuel tank
after rendering it empty.Next, activate the engine and empty the carburetor of the
composite fuel.
6 In the case of scrapping the used mixed oil container, scrap it only at an
authorized repository site.

Note: As for details of quality assurance, read the description in the section Limited
Warranty carefully.Moreover ,normal wear and change in product with no functional
influence are not covered by the warranty.Also , be careful that, if the usage in the
instruction manual is not observed as to the mixed gasoline, etc. described Therein,
it may not be covered by the warranty.

CHAIN OIL

Use motor oil SAE #10W-30 all year round or SAE
#30 - #40 in Summer and SAE #20in winter

Note: Do not use wasted or regenerated oil that can cause damage to the oil pump.

5 Operating the Engine

It is very dangerous to run a chainsaw that mounts
broken parts or lacks any parts.

Before staining engine. make sure that all the parts
including bar and chain are installed properly.

STARTING THE ENGINE

1. Fill fuel and chain oil tanks respectively. and tighten the caps
securely.

2. Continuouslypush the priming bulb until fuel comes in the bulb.

3. Set the switch to 'I' position Throttle interlock switch.

4. Pull out the choke knob to the second-stage position.The choke
will close and that throttle lever will than be set in the starting
position.

Note: When restarting immediately after stopping the engine,set the Choke knob in
the first-stage position(choke open and throttle lever in the starting position ).

Note:Once the choke knob has been pulled out, it will not return to the operating
position even if you press down on it with your finger.When you wish to return the
choke knob to the operating position,pull out the throttle lever instead.

5. While holding the saw unit securely on the ground,pull the starter rope vigorously.

Do not start the engine while the chain saw hangs in one hand.The
saw chain may touch your body. This in very dangerous.

6. When engine has ignited, first push in the choke knob to the first-stage position
and then pull the starter Again to start the engine.

7. Allow the engine to warm up with the throttle lever pulled slightly.

Keep clear of the saw chain as it will start rotating upon starting of
engine.

Before you start the engine, make sure the saw chain is not
contacting anything.

CHECKING THE OIL SUPPLY

Make sure to set up the bar and the chain when checking the oil
supply.
If not ,the rotating parts may be exposed. It is very
Dangerous.

After starting the engine. run the chain at medium speed
and see if Chain oil is scattered off as shown in the figure.

The chain oil flow can be changed by inserting a screwdriver in the
hole on bottom of the clutch side.Adjust according to your work
conditions.

Nota: The oil tank should become nearly empty by the time fuel is used up. Be sure
to refill the oil tank every time when refueling the saw.

ADJUSTING THE CARBURETOR

The carburetor on your unit has been factory adjusted.but may
require fine tuning due to a change in operating conditions.

Before adjusting the carburetor, make sure that the provided
air/fuel filters are clean and fresh and the fuel properly mixed.

When adjusting, take the following steps:

Note: Be sure to adjust the carburetor with the bar chain attached.

1 Stop engine and screw in both the H and L needles until they stop. Never force

them. Then set them back the initial number of turns as shown below.

2 Start the engine and allow it to warm up at half-throttle.

3 Turn the L needle slowly clockwise to find a position where idling speed is
maximum, then set the needle back a quarter(1/4) turn counterclockwise.

4 Turn the idle adjusting screw (T) counter clockwise so that the saw chain does
not turn. if the idling speed is too slow. turn the screw clockwise.

5 Make a test cut and adjust the H needle for best cutting power. not for maximum
speed.

CHAIN BRAKE

The chain brake is a device which stops the chain instantaneously if the chain saw
recoils due to kickback.Normally. the brake is activated automatically by inertia
force. It can also be activated manually by pushing the brake lever (left-hand guard)
down toward the front.
When the brake operates, a yellow cone pops up from
the base of the brake lever.

Releasing the Brake

Pull the brake lever up toward the left-hand handle until it clicks into place.

When the brake operates. release the throttle lever to slow down the engine speed.
Continuous operation with the brake engaged will generate heat from the clutch
and may cause trouble.

At machine inspection prior to each job. Check the operating condition of the brake
following the steps.

1 Start the engine and grasp the handle securely with both hands.
2 Pulling the throttle lever to maintain the chain operation. push the brake lever
(left-hand guard) down toward the front using the back of your left hand.
3 When the brake operates and the chain is stopped,release the throttle lever.
4 Release the brake.

STOPPING THE ENGINE

1. Release the throttle lever to allow the engine to
idle for a few minutes.

2. Set the switch to the o (STOP) position.

6. Sawing

Before proceeding to your job,read the section 'For Safe Operation'.
it is recommended to first practice sawing easy logs. This also
helps you get
accustomed to your unit.

Always follow the safety regulations. The chain saw must only be
used for cutting wood.It is forbidden to cut other types of material.
Vibrations and kickback vary with different materials and the
requirements of the safety regulations would not be respected. Do
not use the chain saw as a lever for lifting. moving or splitting
objects. Do not lock it over fixed stands. It is forbidden to hitch tools
or applications to
the PTO other than those specified by the manufacturer.

It is not necessary to force the saw into the cut. Apply only light
pressure while running the engine at full throttle.

When the saw chain is caught in the cut. Do not attempt to pull it out
by force, but use a wedge or a lever to open the way.

GUARD AGAINST KICKBACK

This saw is equipped with a chain brake that will stop the chain in
the event of kick-

back if operating properly.You must check the chain brake
operation before each usage by running the saw at full the Throttle
for l-2 seconds and pushing the front hand guard toward. The chain
should stop immediately with the engine at full speed. if the chain is
slow to stop or does not stop. replace the brake band and clutch
drum before use.
It is extremely important that the chain brake be checked for
proper operation before each use and that the chain be sharp in
order to maintain the kickback safety level of this saw. Removal of
the safety devices. Inadequate maintenance. or incorrect
replacement of the bar or chain may increase the risk of serious
personal injury due to kickback.

FELLING A TREE

1. Decide the felling detection considering the wind, lean of the tree,location of
heavy branches, ease of completing the task after felling and other factors.

2. While clearing the area around the tree. arrange a good foot hold and recreate
path.

3. Make a notch cut one-third of the way into the tree on the felling side.

4. Make a felling cut from the opposite side of the notch and at a level slightly
higher than the bottom of the notch.

When you fell a tree ,be sure to warn neighboring workers of the
danger.

Bucking and Lambing

Always ensure your foothold. Do not stand on the log.

Be alert to the rolling over of a cut log. Especially when working on
a slope. stand on the uphill side of the log.

Follow the instructions in "For Safe Operation" to avoid kickback of
the saw.

Before starting work. check the direction of bending force inside the log to be cut.
Always finish cutting from the opposite side of the bending direction to prevent the
guide bar from being caught in the cut.

A log lying on the ground

Saw down halfway. then roll the log over and cut from the opposite side.

A log lyanging off the ground

In area A, saw up from the bottom one- third and finish by sawing down from the top.
In area B. saw down from the top one-third and finish by sawing up from
the bottom.

Cutting the limbs of Fallen Tree

First check to which side the limb is bent. Then make the initial cut from the bent
side and finish by sawing from the opposite side.

Bealerttothespringingbackofacutlimb.

Pruning of Standing Tree

Cut up from the bottom,finish down from the top.

Do not use an unstable foothold or ladder.
Do not overreach.
Do not cut above shoulder height.
Always use both your hands to hold the saw.

7. Maintenance
Before cleaning . the inspecting or repairing the unit.
make sure that engine has stopped and is cool.
Disconnect the spark plug to prevent accidental

starting .

7. MAINTENANCEAFTER EACH USE

Before cleaning, the inspecting or repairing the unit, make sure that
engine has stopped and is cool. Disconnect the spark plug to
prevent accidental starting.

MAINTENANCE AFTER EACH USE

1.Air filter

Loosen the knob and remove the air cleaner cover. Take off the filter elements and
tap off attached saw dust. When they are extremely dirty. Shake wash with gasoline.
Dry them completely before re installing.

2. Oiling port

Dismount the guide bar and check the oiling port for clogging.

3. Guide bar

When the guide bar is dismounted. remove sawdust in the bar groove and the oiling
port.
<type:sprocket nose>
Grease the nose sprocket from the feeding port on the tip of the bar.

4. Others

Check for fuel leakage and loose fastenings and damage to major parts, especially
handle joint sand guide bar mounting.if any defects are found. make sure to have
them repaired before operating the saw again.

PERIODICAL SERVICE POINTS

1. Cylinder fins.

2. Remove the starter case.

3. Remove sawdust between the cylinder fins.

2. Fuel filter

(a) Using a wire hook, take out the filter from the filler port.

(b) Wash the filter with gasoline.

Replace with new one if clogged with dirt completely.

When returning the filter ,use a pinch not to be

folded the suction pipe.

3. Oil filter

1.With a wire hook,take out the oil filter from the feeding port.

2.Wash the filter with gasoline.

When returning the filter ,use a pinch not to be
folded the suction pipe.

4. Spark plug

Clean the electrodes with a wire brush and reset the gap to 0.6mm as necessary.

5. Sprocket

Check for cracks and for excessive wear interfering with the chain drive.if the wear
is considerable, replace it with new one .Never fit a new chain on a worn sprocket,
or a worn chain on a new sprocket.

6.Way of the cooling air

The engine metal parts can burn your skin. Never touch the cylinder.
muffler or ignition plug etc .during operation or right after stopping the
engine.

Before starting the engine. Check around the muffler and take Off
sawdust. If you do not. it will cause the overheating and a fire For
preventing the trouble. please keep clean around the muffler.

This engine is air- cooled Dust clogging between the inlet port of the cooling air and
cylinder fins will cause overheating of the engine.periodically Check and clean the
cylinder fins after removing the air cleaner and the cylinder cover.

Important:When installing the cylinder cover ,make sure that switch wires and
grommets are positioned correctly in place.

7 . Muffler

If you do not attach the muffler correctly, after engine starts,the muffler
will be loosen and the high temperature exhaust gas spout,After
cleaning the muffler ,pay attention to fit up the muffler according to the
explanation as follows.

1. Muffler body ,muffler cover and baffle will be combined correctly .

2. Be sure the gasket 'is not broken. if it IS broken. change to the new one.

3. before tightening the screw. rub the gross on it

4.After making a test run, re-tighten the screw (TOROUE:6.9-7.8 N m/70-80 kg-cm)

Right after stopping the engine, do not touch the muffler with one’s
bare hands. It will cause to burn your hands.

If carbon clogs between the muffler. it will cause the poor-out put and the trouble in
starting. After each 100 hours, check and clean inside the muffler .

8. Maintenance of Saw Chain and Guide Bar

Saw Chain

It is very important for smooth and safe operation to always keep the
cutters sharp.

z The cutters need to be sharpened when:
z Sawdust becomes powder-like.
z You need extra force to saw in.
z The cut path dose not go straight
z Vibration increases.
z Fuel consumption increases.

Cutter setting standards:

Be sure to wear safety gloves.

Before filing:

z Make sure the saw chain is held securely
z Make sure the engine is stopped.
z Use a round file of proper size for the chain.

Chain type: 91VG l 25AP/K1
File size: 5/32 in (4.0 mm)

Place the file on the cutter and push straight forward
Keep the file position as illustrated.

After each cutter has been filed, check the depth gauge and file it
to the proper level as illustrated.

Be sure to round off the front edge to reduce the chance of kickback
or tie-strap breakage.

Make sure every cutter has the same length and edge angles as illustrated .

 Guide Bar
z Reverse the bar occasionally to prevent partial wear.
z The bar rail Should always be square.Check for wear of the bar rail. Apply a ruler

to the bar and the outside of a cutter. if a gap is observed between them. the rails
is normal. Otherwise. the bar rail is worn. Such a bar needs to be corrected or
replaced.

9. Troubleshooting Guide

Case 1. Starting failure

Make sure the icing prevention system is not working.

Case 2. Lack of power/poor acceleration/ Rough idling.

Case 3. Oil does not come out.

If the unit seems to need further service, please consult with an authorized service
shop in your area.

10. Specifications

Power unit:

Displacement(cc)...........................................................................25.4

Fuel:.............................................Mixture(Gasoline25:Two-cycle oil1)

Fuel tank capacity(ml)....................................................................230

Chain oil:..........................................................Motor oil SAE#10W-30

Oil tank capacity(ml)......................................................................160

Carburetor...................................................................Diaphragm type

Spark plug.................................................................................LD-M7

Oil feeding system....................................................Mechanical pump

Dimensions (L x W x H) (m m): ...................................265 x 220 x 220

Dry weight

Power unit only(kg)...........................................................................28

Cutting head:
<Sprocket bar>
Guide bar

Type ................................................................................Sprocket nose

Size (in.(mm))....................................................................10(25)/12(30)

Saw chain

Type..........................................................................oregon 9vg

Pitch(in.(mm)).............................................................................3/8(9.4)

Gauge(in.(mm))......................................................................0.05(1.25)

<Hard nose bar>
Saw chain

Type........................................................................oregon 25AP/

Pitch(in.(mm))...........................................................................1/4(6.25)

Gauge(in.(mm))......................................................................0.05(1.25)

2500 are equipped with Chain Brake.
Specifications are subject to change without notice.

34 Yarraman Place

Virginia, QLD, 4014

Ph: 03 8726 1471

Email: [e-mail]

Web: www.bosspowertools.com.au