Air filter ........................................ 101
Tank unit....................................... 103
Anti-vibration system.................. 106
Piston cylinder............................. 108
Crankcase and crankshaft.......... 114
2 – English
INTRODUCTION
GeneralUpdates
This workshop manual provides a detailed description of procedures for trouble shooting, repair
and testing of the chain saws. Safety precautions
that should be taken during repair are also
described.
This workshop manual applies to the engine
assembly in the following chain saws:
36
40
257
262XP
268
41
42
272XP
268K
45
51
272K
272S
55
61
281XP
288XP
242XP
246
254XP
394XP
3120XP
As production continues, changes will be introduced successively to the chain saw. If at any
time these changes influence service and/or
spares, special service announcements will be
sent out, which means that this manual will cease
to be current with time. In order to avoid problems, 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 required. 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
•Service tools
•Accessories
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 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 understood 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.
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 are 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:
•Repair of a specific sub-assembly
•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 subassembly.
2.Carry out the steps: Dismantling
Cleaning and inspection
Reassembly
Dismantling and reassembly of the entire
chain saw
When the entire chain saw is to be dismantled
and reassembled, proceed as follows:
1.Refer to page 57, which deals with the
Starter and carry out the instructions
under the heading Dismantling.
2.Work forwards through the manual and
carry out Dismantling instructions in the
order that the sections occur.
3.Return to the Starter on page 58 and
follow the instructions under Cleaningand Inspection.
4.Work forward through the manual and
carry out Cleaning and Inspection in the
order that the sections occur.
5.Order or collect all the required spare
parts from the spare parts stores.
6.In order to Assemble the chain saw,
proceed as follows:
•Refer to pages 117-120 which deals with
the Crankcase and carry out the instructions under Assembly.
•Refer to pages 111-112 which deals with
the Piston and Cylinder and carry out
the instructions under Assembly.
•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.
4 – English
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.
Special instructions
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. Is 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..
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.
After testing, do not touch the
silencer until it has cooled. Risk
1
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.
tension before the cord pulley is removed.
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.
of burns. This especially applies if
Make sure that the starter recoil
spring does not fly out and cause
personal injury. Release the spring
When removing the pressure
spring for the chain brake, ensure
that the brake is in the 'on'
position which reduces the spring
When replacing the crankshaft 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.