Tanaka TCS 27EPA (S) Handling Instructions Manual

Page 1

Pole Saw Model TCS 27EPA (S)

Handling instructions

Note: Before using this machine, carefully read through these HANDLING INSTRUCTIONS to ensure eﬃ cient, safe operation. It is recommended that these INSTRUCTIONS be kept readily available as an important reference when using this machine.

Page 2

MEANINGS OF SYMBOLS

NOTE: Some units do not carry them.

Symbols

WARNING

The following show symbols used for the machine. Be sure that you understand their meaning before use.

It is important that you read, fully understand and observe the following safety precautions and warnings. Careless or improper use of the unit may cause serious or fatal injury.

15 m

Read, understand and follow all warnings and instructions in this manual and on the unit.

Always wear eye, head and ear protectors when using this unit.

Before using your machine

• Read the manual carefully.

• Check that the cutting equipment is correctly assembled and adjusted.

• Start the unit and check the carburetor adjustment. See “MAINTENANCE”.

Index

WHAT IS WHAT ................................................................................ 3

WARNINGS AND SAFETY INSTRUCTIONS .................................. 4

SPECIFICATIONS ............................................................................ 5

ASSEMBLY

OPERATING PROCEDURES ........................................................... 7

MAINTENANCE ................................................................................ 9

PROCEDURES .............................................................5

Keep all children, bystanders and helpers 15 m away from the unit. If anyone approaches you, stop the engine and cutting attachment immediately.

All overhead electrical conductors and communications wires can have electricity flow with high voltages. Never touch wires directly or indirectly when pruning, otherwise serious injury or death may result

Page 3

WHAT IS WHAT

Since this manual covers several models, there may be some diﬀ erence between pictures and you r unit. Use the instructions that apply to your unit.

1. Fuel cap

2. Throttle trigger

3. Starter handle

4. Cutting attachment

5. Drive shaft tube

6. Handle bar

7. Priming pump

8. Ignition switch

9. Guide bar

10. Throttle

11. Choke lever

12. En gine

13. Angle transmission

14. Handle grip

15. Saw chain

16. Guide bar cover

17. Suspension eyelet

18. Oil tank cap

19. Combi box spanner

20. Handling instructions

trigger lockout

Page 4

WARNINGS AND SAFETY INSTRUCTIONS

Operator safety

○ Always wear head protection with full face shield to help protect

against falling branches and debris.

○ Avoid all power lines. This unit is not insulated against electrical

current.

○ Gloves should be used when sharpening chain. ○ Always wear heavy, long pants, boots and gloves. Do not wear

clothing, jewelry, short pants, sandals or go barefoot.

loose Secure hair so it is above shoulder length.

○ Do not operate this tool when you are tired, ill or under the

inﬂ uence of alcohol, drugs or medication.

○ Never let a child or inexperienced person operate the machine. ○ Wear hearing protection.

Be aware of any bystanders who may be signaling a problem. Remove safety equipment immediately upon shutting oﬀ engine.

○ Wear head protection. ○ Never start or run the engine inside a closed room or building.

Breathing exhaust fumes can kill.

○ Keep handles free of ○ Keep hands away from cutting equipment. ○ Do not grab or hold the unit by the cutting equipment. ○ When the unit is turned oﬀ , make sure the cutting attachment

has stopped before the unit is set down.

○ When operation is prolonged, take a break from

so that yo u may avoid possible Hand-Arm Vibration Syndrome (HAVS) which is caused by vibration.

○ The operator must obey the local regulations of cutting area.

WARNING

○ Antivibration systems do not guarantee that you will not sustain

Hand-Arm Vibration Syndrome or carpal tunnel syndrome. Therefore, continual and regular users should monitor closely the condition of their hands and ﬁ ngers. If any sym ptoms of the above appear, seek medical advice immediately.

○ If you are using any

as a pacemaker, consult your physician as well as the device manufacturer prior to operating any power equipment.

Unit / machine safety

○ Inspect the entire unit / machine before each use. Replace

damaged parts. Check for fuel leaks and make sure all fasteners

place and securely tightened.

are in

○ Replace parts that are cracked, chipped or damaged in any way

before using the unit / machine.

○ Keep others away when making carburetor adjustments. ○ Use only accessories as recommended for this unit / machine by

the manufacturer.

○ Never let the chain strike any obstacle.

If the chain makes contact, the machine should be stopped and checked carefully.

○ Make sure the automatic oiler is working. Keep the oil tank ﬁ lled

with clean oil. Never let chain run dry on the bar

○ All unit service, other than the items listed in the operator's / owner's

Never modify the unit/machine in any way. Do not use your unit /

Fuel safety

○ Mix and pour fuel outdoors and where there are no sparks or

○ Use a container approved for fuel. ○ Do not smoke

○ Wipe up all fuel spills before starting engine. ○ Move at least 3 m away from fueling site before starting engine. ○ Stop engine before removing fuel cap. ○ Empty the fuel tank before storing the

should be performed by competent chain-saw service

manual, personnel. (For examp le, if improper tools are used to remove the ﬂ ywheel or if an improper tool is used to hold the ﬂ ywheel in order to remove the clutch, structural damage to the ﬂ ywheel could occur and could subsequently cause the ﬂ ywheel to

WARNING

machine for any job except that for which it is intended.

ﬂ ames.

while using the unit / machine.

recommended that the fuel be emptied after each use. If fuel is left in the tank, store so fuel will not leak.

or allow smoking near fuel or the unit /machine or

Pay attention to your surroundings.

oil and fuel.

time to time

medical electric / electronic devices such

burst.)

unit/machine. It is

○ Store unit / machine and fuel in area where fuel vapor s cannot

reach sparks or open ﬂ ames from water heaters, electric motors or switches, furnaces.

WARNING

Fuel is easy to ignite or get explosion or inhale fumes, so that pay

special attention when handling or ﬁ lling fuel.

Cutting safety

○ Do not cut any material other than wood or wooden objects. ○ For respiratory protection, wear an ae rosol protection mask

when cutting the wood after insecticide has

○ Keep others including children, animals, bystanders and helpers

outside the 15 m hazard zo ne. Stop the engine immediately if you are approached.

○ Hold the unit / machine ﬁ rmly with both hands. ○ Keep ﬁ rm footing and balance. Do not over-reach. ○ Keep all parts of your body away

attachment when the engine is running.

○ Before pruning branches, the operator must be accustomed to

the pruning techniques of the machine.

○ Be sure to pre-plan a safe exit from falling objects. ○ While cutting, hold the machine ﬁ rmly with both hands with

thumb ﬁ rmly balanced and your body balanced.

○ Be alert against kickback (w hen saw kicks up and back at

operator). Never cut with the nose of the bar.

○ When relocating to a new work area, be sure to shut oﬀ the

machine and

○ Never place the machine on the ground when running. ○ Always ensure that the engine is shut o ﬀ and any cutting

attachments have completely stopped before clearing debris or removing grass from the cutting attachment.

○ Always carry a ﬁ rst-aid kit when operating ○ Never start or run the engine inside a closed room or building

and/or near inﬂ ammable liquids. Breathing exhaust fumes can kill.

Maintenance safety

○ Maintain the unit /machine according to rec ommended

procedures.

○ Disconnect the spark plug before performing maintenance

except for carburetor adjustments.

○ Keep others away when ○ Use only genuine Tana ka replacement parts as recommended

by the manufacturer.

CAUTION

Do not disassemble the recoil starter. You may get a possibilit y

of personal injury with recoil spring.

Tra ns po rt and storage

○ Carry the unit / machine by hand with the engine stopped and the

○ Allow the engine to cool, empty the fuel tank, and secure the

○ Empty the fuel tank before storing the unit / machine. It is

○ Store unit / machine out of the reach of children. ○ Clean and maintain the unit carefully and store it in a dry place. ○ Make sure engine switch is oﬀ when transporting or storing. ○ When transporting in a vehicle,

If situations occur which are not covered in this manual, take care and use common sense. Contact Ta na ka dealer if you need assistance. Pay special attention to statements preceded by the following words:

Indicates a strong possibility of severe personal injury or loss of

CAUTION

Indicates a possibility of personal injur y or equipment damage, if

NOTE

Helpful information for correct function and use.

away from your body.

muﬄ er

unit / machine before storing or transporting in a vehicle.

recommended that the fuel be emptied after each use. If fuel is left in the tank, store so fuel will not leak.

WARNING

life, if instructions are not followed.

instructions are not followed.

etc.

been applied.

from the muﬄ er and cutting

locked around front handle, and stand with feet well

ensure that all cutting attachments are stopped.

any power equipment.

making carburetor adjustments.

cover chain with chain cover.

Page 5

SPECIFICATIONS

Model TCS27EPA (S)

Engine Size (cm

Spark plug CHAMPION CJ6

Fuel tank capacity (cm

Chain Oil Tan k Capacity (cm3)160

Dry Weight (kg) (Without guide bar and chain) 5.2

Guide bar length (mm) 250

Chain pitch (mm) 9.52

Chain gauge (mm) 1.0 9

Sound pressure level LpA (dB (A)) by ISO 11680

Equivalent Uncertainty

Sound power level LwA (dB (A)) by ISO 11680 Measured Uncertainty Sound power level LwA (dB (A)) by 2000/14/EC Measured Guaranteed

Vibration level (m/s Front handle Rear handle

Max. engine power by ISO 8893 (kW) 0.9

Max. engine speed (min

Idle engine speed (min

NOTE: Equiva lent noise level / vibration levels by ISO 11680 are calculated as the time -weighted energy total for noise / vibration levels under

ASSEMBLY PROCEDURES

Drive shaft to engine (Fig. 1)

Loosen tube locking bolt (1) about ten turns so that the bolt point will not obstruct drive shaft tube to be inserted. When inserting drive shaft tube, hold the tube locking bolt out ward preventing inside ﬁ tting from obstructing as well.

Insert the drive shaft into the marked position (2) on the drive shaft tube meets the clutch case.

) 26.9

)520

) by ISO 11680

-1

) 11000

-1

) 3000

various worki ng conditions with the following time distribution: 1/2 idle, 1/2 racing speed. * All data subject to change without notice.

the clutch case of the engine properly until

Installation of handle (Fig. 3)

Attach the handle to the drive shaft tube with the angle towards the engine. Adjust the location to the most comfortable position before operation.

105

108 111

4.9

9.2

Fig. 2

Fig. 1

NOTE

When it is hard to insert drive shaft up to the marked position on

the drive shaft tube, turn drive shaft by the cutter mounting end clockwise or counter-clockwise. Tighten tube locking bolt lining up the hole in the shaft tube. Then tighten clamp bolt securely.

Cutting attachment

Loosen tube locking bolt (3). Insert the drive shaft into the gear case of the attachment properly until the marked position (4) on the drive shaft tube meets the gear case.

to drive shaft (Fig. 2)

Fig. 3

Page 6

Throttle wire / stop cord

Press the upper tab (6) and open the air cleaner cover. (Fig. 4) Connect stop cords. (Fig. 5)

Installation of bar and chain

1. Remove chain bar clamp nuts (15).

2. Remove the side case (16). (Fig. 8)

Fig. 4

Fig. 5

If the throttle outer end (7) is threaded on your unit, screw it and the earth termina l (8) (if so equipped) into the cable adjuster stay (9) all the way, and then tighten this cable end using the adjuster nut (10) against the cable adjuster stay (9). Connect throttle wire cap (13) (if so equipped) where is included in tool bag, onto swivel (12) (Fig. 6). Some models may come with the parts installed.

WARNING

Never try to start engine without side case securely fastened.

NOTE

When assembling brand new unit, take oﬀ and discard a piece of

cardboard (14) between gear case and side case. (Fig. 7)

end (11) to carburetor (12 ) and install swivel

Fig. 6

Fig. 8

3. Install the chain bar (17 ) onto the bolts (18), then push it toward the sprocket (19) as far as it will go. Make sure that the boss of chain tension adjust bolt (20) ﬁ ts into the hole (21) of the bar. (Fig. 9)

Fig. 9

NOTE

Slightly move the bar back and forth and make sure the chain

tension boss (20) ﬁ ts into the hole (21) in the bar properly.

4. Conﬁ rm the direction of saw chain (22) is correct as in the ﬁ gure, and align the chain on the sprocket.

5. Guide the chain drive links into the bar groove all around the bar.

6. Install the side case (16) onto the guide bar clamp bolt. Then ﬁ x the clamp nut (15) temporarily. (Fig. 10)

7. Raise the bar end, and tighten the chain (22) by turning the tension adjustment bolt (23) clockwise. To check proper tension, lightly lift up the center of chain and there should be about

0.5 – 1.0 mm clearance (24) between bar and edge of drive link. (Fig. 11, 12)

Fig. 10

(Fig. 10)

Fig. 7

Fig. 11

Page 7

0.5 – 1 mm

CAUTION

PROPER TENSION IS EXTREMELY IMPORTANT(Fig. 11, 12)

8. Raise the bar end and securely tighten the chain bar clamp nuts

with the box wrench. (Fig. 11)

9. A new chain will stretch so ad just the chain after a few cuts and watch chain tension carefully for the ﬁ rst half hour of cutting.

NOTE

Check the chain tension frequently for optimum performance

and durability.

CAUTION

○ When the chain is excessive ly tightened, the bar and chain will

be damaged rapidly. Conversely, when the chain is excessive ly loosened, it may get out of the groove in the

○ Always wear gloves when touching the chain.

WARNING

During operation, hold chain saw ﬁ rmly with both hands. A single

hand operation may cause serious injury.

Fig. 12

bar.

OPERATING PROCEDURES

Fuel (Fig. 13)

Fig. 13

WARNING

○ This unit is equipped with a two-stroke engine. Always run the

engine on fuel, which is mixed with oil.

Provide good ventilation, when fueling or handling fuel. ○ Fuel contains highly ﬂ ammable and it is possible to get the

serious personal injury when inhaling or spilling on you r body. Always pay attention when handling fuel. Always have good ventilatio n when handling fuel inside building.

Fuel

○ Always use branded 89 octane unleaded gasoline. ○ Use genuine two-cycle oil or use a mix between 25:1 to 50:1,

please consult the oil bottle for the ratio or Tana ka dealer.

○ If genuine oil is

oil express ly labeled for air-cooled 2-cycle engine use (JASO FC GRADE OIL or ISO EG C GRADE). Do not use BIA or TCW (2-str oke water-cooling type) mixed oil.

○ Never use multi-grade oil (10 W/30) or waste oil. ○ Always mix fuel and oil in

not availab le, use an anti-oxidant added quality

a separate clean container.

Always star t by ﬁ ling half the amount of fuel, which is to be used. Then add the whole amount of oil. Mix (sh ake) the fuel mixture. Add the remaining amount of fuel. Mix (shak e) the fuel-mix thoroughly before ﬁ lling the fuel tank.

Fuelin g

WARNING

○ Always shut oﬀ the engine before refueling. ○ Slowly open the fuel tank, when ﬁ lling up with fuel, so that

possible over-pressure disappears.

○ Tighten the fuel cap carefully, after fueling. ○ Always move the unit at least 3 m from the fueling area before

starting.

○ Always wash any

soap.

○ Be sure to check for any fuel leakage after refueling.

Before fueling, clean the tank cap area carefully, to ensure that no dirt falls into the tank. Make sure that the fuel is well mixed by shak ing the container, before fueling.

Chain oil (Fig.

Fill up with chain oil (25). Always use good quality chain oil. When the engine is running, the chain oil is automatically discharged.

NOTE

Add chain oil when its level lowers to one centimeter from

bottom, (Fig. 14)

ADJUSTMENT OF CHAIN OIL SUPPLY

The chain oil quantity discharged through the lubrication system is factory-adjusted to the standard. Adjust the quantity in accordance with the operating condition. The numbered label (26) order of chain oil adjustment. (Fig. 15)

○ Loosen the ﬁ xing screw (27) one turn. (Fig. 15) ○ Tur n the adjusting screw (28) clockwise to decrease the quantity

and turn it counter-clockwise to increase the quantity. (Fig. 16)

○ Do not try to turn the screw (28) clockwise beyond I turn from

its most counter-clockwise position or the maximum quantity discharged position.

○ After adjustment has been made, tighten ﬁ xing screw (27 ).

(Fig. 15)

spilled fuel from clothing immediately with

14)

1 cm

Fig. 14

Fig. 15

describes

Page 8

Fig. 16

NOTE

When you have lost the proper position of the screw (28), start

with the most counterclockwise position.

Starting

CAUTION

Before starting, make sure the cutting attachment does not

touch anything.

1. Set ignition switch (29) to ON position. (Fig. 17)

Fig. 17

* Push priming bulb (31) several times so that fuel ﬂ ows through

return pipe. (Fig. 18)

3. Pull recoil starter briskly, taking care to keep the handle in your

grasp and not allowing it to snap back. (Fig. 20)

Fig. 20

4. When you hear the engine want to start, return choke lever to RUN position (open) (B). Then pull recoil starter briskly again.

NOTE

If engine does not start, repeat procedures from 2 to 5.

5. Then allow the engine about 2 – 3 minutes to warm up before

Stopping (Fig. 21)

Decrease engine speed and run at an idle for a few minutes, then turn oﬀ ignition switch (29). For models with an engine ignition switch, keep the ignition switch pressed until the engine comes to a complete stop.

subjecting

it to any load.

Fig. 18

2. Set choke lever (31) to CLOSED position (A). (Fig. 19)

Fig. 19

Fig. 21

WARNING

A cut ting at tachment can injure while it continues to spin after

the engine is stopped or power control is released. When the unit is turned oﬀ , make sure the cutting attachment has stopped before the unit is set down.

SAFE OPERATION

CAUTION

○ Always wear gloves during operation or ○ Review the area to be trimmed. Look for hazards that could

contribute to unsafe conditions. DO NOT operate unit if any wires (power, telephone, cable, etc.) are closer than 15M to any part of the operator or unit. (Fig. 22)

15 m

Fig. 22

maintenance.

Page 9

○ Spectator and fellow workers must be warned, and children and

animals prevented from coming nearer than 15 M while the pole saw is in use. (Fig. 23)

15 m

Fig. 23

○ Avoid all power lines. This unit is not insulated against electrical

current.

○ Always wear head protection with full face shield to help protect

against falling branches and debris. (Fig. 24)

Fig. 24

Pruning techniques

This attachment is designed for pruning small limbs and branches up to 200 mm in diameter. Follow these tips for successful operation.

○ Plan cut carefully. Check direction branch will fall. ○ Long branches should be removed in several pieces. ○ Do not stand directly beneath branch being cut.

When ready to cut: Hold "front cutting guide" against branch.

○

This will prevent whipping of the branch. DO NOT use back and forth sawing action. (Fig. 24)

○ Look out for branch immediately behind the branch being cut, If

blade hits rear branch damage to blade may occur. (Fig. 25

)

Fig. 26

○ DO NOT use for felling or bucking.

MAINTENANCE

MAINTENANCE, REPLACEMENT OR REPAIR OF THE EMISSION CONTROL DE VICES AND SYSTEMS MAY BE PERFORMED BY ANY NON-ROAD ENGINE REPAIR ESTABLISHMENT OR INDIVIDUAL.

Carburetor adjustment (Fig. 27)

WARNING

○ The cutting attachm ent may be spinning during carburetor

adjustments.

○ Never star t the engine without the complete clutch cover and

tube assembled! Otherwise the clutch can come loose and cause personal injuries.

In the carburetor, fuel is mixed with air. When the engine is test run at the factory, the may be required, according to climate and altitude. The carburetor has one adjustment possibility:

T = Idle speed adjustment screw.

Idle speed adjustment (T)

Check that the air ﬁ lter is clean. When the idle speed is correct, the cutting attachment will not rotate. If (clo ckwi se) the T-screw, with the engine running, until the cut ting attachment starts to rotate. Open (co unte r-clo ckwi se) the screw until the cutting attachment stops. You have reached the correct idle speed when the engine runs smoothly in all positions well below the rpm when the cutting attachment starts If the cutting attachment still rotates after idle speed adjustment, contact Tan ak a dealer.

carburetor is basically adjusted. A further adjustment

adjustment is required, close

to rotate.

○ Accelerate to full throttle. ○ Apply a light cutting pressure. ○ Ease cutting pressure when nearing end of cut to mainta in

control.

○ When pruning a limb 10 0 mm diameter or larger, cut as follows:

(Fig. 26)

1. Undercut 1/4 limb diameter near tree trunk.

2. Finish top cut slightly

3. Flush cut stub at trunk.

Fig. 25

farther out on limb.

Fig. 27

NOTE

Standard Idle rpm is 2500 – 3000 min

WARNING

When the engine is idling the cutting attachment must under no

circumstances rotate.

Air ﬁ lter (Fig. 28)

The air ﬁ lter must be cleaned from dust and dirt in order to avoid:

○ Carburetor malfunctions ○ Starting problems ○ Engine power reduction

-1

Page 10

○ Unnecessary wear on the engine parts ○ Abnormal fuel consumption

Fig. 28

Clean the air ﬁ lter daily or more often if wo rking in exceptionall y dusty areas.

Cleaning the air ﬁ lter

Remove the air ﬁ lter cover and the ﬁ lter (32). Rinse it in warm soap suds. Check that the ﬁ lter is dry before reassembly. An air ﬁ lter that has been used for Therefore, it must regularly be replaced with a new one. A damaged ﬁ lter must always be replaced.

Fuel ﬁ lter (Fig. 29)

Drain all fuel from fuel tank and pull fuel ﬁ lter line from tank. Pull ﬁ lter element out of holder assembly and rinse element detergent.

Rinse thoroughly until all traces of detergent are eliminated. Squeeze, do not wring, away exce ss water and allow element to air dry.

some time cannot be cleaned completely.

in warm water with

These factors cause deposits on the spark plug electrodes, which

in malfunction and starting diﬃ culties. If the engine is

may result low on power, diﬃ cult to star t or runs poorly at idling speed, always check the spark plug ﬁ rst. If the spark plug is dirty, clean it and check the electrode gap. Re-adjust if necessary. The correct gap is mm. The spark plug should be replaced af ter about 10 0 operation hours or earlier if the electrodes are badly eroded.

0.6 mm

Fig. 31

NOTE

In some areas, local law requires using a resistor spark plug

to suppress ignition signals. If this machine was originally equipped with resistor spark plug, use same type of spark plug for replacement.

Muﬄ er (Fig. 32)

Remove the muﬄ er and clean out any exce ss exhaust port or muﬄ er inlet every 100 hours of operation.

carbon from the

0.6

Fig. 29

NOTE

If element is hard due to excessive dirt build-up, replace it.

Chain oil ﬁ lter (Fig. 30)

Remove the oil ﬁ lter and thoroughly wash it in solvent.

Fig. 30

Spark plug (Fig. 31)

The spark plug condition is inﬂ uenced by:

○ An incorrect carburetor setting ○ Wrong fuel mixture (too much oil in the gasoline) ○ A dirty air ﬁ lter ○ Hard running conditions (such as cold weather)

Fig. 32

Cylinder (Engine cooling) (Fig. 33)

The engine is air cooled and air must circulate freely around engine and over cooling ﬁ ns on cylinder head to prevent overheating. Every 10 0 operating hours, or once a ye ar (more often if conditions require) clean ﬁ ns and external surfaces of engine of dust, dirt deposits which can contribute to improper cooling.

Fig. 33

and oil

Page 11

NOTE

Do not operate engine with engine shroud or muﬄ er guard

removed as this will cause overheating and engine damage.

Oiler port (Fig. 34)

Clean the chain oiler port (33) whenever possible.

Fig. 34

Guide bar (Fig. 35)

Before using the machine, clean the groove and oiler port (34) in the bar with the special gauge oﬀ ered as an optional accessory.

Fig. 35

Side case (Fig. 36)

Always ke ep the side case and drive area clean of saw dust and debris.

Fig. 36

Angle transmission (Fig. 37)

Check angle transmission or angle gear for grease level about every 50 hours of operation by removing the grease ﬁ ller plug on the side of angle transmission. If no grease can be seen on the ﬂ anks of the gears, ﬁ ll the transmission with quality lithium based 3/4. Do not completely ﬁ ll the transmission.

multipurpose grease up to

Fig. 37

Maintenance schedule

Below you will ﬁ nd some general maintenance instruct ions. For further information please contact Tana ka dealer.

Daily maintenance

○ Clean the exterior of the unit. ○ Clean the chain oil ﬁ lter port. ○ Clean the groove and oil ﬁ lter port in the guide bar. ○ Clean the side case of saw ○ Check that the saw chain is sharp. ○ Check that the bar nuts are suﬃ ciently tightened. ○ Make sure that the chain transport guard is undamaged and that

it can be securely ﬁ tted.

○ Check that nuts and screws are suﬃ ciently tightened.

Weekl y maintenance

○ Check the starter, especially ○ Clean the exterior of the spark plug. ○ Remove the spark plug and check the electrode gap. Adjust it to

0.6 mm or change the spark plug.

○ Clean the cooling ﬁ ns on the cylinder and check that the air

intake at the starter is not clogged.

○ Clean the air ﬁ lter.

Monthly maintenance

○ Rinse the fuel tank with gasoline, and clean fuel ﬁ lter. ○ Clean chain oil ﬁ lter. ○ Clean the exterior of the carburetor and the space around it. ○ Clean the fan and the space around it. ○ Clean the muﬄ er of carbon.

CHAIN SHARPENING

of a cutter (Fig. 38, 39)

Parts

WARNING

Gloves should be used when sharpening chain.

dust.

cord and return spring.

Fig. 38

Page 12

Fig. 39

35. Top plate

36. Working corner

37. Side plate

38. Gullet

39. Heel

40. Chassis

41. Rivet hole

42. Toe

43. Depth gauge

44. Correct angle on top plate (degre e of angle depends on chain type)

45. Slightly protruding “hook” or point (cur ve on non-chisel chain)

46. Top of depth gauge at correct

47. Fron t of depth gauge rounded oﬀ .

LOWERING DEPTH GAUGES WITH A FILE

1) If you sharpen your cutters with a ﬁ le holder, check and lower the depth.

2) Check depth gauges every third sharpening.

3) Place depth gauge tool on cutter. If depth gauge projects, ﬁ le it level with the top of the tool. Always ﬁ le from the inside of the chain toward an outside cutter. (Fig. 40)

height below top plate

48 48

Fig. 42

Fig. 43

SHARPENING ANGLES FOR SHARPENING SAW CHAIN

1. Part Number 90SG-40E

2. Pitch 3/8”

3. Depth Gauge Setting 0.025"

4. Side Plate Filing Angle 80°

Fig. 44

Fig. 40

4) Round oﬀ front corner to maintain original shape of depth gauge after using depth gauge tool. Always follow the recommended depth gauge setting fo und in the maintenance or operator manual for your saw. (Fig. 41)

Fig. 41

GENERAL INSTRUCTIONS FOR FILING CUTTERS

File (48 ) cutter on one side of the chain from the inside out. File on forward stroke only. (Fig. 42)

5) Keep all cutters the same length. (Fig. 43)

6) File enough to remove any damage to cutting edges (sid e plate (49) and top

plate (50)) of cutter. (Fig. 44)

5. Top Plate Angle 30°

6. File Guide Angle 90°

Page 13

136

131

130

129

106

107

128

110

109

108

133

132

135

134

126

125

127

124

123

122

121

120

119

105

137

138

139

144

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140

141

145

142

104

102

103

101

282930

118

117

113

111

112

114

116

115

Page 14

Page 15

ITEM

NO.

1 CYLINDER COVER 1 2 LABEL 1 3 SCREW 4×22/PS 4 4 MUFFLER COVER 1 5 SCREW 5×16/PS 2 6 HEX.HOLE BOLT 6×65 2 7 WASHER 62 8 MUFFLER (B) 1

10 HEAT PROTECTION PANEL 1 11 HEX. HOLE BOLT 5×20S 8 12 SPARK PLUG BMR7A 1 13 COVER PACKING 2 14 SCAVENGING COVER (A) 1 15 HEX. HOLE BOLT 4×12WS 4 16 WASHER T1.6 2 17 SCAVENGING COVER (B) 1 18 CYLINDER GASKET 1 19 CYLINDER SET PN 1 20 SWIVEL 1 21 STOP RING 1 22 O-RING 1 23 PUMP GASKET 1 24 PUMP DIAPHRAGM 1 25 PUMP BODY ASS'Y 1 26 SPRING 1 27 CONTROL LEVER 1 28 DIAPHRAGM GASKET 1 29 PRIMING BODY 1 30 DIAPHRAGM COVER 1 31 THROTTLE SET SCREW 2 32 THROTTLE VALVE 1 33 O-RING 1 34 MAIN JET #32 1 35 INLET SCREEN 1 36 NEEDLE VALVE 1 37 HINGE PIN SET SCREW 1 38 HINGE PIN 1 39 METERING DIAPHRAGM 1 40 PRIMING PUMP COMP. 1 41 SET SCREW 4 42 INLET MANIFOLD GASKET 1

45 CARBURETOR GASKET 1

47 CARBURETOR GASKET 1 48 CARBURETOR ASS'Y 1 49 SWIVEL CAP 1 50 PLUS 51 CLEANER ELEMENT 1 52 CLEANER COVER 1 53 CLEANER ASS'Y 1 54 PISTON SET PN 1 55 PISTON RING 1 56 PISTON PIN CIRCLIP 2 57 PISTON PIN 1 58 NEEDLE BEARING 1 59 CRANK SHAFT COMP. 1 60 CRANK CASE ASS'Y 1 61 CRANK CASE GASKET 1 62 OIL SEAL TB 12227 2 63 BALL BEARING 6001C3 2 64 CRANKSHAFT WASHER 2

PART NAME

SEAL LOCK HEX. SOCKET BOLT (W/WASHERS) M5×30

CARBURETOR INSULATOR SET PN

SEAL LOCK HEX. SOCKET BOLT M5×25

THROTTLE WIRE FIXING PLAT

SCREW 5×60WS 2

ITEM

Q’TY

NO.

65 KNOCK PIN 4×12 2 66 STARTER PULLEY ASS'Y 1 67 STOP RING E-5 2 68 STARTER PAWL SPRING 2 69 STARTER PAWL 2

RECOIL STARTER BODY

ASS'Y 71 SET SCREW 1 72 CAM PLATE 1

73 DUMPER SPRING 1 74 STARTER ROPE REEL 1 75 RECOIL SPRING 1

RECOIL STARTER BODY 76

COMP. 77 STARTER ROPE 3.5×860 1 78 STARTER HANDLE 1 79 NAME PLATE 1

101 D4 TAPPING SCREW 4 102 HANDLE (B) 1 103 LOCK LEVER 1 104 LEVER 1 105 SPRING (A) 1 106 STOP SWITCH 1 107 STOP SWITCH CORD 2 108 PROTECTION TUBE 1 109 THROTTLE WIRE 1 110 HANDLE (A) 1 111 HEX.

HOLE BOLT M5×12 1 112 HEX. HOLE BOLT M5×25/S 2 113 ANTI-VIBE RUBBER A1 114 PIPE HOLDER (A) 1 115 PIPE HOLDER(B) 1 116 ANTI-VIBE RUBBER B1 117 STOP RING C-12 OUTER 1 118 FAN CASE 1 119 CLUTCH DRUM COMP. 1 120 STEP BOLT 2 121 BENT WASHER 82 122 CLUTCH PLATE A2 123 CLUTCH ASS'Y 1 124 CLUTCH WASHER B2 125 HEX. NUT M8 1 126 WASHER M8 1 127 HEX. HOLE BOLT 4×18WS 2

128 EARTH CORD 1 129 IGNITION COIL ASS'Y 1

130 CORD 1 131 CORD 1 132 CORD 1

133 MAGNETO ROTOR COMP. 1 134 SHIELD TUBE ASS'Y 1 135 FUEL 136 TANK CAP ASS'Y 1 137 TANK CAP CHAIN 1 138 RETURN GROMMET 1 139 SPACER 1 140 TANK 1 141 STAND 1 142 FLANGE BOLT 2 143 PUMP FILTER BODY COMP 1 144 CLIP, 6.3 DIA. 1 145 FLANGE BOLT 1 161 LOOP HANDLE ASS'Y 1 162 HANDLE GRIP 1 163 HEX. NUT 62 164 BRAKE SHAFT WASHER 1 165 TAPPING SCREW 5×20 1 166 CAP (A) 2

PIPE 1

PART NAME

ITEM

Q’TY

NO. 167 LEVEL MARK 2 168 CAUTION PLATE 1 169 LEVEL MARK 1 170 MAIN PIPE COMP. 1 171 DRIVE SHAFT 1829L 1 172 LIFTING METAL ASS'Y 1

173 HANDLE BRACKET A1 174 BOLT 6×43/P 2 175 OIL ADJUSTMENT MARK 1 176 OIL TANK COVER 1 177 OIL TANK GASKET 1 178 O-RING P-5 2 179 8 PUSH NUT 1

180 STEP BOLT A1 181 OIL PUMP COMP. 1 182 O-RING 1 183 O-RING 1.4 1 184 WASHER 21 185 OIL PUMP SPRING 1 186 OIL PUMP PISTON COMP. 1 187 O-RING P-15 1 188 OIL TANK CAP ASS'Y 1 189 SCREW 6×8 1 190 HEX. HOLE BOLT M5×22/S 1 191 MANUAL MARK 1 192 PINION 1 193 BALL BEARING 609 1 194 BALL BEARING 609Z ST 1 195 STOP RING C-9, OUTER 1 196 STOP RING C-24, INNER 1 197 STARTER PAWL WASHER 1 198 HEX. HOLE BOLT M5×10 1 199 BALL BEARING 627 C3 1 200 CAM 1 201 GEAR 1 202 BALL BEARING 638Z 1 203 STOP RING C-28, INNER 1 204 COLLER 1 205 SPROCKET COMP., 3/8 1 206 FLANGE NUT 61 207 SIDE COVER COMP. 1 208 SYMBOL MARK 1 209 SMALL SCREW 4×12WS 4 210 COLLER 34 211 FILTER ASS'Y 1 212 OIL FILTER 1 213 WASHER 214 FUEL PIPE 3×5×60 1 215 FUEL PIPE 3×5×75 1 216 BANJO, OIL PUMP 1 217 OIL PUMP ADJUSTER 1 218 STOP RING E-6 1 219 OIL MARK 1 220 CASE 1 221 CHAIN TENSIONER ASS'Y 1

222

223 GUIDE PLATE 1 224 CHAIN BAR KNOCK PIN 1 225 SAW CHAIN, 10 INCH, 3/8 1 226 CHAIN BAR 10 INCH 3/8 1 227 CHAIN BAR CLAMP NUT 1

501

502 WRENCH 8×10 1 503 HEX. BAR WRENCH 4MM 1 504 GUIDE 505 SHOULDER BELT 1

PART NAME

CHAIN BAR TIGHTENING BOLT

COMBI. BOX SPANNER 13×19 MINUS

BAR COVER, 10 1

Q’TY

Page 16

Shinagawa Intercity Tower A, 15-1, Konan 2-chome,

Minato-ku, Tokyo, Japan

204 Code No. E99247011 Printed in Japan