Workshop Manual 340 345 346XP 350 351 353

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Workshop manual340 345 346XP350 351 353English

Workshop manualHusqvarna 340/345/346XP/350/351/353ContentsIntroduction . 2Safety regulations . 3General instructions . 3Special instructions . 3Special tools . 4Technical data . 6Construction and function . 8Carburettor . 8Troubleshooting . 10Repair instructions . 12Chain brake . 12Silencer . 14Chain catcher . 14Stop switch . 15Stop switch – resistance measurement . 15Choke control . 16Throttle trigger . 17Hand grip heater . 18Starter assembly . 21Starter cord . 21Recoil spring . 22Ignition module – testing . 23Ignition module and flywheel . 23Generator . 24Centrifugal clutch . 26Oil pump . 27Carburettor . 30Carburettor – pressure testing . 33Carburettor heater . 34Air intake system . 35Carburettor – adjustment . 37Fuel tank . 38Fuel filter . 39Fuel hose . 39Piston and cylinder . 41Decompression valve – pressure testing . 42Cylinder – pressure testing . 44Crankcase and crankshaft . 45Crankshaft bearings . 46Repairing damaged threads . 49Thread insert . 49Guide bar bolts . 49Appendix A, Carburettor – EPA models . 50English – 1

IntroductionArrangement of the manualTroubleshootingThis workshop manual can be used in two differentways.These pages describe the most common faults thataffect a chainsaw. They are divided into fourdifferent groups with the most likely faults described first. To repair a specific sub-assembly on a chainsaw. To dismantle and reassemble a completechainsaw.Repairing a specific sub-assemblyIf a specific sub-assembly on the chainsaw needsto be repaired:1. Look up the page referring to the relevant subassembly.2. Follow the instructions under the headings:Removal/DismantlingCleaning and inspectionRefitting/ReassemblyDismantling and reassembling the entirechainsawIf the entire chainsaw is to be dismantled, followthe instructions under the heading “Removal/Dismantling”.Work through the manual and follow the instructions given in each section under the heading“Removal/Dismantling”.Then follow all the “Cleaning and inspection”instructions in each section.Working from the back of the manual, follow all theinstructions under the headings “Refitting/Reassembly” in reverse order.Each of the sections covering removal/dismantlingand refitting/reassembly include the relevantlubrication instructions and bolt torques for eachstage of repair.Construction and functionThis chapter gives a simple description of thechainsaw carburettor and its various parts.2 – EnglishRepair instructionsThe section that describes how to repair thechainsaw consists of detailed, step-by-step instructions. It explains in detail the special tools, lubricants and bolt torques that are needed whenworking on each component.This workshop manual covers the followingchainsaw models:340345346XP350351353

Safety regulationsGeneral instructionsSpecial instructionsThis workshop manual gives detailed instructionson how to troubleshoot, repair and test a chainsaw.This section also describes the various safetyprecautions that should be taken when carrying outrepairs.The fuel that is used in a chainsaw poses thefollowing hazards:The workshop manual has been written for personnel who are assumed to have general experienceof repairing and servicing chainsaws. May cause breathing difficulties.Workshops where chainsaws are repaired must beequipped with safety equipment that meets localregulations.When using compressed air the air jet shouldnever be pointed at the body. Air can be forced intothe bloodstream and cause fatal injury.No-one should carry out repairs on a chainsawuntil they have read and understood the contentsof this workshop manual.Wear ear protection when testing saws.Chainsaws are type-approved to meet the relevantsafety legislation, but this only applies when thesaw is fitted with the cutting equipment specified inthe user’s manual. The fitting of any other equipment, or of accessories or parts that are notapproved by Jonsered, could mean that the saw nolonger meets these safety requirements and theperson who carried out the work may be heldresponsible for its non-conformance.In this workshop manual the following boxesindicate where caution should be taken.WARNING!The warning text warns of the riskof personal injury if the instructions are not followed.NOTE!The warning text warns of the risk ofmaterial damage if the instructions arenot followed. The fuel and its fumes are toxic. May cause irritation to skin or eyes. Highly flammable.After testing a saw do not touch the silencer until ithas cooled down. The silencer gets very hot andyou may burn yourself. Wear protective gloveswhen working on the silencer.The guide bar, chain and clutch cover (chain brake)must be fitted before the saw is started. If not, theclutch may come loose and cause injury.Poor chain lubrication can result in failure of thechain, which could cause serious or fatal injury.Take care to ensure that the spring inside thestarter assembly does not fly out and cause injury.Wear eye protection. If the spring is under compression when the pulley is removed it could fly outand cause injury.Before removing the tensioning spring from thechain brake, ensure that the brake is in the onposition, otherwise the spring may fly out andcause injury.After completing the repair the chain brake must betested, see “Chain brake – reassembly \ Operatingtest”.Always consider the fire risk. A chainsaw canproduce sparks that could start a fire.Inspect the chain catcher and replace it if it isdamaged.English – 3

Special tools2143658710134 – English9111412

Special tools151617191820 b20 cItem DescriptionUsed forOrder no.1Clutch toolCentrifugal clutch502 54 16-012Piston stopLocking crankshaft502 54 15-013Stop plateLocating intake gaiter502 54 17-014Fuel filter hookWithdrawing the fuel filter502 50 83-015Allen keyFor M5 bolts502 50 18-016PullerFrame bearing504 90 90-027Removal toolRemove seal from clutch side502 50 55-018Mandrel, sealing ring Removing crankshaft9Cover plateSealing during pressure testing 502 54 11-0210Pressure testerConnection to cylinder503 84 40-0211Feeler gaugeAdjusting ignition module502 51 34-0212Clamp standClamping the saw502 51 02-0113Pressure gaugePressurisation during testing502 50 38-0114Piston fitting kitFitting piston502 50 70-0115Test plugChecking ignition module502 71 13-0116Rev counterAdjusting carburettor502 71 14-0117Removal toolRemoving crankshaft502 51 61-0118Vacuum gaugeVacuum test502 50 37-0119Assembly pliersFitting spark plug guard502 50 06-0120a SleeveFitting crankshaft502 50 30-1820b Shaft extensionFlywheel side502 50 30-1820c Shaft extensionClutch side502 50 30-1821Stop plateRemoving crankshaft502 54 18-0122Assembly toolAssembling spring, chain brake 502 50 67-0123Crankshaft toolFitting crankshaft seal20 a21502 54 21-012223502 50 30-16English – 5

Technical data340:345:346XP/G:350:350 EPA:351/G:353/G:Cylinder boreØ mm/Ø inchesStrokemm/inchesMax power/speedkW/hp/rpm40,8 / 2,4445,0 / 2,7545,0 / 2,7549,4 / 3,0151,7 / 3,1549,4 / 3,0151,7 / 3,1540 / 1,57"42 / 1,65"42 / 1,65"44 / 1,73"45 / 1,77"44 / 1,73"45 / 1,77"32 / 1,28"32 / 1,28"32 / 1,28"32 / 1,28"32 / 1,28"32 / 1,28"32 / 1,28"2,0 / 2,7 / 9 0002,2 / 3,0 / 9 0002,5 / 3,4 / 9 6002,3 / 3,1 / 9 0002,3 / 3,1 / 9 0002,3 / 3,1 / 9 0002,4 / 3,3 / 9 000Spark plug gapmm/inchesIgnition systemAir gapmm/inchesCarburettor type0,5 / 0,02"0,5 / 0,02"0,5 / 0,02"0,5 / 0,02"0,5 / 0,02"0,5 / 0,02"0,5 / 0,02"SEM CDSEM CDSEM CDSEM CDSEM CDSEM CDSEM CD0,3 / 0,012"0,3 / 0,012"0,3 / 0,012"0,3 / 0,012"0,3 / 0,012"0,3 / 0,012"0,3 / 0,012"Walbro HDA 195Walbro HDA 195Zama C3-EL17Walbro HDA 195Zama C3-EL18Zama C3-EL17Zama C3-EL17Effective cutting lengthcm/inchesChain speed atmax power – revsm/s – rpmChain pitchmm/inchesDrive linkmm/inches17,3 / 9 00017,3 / 9 00018,5 / 9 60017,3 / 9 00017,3 / 9 00017,3 / 9 00017,3 / 9 0008,25 / 0,325"8,25 / 0,325"8,25 / 0,325"8,25 / 0,325"8,25 / 0,325"8,25 / 0,325"8,25 / 0,325"1,3 / 0,050" - 1,5 / 0,058"1,3 / 0,050" - 1,5 / 0,058"1,3 / 0,050" - 1,5 / 0,058"1,3 / 0,050" - 1,5 / 0,058"1,3 / 0,050" - 1,5 / 0,058"1,3 / 0,050" - 1,5 / 0,058"1,3 / 0,050" - 1,5 / 0,058"340:345:346XP/G:350:350 EPA:351/G:353/G:340:345:346XP/G:350:350 EPA:351/G:353/G:6 – EnglishDisplacementcm3/cubic inches30-48 / 12"-19"30-48 / 12"-19"30-48 / 12"-19"30-48 / 12"-19"30-48 / 12"-19"30-48 / 12"-19"30-48 / 12"-19"

Technical datarpm340:345:346XP/G:350:350 EPA:351/G:353/G:Idling speedrpmEngagement speedrpmMax. speedrpmSpark plug2 7002 7002 7002 7002 7002 7002 7003 8003 8003 8003 8003 8003 8003 80012 50012 50014 20013 00013 00013 00013 000NGK BPMR 7A, Champion RCJ 7YNGK BPMR 7A, Champion RCJ 7YNGK BPMR 7A, Champion RCJ 7YNGK BPMR 7A, Champion RCJ 7YNGK BPMR 7A, Champion RCJ 7YNGK BPMR 7A, Champion RCJ 7YNGK BPMR 7A, Champion RCJ 7YGAS340:345:346XP/G:350:350 EPA:351/G:353/G:340:345:346XP:346XPG:350:350 EPA:351:351G:353:353G:OILFuel tank capacityLitres/US pintsOil pump capacity at8,500 rpm,ml/minOil tank capacityLitres/US pintsAutomatic oil pump0,5 / 1,050,5 / 1,050,5 / 1,050,5 / 1,050,5 / 1,050,5 / 1,050,5 / 1,06995 - 125 - 125 - 125 - 125 - 120,25 / 0,530,25 / 0,530,28 / 0,590,26 / 0,550,26 / 0,550,28 / 0,590,28 / 0,59YesYesYesYesYesYesYesWeight without bar and chainkg / lbsWeight with bar and chainkg / lbsHeated hand grips4,7 / 10,34,7 / 10,34,8 / 10,64,9 / 10,84,8 / 10,64,8 / 10,64,8 / 10,64,9 / 10,85,0 / 11,05,1 / 11,25,5 / 12,15,5 / 12,15,6 / 12,25,7 / 12,45,6 / 12,25,6 / 12,25,6 / 12,25,7 / 12,45,8 / 12,65,9 / 13,0YesYesYesEnglish – 7

Construction and functionCarburettorThe carburettor consists of three sub-systems:The carburettor works in different ways dependingon the setting: Cold start mode Idling mode Part throttle mode Full throttle mode The metering unit (A) which contains the jetsand the fuel control mechanism. This measuresout the right amount of fuel to suit the speed ofthe saw and the power demand. The mixing unit (B) consists of the choke,diffuser jets and throttle valve. This is where theair and fuel are mixed to create a flammablemixture.In the cold start mode the choke valve (D) iscompletely closed. This increases the vacuum inthe carburettor so that fuel is sucked through thediffuser jets faster (E). The pump unit (C) pumps fuel from the tank tothe metering system inside the carburettor. Oneside of the pump diaphragm is connected to thecrankcase and pulses as a result of pressurechanges in the crankcase. The other side of thediaphragm sucks in the fuel.In idling mode the throttle valve (F) is closed. Air issucked through an aperture in the throttle valveand a small amount of fuel is supplied through thediffuser jet (E).8 – English

Construction and functionIn part throttle mode the throttle valve (F) is partially open. Fuel is supplied through the diffuser jets(E).In full throttle mode both valves are open and fuelis supplied through all the diffuser jets (E).English – 9

TroubleshootingThe various faults that can affect a chainsaw are divided into four groups. In each group the likely symptoms are given on the left and possible causes are listed on the right. The most likely faults are given first,and so on.Idling (low rpm) (cont.)StartingDifficulty startingAdjust L screwAir filter blockedChoke not workingWorn choke pivotWorn choke valveFuel filter blockedFuel line blockedPiston ring seizedBlocked impulse channelCarburettorleaking fuelLoose or faulty fuel pipeHole in diaphragmWorn needle valveNeedle valve assembly stickingNeedle valve set too highLeak in metering system (airor fuel)Loose cover on carburettorpump sideFlooding whenengine notrunningWorn needle valveNeedle valve set too highNeedle valve assembly stickingIdles when Lscrew closedWorn needle valveLeaking control diaphragm/cover plateNeedle valve assembly stickingWorn needle valve leverFaulty diffuser jetIdling unevenFuel filter blockedFuel line blockedLeaking air intake hose (rubber)Loose carburettor mountingboltsWorn throttle valve pivotLoose throttle valve screwWorn throttle valveNeedle valve assemblystickingLeak in metering system (airor fuel)Metering system centre knobis wornHole in diaphragmLeaking control diaphragm/cover plateCrankcase leakingL screw requiresconstantadjustmentFuel line blockedNeedle valve set too highNeedle valve assembly stickingLeak in metering system (airor fuel)Leaking control diaphragm/cover plateFaulty diffuser jetsCrankcase leakingToo much fuel atidlingNeedle valve set too highNeedle valve assembly stickingMetering system damagedWorn needle valveLeaking control diaphragm/cover plateMetering system incorrectlyassembledIdling (low rpm)Will not idleIdling too rich10 – EnglishAdjust L screwLeaking air intake hose(rubber)Loose carburettor mountingboltsLoose or faulty fuel hoseFuel filter blockedFuel line blockedFuel tank vent blockedThrottle valve pivot stiffThrottle pushrod stickingDefective throttle return springBent throttle stopFaulty diffuser jetAdjust L screwWorn needle valveNeedle valve set too highWorn needle valve leverLeaking control diaphragm/cover plateNeedle valve assemblysticking

TroubleshootingHigh rpmAcceleration and retardationWill not run at Adjust H screwfull throttleBlocked air filterBlocked fuel tank ventBlocked fuel filterFuel line blockedLoose or damaged fuel hoseImpulse channel leakingImpulse channel blockedLoose cover on carburettor pumpsideFaulty pump diaphragmLeaking air intake hose (rubber)Loose carburettor mounting boltsNeedle valve set too lowMetering system damagedMetering system incorrectlyassembledLeaking control diaphragm/coverplateNeedle valve assembly stickingBlocked silencerDoes notaccelerateAdjust L screwAdjust H screwBlocked air filterBlocked fuel tank ventBlocked fuel filterFuel line blockedLoose or damaged fuel hoseImpulse channel blockedLoose cover on carburettor pumpsideFaulty pump diaphragmLeaking air intake hose (rubber)Loose carburettor mounting boltsNeedle valve set too lowMetering system incorrectlyassembledNeedle valve assembly stickingFaulty diffuser jetsBlocked silencerEngine stallswhen throttlereleasedAdjust L screwAdjust H screwFaulty pump diaphragmNeedle valve set too highNeedle valve assembly stickingFaulty diffuser jetsOver richaccelerationAdjust L screwAdjust H screwBlocked air filterFaulty pump diaphragmFaulty diffuser jetsLow powerWill not “fourstroke”Adjust H screwBlocked fuel tank ventBlocked fuel filterImpulse channel leakingImpulse channel blockedLoose cover on carburettor pumpsideFaulty pump diaphragmBlocked air filterNeedle valve assembly stickingLeak in metering system (air or fuel)Metering system incorrectlyassembledLoose diaphragm rivetHole in diaphragmLeaking control diaphragm/coverplateBlocked fuel tank ventBlocked fuel filterFuel line blockedLoose or damaged fuel hoseImpulse channel leakingImpulse channel blockedLoose cover on carburettor pumpsideFaulty pump diaphragmLeaking air intake hose (rubber)Loose carburettor mounting boltsNeedle valve set too lowLeak in metering system (air or fuel)Metering unit incorrectly assembledLoose diaphragm rivetHole in diaphragmLeaking control diaphragm/coverplateTroubleshooting methodsIn addition to the faults described in the abovetable, trouble shooting can be carried out onspecific components or sub-systems of thechainsaw. The various procedures are described inthe relevant chapters, see the contents page, asfollows: Checking the operation of the chain brake Measuring the resistance of the stop plate Pressure testing the carburettor Pressure testing the decompression valve Pressure testing the cylinderEnglish – 11

Repair instructionsChain brake – dismantling31Disengage the brake by pushing the kickbackguard backwards. Unscrew the guide bar bolts andremove the clutch cover, chain and guide bar.2Grip the clutch cover carefully in a vice. Releasethe brake spring by using the kickback guard fromthe saw as a tool. Engage it with the brake mechanism and turn anticlockwise to activate the brake.WARNING!Make sure the spring does not flyout and cause injury. Wear eyeprotection.Remove the screws and carefully remove the coverfrom the chain brake spring.4Place one hand over the spring and insert a smallscrewdriver between the bottom end of the springand the clutch cover. Carefully prise the springupwards so that it slides onto the screwdriver shaft.Cleaning and inspection Clean and inspect all parts carefully. If there areany cracks or other defects replace the damagedparts with new ones. Always use original parts. Measure the thickness of the chain brake band.It must be no less than 0.6 mm at any point. Lubricate the elbow joint with grease.min 0,6 mm12 – English

Repair instructionsChain brake – reassembly41Bolt the elbow joint to the brake band and tightento a torque of 1–1.5 Nm.Locate the elbow joint and connected brake bandin their recesses in the clutch cover. Lubricate therecess for the spring with grease.2WARNING!Make sure the spring does not flyout and cause injury. Wear eyeprotection.Tension the brake spring by using the kickbackguard from the saw as a tool. Engage it with thebrake mechanism and turn clockwise to releasethe brake.5Turn the chain tensioner anticlockwise as far as itwill go.Refit: guide bar chain clutch coverNOTE!After completing the repair the chainbrake must be tested as described below.Operating test:The engine must not be running during the test.Grip the clutch cover in a vice. Compress thespring with special tool 502 50 67-01 and push itdown with your thumb.3Guide bar lengthHeight38cm/15"50 cm/20" Hold the chainsaw over a firm surface. Theheight of the guide bar above the surface isgiven in the table above. Let go of the front handle and let the chainsawfall towards the surface. When the guide bar hits the surface the chainbrake must engage.Fit the cover over the chain brake spring, tighteningthe screws to a torque of 1–1.5 Nm.English – 13

Repair instructionsSilencer – removalWARNING!Do not touch the silencer until ithas cooled down, otherwise youmay burn yourself.1Silencer – refitting1If the saw is equipped with a spark arrestor meshthis should be fitted first.2Refit cooling plate gasket silencer, tighten bolts to a torque of 8–10 Nm

chainsaw consists of detailed, step-by-step instruc-tions. It explains in detail the special tools, lubri-cants and bolt torques that are needed when working on each component. This workshop manual covers the following chainsaw models: 340 345 346XP 350 351 353

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