EMAK 63.4 cm3 Workshop Manual Download Page 3

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General failures’ analysis

63,4 cm³ chainsaws

p/n 001000392A

p/n 3055125

III.

II.

p/n 001000785

Suggested tools

Emak tool kit

II.

Compression tester:

to check thermal group

III.

Electronic tachometer

: for 2 and 4 stroke engines, measurement range from 100 to 30,000 RPM

Summary of Contents for 63.4 cm3

Page 1: ...WORKSHOP MANUAL 63 4 cm chainsaws ...

Page 2: ...General failures analysis 63 4 cm chainsaws ...

Page 3: ...cm chainsaws p n 001000392A p n 3055125 I III II p n 001000785 Suggested tools I Emak tool kit II Compression tester to check thermal group III Electronic tachometer for 2 and 4 stroke engines measurement range from 100 to 30 000 RPM ...

Page 4: ...plug inspection c Spark test d Flywheel coil air gap inspection e Flywheel key inspection 4 Oil pump bar and shock absorber a Oil tank breather inspection b Oil filter inspection c Sprocket power mate ring inspection d Oil pump inspection e Chain brake inspection f Lubrication and bar maintenance g Shock absorber replacement 5 Tuning a Air filter inspection b Needle valve inspection c Carburetor i...

Page 5: ...ompressor inspection d Cooling system cleaning e Muffler inspection a Compression test Apply the Emak compression tester I on cylinder Pull energetically the rope 10 times Verify that the compression value in not less than 8 bar 130 psi If the value in higher than 8 bar 130 psi start inspection c if lower carry on with inspection b ...

Page 6: ...ing assembly make sure the circlip has the feet pointing up Warning The arrow on the top of the cylinder points towards the exhaust port b Cylinder and piston inspection Verify the diamond scoring on piston and the nickel lining on cylinder Replace if necessary Verify the piston rings wear using feeler gauge gap max 1 0 mm ...

Page 7: ...eral failures analysis 63 4 cm chainsaws c Decompressor inspection Verify that the decompressor and the decompression hole on the cylinder is not closed to carbon deposits Clean and or replace if necessary ...

Page 8: ...ed air cylinder fins starter case and flywheel Important Clean weekly the cooling system For heavy duty work clean it every day Use Loctite 243 to tighten plastic component Tightening torque Cover 0 4 kgm 35 4 in lb Loctite 243 Tightening toque cover basement 0 4 kgm 35 4 in lb Loctite 243 ...

Page 9: ...ainsaws Tightening torque cover muffler basement 0 6 kgm 52 1 in lb Loctite 243 Tightening torque muffler cylinder 1 0 kgm 88 5 in lb Loctite 243 Back to index e Muffler inspection If the muffler is blocked or damaged clean or replace it ...

Page 10: ... oxidation replace it 2 Fuel system b Fuel system test Apply the pressure gauge at the fuel line Check any possible leakage at 0 5 bar If the pressure is not stable it may indicate worn fuel system or loose at the carburetor parts Sintered internal filter a Fuel and fuel filter inspection b Fuel system test c Tank breather inspection d Engine seal test e Manifold inspection Carburetor inspection G...

Page 11: ...e pressure gauge I supplied with Emak tool kit at the breather valve and verify the correct working in both ways To check the inlet direction use the adaptor II supplied with the pressure gauge s box as shown on the photo Replace or clean if necessary I p n 1043900 Breather sealing test 0 2 0 3 bar Breathing system test 0 00 bar ...

Page 12: ... carburetor and muffler Cover the intake side with insulator and exhaust side using the special flanges supplied with Emak tool kit I and II Tap the impulse s tube with a cap III and replace the decompressor with a special cap IV The pressure has to remain stable at 0 5 bar If the engine looses pressure find the leakage and fix it Repeat seal test ...

Page 13: ...analysis 63 4 cm chainsaws e Manifold inspection Check the manifold for wear Verify that the manifold s rubber is not deteriorated or hardened and check that there are no cuts or holes Replace if necessary Back to index ...

Page 14: ...inspection b Spark plug inspection c Spark test d Flywheel coil air gap inspection e Flywheel key way inspection Wind the spring 7 times ø 4 0 x 1035 mm a Starter housing inspection Remove housing Inspect parts for wear If necessary clean or replace Important grease moving parts ...

Page 15: ...rk plug inspection Remove the spark plug and check the gap between the electrodes 0 5 mm c Spark test Fit the tester I between spark plug and spark plug cap Pull the rope and verify the current Replace the spark plug if necessary Check the two wires ignition coil and switch ...

Page 16: ...e air gap using the shim II 0 3 mm Adjust if not correct Tightening torque coil screws 0 35 kgm 30 98 in lb Loctite 243 e Flywheel key way inspection Remove flywheel with corrector tool III Inspect key way s condition and position If necessary replace or adjust Tightening torque flywheel nut 2 kgm 177 0 in lb Back to index ...

Page 17: ...ain brake inspection f Lubrication and bar maintenance g Shock absorber replacement Make sure that the height of the oil tank breather is 1 mm lower than bar face Tightening torque crankcase screws 0 8 kgm 69 44 in lb Loctite 243 a Oil tank breather inspection Clean with compressed air Verify the quality of the bar and chain oil b Oil filter inspection Check the oil filter If it is dirty clean it ...

Page 18: ... ring after removing Attention When reassembling the clutch make sure that the worm gear drive spring I lodges into the clutch drum correctly II I II c Sprocket power mate ring inspection Check the sprocket power mate ring wear periodically Replacement is suggested every 100 hrs or before ...

Page 19: ...rt the piston stop I in the spark plug hole and remove the clutch Remove the oil pump check the pump and worm gear Important If the gear inside the pump is hard to turn disassemble all components and clean them using Emak detergent Tightening torque clutch 4 5 kgm 398 3 in lb Loctite 270 ...

Page 20: ...General failures analysis 63 4 cm chainsaws e Chain brake inspection Check the brake band for wear This must be changed if the wear limit is less than 0 6 mm ...

Page 21: ...nd bar maintenance Lubricate the sprocket nose Keep the rail and the lubrication holes cleaned Check the parallelism of the guide bar and for sharp metal edges Turn the bar every 8 hrs to grant uniform wear The angled lubrijet oilway hole must be cleaned GREASE ...

Page 22: ...cm chainsaws g Shock absorber replacement I p n 001000680A Control the AV mounts for wear or damage A Change when necessary In case of wear or breakage replace the parts with special tool I supplied with Emak tool kit as in photo A A ...

Page 23: ...s Check for wear or damage of the AV mounts exchange if necessary Important Make sure when assembling the springs fit correctly into the crankcase B as shown in photo B C Substitute spring AV mounts loosen the spring support C insert the screwdriver and loosen the spring ...

Page 24: ...General failures analysis 63 4 cm chainsaws Substitute AV mounts on inlet flange Control the wear and damage and exchange if necessary Back to index ...

Page 25: ...e 243 a Air filter inspection b Needle valve inspection c Carburetor inspection d Suggested tools for carburetion setting e Carburetor tuning a Air filter inspection Clean with Emak detergent rinse with water and blow with compressed air in the opposite direction of the normal air flow Replace the filter when damaged ...

Page 26: ...ck the right position of the valve using a caliper Adjust if necessary c Carburetor inspection Check and clean all components diaphragm needle filter Use the repair kit to replace worn components If the carburetor is oxidized replace it Back to fuel system OK REPLACE Needle ...

Page 27: ...General failures analysis 63 4 cm chainsaws I p n 001001070R d Suggested tools for carburetion setting Euro 0 Special screwdriver I to adjust the jets for adjustment the jets L e H ...

Page 28: ...is 63 4 cm chainsaws Suggested tools for carburetion setting Euro 1 Special screwdriver I to adjust the jets for adjustment the jets L e H I p n 3055130 Insert the special screwdriver as shown on the photo and adjust the jets ...

Page 29: ... idle rpm between 3700 and 4100 RPM 4 Open the jet L until the rpm go from 3700 4100 to 2700 3100 RPM Maximum adjustment H 5 Adjustment of the jet H for wide open throttle operation whit bar standard 20 51 cm and chain until the unit reaches an maximum rpm between 11800 RPM and 12800 RMP e Carburetor tuning Correct tuning of the EURO 0 and EURO 1 direttiva 97 68 CE 2002 88 CE The jets have the fol...

Page 30: ...sis 63 4 cm chainsaws Tightening torques kgm in lb lubrication Loctite 243 Loctite 270 G Grease O Oil O 0 4 35 4 0 1 8 85 0 1 8 85 0 6 52 1 0 35 30 98 2 177 0 7 61 95 1 4 123 9 1 2 106 2 2 177 6 Tightening torques 0 35 30 98 ...

Page 31: ...lures analysis 63 4 cm chainsaws Euro 1 Euro 0 0 4 35 4 0 45 39 83 0 17 15 04 0 15 13 28 0 1 8 85 0 3 26 55 0 6 52 1 1 88 5 Tightening torques kgm in lb lubrication Loctite 243 Loctite 270 G Grease O Oil 0 4 35 4 ...

Page 32: ...3 4 cm chainsaws 0 8 70 8 0 5 44 25 0 4 35 4 0 1 8 85 0 4 35 4 0 5 44 25 0 1 8 85 0 4 35 4 0 3 26 55 0 8 70 8 0 45 39 83 0 45 39 83 0 8 70 8 Tightening torques kgm in lb lubrication Loctite 243 Loctite 270 G Grease O Oil 0 4 35 4 ...

Page 33: ...alysis 63 4 cm chainsaws 0 4 35 4 0 3 26 55 0 35 30 98 0 3 26 55 4 5 398 3 0 35 30 98 1 2 106 2 0 3 26 55 0 45 39 83 0 15 13 28 Tightening torques kgm in lb lubrication Loctite 243 Loctite 270 G Grease O Oil Back to index ...

Page 34: ...or replace 4 b Tightness test on fuel system 4 c Carburetor inspection point 5 c Take off spark plug rotate the engine blow inside cylinder passing through spark plug hole dry the spark plug and restart 4 a Fuel filter or breather blocked 4 b Fuel system is leaking air 4 c Wet spark plug flooded cylinder 4 Fuel does not reach the carburetor the machine stops after 5 minutes 3 a Switch ON and resta...

Page 35: ...amaged 2 c Water in the fuel 2 d Seizure 2 e Faulty carburetor or diaphragm 2 Engine performance is not stable 1 a Set the carburetor 1 b Find air leaking and eliminate it 1 c Replace with fresh fuel and right oil ratio 1 d Clean or replace it 1 e Eliminate deposit 1 a Carburetor mixture too lean 1 b Air leaking in the engine or in fuel system 1 c Wrong oil fuel ratio 1 d Fan starter housing cylin...

Page 36: ...t 1 d Sharpen the chain 1 e Correct tension assembly bar and chain 1 a Bended or worn bar 1 b Lubrication system blocked 1 c Worn sprocket 1 d The chain is not sharp 1 e Chain to tight 1 The chain does not work correctly or does not rotate Remedies Causes Symptoms Trouble shooting ADDITIONAL PROBLEMS Back to index Owner s manual Owner s manual ...

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