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EMAK GS35, Workshop Manual

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EMAK GS35 Workshop Manual Download Page 5

General failures’ analysis

GS35 – GS350 – MT350 – MT3500 chainsaws

1) Rendimento

a)

 

Compression test

b)

 

Cylinder and piston inspection

c)

 

Cylinder and piston assembly

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 7,5 bar –

 

110 psi

•

 

If the value in higher than 

 

 

 

 

 

7,5 bar –

 

110 psi, start 

inspection 

d)

, if lower, carry on 

with inspection 

b)

I

p/n 001000392A

Summary of Contents for GS35

Page 1: ...WORKSHOP MANUAL Chainsaw GS35 GS350 MT350 MT3500 ...

Page 2: ...General failures analysis GS35 GS350 MT350 MT3500 chainsaws ...

Page 3: ...350 MT3500 chainsaws 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 I II p n 001000392A p n 001000785 III Suggested tools p n 3055125 ...

Page 4: ...on b Spark 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 Sprocket inspection c Chain brake inspection d Oil pump and oil filter inspection e Worm gear inspection f Shock absorber replacement g Lubrication and bar maintenance 5 Tuning a Air filters inspection b Needle valve inspection c Ca...

Page 5: ...on assembly 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 7 5 bar 110 psi If the value in higher than 7 5 bar 110 psi start inspection d if lower carry on with inspection b I p n 001000392A ...

Page 6: ...ining on cylinder Replace if necessary Verify the piston rings wear using feeler gauge gap max 1 0 mm Attention de grease the contact surfaces of the cylinder and the cover Use a liquid gasket to re seal be careful with the quantity so it does not pollute internal engine parts Warning during assembly make sure the circlip has the feet pointing up ...

Page 7: ...50 MT3500 chainsaws c Cylinder and piston assembly Warning The arrow on the top of the cylinder points towards the exhaust port Warning The arrow must point towards the exhaust Tightening torque cylinder screws 0 6 Kgm 52 08 in lb Loctite 243 ...

Page 8: ...Tightening toque cover basement 0 4 kgm 34 72 in lb Loctite 243 Important Clean weekly the cooling system more frequently in heavy duty work conditions Use Loctite 243 to tighten plastic component d Cooling system cleaning Dismount the cylinder s cover Blow with compressed air cylinder fins starter case and flywheel ...

Page 9: ...ffler inspection Back to index Tightening torque cover muffler muffler 0 6 kgm 53 10 in lb Loctite 243 Catalytic muffler Verify the conditions of the muffler dirt oily change if necessary Non catalytic muffler If the muffler is blocked or damaged clean or replace it ...

Page 10: ... dirt or 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 insp...

Page 11: ...ction Dismount the breather and check the components Apply the pressure gauge I supplied with Emak tool kit at the breather valve and verify the correct working in both ways 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: ...let port with the correct flange from the tool kit I and II Close the exhaust port by putting the flange between the muffler and cylinder III flange in tool kit Refit the muffle with the 3 screws M5x25 III p n 001000018 II p n 094500388A IV n 3 screws M5x25 Warning During the seal test use only a light torque of 0 4 Kgm 35 in lb ...

Page 13: ...General failures analysis GS35 GS350 MT350 MT3500 chainsaws Fit the pressure gauge V to the inlet and apply 0 5 bar The pressure should not descend V p n 1043900 ...

Page 14: ...fold inspection Check the manifolds 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 Warning Make sure the impulse path is correctly inserted into the cylinder hole ...

Page 15: ...n c Spark arrester test d Flywheel coil air gap inspection e Flywheel key way inspection 3 Ignition system a Starter housing inspection Remove housing Inspect parts for wear If necessary clean or replace Important grease moving parts Counterclockwise turn to release the spring Clockwise turn to wind the spring Important make sure the spring does not wind fully with the rope fully out ...

Page 16: ...7 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 Verify that the spark plug thermal grade and type resistive R are correct Check that the spark plug pipe is correctly connected cables are not damaged and coil works properly 0 5 0 7 mm I cod 001000515R RCJ 7Y ...

Page 17: ...0 3 mm Adjust if not correct II p n 001000004 Tightening torque coil screws 0 4 kgm 34 72 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 III p n 001000782 Tightening torque flywheel nut 1 9 kgm 168 2 in lb Back to index ...

Page 18: ...Oil pump bar and shock absorber a Oil tank breather inspection b Sprocket inspection c Chain brake inspection d Oil pump and oil filter inspection e Worm gear inspection f Shock absorber replacement g Lubrication and bar maintenance a Oil tank breather inspection Clean with compressed air Verify the quality of the bar and chain oil ...

Page 19: ...r mate ring inspection Check the sprocket power mate ring wear periodically Replacement is suggested every 100 hrs or before c Chain brake inspection Check the brake band the plate and the protection s rubber for wear This must be changed if the wear limit is less than 0 6 mm ...

Page 20: ...d Oil pump and oil filter inspection Use the piston stop I in the spark plug hole Remove the clutch anticlockwise with tool II I p n 001000684 Tightening torque clutch 2 Kgm 177 0 in lb Loctite 243 II p n 3055133 Warning Make sure the spacer washer is fitted I I ...

Page 21: ...350 MT3500 chainsaws Remove the oil pump Check the pump and worm gear Inspect the supply hose and filter clean Tightening torque screws oil pump 0 45 kgm 39 83 in lb Loctite 243 Warning Use a liquid gasket to seal in the hose to the saw body ...

Page 22: ...h the correct tool from the tool box I I p n 3055133 Insert the worm gear into the fitting tool I leave about 2 mm sticking out Fit the worm gear spring on the crankshaft until the end of the spring touches the crank seat Photo 1 2 Screw in the tool until stop I to give the correct pitch to the worm gear Photo 2 Photo 1 ...

Page 23: ...General failures analysis GS35 GS350 MT350 MT3500 chainsaws f Shock absorber replacement In case of wear or breakage replace the parts ...

Page 24: ...aws g Lubrication and 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 Back to index GRASSO Keep clean ...

Page 25: ...arburetor tuning a Air filters inspection Sponge air filter A clean with Emak degreaser rinse with water and blast dry with compressed air Cloth air filter B shake it and clean it with a soft brush Replace the filter when damaged Tightening torque Support air filter carburetor 0 4 Kgm 34 72 in lb Loctite 243 Tightening torque Support air filter insulator 0 2 Kgm 17 7 in lb Loctite 243 A B ...

Page 26: ...alve inspection Check 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 Needle Back to fuel system ...

Page 27: ...alysis GS35 GS350 MT350 MT3500 chainsaws d Suggested tools for carburetor setting Special screwdriver I for adjustment the jets L e H Insert the special screwdriver as shown on the photo and adjust the jets I p n 3055130 ...

Page 28: ... and 4200 RPM 4 Open the jet L until the rpm go from 3700 4200 to 2800 3100 RPM Maximum adjustment H 5 Adjustment of the jet H for wide open throttle operation whit bar standard 16 41 cm and chain 10600 RPM with the new motor and 12100 RMP with run in engine e Carburetor tuning Correct tuning of the EURO 1 direttiva 97 68 CE 2002 88 CE and EURO 2 direttiva 97 68 CE 2002 88 CE 2004 26 CE The jets h...

Page 29: ...ral failures analysis GS35 GS350 MT350 MT3500 chainsaws O 1 9 168 2 0 4 34 72 0 25 22 13 0 6 52 08 2 177 0 6 Tightening torques Tightening torques kgm in lb lubrication Loctite 243 G Grease O Oil 0 4 34 72 ...

Page 30: ...General failures analysis GS35 GS350 MT350 MT3500 chainsaws 0 2 17 7 Tightening torques kgm in lb lubrication Loctite 243 G Grease O Oil 0 25 22 13 0 25 22 13 0 6 52 08 0 4 34 72 ...

Page 31: ...ilures analysis GS35 GS350 MT350 MT3500 chainsaws Tightening torques kgm in lb lubrication Loctite 243 G Grease O Oil 0 7 61 96 0 7 61 96 0 4 34 72 0 35 30 98 0 35 30 98 0 35 30 98 0 35 30 98 0 04 3 54 0 4 34 72 ...

Page 32: ...General failures analysis GS35 GS350 MT350 MT3500 chainsaws G 0 45 39 83 2 177 0 0 25 22 13 0 5 44 25 1 5 132 76 Back to index Tightening torque kgm in lb lubrication Loctite 243 G Grease O Oil ...

Page 33: ...park plug or wrong type 3 a Switch ON and restart 3 b Inspect and or replace 3 c Replace the spark plug Section 3 Section 3 4 Fuel does not reach the carburetor the machine stops after 5 minutes 4 a Fuel filter or breather blocked 4 b Fuel system is leaking air 4 c Wet spark plug flooded cylinder 4 a Clean or replace 4 b Tightness test on fuel system 4 c Carburetor inspection point 5 c Take off sp...

Page 34: ...t 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 Section 5 Section 1 Section 2 Section 1 Section 1 2 Engine performance is not stable 2 a Dirty air filter 2 b Loose spark plug or damaged 2 c Water in the fuel 2 d Seizure 2 e Faulty carburetor or diaphragm 2 a Clean or replace 2 b Tighten or replace ...

Page 35: ...k correctly or does not rotate 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 a Replace or maintain 1 b Clean or replace 1 c Replace sprocket 1 d Sharpen the chain 1 e Correct tension assembly bar and chain Section 4 Section 4 Section 4 Back to index Owner s manual Owner s manual ...

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