Hitachi CS 51EA Service Manual Download

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PRODUCT NAME

Hitachi Engine Chain Saw

Models

CS 51EAP

CS 51EA

International Sales Division

䌃

TROUBLESHOOTING GUIDE ---------------------------------------------------------------------------------------------- 1

1. Troubleshooting and correction ------------------------------------------------------------------------------- 1

REPAIR GUIDE ----------------------------------------------------------------------------------------------------------------- 3

1. Precaution on maintenance, inspection and repair ------------------------------------------------------ 3

2. Inspection criteria for each section and consumable parts -------------------------------------------- 3

CONTENTS

Page

LIST Nos.
CS 51EAP: F009
CS 51EA: F008
Feb. 2012

Summary of Contents for CS 51EA

Page 1: ...tional Sales Division 䌃 TROUBLESHOOTING GUIDE 1 1 Troubleshooting and correction 1 REPAIR GUIDE 3 1 Precaution on maintenance inspection and repair 3 2 Inspection criteria for each section and consumable parts 3 CONTENTS Page LIST Nos CS 51EAP F009 CS 51EA F008 Feb 2012 ...

Page 2: ...or improperly connected high voltage cord Repair or replacement Ground connection of high voltage cord Repair Disconnected or faulty ignition coil ass y Replacement Large gap between the magneto rotor circumference and ignition coil ass y Adjustment The spark plug does not become wet with fuel after repeated starting operation No fuel in the fuel tank Add properly mixed fuel 25 1 to 50 1 Clogged f...

Page 3: ...ent Starts but Fluctuating revolutions at high speed Dirt clogged high speed fuel line Cleaning Defective sealing of the packing Replacement Faulty carburetor ass y Adjustment cleaning or replacement Excessive fuel consumption Clogged air cleaner Cleaning Poorly adjusted carburetor ass y Adjustment Chain oil is not discharged Insufficient amount of chain oil in the oil tank Insufficient chain oil ...

Page 4: ... and spark plug Before running the product with the guide bar and saw chain attached make sure that there are no other people nearby Ensure proper ventilation when performing repair in a small room or other poorly ventilated space 2 Inspection criteria for each section and consumable parts Model Item CS 51EAP CS 51EA Idling revolutions 3 000 200 min 1 rev min No load maximum revolutions with guide...

Page 5: ...ion Disconnected or faulty ignition coil Replacement Excessive gap between magneto rotor circumference and ignition coil Adjustment No fuel in fuel tank or improper mixing ratio Add properly mixed fuel 25 1 to 50 1 Clogged fuel filter Cleaning replacement Bent fuel pipe Adjustment Cracked fuel pipe Replacement Fallen fuel pipe Connection Faulty tank vent hole inner cap Replacement Faulty pump diap...

Page 6: ...ng Dirt clogged high speed fuel line of the carburetor ass y Cleaning Air intake from the packing section Inspection Faulty carburetor ass y pump diaphragm Replacement Poorly adjusted carburetor ass y Adjustment Revolutions too low for idling Adjustment Poorly adjusted carburetor ass y Adjustment Clogged air cleaner Cleaning Poorly adjusted carburetor ass y Adjustment Insufficient chain oil in the...

Page 7: ...the Throttle Lever 149 d Pull the starter handle several times 2 Insert the Spark Plug 46 into the Plug Cap 162 and then place the electrodes in contact with the metallic portion of the engine Under these conditions set the Stop Switch 95 to the startup position and pull the starter handle 3 When all the above are normal the Spark Plug 46 electrodes make a snapping sound to generate sparks 2 Adjus...

Page 8: ... 72 from the Carburetor Ass y 52 Use a hex bar wrench 4 mm to remove the Hex Socket Hd Bolt M5 x 12 Precote 38 and two Hex Socket Hd Bolts M5 x 45 70 Then remove the Cleaner Support 71 and Carburetor Ass y 52 2 Reassembly Reassembly can be conducted by reversing the disassembly procedure However special attention should be given to the following items Ɣ Do not bend the Fuel Pipes 68 51 72 See 2 Co...

Page 9: ... the edge of the Fuel Grommet 152 by 55 to 60 mm and 167 to 172 mm respectively CAUTION Never mix up fuel pipes inserted into the Priming Pump Comp 44 Ɣ Fuel pipe connection chart Priming Pump Comp 44 Fuel Pipe 72 Carburetor Ass y 52 Fuel Pipe 2 5 x 4 x 90 43 Fuel Pipe 68 Cleaner Support 71 Clip 31 Fuel Pipe FKM 51 Clip 31 Fuel Grommet A 41 Grommet 42 7 mm or more Color Black Color Transparent CAU...

Page 10: ...o loosen the four Cover Set Bolts 4 and then remove the Recoil Starter 176 and Air Deflector 175 2 Reassembly Reassembly can be conducted by reversing the disassembly procedure However special attention should be given to the following items Ɣ Place Cord A 163 and Cord B 164 into the groove of the Air Deflector 175 for assembly Ɣ Place the high voltage cord of the ignition coil into the groove of ...

Page 11: ...ls do not protrude from the first coils of the Spring Holders 155 12 See the illustration above Ɣ Apply 0 1 to 0 3 g of Chemiseal L 391 manufactured by Chemitech Inc to the bolts of the Spring Holders 155 12 or on the female threads of Nut M6 10 Ɣ Secure the Spring Holders 155 12 by inserting a flat blade screwdriver into the groove of the bolt as illustrated on the right and then tighten Nut M6 1...

Page 12: ...asily broken Therefore do not tighten the screws too much Ɣ Remove the Machine Screw M4 x 16 28 and Clip 31 and then remove the Oil Pipe 29 from the Oil Pump 30 Finally remove the Oil Pump 30 from the main body 2 Reassembly Reassembly can be conducted by reversing the disassembly procedure However special attention should be given to the following items Ɣ Before mounting the Worm 138 apply 0 1 to ...

Page 13: ...end face of the Crank Shaft 83 made flush with the upper face of a commercially available M8 nut rotate the J 363 jig 8 x 120 handle in the arrow direction and tighten the J 357 jig center bolt as shown in the illustration on the right Then remove the Magneto Rotor 169 2 Reassembly Reassembly can be conducted by reversing the disassembly procedure However special attention should be given to the f...

Page 14: ...t Hd Bolt W Flange M4 x 18 167 so as to temporarily secure the Ignition Coil 166 2 Insert a 0 3 mm thickness gauge between the Ignition Coil 166 and the perimeter of the Magneto Rotor 169 3 Under this condition firmly tighten the Hex Socket Hd Bolt W Flange M4 x 18 167 Ɣ Adjustment of clearance between the magneto rotor and ignition coil Magneto Rotor 169 0 2 to 0 4 mm 0 2 to 0 4 mm Hex Socket Hd ...

Page 15: ... B 164 Cord B 164 Cord A 163 Cable Tie 161 8 Wiring diagram The following diagram shows the wiring 1 Connect the connector silver of Cord A 163 to the Ignition Coil 166 2 Fix Cord B 164 to the Ignition Coil 166 with the Hex Socket Hd Bolt W Flange M4 x 18 167 3 Fit the Stop Switch 95 into the Operation Plate 94 so that indication 1 faces up 4 Connect the connectors brass color of Cord A 163 and Co...

Page 16: ...2 Precote 38 Then remove the Muffler 39 Ɣ Use a 3 mm hex bar wrench to remove the five Hex Socket Hd Bolts M4 x 10 24 and five Bolt Washers M4 25 Then remove the Muffler Protector 26 Muffler Protector Gauze 27 Exhaust Pipe 19 and Muffler Gauze 20 2 Reassembly Reassembly can be conducted by reversing the disassembly procedure However special attention should be given to the following items Ɣ Do not...

Page 17: ...e the screw holes of the Engine Case A Ass y 87 and Engine Case B Ass y 80 Ɣ Before mounting Scavenging Cover A 74 and Scavenging Cover B 17 degrease the screw holes of the Cylinder 73 Ɣ Before mounting the Intake CS51 48 degrease the screw holes of the Cylinder 73 Ɣ Reassemble the packings by ensuring the proper alignment of the holes Ɣ Pay attention to the directional property of the Cylinder Pa...

Page 18: ...diameter 1 Disassembly Ɣ Remove the two Circlips 78 with long nose pliers Ɣ Insert a hex socket hd bolt M5 x 12 into the pushing side of the Piston Pin 85 and then turn the pin pullout bolt of the J 359 jig piston pin extraction tool ass y clockwise to pull out the Piston Pin 85 CAUTION Do not scratch the Piston 44 M 77 2 Reassembly Ɣ Do not reuse the Circlips 78 Ɣ When removing the Piston 44 M 77...

Page 19: ... and then cover it with the Piston 44 M 77 Align the triangular arrow on top of the Piston 44 M 77 with the direction of the exhaust port of the Cylinder 73 Insert a round bar about 9 8 mm in diameter e g borer 10 mm in diameter into the Piston 44 M 77 opposite the side where the Piston Pin 85 is inserted in order to prevent Needle Bearing A 86 and the two Piston Pin Collars C51 79 from becoming m...

Page 20: ...can be conducted by reversing the disassembly procedure However special attention should be given to the following items Ɣ Do not reuse the Oil Seal 81 and Ball Bearing 6202C3 82 removed from the Engine Case A Ass y 87 and Engine Case B Ass y 80 Ɣ Do not reuse the Crank Case Packing C51 84 Ɣ Do not reuse the Seal Lock Hex Socket Hd Bolts M5 32 and Seal Lock Hex Socket Hd Bolts M5 x 45 35 Ɣ Apply 5...

Page 21: ...the side case such as Brake Band 128 CAUTION The threads of the Seal Lock Screws M4 x 10 16 may be easily broken Therefore do not tighten the screws too much 2 Reassembly Reassembly can be conducted by reversing the disassembly procedure However special attention should be given to the following items Ɣ Do not reuse the Seal Lock Screws M4 x 10 16 Ɣ Align Guide Plate B 116 with the groove of the B...

Page 22: ...Clutch oil pump Clutch 131 1 Clutch 131 35to40 357to408 Oil Pump Cover C51 137 3 Seal Lock Screw M4 x 10 16 1 4to2 2 14to22 Guide Plate A 123 1 Oil Pump 30 1 Machine Screw M4 x 16 28 1 4to2 2 14to22 Magneto rotor Magneto Rotor 169 1 Flange Nut M8 112 20to22 204to224 Starter Pawl 172 1 each Step Bolt 174 5 9to6 9 60to70 Engine Cylinder 73 4 Seal Lock Hex Socket Hd Bolt M6 x 20 37 9 0to10 0 91to101 ...

Page 23: ...returns automatically to the OFF position under combustion pressure 9 Pull the starter handle to start the engine Tip 2 or 3 times at ordinary temperature 20 C Pull the handle more under low ambient temperature 10 Lightly pull the throttle lever and confirm that half throttle status is canceled and the engine returns to idling Do not run the engine in half throttled status with the chain brake on ...

Page 24: ...3 14 21 22 23 11 15 24 25 24 25 26 27 28 29 30 16 17 18 16 18 36 37 38 39 40 35 31 32 33 34 45 46 47 48 38 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 31 68 38 69 71 69 70 72 37 73 19 20 74 75 76 77 43 44 78 78 79 79 80 81 82 83 85 86 87 84 88 89 90 28 69 69 28 91 92 93 94 95 82 81 41 42 ...

Page 25: ...125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 178 149 150 151 146 152 153 154 155 156 157 159 160 160 159 147 157 156 155 162 163 164 165 124 166 167 168 169 170 171 172 174 175 176 177 501 502 161 15 15 16 16 16 31 16 33 10 31 10 4 173 158 145 148 ...

Page 26: ... 1 23 302 089 TAPPING SCREW W FLANGE D5 X 20 BLACK 2 24 949 812 HEX SOCKET HD BOLT M4 X 10 10 PCS 5 25 949 429 BOLT WASHER M4 10 PCS 5 26 669 8904 MUFFLER PROTECTOR 1 27 669 8905 MUFFLER PROTECTOR GAUZE 1 28 949 219 MACHINE SCREW M4 X 16 10 PCS 3 29 669 8900 OIL PIPE CS40 1 30 669 8554 OIL PUMP 1 31 668 5311 CLIP 5 32 668 5412 SEAL LOCK HEX SOCKET HD BOLT M5 4 33 669 8901 SEAL LOCK SCREW M5 X 12 3...

Page 27: ... X 45 2 71 669 8553 CLEANER SUPPORT C51 1 72 669 8721 FUEL PIPE 1 73 669 8537 CYLINDER 1 74 669 8538 SCAVENGING COVER A 1 75 669 8542 CYLINDER PACKING C51 1 76 669 8534 PISTON RING 2 77 669 8909 PISTON 44 M 1 78 669 6854 CIRCLIP 2 79 669 8910 PISTON PIN COLLAR C51 2 80 669 8531 ENGINE CASE B ASS Y 1 INCLUD 81 82 81 669 8914 OIL SEAL 2 82 620 2C3 BALL BEARING 6202C3 2 83 669 8532 CRANK SHAFT 1 84 6...

Page 28: ...123 669 8561 GUIDE PLATE A 1 124 669 8913 DAMPER C51 2 125 669 6894 CHAIN CATCHER 1 126 669 8587 BRAKE LINK 1 127 669 8588 BRAKE SPRING 1 128 669 8589 BRAKE BAND 1 129 668 5391 NEEDLE ROLLER D3 1 130 669 8590 BRAKE LINK COVER 1 131 669 8560 CLUTCH 1 132 669 6882 CLUTCH WASHER B 1 133 669 8558 CLUTCH HOUSING 1 134 669 6884 NEEDLE BEARING 1 135 669 8557 RIM SPROCKET 1 136 669 8556 CLUTCH WASHER 1 13...

Page 29: ...NG OF PLUG CAP 1 166 669 8544 IGNITION COIL 1 167 669 6326 HEX SOCKET HD BOLT W FLANGE M4 X 18 2 168 669 8918 MAGNETO ASS Y 1 INCLUD 169 174 169 669 8543 MAGNETO ROTOR 1 170 669 8417 STARTER PAWL SPRING 2 171 669 6857 WASHER 0 8 2 172 669 6877 STARTER PAWL 2 173 669 6434 SHIM 2 174 669 6878 STEP BOLT 2 175 669 8571 AIR DEFLECTOR 1 176 669 8583 RECOIL STARTER 1 176 669 8584 RECOIL STARTER 1 FOR USA...

Page 30: ...3 14 21 22 23 11 15 24 25 24 25 26 27 28 29 30 16 17 18 16 18 36 37 38 39 40 35 31 32 33 34 45 46 47 48 38 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 31 68 38 69 71 69 70 72 37 73 19 20 74 75 76 77 43 44 78 78 79 79 80 81 82 83 85 86 87 84 88 89 90 28 69 69 28 91 92 93 94 95 82 81 41 42 ...

Page 31: ... 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 148 149 150 151 146 152 153 154 155 156 157 159 160 160 159 147 157 156 155 162 163 164 165 124 166 167 175 176 177 501 502 161 15 15 16 16 16 31 16 33 10 31 10 4 158 145 168 169 170 171 172 174 173 ...

Page 32: ...X 20 BLACK 2 24 949 812 HEX SOCKET HD BOLT M4 X 10 10 PCS 5 25 949 429 BOLT WASHER M4 10 PCS 5 26 669 8904 MUFFLER PROTECTOR 1 27 669 8905 MUFFLER PROTECTOR GAUZE 1 28 949 219 MACHINE SCREW M4 X 16 10 PCS 3 29 669 8900 OIL PIPE CS40 1 30 669 8554 OIL PUMP 1 31 668 5311 CLIP 5 32 668 5412 SEAL LOCK HEX SOCKET HD BOLT M5 4 33 669 8901 SEAL LOCK SCREW M5 X 12 3 34 668 5400 SPIKE 1 35 669 8902 SEAL LO...

Page 33: ...69 8721 FUEL PIPE 1 73 669 8537 CYLINDER 1 74 669 8538 SCAVENGING COVER A 1 75 669 8542 CYLINDER PACKING C51 1 76 669 8534 PISTON RING 2 77 669 8909 PISTON 44 M 1 78 669 6854 CIRCLIP 2 79 669 8910 PISTON PIN COLLAR C51 2 80 669 8531 ENGINE CASE B ASS Y 1 INCLUD 81 82 81 669 8914 OIL SEAL 2 82 620 2C3 BALL BEARING 6202C3 2 83 669 8532 CRANK SHAFT 1 84 669 8535 CRANK CASE PACKING C51 1 85 669 6855 P...

Page 34: ...G 1 128 669 8589 BRAKE BAND 1 129 668 5391 NEEDLE ROLLER D3 1 130 669 8590 BRAKE LINK COVER 1 131 669 8560 CLUTCH 1 132 669 6882 CLUTCH WASHER B 1 133 669 8558 CLUTCH HOUSING 1 134 669 6884 NEEDLE BEARING 1 135 669 8557 RIM SPROCKET 1 136 669 8556 CLUTCH WASHER 1 137 669 8555 OIL PUMP COVER C51 1 138 669 6886 WORM 1 139 668 5371 AIR VENT SPONGE 1 140 668 5370 AIR VENT VALVE B 1 141 305 812 TAPPING...

Page 35: ... 167 669 6326 HEX SOCKET HD BOLT W FLANGE M4 X 18 2 168 669 8918 MAGNETO ASS Y 1 INCLUD 169 174 169 669 8543 MAGNETO ROTOR 1 170 669 8417 STARTER PAWL SPRING 2 171 669 6857 WASHER 0 8 2 172 669 6877 STARTER PAWL 2 173 669 6434 SHIM 2 174 669 6878 STEP BOLT 2 175 669 8571 AIR DEFLECTOR 1 176 669 8583 RECOIL STARTER 1 177 HITACHI LABEL 1 STANDARD ACCESSORIES DESCRIPTION REMARKS 501 668 5439 CHAIN CO...

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