RedMax 967683802 Workshop Manual Download

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Workshop Manual

English

G9000

Summary of Contents for 967683802

Page 1: ...Workshop Manual English G9000...

Page 2: ...20 9 1 2 Cleaning and inspection 20 9 1 3 Assembly 21 9 2 Stop switch 21 9 3 Hand grip heater and carburettor heater 385 22 9 3 1 Trouble shooting 22 9 3 2 Replacing the generator 23 9 3 3 Replacing t...

Page 3: ...ether with all ser vice information issued concerning the chainsaw in question 1 5 Tools Special tools must be used during specific steps All service tools are listed in the Workshop Manual Us age is...

Page 4: ...been adjusted so that the chain remains still when idling After test running do not touch the muffler until it has cooled Risk of burn injuries Insufficient lubrication of the chain can result in the...

Page 5: ...saw casing xxx Choke Switch for hand grip heater Fuel filler Stop switch Screw to adjust chain lubrication Chain oil filler Electric carburettor heating 2 2 Symbols in this Workshop manual This symbol...

Page 6: ...m inch mm inch kW hp rpm G9000 88 cm 3 5 4 55mm 2 2 3 7 1 5 4 8kW 9600rpm Guide bar length Chain speed at max Chain pitch Drive link power and 9600 rpm h c n i m m h c n i m m s m h c n i m c G9000 46...

Page 7: ...tank volume Oil pump capacity Oil tank volume Automatic oil pump Litres US pint cm 3 min Litres US pint s e Y 1 1 0 5 0 m p r x x 0 2 4 9 1 0 9 0 G9000 G9000 Weightwithoutbarandchain Weightwithbarand...

Page 8: ...English 8 Service tools 4 Service tools 5 4 2 1 1 1 0 1 9 7 6 8 3 12 13 14...

Page 9: ...mbly set Assembling the piston 502 50 70 01 10 Assembly tool Assembling the crankshaft 502 50 30 17 11 Extractor Removing seal on fly wheel side 502 50 55 01 12 Feeler gauges air gap Adjustment of the...

Page 10: ...ilator blocked Throttle valve axle stiff Throttle wire sticks Defective throttle return spring Bent valve axle stop Faulty diffuser jet 2 Too rich idling Adjust the L screw Worn needle needle tip Cont...

Page 11: ...system set too low Leaking control system air or fuel Control system incorrectly as sembled Loose diaphragm Hole in diaphragm Leaking diaphragm cover plate Acceleration and retardation Does not accele...

Page 12: ...English 12 6 Service data Service data 10 10 14 5 8 8 6 15...

Page 13: ...13 English Service data 4 10 4 35 4 4 4 6 6 10 15 15 1 5...

Page 14: ...ove the spark plug and fit the piston stop Remove the clutch with the clutch tool Note left hand thread Screw in the direction of the arrow as in fig 4 7 Remove the four screws B and the cover over th...

Page 15: ...de plate with bolt A See fig 1 7 Fit the hand guard with the sleeve on the starter side See fig 2 8 Push back the hand guard so that the chain brake is in the off position 9 Check that the brake strap...

Page 16: ...21 28 inches 50 cm 70 cm 2 Let go of the front hand grip and let the chainsaw pivot round on the rear hand grip 3 3 When the bar hits the surface the chain brake should cut in 7 1 5 Chain catcher Dism...

Page 17: ...with a spark arrester refit it See fig 9 6 Fit the cooling plate gasket and muffler to the cylinder Tighten the two M6 bolts to the cylinder to 14 Nm Tighten the four M5 bolts to 10 Nm 7 3 Stop switc...

Page 18: ...g 15 7 4 2 Inspection Clean all components and check the following 1 That the throttle cable and lever are undamaged and run easily 2 That the lock activation mechanism is not worn See fig 13 7 4 3 As...

Page 19: ...starter pulley See fig 3 8 If the starter cord is to be replaced cut it off pull out the ends from the handle and starter pulley with pointed pliers 9 If the spring is to be replaced remove the old sp...

Page 20: ...the pulley on the spindle Turn gently backwards and forwards until the spring catches on the stop in the housing 5 Fit the washer and bolt See fig 3 Tighten the bolt to 4 Nm 6 Pull out the cord throug...

Page 21: ...e two pawls E for the starter See fig 1 and fig 6 6 Remove the spark plug and fit the piston stop in spark plug hole See fig 2 7 Release the flywheel nut Unscrew the nut until it comes level with the...

Page 22: ...tion module See fig 7 7 Insert the feeler gauge H 0 3 mm between the ignition module and the flywheel magnet The clearance only applies to the two lower pegs on the ignition module See fig 7 and 8 8 P...

Page 23: ...alues deviate Front hand grip with heating element Measure the resistance in the front hand grip element between points A and B See fig 10 The ohmmeter should show 3 4 ohms If the value is higher repl...

Page 24: ...the generator by unscrewing the three bolts See fig 15 3 Release the cable from the switch and remove the generator 4 Fit the new generator as shown in fig 16 and tighten the bolts to 4 Nm 5 Position...

Page 25: ...ating element and cable connections 9 3 5 Replacing the front hand grip 1 Release the two cable clips beside the spring See fig 20 2 Remove the five bolts A B C and D which hold the front hand grip Se...

Page 26: ...needle bearing D and chain drive sprocket E See fig 2 4 Remove the spark plug and fit the piston stop Remove the clutch with the clutch tool 5 Note left hand thread Screw in the direction of the arrow...

Page 27: ...act and the bearing surface undamaged 10 1 3 Assembly When assembling the centrifugal clutch the chain brake must be in the off position 1 Fit the clutch shoes on the hub and fit the springs with circ...

Page 28: ...pump from the crankcase See fig 2 5 Use a screwdriver to push up the oil pipe at A Lift up the pipe and pull it out of the oil pump See fig 2 6 Use pointed pliers and pull up the suction pipe C with...

Page 29: ...28 3 Use a screwdriver to press in the pump piston and screw home the adjuster screw E See fig 4 page 28 4 Fit the cover plug G See fig 4 page 28 5 Fit the clip D See fig 4 page 28 6 Fit the oil pump...

Page 30: ...d for the actual speed and power output The mixing venturi B houses the choke throttle valve and diffuser jets Here air is mixed with the fuel to give a fuel air mixture that can be ignited by the ign...

Page 31: ...ser jets E F and G The throttle valve H is partly open In the idling mode fig 5 the throttle valve H is closed Air is sucked in through an aperture in the throttle valve and a small amount of fuel is...

Page 32: ...t and carefully remove the metering diaphragm F and gasket See fig 9 2 Remove the screw G and take out the needle valve H with lever spindle and spring See fig 9 3 Remove the cover I over the pump uni...

Page 33: ...Air can penetrate into the blood circulation which means mortal danger Direct the air through all channels in the carburettor housing and make sure that they are not blocked See fig 11 and 12 and che...

Page 34: ...springs Note Do not fully tighten the screws This will damage the seats and needle tips 3 Fit the fuel filter L by using the handle of a small screwdriver See fig 13 4 Fit the pump diaphragm K gasket...

Page 35: ...ump up the pressure to 50 kPa 0 5 bar and squeeze together the tube 5 No leakage is permitted If a leakage occurs refer to the table below Leakage at Fault with Diffuser jets Leakage in impulse tube V...

Page 36: ...a tachometer then the H jet should not be set to a leaner mixture than stated in the basic settings The recommended max overspeed must not be exceeded WARNING The bar chain and clutch cover must be f...

Page 37: ...ou have now run the chainsaw at H 0 H 1 4 and H 1 2 from the basic settings At full throttle the engine will have sounded different for each setting The H screw is set correctly when the chainsaw splu...

Page 38: ...If the chainsaw is fitted with hand grip heating dis connect the switch and leads 9 If the tank guard chain deflection break G is damaged it must be replaced See fig 2 10 If necessary lift out the fu...

Page 39: ...page 16 4 Lift the engine unit over the tank unit and push the fuel pipe and throttle cable into their holes in the bottom of the carburettor space 5 The vent for the fuel tank is placed on the right...

Page 40: ...Assembly 1 Remove the springs on the cylinder with a 4 mm Allen key See fig 1 2 Assemble the following parts Tank unit See page 39 Cylinder cover See the Operator Guide Chain and bar See the Operator...

Page 41: ...e fig 2 6 Remove one of the piston s circlips press out the gudgeon pin and remove the piston See fig 2 7 Remove the needle bearing from the connecting rod s little end 8 Unscrew the decompression val...

Page 42: ...eedle bearing is undamaged 7 That the intake manifold is undamaged 8 Pressure test the decompression valve as follows See also fig 5 A Connect tool 502 50 38 01 to the decompression valve B Pump up th...

Page 43: ...Compress the piston ring either by hand or with tool 502 50 70 01 See fig 10 Carefully fit on the cylinder 8 Guide up the cylinder base gasket with the four bolts C and tighten them alternately Tight...

Page 44: ...ifold See fig 13 Fit cover plate 502 71 39 01 with M6x20 mm on the exhaust port See fig 12 2 Connect tool 502 50 38 01 to the cover plate on the intake manifold See fig 14 The decompression valve shou...

Page 45: ...clutch See page 26 E Lubrication system See page 28 F Carburettor See page 30 G Muffler See page 17 H Piston and cylinder See page 41 I Tank unit See page 38 2 Remove the carburettor space bottom by...

Page 46: ...ck the following 1 That the big end bearing does not have any radial play Axial play is acceptable 2 That the big end bearing does not have any score marks or is discoloured on the sides See fig 7 3 T...

Page 47: ...es should be greased in When fitting the seal on the flywheels side use tool 502 50 30 17 The seal on the clutch side is fitted in the ball bearing See fig 10 The seals can also be fitted when the cra...

Page 48: ...bolts to 5 Nm 6 Assemble the following parts A Tank unit See page 38 B Piston and cylinder See page 41 C Muffler See page 17 D Carburettor See page 35 E Lubrication system See page 29 F Centrifugal cl...

Page 49: ...in the new seal with the drift pos 10 or 11 on page 6 and 7 See fig 16 4 Fit the parts in accordance with pos 1 above 16 1 5 Bar bolts 1 Drain off the chain oil 2 Tap in the old bar bolt from outside...

Page 50: ...www redmax com 115 96 37 26 2 4 2019...

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