Hitachi CS 51EAP Service Manual
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Hitachi CS 51EAP Service Manual

Engine chain saw
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PRODUCT NAME
Hitachi Engine Chain Saw
CS 51EAP
Models
CS 51EA
CONTENTS
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
LIST Nos.
CS 51EAP: F009
CS 51EA: F008
Feb. 2012
Page
International Sales Division

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Summary of Contents for Hitachi CS 51EAP

  • Page 1 LIST Nos. CS 51EAP: F009 CS 51EA: F008 Feb. 2012 PRODUCT NAME Hitachi Engine Chain Saw CS 51EAP Models CS 51EA CONTENTS Page TROUBLESHOOTING GUIDE ---------------------------------------------------------------------------------------------- 1 1. Troubleshooting and correction ------------------------------------------------------------------------------- 1 REPAIR GUIDE ----------------------------------------------------------------------------------------------------------------- 3 1. Precaution on maintenance, inspection and repair ------------------------------------------------------ 3 2.

  • Page 2: Troubleshooting Guide

    TROUBLESHOOTING GUIDE 1. Troubleshooting and correction Trouble Cause Corrective action Faulty piston ring Seized piston and cylinder The crank shaft does Disassembly and parts Starter Faulty crank shaft bearings not rotate. replacement handle Magneto rotor contact with cannot be ignition coil pulled.
  • Page 3 Trouble Cause Corrective action Clogged fuel filter Cleaning or replacement Insufficient warm-up Warm-up The engine stalls. Poorly adjusted carburetor ass’y Adjustment Starts, but Clogged cylinder vent passage, when exhaust port and/or accelerating Cleaning carbon-clogged muffler … Poor acceleration; no Clogged air cleaner increase in revolutions Chain brake set on Release...

  • Page 4: Repair Guide

    • 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 CS 51EAP CS 51EA Item Idling revolutions 3,000 ± 200 min (rev./min.)

  • Page 5: Repair Flow Chart

    Repair flowchart Seized or broken piston ring Replacement Pull the starter handle. Is pulling possible? Seized piston or cylinder Replacement Seized or broken needle bearing of the crank Replacement shaft Impossible to pull Seized ball bearing Replacement Magneto rotor contact with ignition coil Adjustment Broken recoil starter Inspection/replacement...
  • Page 6 Dirty or faulty spark plug Cleaning/replacement Starts up, and when idling Defective air gap Adjustment mode is set… Worn piston ring Replacement The engine stalls Expired oil seal service life Replacement Defective decompression valve Cleaning/replacement Revolutions too low for idling Adjustment Poorly adjusted carburetor ass’y Adjustment...
  • Page 7 Inspection and repair procedures [Bold] numbers in the descriptions below correspond to item numbers in the Parts List and exploded assembly diagram for the Models CS 51EAP and CS 51EA. Always stop the engine prior to disassembly or when replacing the saw chain.

  • Page 8: Disassembly And Reassembly

    Disassembly and reassembly 1. Disassembly and reassembly of the cleaner and carburetor [Tools required] Phillips screwdriver Hex. bar wrench (4mm) (1) Disassembly Loosen the Cleaner Knob [6] and remove the Cleaner Cover [2]. Use a Phillips screwdriver to loosen the three Cover Set Bolts [4], and then remove the Cylinder Cover [5]. Pull out Cleaner Element (A) [9] and Cleaner Element (B) [8].

  • Page 9: Connecting The Fuel Pipes

    2. Connecting the fuel pipes Make the connections as shown in the illustration below. (1) Fully insert the pipes down to their roots. (2) Do not bend or twist the pipes. (3) Be careful not to get pipes in the respective portions caught in other parts. (4) The end faces of the Fuel Pipe 2.5 x 4 x 90 [43] and Fuel Pipe [68] should protrude from the edge of the Fuel Grommet [152] by 55 to 60 mm and 167 to 172 mm, respectively.
  • Page 10 3. Disassembly and reassembly of the recoil starter [Tool required] Phillips screwdriver (1) Disassembly Pull out the Plug Cap [162] from the Spark Plug [46]. Use a Phillips screwdriver to loosen the four Cover Set Bolts [4], and then remove the Recoil Starter [176] and Air Deflector [175].
  • Page 11 4. Disassembly and reassembly of the rear handle and engine case [Tools required] Flat-blade screwdriver Assembling the antivibration structure of coil spring Box end wrench 10 x 19 mm The Antivibration Springs [157] [14] should not protrude from this surface of the Spring Holders [155] [12]. (1) Disassembly Remove the Fuel Pipe 2.5 x 4 x 90 [43] from the Spring Holders [155] [12]...
  • Page 12 Before mounting the Clutch [131], degrease the female threads of the Clutch [131] and the threads of the Crank Shaft [83]. Use the Hitachi 14.4V impact driver to tighten the Clutch [131] for about one second, in order to obtain the specified torque.
  • Page 13 Mounting the clutch washer Clutch Housing [133] Needle Bearing [134] Place the Clutch Washer [136] on the protrusion Crank Shaft [83] Clutch [131] of the Worm [138] before assembly. Clutch Washer [136] Worm [138] Worm [138] Clutch Washer (B) [132] Protrusions Rim Sprocket [135] Clutch Washer [136]...
  • Page 14 Magneto rotor Magneto Rotor [169] Starter Pawl Spring [170] Washer 0.8 [171] Starter Pawl [172] Shim [173] Step Bolt [174] Crank Shaft [83] Flange Nut M8 [112] 7. Adjustment of clearance between the magneto rotor and ignition coil (1) Loosen the Hex. Socket Hd. Bolt (W/Flange) M4 x 18 [167] so as to temporarily secure Adjustment of clearance between the magneto rotor and the Ignition Coil [166].

  • Page 15: Wiring Diagram

    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”...
  • Page 16 9. Disassembly and reassembly of the muffler [Tools required] Hex. bar wrenches (3 mm, 4 mm and 5 mm) Flat-blade screwdriver (1) Disassembly Use a flat-blade screwdriver to remove the two Muffler Caps [36]. Use a 5-mm hex. bar wrench to remove the two Seal Lock Hex.
  • Page 17 10. Disassembly and reassembly of the cylinder and scavenging cover [Tools required] Hex. bar wrenches (4 mm and 5 mm) Phillips screwdriver Socket wrenches (13 mm and 19 mm) (1) Disassembly Use a 19-mm socket wrench to remove Spark Plug BPM-7A/BPMR7A [46]. Use a 5-mm hex.
  • Page 18 • Cylinder and scavenging cover Carburetor Insulator (C51) [50] Cab. Insulator Rubber [49] Spark Plug BPM-7A/BPMR7A [46] Hex. Socket Hd. Bolt M5 x 12 (Precote) [38] Seal Lock Screw M4 x 10 [16] Decomp. [45] Lip portion Intake (CS51) [48] Intake Packing (C51) [47] Scavenging Cover (B) [17] Seal Lock Hex.
  • Page 19 Insert the Piston Pin [85] by following the procedure below. (See “Mounting the piston.”) (1) Insert the Piston Pin [85] into the Piston (44) (M) [77] by about 7 mm. CAUTION: Be sure to support the flat portion (casting surface) of the Piston (44) (M) [77] when using a hand press.
  • Page 20 12. Disassembly and reassembly of the engine case [Tools required] Hex. bar wrench (5 mm) Phillips screwdriver Long-nose pliers (1) Disassembly Use long-nose pliers to pull out the Rear Damper (C51) [88]. Use a Phillips screwdriver to remove the two Seal Lock Screws M5 x 12 [33], and then remove the Spike [34]. CAUTION: The threads of the Seal Lock Screws M5 x 12 [33] may be easily broken.
  • Page 21 13. Disassembly and reassembly of the side case [Tool required] Phillips screwdriver (1) Disassembly Remove Flange Nut M8 [112] and remove the side case from the main body. With the Brake Link [126] being held in a vise, push it down to apply the brake. Use a Phillips screwdriver to remove the six Seal Lock Screws M4 x 10 [16].

  • Page 22: Tightening Torque

    Tightening torque Unit: N•m {kgf•cm} Location Quantity Part name Tightening torque Recoil Recoil Starter [176] Cover Set Bolt [4] 2.7 to 3.2 {28 to 33} starter Hex. Socket Hd. Bolt (W/Flange) M4 x 18 Ignition Coil [166] 3.0 to 4.0 {31 to 41} [167] Electrical Spark Plug...

  • Page 23: Confirmation After Reassembly

    Confirmation after reassembly 1. Check the following before starting the engine. Confirm that the crank shaft rotates and there is compression when pulling the starter handle. Turn on (push) the decompression valve and confirm that the starter handle can be pulled lightly. Perform priming ten times and then confirm that the priming pump is full of fuel.
  • Page 24 LIST NO. F009 ENGINE ENGINE CHAIN SAW 2012 · 2 · 2 Model CS 51EAP (E2)
  • Page 25 CS 51EAP - 2 - 2 - 12...
  • Page 26 PARTS CS 51EAP ITEM ITEM CODE NO. CODE NO. DESCRIPTION REMARKS USED USED 669-8919 START LABEL (C51) (EX) 669-8568 CLEANER COVER (C51) 669-8569 SHUTTER PLATE 669-6903 COVER SET BOLT 669-8708 CYLINDER COVER (C51) 669-8595 CLEANER KNOB (VERMILION) 669-8596 CLEANER KNOB (GREEN)
  • Page 27 PARTS CS 51EAP ITEM ITEM CODE NO. CODE NO. DESCRIPTION REMARKS USED 669-8551 CAB. INSULATOR RUBBER 669-8552 CARBURETOR INSULATOR (C51) 669-8907 FUEL PIPE (FKM) 669-8705 CARBURETOR ASS'Y INCLUD. 53-67 668-5210 SCREW 668-5212 PUMP GASKET 668-5213 PUMP DIAPHRAGM 668-4700 INLET SCREEN...
  • Page 28 PARTS CS 51EAP ITEM CODE NO. DESCRIPTION REMARKS USED NAME PLATE 669-8581 FLANGE NUT M8 669-8585 SIDE CASE SUB 669-8586 SIDE CASE SUB FOR USA, CAN 669-8591 CHAIN PULLER BOLT 668-7270 SAW CHAIN 13 INCH EXCEPT FOR USA, CAN 668-7335 SAW CHAIN 15 INCH...

  • Page 29: Standard Accessories

    PARTS CS 51EAP ITEM CODE NO. DESCRIPTION REMARKS USED 669-8580 AIR VALVE CAP 668-5351 INNER CAP 669-6167 FUEL GROMMET 669-2285 PUMP FILTER BODY 669-6873 FRONT DAMPER 669-8409 SPRING HOLDER 669-6872 FLANGED TAPPING SCREW D6 669-8408 ANTIVIBRATION SPRING 669-8921 TANK MARK LABEL (50:1)
  • Page 30 LIST NO. F008 ENGINE ENGINE CHAIN SAW 2012 · 2 · 2 Model CS 51EA (E2)
  • Page 31 CS 51EA - 2 - 2 - 12...
  • Page 32 PARTS CS 51EA ITEM ITEM CODE NO. CODE NO. DESCRIPTION REMARKS USED USED 669-8919 START LABEL (C51) (EX) 669-8568 CLEANER COVER (C51) 669-8569 SHUTTER PLATE 669-6903 COVER SET BOLT 669-8708 CYLINDER COVER (C51) 669-8595 CLEANER KNOB (VERMILION) 669-8570 KNOB PACKING 669-8563 CLEANER ELEMENT (B) 669-8562 CLEANER ELEMENT (A) 669-8449 NUT M6...
  • Page 33 PARTS CS 51EA ITEM ITEM CODE NO. CODE NO. DESCRIPTION REMARKS USED 669-8552 CARBURETOR INSULATOR (C51) 669-8907 FUEL PIPE (FKM) 669-8705 CARBURETOR ASS'Y INCLUD. 53-67 668-5210 SCREW 668-5212 PUMP GASKET 668-5213 PUMP DIAPHRAGM 668-4700 INLET SCREEN 668-5215 NEEDLE VALVE 669-0873 VALVE SPRING 668-5220 DIAPHRAGM PACKING-METERING 668-4690 METERING DIAPHRAGM 668-5222 DIAPHRAGM COVER-METERING...
  • Page 34 PARTS CS 51EA ITEM CODE NO. DESCRIPTION REMARKS USED 669-8591 CHAIN PULLER BOLT 668-7270 SAW CHAIN 13 INCH 668-7335 SAW CHAIN 15 INCH 668-7296 SAW CHAIN 16 INCH 668-7284 SAW CHAIN 18 INCH 669-8710 SAW CHAIN 20 INCH 0.325 669-8592 GUIDE PLATE (B) 669-6911 CHAIN BAR 13 INCH 669-6912 CHAIN BAR 15 INCH 669-6983 CHAIN BAR 16 INCH...
  • Page 35 669-8543 MAGNETO ROTOR 669-8417 STARTER PAWL SPRING 669-6857 WASHER 0.8 669-6877 STARTER PAWL 669-6434 SHIM 669-6878 STEP BOLT 669-8571 AIR DEFLECTOR 669-8583 RECOIL STARTER HITACHI LABEL STANDARD ACCESSORIES ITEM CODE NO. DESCRIPTION REMARKS USED 668-5439 CHAIN COVER 14" FOR 13", 15" CHAIN BAR 669-6909 CHAIN COVER 16"...

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