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Table of Contents
Troubleshooting
Related Manuals for RedMax G9000
Summary of Contents for RedMax G9000
- Page 1 Workshop Manual G9000 English...
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Page 2: Table Of Contents
Workshop Manual G9000 Contents 9.1.1 Dismantling ................20 1 Introduction and safety regulations ........2 9.1.2 Cleaning and inspection ............20 1.1 General ......................2 9.1.3 Assembly ..................21 1.2 Safety ......................2 9.2 Stop switch .....................21 1.3 Target group ....................2 9.3 Hand grip heater and carburettor heater 385 ......22 9.3.1 Trouble shooting ..............22... -
Page 3: Introduction And Safety Regulations
Introduction and safety regulations 1 Introduction and safety regulations 1.1 General 1.6 Layout This Workshop Manual provides a comprehensive This Workshop Manual can be used in two different description of how to trouble shoot, repair and ways: test the chainsaw. A description of different safety •... -
Page 4: Numbering
Introduction and safety regulations 1.7 Numbering 1.9 Special instructions Position references to components inside the The fuel used in the chainsaw has the following haz- figures are designated A, and B, etc. The figures ardous properties: are number 1, 2 etc. The position references figure The fluid and its fumes are poisonous. -
Page 5: Symbols
Symbols 2 Symbols 2.1 Symbols On The Chainsaw 2.2 Symbols in this Workshop manual The following symbols are moulded into the chain- saw casing. This symbol indicates a risk of personal injury if instructions are Choke not followed. Switch for hand grip heater Fuel filler Stop switch Screw to adjust chain... -
Page 6: Technical Data
Technical data 3 Technical data / cubic inch Ø mm/Ø inch mm/inch kW/hp/ rpm G9000 88 cm /5.4 55mm/2.2" 3,7/1,5 4,8kW, 9600rpm Spark plug gap Ignition system Air gap n i / n i / G9000 0,5/0,02 FHP/CD 0.30mm/X Guide bar length Chain speed at max. - Page 7 Technical data Idling speed Engage speed Max. speed Spark plug G9000 Fuel tank volume Oil pump capacity Oil tank volume Automatic oil pump Litres/US pint /min Litres/US pint G9000 Weight without bar and chain Weight with bar and chain Hand grip heater...
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Page 8: Service Tools
Service tools 4 Service tools English – 8... - Page 9 Service tools Extractor Removing seal on fly- 502 50 The tools listed here are service tools intended wheel side 55-01 for use on the chainsaw in question. In addition to Feeler gauges, Adjustment of the ignition 502 51 these tools, a standard set of hand tools is required. air gap module 34-02...
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Page 10: Trouble Shooting
Trouble shooting 5 Trouble shooting 5.1 Trouble shooting chart The different faults that can occur on the chainsaw Idling (low speed) (continued) are divided into four groups as follows. Within each group possible operating faults are listed to the left Idles with closed Worn needle/needle tip while the probable fault alternatives are listed to the... -
Page 11: Trouble Shooting Methods
Trouble shooting High speed Acceleration and retardation Will not run at Adjust H-screw Does not accelerate Adjust the L-screw full Blocked air filter Adjust the H-screw throttle Tank ventilator blocked Blocked air filter Blocked fuel filter Tank ventilator blocked Blocked fuel line Blocked fuel filter Loose or faulty fuel pipe Blocked fuel line... -
Page 12: Service Data
Service data 6 Service data English – 12... - Page 13 Service data 13 – English...
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Page 14: Safety Equipment
Safety equipment 7 Safety equipment 7.1 Chain brake 7.1.1 Dismantling Dismantle the following parts first: • Chain and bar. See the Operator Guide. • Centrifugal clutch. See page 23. Push the hand guard forward so that the chain brake is on. See fig. 1. Remove the hand guard, two screws. -
Page 15: Inspection
Safety equipment 7.1.2 Inspection Clean and inspect all parts. The thickness of the brake strap must nowhere be less than 0.8 mm. See fig. 7. 7.1.3 Assembly Assemble the chain brake as follows: Fit the toggle joint and brake strap. See fig. 7. Grease the moving parts of the toggle joint (E) Fig. -
Page 16: Function Check
Safety equipment 7.1.4 Function check WARNING! After repair, the chain brake must be checked according to the following instructions. For this test, the engine must not be running. Check that the chain brake cuts in as follows: Hold the chain saw over a stable surface as shown in fig. -
Page 17: Muffler
Safety equipment 7.2 Muffler WARNING! Do not touch the muffler until it has cooled. Risk of burn injuries. 7.2.1 Dismantling Remove the two lower M5 bolts and the muffler’s two M6 bolts. See fig. 9 Remove the gasket and cooling plate. See fig. 9 If the saw is fitted with a spark-arrester, remove it. -
Page 18: Throttle Lock
Safety equipment 7.4 Throttle lock 7.4.1 Dismantling Remove the hand grip insert (C). See fig. 12. Remove the throttle lock pivot (A) with the help of a driver. See fig. 12. Press apart with a screwdriver or the like the throttle lock/control and take out the throttle lock from the recess in the hand grip. -
Page 19: Starter
Starter 8 Starter 8.1 Starter 8.1.1 Dismantling Remove the four bolts holding the starter to the crankcase and remove the starter. See fig. 1. Pull out the handle 20-30 cm and take out the cord from the slot in the starter pulley. See fig. 2. Rotate the starter pulley anticlockwise until the tension on the pulley is released. -
Page 20: Assembly
Starter 8.1.3 Assembly If a new spring is to fitted, place the new spring with steel wire so that the end loop comes over the peg (A) in starter pulley. See fig. 4. Press down the spring in the starter pulley and remove the wire. -
Page 21: Electrical System
Electrical system 9 Electrical system 9.1 Ignition system 9.1.1 Dismantling Remove the cylinder cover and starter unit. See page 16. Release the blue lead (A) (which connects to the stop button) from the ignition module (B). See fig. 1. Remove the ignition cable (C) from the spark plug and release both cables from the cable guide (D), and lift off the cable guide. -
Page 22: Assembly
Electrical system 9.1.3 Assembly Assemble the ignition system as follows: Fit the flywheel on the spindle. Turn it gently until the key on the flywheel mates with the recess in the shaft. Fit the flywheel washer and nut. Tighten the nut to 35 Nm. -
Page 23: Hand Grip Heater And Carburettor Heater 385
Electrical system 9.3 Hand grip heater and carburettor heater 385 Some chainsaws are fitted with hand grip heaters and carburettor heaters, and consist of the following parts: • Generator. • Switch. • Heating element in rear hand grip. • Front hand grip with heating element. •... -
Page 24: Replacing The Generator
Electrical system 9.3.2 Replacing the generator The following components must be removed before the generator can be replaced: A. Starter. See page 17. B. Flywheel. See page 19. Remove the bolts for the rear damper element (A) and the travel inhibiting bolts (B). See fig. 14. Remove the generator by unscrewing the three bolts. -
Page 25: Replacing The Heating Element In The Tank Unit
Electrical system 9.3.4 Replacing the heating element in the tank unit Remove the rear hand grip insert. See fig. 18. Remove the cable connections. See fig. 18. Fit the heating element and cable connections. Fig. 18 9.3.5 Replacing the front hand grip Release the two cable clips beside the spring. -
Page 26: Centrifugal Clutch
Centrifugal clutch 10 Centrifugal clutch 10.1 Centrifugal clutch 10.1.1 Dismantling When dismantling the centrifugal clutch the chain brake must be in the off position. Remove the cylinder cover, chain and bar. See the instruction book. Remove the chain guide plate by unscrewing the bolt (A). -
Page 27: Cleaning And Inspection
Centrifugal clutch 10.1.2 Cleaning and inspection Clean all components and check the following: The lining thickness on the clutch shoes must not be less than 3.5 mm at the most worn point. See fig. 5. To avoid imbalance all the clutch min 3.5 mm shoes should be replaced at the same time. -
Page 28: Lubrication System
Lubrication system 11 Lubrication system 11.1 Lubrication system WARNING! Insufficient lubrication of the chain can result in the chain breaking, which can cause serious or even life-threatening injury. Fig. 1 The lubrication system consists of the following parts: • Oil pump. •... -
Page 29: Cleaning And Inspection
Centrifugal clutch 11.1.2 Cleaning and inspection Clean all parts, including the pump and oil pipe mounts in the crankcase, and check the following: The taper on the adjuster screw (E) should not have any wear marks. See fig. 5. The eccentric face on the pump piston should not have any wear marks. -
Page 30: Carburettor
Caburettor 12 Carburettor 12.1 Carburettor WARNING! The fuel used in the chainsaw has then following hazardous properties: 1. The fluid and its fumes are poisonous. 2. Can cause skin irritation. 3. Is highly inflammable. 12.1.1 Description The drawings accompanying this description do not correspond with the carburettor on the chainsaw. - Page 31 Caburettor Function The carburettor operates differently in the following modes: • Cold start mode • Idling mode • Part throttle mode • Full throttle mode In the cold start mode (fig. 4) the choke valve (D) is fully closed. This increases the vacuum in the Fig.
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Page 32: Dismantling
Carburettor 12.1.2 Dismantling WARNING! The fuel used in the chainsaw has then following hazardous properties: 1. The fluid and its fumes are poisonous. 2. Can cause skin irritation. 3. Is highly inflammable. Dismantling Remove the cylinder cover and air filter. Remove the carburettor control (A) by pushing it towards the carburettor and lifting. -
Page 33: Cleaning And Inspection
Carburettor 12.1.3 Cleaning and inspection Direct the air through all channels in the carburettor housing and make sure that they are not blocked. WARNING! See fig. 11 and 12 and check the following: That gaskets, pump and control diaphragms are The fuel used in the chainsaw has undamaged. -
Page 34: Assembly
Carburettor 12.1.4 Assembly Where no figure is referred to, see exploded dia- gram 12 on the previous page. Maintain a high level of cleanliness when assem- bling the carburettor. The slightest contamination can result in running problems. If the throttle and choke valves, together with levers and springs were removed, they should be refitted. - Page 35 Carburettor Pressure testing Pressure testing should be carried out with the car- burettor fully assembled. Testing should always be carried out after the carburettor has been repaired, but it can also be carried out as trouble shooting before dismantling the carburettor. See fig. 17 and carry out the test as follows: Unscrew the high and low speed screws one turn from home position.
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Page 36: Adjustment
Carburettor 12.1.5 Adjustment WARNING! The bar, chain and clutch cover must be fitted before the chainsaw is started, otherwise the clutch can work loose and cause personal injury. WARNING! Wear ear-muffs when making adjustments with the engine running. Adjusting the carburettor means adapting the engine to local conditions, e.g. - Page 37 Carburettor Low speed jet L Find the highest idling speed by slowly turning the low speed screw clockwise then anticlockwise. + 1/4 When the highest speed has been found, turn the L-screw anticlockwise 1/8 - 1/4 of a turn. NOTE! If the chain goes round at idling speed the T-screw should be turned anticlockwise until it stops.
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Page 38: Tank Unit
Tank unit 13 Tank unit 13.1 Tank unit WARNING! The fuel used in the chainsaw has then following hazardous properties: 1. The fluid and its fumes are poisonous. 2. Can cause skin irritation. 3. Is highly inflammable. 13.1.1 Dismantling Fig. 1 Drain off the fuel from the tank. -
Page 39: Cleaning And Inspection
Tank unit 13.1.2 Cleaning and inspection Clean all parts and check that the fuel pipe is intact. 13.1.3 Assembly 1. If the chainsaw is fitted with hand grip heating, fit the heating element if it has been removed. See page 21 and 23. 2. -
Page 40: Anti-Vibration System
Anti-vibration system 14 Anti-vibration system 14.1Anti-vibration system WARNING! The fuel used in the chainsaw has then following hazardous properties: 1. The fluid and its fumes are poisonous. 2. Can cause skin irritation. 3. Is highly inflammable. 14.1.1 Dismantling Dismantle the following parts: Fig. -
Page 41: Piston And Cylinder
Piston and cylinder 15 Piston and cylinder 15.1 Piston and Cylinder 15.1.1 Dismantling Dismantle the following parts: • Cylinder cover. • Spark plug. • Carburettor. See page 30. • Muffler. See page 17. Unscrew the anti-vibration spring (B) from the cylinder. -
Page 42: Faults And Causes
Piston and cylinder Check the following: That the cylinder’s surface coating is not worn. Especially in the upper part of the cylinder. See fig. 3. 2. That the cylinder is free of score marks. Max. 1 mm That the piston is free of score marks. Minor scratches can be polished off with fine emery paper. -
Page 43: Assembly
Piston and cylinder 15.1.4 Assembly Assembly of the piston and cylinder is carried out as follows: NOTE! Exercise care so that dirt and foreign particles do not get into the crankcase. Lubricate the needle bearing and fit it in the connecting rod’s little-end. - Page 44 Piston and cylinder Pressure testing The following parts must be removed to pressure test the crankcase and cylinder: • Carburettor. See page 32. • Muffler. See page 17. Carry out pressure testing as follows: Remove the support ring in the intake manifold. Fit cover plate 502 54 05-01 with M4x15 mm bolt on the intake manifold.
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Page 45: Crankcase And Crankshaft
Crankcase and crankshaft 16 Crankcase and crankshaft This section deals with the following: • Crankcase and crankshaft (describes how the whole assembly is dismantled and reas- sembled) • Seals (describes only replacement of seals) • Bar bolts (describes only replacement of bar bolts) 16.1 Crankcase and crankshaft 16.1.1 Dismantling... -
Page 46: Cleaning And Inspections
Crankcase and crankshaft WARNING! The crankcase halves are hot and can cause burn injuries. Wear protective gloves. Do as follows: A Remove the oil filler cap. B Heat the relevant crankcase half to 200°C. C. Use protective gloves and press the bearing out from the crankcase half. -
Page 47: Assembly
Crankcase and crankshaft 16.1.3 Assembly Fit the crankcase and crankshaft as follows: WARNING! The crankcase halves are hot and can cause burn injuries. Wear protective gloves. If bearings are to be fitted, do as follows: A Heat the relevant crankcase half to 200°C. B. - Page 48 Crankcase and crankshaft Place the guide pegs in the clutch side’s crankcase half, and grease in and insert the gasket. See fig. 12. NOTE! Continuing to pull with the assembly tool after the gasket is clamped will damage the crankshaft. Use tool 502 50 30-17 and pull on the flywheel side’s crankcase half.
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Page 49: Seals
Crankcase and crankshaft 16.1.4 Seals To replace the seals on the crank shaft, remove the following parts first: On the flywheel side: • Starter. See page 19. • Flywheel. See page 21. • Generator, where appropriate. See page 22. On the clutch side: •... - Page 50 115 96 37-26 2/4/2019...