RedMax GZ3500T Workshop Manual
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RedMax GZ3500T Workshop Manual

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Workshop Manual
GZ3500T
English

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  • Page 1 Workshop Manual GZ3500T English...

  • Page 3: Table Of Contents

    List of contents Workshop Manual GZ3500T List of contents Index ....................4 Introduction and safety regulations ........6 Technical data ................10 Service tools ................12 Service data ..................14 Safety equipment ..............16 Repair instructions ..............26 Carburettor ..................35 Trouble shooting ...............53 Husqvarna AB has a policy of continuous product development and therefore reserves the right to modify the design and appearance of products without prior notice.

  • Page 4: Index

    Index Index Numbering 7 Safety 7 Carburettor 35 Special instructions 8 Adjusting the carburettor 43 Structure 7 Assembly 39 Symbols in the Workshop Manual 9 Cleaning and checking 39 Symbols on the saw 9 Design 35 Target group 7 Dismantling 37 Tools 7 Function 35 Pressure testing the carburettor 41...
  • Page 5 Index Tank unit 46 Dismantling 46 Technical data 10 Throttle lockout, throttle and spring 23 Assembling the throttle lockout, throttle and spring 24 Cleaning and checking 23 Dismantling the throttle lockout, throttle and spring 23 Trouble shooting 54 Trouble shooting techniques 55 Vibrating damping system 48 Assembly 48 Cleaning and checking 48...

  • Page 6: Introduction And Safety Regulations

    Introduction and safety regulations 2 Introduction and safety regulations List of contents General information ..............................7 Safety .....................................7 Target group ................................7 Modifications ................................7 Tools ....................................7 Structure ..................................7 Numbering ..................................7 General instructions ..............................8 Special instructions ..............................8 2.10 Symbols on the saw ..............................9 2.11 Symbols in the Workshop Manual ........................9 –...
  • Page 7 Introduction and safety regulations 2 Introduction and safety regulations 2.1 General information 2.6 Structure This Workshop Manual provides a comprehensive This Workshop Manual can be used in two diffe- description of how to trouble shoot, repair and rent ways: test the chain saw. A description of different safety measures that should be taken during repair work •...
  • Page 8 Introduction and safety regulations 2.8 General instructions 2.9 Special instructions The workshop where the chain saw is to be repai- The fuel used for the chain saw has the following red must be equipped with safety equipment in hazardous properties: accordance with local regulations.
  • Page 9 Introduction and safety regulations 2.10 Symbols on the saw 2.11 Symbols in the Workshop Manual The symbols below are embedded in the chain saw. This symbol warns of personal injury Choke control when the instructions are not followed. Refuelling Stop button Filling up saw chain oil English –...

  • Page 10: Technical Data

    3 Technical data Displacement Cylinder diameter Length of stroke Max. output/speed /cubic inch Ømm/Øinch mm/inches kW/hp/rpm GZ3500T 35.235 / 2.15 40 / 1.57 28 / 1.10 1.5 / 2.0 / 9,500 Electrode gap Ignition system Air gap Carburettor type mm/inches...
  • Page 11 Technical data Idle speed Engage speed Spark plug GZ3500T 2,900 3,800 NGK CMR 7H Volume fuel tank Capacity oil pump at Volume oil tank Automatic oil pump Litres/US.pint 9,500 rpm, Litres/US.pint ml/min GZ3500T 0.26 / 0.55 0.17 / 0.36 Weight without bar and chain...

  • Page 12: Service Tools

    Service tools 4 Service tools – English...
  • Page 13 Service tools Pos. Description Used for Order No. Piston stop Locking the crankshaft 521 34 51-01 Hook for fuel filter Lifting out the fuel filter 502 50 83-01 Screwdriver Carburettor adjustment 516 84 79-01 Combination spanner For torx screws 516 97 42-01 Pressure tester Pressure testing the cylinder 503 84 40-03...

  • Page 14: Service Data

    Service data 5 Service data The numbers by the components to be assembled with screws state the tightening torque in Nm. s = Lubricate with two-stroke oil. n = Lubricate with engine oil. l = Lubricate with grease. q = Glued using 2 component adhesive. m = Sealed with silicone.
  • Page 15 Service data English –...

  • Page 16: Safety Equipment

    Safety equipment 6 Safety equipment List of contents Dismantling the chain brake ..........................17 Assembling the chain brake ..........................18 Dismantling the muffler ............................20 Assembling the muffler ............................20 Replacing the chain catcher ..........................20 Dismantling the start/stop switch ........................21 Assembling the start/stop control ........................21 Resistance test - stop function ..........................22 Dismantling the throttle lockout, throttle and spring .................23 6.10 Assembling the throttle lockout, throttle and spring .................24...

  • Page 17: Safety Equipment

    Safety equipment 6 Safety equipment 6.1 Dismantling the chain brake Release the brake by moving the kickback guard backwards. Loosen the bar nut and remove the clutch cover, chain and bar. Fig 1 Release the brake by pushing the kickback guard forwards.

  • Page 18: Assembling The Chain Brake

    Safety equipment Loosen the nut E, washer D, spring C, sleeve B and screw A. To remove the knee joint G and H, use a punch to press out the pin F. Pull out the pin J to loosen the brake band K and knee joint H, see figure 7.
  • Page 19 Safety equipment Insert the screwdriver into the end of the spring and press the spring together while pushing it down with the finger. Fig 11 Hold the spring in place with your finger and remove the screwdriver. Insert the screwdriver straight from above and press down until the spring catches against the cut-out edge.

  • Page 20: Dismantling The Muffler

    Safety equipment 6.3. Dismantling the muffler WARNING! Do not touch the muffler before it has cooled down. Risk of burns. Release the brake by moving the kickback guard backwards. Loosen the bar nut and remove the clutch cover, chain and bar. Fig 16 Loosen screws 1 and 2, see figure 17.

  • Page 21: Dismantling The Start/Stop Switch

    Safety equipment 6.6 Dismantling the start/stop switch Bend the start/stop switch loose with a screwdriver, see figure 22. Check that the start/stop switch is intact. Cleaning and checking Fig 22 Clean and check carefully all components. If there are cracks or other defects, these details should be replaced with new ones.

  • Page 22: Resistance Test - Stop Function

    Safety equipment 6.8 Resistance test - stop function Remove the starter, see “Dismantling the starter”. Remove the cold air wire. Fig 25 Clean the contact areas and check the resistance as follows: Test the resistance by connecting a multimeter to the ignition coil.

  • Page 23: Dismantling The Throttle Lockout, Throttle And Spring

    Safety equipment 6.9 Dismantling the throttle lockout, throttle and spring Unscrew the air filter housing, the air filter holder and the filter. Dismantle the handle part by loo- sening screws A. Remove the throttle lockout B. Remove the throttle C and the spring D. Loosen the carburettor screw E.

  • Page 24: Assembling The Throttle Lockout, Throttle And Spring

    Safety equipment 6.10 Assembling the throttle lockout, throttle and spring Put the electrical cables J back in the cable slot as shown in figure 32. Fig 32 Insert the throttle actuator rod into the carburettor. Fig 33 Fold the throttle actuator rod forwards so that it can be placed in the handle part.
  • Page 25 Safety equipment Hook the throttle actuator rod E to the throttle, put the spring back onto the throttle. Place the throttle and the spring in the handle part as shown in figure 36. Refit the electrical cables H in the slot as shown in figure 36.

  • Page 26: Repair Instructions

    Repair instructions 7 Repair instructions List of contents Dismantling the starter ............................27 Changing a broken or worn starter cord ......................28 Loading the return spring ............................28 Replacing a broken return spring ........................29 Assembling the starter ............................29 Testing the ignition module ..........................29 Dismantling the ignition module and flywheel .....................30 Assembling the ignition module and flywheel ....................31 Dismantling the centrifugal clutch ........................32...

  • Page 27: Repair Instructions

    Repair instructions 7 Repair instructions 7.1 Dismantling the starter Loosen the starter with the screws A, B and C (four screws). Fig 1 Pull the cord out about 30 cm and lift it into the notch on the starter pulley’s outer edge. Release the tension in the return spring by allowing the star- ter pulley to rotate slowly backwards, see figures 2 and 3.

  • Page 28: Changing A Broken Or Worn Starter Cord

    Repair instructions 7.2 Changing a broken or worn starter cord When the starter cord is worn and must be replaced, the tension in the return spring must be released. Pull the cord out about 30 cm and lift it into the notch on the outside of the starter pulley.

  • Page 29: Replacing A Broken Return Spring

    Repair instructions 7.4 Replacing a broken return spring WARNING! Exercise care to ensure the spring does not fly out and causes perso- nal injury. Wear protective goggles. Undo the screw in the centre of the pulley and remove the pulley and spring. Remove the broken return spring and replace it with a new one.

  • Page 30: Dismantling The Ignition Module And Flywheel

    Repair instructions 7.7 Dismantling the ignition module and flywheel Loosen the starter with the screws A and B (four screws). Fig 9 Loosen the screws D and remove the entire igni- tion module. Remove the spacers between the cylinder and the ignition coil, see figure 11. Loosen the electrical cable E and the earthing cable F from the ignition module C.

  • Page 31: Assembling The Ignition Module And Flywheel

    Repair instructions 7.8 Assembling the ignition module and the flywheel Fit the flywheel onto the crankshaft journal. Turn the flywheel until the key goes into the keyway on the shaft. Fit the nut H, tightening torque 20-25 Nm, see figure Fig 14 The ignition module must be fitted as follows: Turn the flywheel so that the magnets are positioned...

  • Page 32: Dismantling The Centrifugal Clutch

    Repair instructions 7.9 Dismantling the centrifugal clutch Release the brake by moving the kickback guard backwards. Loosen the bar nut and remove the clutch cover, chain and bar. Fig 17 Unscrew the spark plug and put in piston stop A. Fig 18 Loosen the clutch using a suitable socket spanner or combination spanner.

  • Page 33: Assembling The Centrifugal Clutch

    Repair instructions 7.10 Assembling the centrifugal clutch Hook the springs into the clutch shoes. Press in the clutch hub from above while bending back the clutch shoes around the clutch hub as shown in figures 23 and 24. Fig 23 Fit the clutch by turning it counter clockwise.

  • Page 34: Assembling The Oil Pump And Screen

    Repair instructions Use pliers with a shrinkable tube in order to loosen hose H so that nozzle E can be loosened. See fi- gures 28 and 30. Note! Figure 30 shows the inside without tank unit. If you experience problems loosening the hose, dismantle the tank unit, see chapter ”Dismantling the tank unit”.

  • Page 35: Carburettor

    Repair instructions 7.13 Carburettor WARNING! The fuel used for the chain saw has the following characteristics: 1. The liquid and its fumes are poi- sonous. 2. Can cause skin irritation. 3. Is very flammable. Description The images for this description do not correspond to the carburettor on the chain saw.
  • Page 36 Repair instructions Function The carburettor functions differently in the following modes: Cold start mode In cold start mode the choke valve D is completely shut. This increases the vacuum in the carburettor and fuel is easier to suck from all the diffuser jets E, F and G.
  • Page 37 Repair instructions Dismantling the carburettor Unscrew the air filter housing, the air filter holder and the filter. Dismantle the handle part by loose- ning screws A. Remove the throttle lockout B. Remove throttle C and spring D. Loosen carburet- tor screw E. Remove guide F, see figure 40. Fig 40 Remove the carburettor and remove the cover for choke outlet H.
  • Page 38 Repair instructions Dismantle the pump cover Q and carefully remove the membrane N with gasket P. Dismantle valve housing S and lever arm T with accompanying details. Unscrew screws A and lift off cover B and carefully remove gasket D and control diaphragm C. Unscrew screw J and remove needle valve G with lever arm F, shaft E and spring H.
  • Page 39 Repair instructions Cleaning and checking That the needle valve G and its lever arm F are not worn, see figure 43. Clean all units in clean petrol. That the fuel screen M is intact and clean, see Use compressed air to dry the petrol on the compo- figure 43.
  • Page 40 Repair instructions Assemble control diaphragm C, gasket D, cover B and tighten screw A. Assemble the valve housing S and lever arm T with accompanying details. Do a pressure test. Fig 47 – English...
  • Page 41 Repair instructions Pressure testing the carburettor Pressure testing should be carried out with the car- burettor fully assembled. The test shall always be done after the carburettor has been repaired, but can also be carried out as trouble shooting before the carburettor is taken apart.
  • Page 42 Repair instructions Assemble on the saw Refit the cables H into the cable slot as shown in figure 49. Fig 49 Insert the throttle actuator rod K into the carburet- tor, and fit the fuel hose J as shown in figure 50. Fig 50 Fold the throttle actuator rod K forwards so that it can be placed in the handle part.
  • Page 43 Repair instructions Adjusting the carburettor Conditions during adjustment • Before any adjustments are made the air filter should be clean and the air filter cover fitted. Note! Adjusting the carburettor with a dirty air filter will give a too lean fuel mixture the next time the air filter is cleaned.

  • Page 44: Dismantling The Intake System

    Repair instructions 7.14 Dismantling the intake system Dismantle: • clutch cover • air filter housing • air filter • air filter holder • handle cover • carburettor Fig 55 Dismantle the vibration elements from the tank unit as shown in figures 55 and 56. Fig 56 Gently press out the inlet bellows A, B and the air intake bellows C, see figure 57.

  • Page 45: Assembling The Intake System

    Repair instructions 7.15 Assembling the intake system Tighten the inlet bellows. Make sure the nipple D is attached to the pump hose, see figure 60. Fig 60 Press the fuel intake together on the inlet bellows E and thread on the fitting cone F, see figure 61. Fig 61 Refit the tank unit.

  • Page 46: Dismantling The Tank Unit

    Repair instructions 7.16 Dismantling the tank unit WARNING! The fuel used for the chain saw has the following hazardous properties: The liquid and its fumes are poisonous. Can cause skin irritation. Is very flammable. When dismantling the tank unit, see chapter ”Dismant- ling the intake system”...

  • Page 47: Replacing The Fuel Filter

    Repair instructions 7.18 Replacing the fuel filter NOTE! Fluted pliers may not be used with the fuel hose. They can cause material damage resulting in damage to the fuel hose. When replacing the fuel filter, the old fuel filter must be taken out of the tank unit using special tool 502 50 83-01.

  • Page 48: Vibration Damping System

    Repair instructions 7.22 Vibration damping system Dismantling Dismantle the following parts: • Chain and bar, see the operator’ s manual. • Handle unit. Dismantle the springs as shown in figures 70, 71 and 72. Cleaning and checking Clean and inspect all parts. Fig 70 Assembly Assemble the springs as shown in figures 70,...
  • Page 49 Repair instructions Loosen the heat shield A, see figure 74. Fig 74 Loosen the four screws as shown in figures 75 and Fig 75 Fig 76 Remove the cylinder cover, see figure 77. Lift out the engine body. Fig 77 Screw apart the crankcase half and the cylinder.
  • Page 50 Repair instructions Remove the seals and the circlip. Carefully pull out piston and crankshaft. Cover with paper over the cylinder opening to prevent dirt from coming in. Fig 79 Carefully loosen the circlips D, see figures 80 and 81, with a small screwdriver. Fig 80 Press out the gudgeon pin E.

  • Page 51: Assembling The Piston And Cylinder

    Repair instructions Faults and causes Cutting marks on the piston (H) Wrong carburettor setting. Too high fast idle speed. Too low octane number of petrol. Too low or incorrect oil in the fuel. Carbon deposits (J) Wrong carburettor setting. Too low fast idle Fig 84 speed.

  • Page 52: Dismantling The Crankcase And Crankshaft

    Repair instructions 7.25 Dismantling the crankcase and crankshaft See chapter “Dismantling the piston and cylinder”. 7.26 Replacing the crankshaft bearing Remove: • the crankshaft completely from the crankcase. Pull out the crankshaft bearing from the crankshaft, see figure 88. Fig 88 Fit the new bearing on the crankshaft using tool 502 50 30-18, see figure 89.

  • Page 53: Trouble Shooting

    Trouble shooting 8 Trouble shooting List of contents Trouble shooting ...............................54 Trouble shooting techniques ..........................55 English –...
  • Page 54 Trouble shooting 8.1 Trouble shooting The different faults which may occur on the chain saw are divided into four groups. Within each group possible operating faults are listed to the left while the probable fault alternatives are listed to the right. The most likely fault is listed first, etc.
  • Page 55 Trouble shooting High speed Acceleration and retardation Does not Does not run Adjust the H-screw Adjust the L-screw accelerate at full throttle Adjust the H-screw Blocked air filter Blocked air filter Tank venting clogged Tank venting clogged The fuel filter is clogged The fuel filter is clogged The fuel hose is clogged The fuel hose is clogged...
  • Page 56 115 96 89-26 3/4/2019...

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