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EMAK 63.4 cm3 Workshop Manual
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EMAK 63.4 cm3 Workshop Manual

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WORKSHOP MANUAL
63,4 cm³ chainsaws

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Summary of Contents for EMAK 63.4 cm3

  • Page 1 WORKSHOP MANUAL 63,4 cm³ chainsaws...
  • Page 2 General failures’ analysis 63,4 cm³ chainsaws...

  • Page 3: Suggested Tools

    General failures’ analysis Suggested tools Emak tool kit Compression tester: to check thermal group III. Electronic tachometer: for 2 and 4 stroke engines, measurement range from 100 to 30,000 RPM p/n 3055125 III. p/n 001000785 p/n 001000392A 63,4 cm³ chainsaws...
  • Page 4 General failures’ analysis Index 1) Performance Oil pump, bar and shock absorber Compression test Oil tank breather inspection Cylinder and piston inspection Oil filter inspection Decompressor inspection Sprocket/power mate ring inspection Cooling system cleaning Oil pump inspection Muffler inspection Chain brake inspection Lubrication and bar maintenance Shock absorber replacement 2) Fuel system...
  • Page 5 Compression test p/n 001000392A Cylinder and piston inspection Decompressor inspection Cooling system cleaning Muffler inspection Compression test • Apply the Emak compression tester (I) on cylinder. Pull energetically rope times • Verify that the compression value in not less than 8 bar –...
  • Page 6 General failures’ analysis Cylinder and piston inspection • Verify the diamond scoring on piston and the nickel-lining on cylinder. Replace if necessary • Verify the piston rings wear using feeler gauge (gap max 1,0 mm) Tightening torque cylinder-screws 1,2 Kgm (106,20 in lb) + Loctite 243 Warning: during assembly make sure the circlip has the feet pointing up...
  • Page 7 General failures’ analysis Decompressor inspection Verify that the decompressor and the decompression hole on the cylinder is not closed to carbon deposits. Clean and/or replace if necessary. 63,4 cm³ chainsaws...
  • Page 8 General failures’ analysis Cooling system cleaning Blow, with compressed air, cylinder fins, starter case and flywheel Important: • Clean weekly the cooling system. For heavy duty work, clean it every day • Use Loctite 243 to tighten plastic component Tightening toque cover-basement 0,4 kgm (35,4 in lb) + Loctite 243 Tightening torque Cover...
  • Page 9 General failures’ analysis Muffler inspection If the muffler is blocked or damaged, clean or replace it Tightening torque muffler-cylinder 1,0 kgm (88,5 in lb) + Loctite 243 Tightening torque cover muffler-basement 0,6 kgm (52,1 in lb) + Loctite 243 63,4 cm³ chainsaws Back to index...

  • Page 10: Fuel System

    General failures’ analysis 2) Fuel system Fuel and fuel filter inspection Fuel system test Tank breather inspection Sintered Engine seal test internal Manifold inspection filter Fuel and fuel filter inspection • Verify fuel quality odor • Dismount and check periodically the fuel filter and the sintered internal filter.
  • Page 11 Dismount the breather and check the components • Apply the pressure gauge (I), supplied with Emak tool kit, at the breather valve and verify the correct working in both ways. To check the inlet direction use the adaptor (II), supplied with the pressure gauge’s box, as shown on the photo.
  • Page 12 Repeat seal test special flanges supplied with Emak tool kit and II). Tap the impulse’s tube with a cap (III) and replace the decompressor with a special...
  • Page 13 General failures’ analysis Manifold inspection Check the manifold for wear. Verify that the manifold’s rubber is not deteriorated or hardened and check that there are no cuts or holes. Replace if necessary 63,4 cm³ chainsaws Back to index...

  • Page 14: Ignition System

    General failures’ analysis 3) Ignition system Check housing inspection Spark plug inspection Spark test Flywheel-coil air gap inspection Wind the spring 7 times Flywheel key way inspection ø 4,0 x 1035 mm Starter housing inspection Remove housing. Inspect parts for wear. If necessary clean or replace Important: grease moving parts 63,4 cm³...
  • Page 15 General failures’ analysis Spark plug inspection Spark test Remove the spark plug and check the gap • Fit the tester (I) between spark plug and spark between the electrodes (0,5 mm) plug cap. Pull the rope and verify the current •...
  • Page 16 General failures’ analysis Flywheel-coil air gap inspection Flywheel key way inspection • Check the air gap using the shim (II-0,3 mm) • Remove flywheel with corrector tool (III) • Adjust if not correct • Inspect key way’s condition and position. If necessary, replace or adjust Tightening torque coil-screws 0,35 kgm (30,98 in lb) + Loctite 243...
  • Page 17 General failures’ analysis 4) Oil pump, bar and shock absorber Make sure that the Oil tank breather inspection height of the oil tank Oil filter inspection breather is 1 mm lower Sprocket/power mate ring inspection Oil pump inspection than bar face Chain brake inspection Lubrication and bar maintenance Shock absorber replacement...
  • Page 18 General failures’ analysis Sprocket/power mate ring inspection Check the sprocket/power mate ring wear periodically. Replacement is suggested every 100 hrs or before REPLACE Attention: When reassembling the clutch make sure that the worm gear drive spring (I) lodges into the clutch drum correctly (II) Attention: always replace the snap ring after removing.
  • Page 19 Remove the oil pump, check the pump and worm gear p/n 001000684 Tightening torque clutch 4,5 kgm (398,3 in lb) + Loctite 270 Important: If the gear inside the pump is hard to turn, disassemble all components and clean them using Emak detergent 63,4 cm³ chainsaws...
  • Page 20 General failures’ analysis Chain brake inspection Check the brake band for wear. This must be changed if the wear limit is less than 0,6 mm 63,4 cm³ chainsaws...
  • Page 21 General failures’ analysis Lubrication and bar maintenance • Lubricate the sprocket nose • Keep the rail and the lubrication holes cleaned • Check the parallelism of the guide bar and for sharp metal edges • Turn the bar every 8 hrs to grant uniform wear The angled lubrijet oilway hole must be...
  • Page 22 • Control the AV mounts for wear or damage (A). Change when necessary • In case of wear or breakage replace the parts with special tool (I), supplied with Emak tool kit, as in photo p/n 001000680A 63,4 cm³ chainsaws...
  • Page 23 General failures’ analysis Substitute spring AV mounts • Check for wear or damage of the AV mounts exchange if necessary. Substitute spring AV mounts: – loosen the spring support (C) – insert the screwdriver and loosen the spring. Important: Make sure when assembling the springs fit correctly into the crankcase (B), as shown in photo 63,4 cm³...
  • Page 24 General failures’ analysis Substitute AV mounts on inlet flange • Control the wear and damage and exchange if necessary. 63,4 cm³ chainsaws Back to index...
  • Page 25 Carburetor inspection Suggested tools for carburetion setting Carburetor tuning Air filter inspection • Clean with Emak detergent, rinse with water and blow with compressed air in the opposite direction of the normal air flow • Replace the filter when damaged...
  • Page 26 General failures’ analysis Needle valve inspection Carburetor inspection Check the right position of the valve using a Check and clean all components (diaphragm, caliper. Adjust if necessary needle, filter). Use the repair kit to replace worn components. If the carburetor is oxidized, replace Needle REPLACE 63,4 cm³...
  • Page 27 General failures’ analysis Suggested tools for carburetion setting (Euro 0) Special screwdriver (I) to adjust the jets: for adjustment the jets “L” e “H” p/n 001001070R 63,4 cm³ chainsaws...
  • Page 28 General failures’ analysis Suggested tools for carburetion setting (Euro 1) Special screwdriver (I) to adjust the jets: for adjustment the jets “L” e “H” Insert the special screwdriver (as shown on the photo) and adjust the jets p/n 3055130 63,4 cm³ chainsaws...
  • Page 29 General failures’ analysis Carburetor tuning Correct tuning of the EURO 0 and EURO 1 (direttiva 97/68/CE + 2002/88/CE). The jets have the following factory registration: L=1; H=1 When, following a repair or engine overhaul, you are obliged to re-tune the carburetor to its’ original setting Idling adjustment (L) Start the unit and warm up for 60 seconds.

  • Page 30: Tightening Torques

    General failures’ analysis 6) Tightening torques 1,2 – 1,4 – 106,2 * 123,9 0,35 – 30,98 * 0,1 – 0,35 – 30,98 * 8,85 * 0,4 – 35,4 * 0,7 – 0,1 - 2 - 177 61,95 8,85 * 0,6 – 52,1 * Tightening torques (kgm) –...
  • Page 31 General failures’ analysis 1 – 88,5 * 0,6 – 52,1 * Euro 1 0,4 – 35,4 * 0,3 – 26,55 Euro 0 0,15 – 13,28 0,4 – 35,4 0,17 – 15,04 Tightening torques 0,1 – 8,85 (kgm) – (in lb) / lubrication * = Loctite 243 ▲...
  • Page 32 General failures’ analysis 0,8 – 70,8* 0,8 – 70,8 * 0,3 – 26,55 * 0,4 – 35,4 * 0,5 – 44,25 * 0,4 – 35,4 * 0,4 – 35,4 * 0,1 – 8,85 0,8 – 0,45 – 0,45 – 70,8 * 39,83* 39,83* Tightening torques...
  • Page 33 General failures’ analysis 0,4 – 35,4 * 0,45 – 39,83 * 0,3 – 26,55 * 0,15 – 13,28 * 0,3 – 26,55 * 4,5 – 398,3 ▲ 0,35 – 30,98 * 0,3 – 26,55 * Tightening torques (kgm) – (in lb) / lubrication * = Loctite 243 ▲...
  • Page 34 General failures’ analysis 7) Trouble shooting: ENGINE DOES NOT START Symptoms Causes Remedies Go to Starter assy defect or Check starter assy or starter rope Section 3 The engine does not broken starter rope replacement turn over Section 1 Internal damage Check thermal group and replace worn components Spark plug looses...
  • Page 35 General failures’ analysis Trouble shooting: LOW PERFORMANCE Symptoms Causes Remedies Go to Carburetor mixture too lean Set the carburetor Section 5 Air leaking in the engine or in Find air leaking and eliminate it Section 1 fuel system Engine Wrong oil-fuel ratio Replace with fresh fuel and right Section 2 overheating...
  • Page 36 General failures’ analysis Trouble shooting: ADDITIONAL PROBLEMS Symptoms Causes Remedies Go to Bended or worn bar Replace or maintain Section 4 Lubrication system blocked Clean or replace Section 4 The chain does not Worn sprocket Replace sprocket Section 4 work correctly or does not rotate The chain is not sharp Sharpen the chain...