Husqvarna 2100 Instruction manual

Workshop
manual
chain saw model
101 88 01-26
210 0
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Contents
TechnicalSpecification
ServiceData
SpecialTools
Fuelsystem,Carburet&or
Electricsystem
Lubricatingsystem,Oil pump
Crankcase,
Starter
Centrifugal
Crankshaft
Clutch
SafetyEquipment
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nloo TechnicalSpecificationn
Displacement
Bore
Stroke
Ignitionsystem
Ignitionadvance
Sparkplug
Electrodegap
Carburetor
Fueltankvolume
Oiltankvolume
Chainlubrication
Clutchdrum/sprocket
Weights
99 cm3 (6 cu in)
56.0 mm (2.20”)
40.0 mm (1.57”)
Electronic. Make SEM type GA 1.
24° before t.d.c. at 133 r/s (8,000 r/rein)
BoschWSR 8F
0.5 mm (0.020”)
Diaphragmcarburetor. Make Tillotson type HS
136C with speedgovernor0.070”.
Basicsetting:
H=1.0
L=1.2
1.0 Iitre (0.26 US gallon, 0.22 Imp gallon).
Fuel mixture 4% (1:25).
With HusqvarnaTwostroke Oil 2% (1:50).
0.65 Iitres (0.17 US gallon, 0.14 Imp gallon).
Two separatelubrication systems:
Automatic
No supply during idling. Adjustable for two different
delivery rates:
Bar 15“ 21”: Position I
Bar 21” and more: Position II
Manual
Hand-operated pump on the left sideof the rear
handle.
Standard:
7teeth, 0.404” Pitch.
Optional:
8teeth, 3/8” Pitch.
1. Weight sawbody (empty) 8.0 kg (17.6 lb)
2. Weight sawbody (empty) incl. 24”
bar and chain (Oregon 52L -76E 0.404 ’’).10.2 kg (22.5 lb)
3. Sameas2 howeverwith full tanks._ 11.4 kg (25.1 lb)
1:1
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2100
Classificationtable
Cylinder class Pistonclass
AA
::
PLEASE NOTE!
As “A” denotes smallest cylinder diameter and “C”
the largest, piston grades should be matched or
one grade smaller. Egit is not permissible to use
agrade Bpiston in agrade Acylinder.
TechnicalSpecificationEl
Fig 1:1
1:2
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ServiceData !2
CrankcaseAssy
Vacuum: 0.04 MPa (0.4 kp/cm2, 5.7 psi)
Max. leakage:0.01 MPa/1 min (0.1 kp/cm2,
1.4 psi, per rein)
TooIs: 5025037-01 Vacuum gauge
5025081-01 Cover plate, exhaust port
5025047-01 Cover plate, inlet port
Fig 2:1
Pressure:0.08 MPa (0.8 kp/cm2, 11.4 psi)
Max. leakage: 0.02 MPa/30 sec(0.2 kp/cm2,
2.8 psi, per 30 see)
Tools: 5025038-01 Pressuregauge
5025081-01 Cover plate, exhaustport
5025047-01 Cover plate, inlet port
Fig 2:2
Fueltank
Pressure:0.05 MPa (0.5 kp/cm2, 7.1 psi)
Leakage: No leakagepermitted.
Tool: 5025038-01 Pressuregauge
Carburetor
Pressure:0.03 MPa (0.3 kp/cm2, 4.3 psi)
Leakage:No leakagepermitted
Tool: 5025038-01 Pressuregauge
Fig 2:3
2:1
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Oilpump
Pressure:0.3 MPa (3 kp/cm2, 42.7 psi)
Pump capacity at 6,000 r/rein:
Pos1: approx 16-18 ml/min (0.98-1 .10 cu in/rein)
Pos2: approx 22-24 ml/min (’
Tools: 5025085-01 Oil pump
Grad. measuringglass.
.34-1.46 cu in;min)
ester
ServiceData a
Fig 2:5
Starter
Make surethat it ispossibleto turn the pulley at
least1/2 turn further when the cord ispulled
out completely.
Fig 2:6
Fuelandoil
The twostroke engineislubricated by oil mixed
with petrol in variousproportions dependingon
the type of oil used:
“Pre-mixed” oil 1:20 (5% oil)
Ordinary twostroke oil 1:25 (4% oil)
HusqvarnaTwostroke Oil 1:50 (2% oil)
Seealsothe mixing table below:
Fig 2:7
Mixing table
Mixingtable
Litres Pints
of oil of oil
0.2 0.35
0.4 0.70
1.0 1.76
2%
Litres Petrolin Petrol in
of petrol Imp gallon USgallon
10 2.2 2.6
20 4.4 5.2
50 11.0 13.2
4% I5% I
Litres Petrolin Petrolin Litres Petrolin Petrol in
of petrol Imp gallon USgallon of petrol Imp gallon USgallon
51.1 1.3 40.8 1.0
10 2.2 2.6 I81.7 2.1
25 5.5 6.6 I20 4.4 5.2
2:2
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ServiceData Q
TorqueNm(ft lb)
(m
—m m
w Ci m
6i-
m“
Com.
—AE
L
2:3
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SpecialTools El
5025006-01
Assemblingpliers
(spark plug protector)
5025007-01
Assemblingpliers
(cable grommet)
T
I@ 5025018-01 NV 4mm
5025019-01 NV 3mm
5025057-01 NV 3/16”
Allen key
NV
P
-..~”-
2062372-11
d
TV
5027002-01 B’ 2024294-45
-. 2024332-55
282 0008-~1 -. ‘2024297-55
2024333-55
5025025.01 (compl.)
5025020-01 (M5)
Stud fitting tool
5025022-01 NV 8mm
5025023-01 NV 10 mm
Socket spanner
5025024-01
Spanner,clutch centre
5025025-01
Holding bar compl.
5025026-01
Puller compl. with screw
5025030-01
Fitting tool compl. for
crankshaft
5025033-01
Pistonstop
5025036-01
Revolution counter
5025037-01
Vacuum gauge,compl.
5025038-01
Pressuregauge,compl.
5025042-01
Lithium grease250 g
(0.55 lb)
5025045-01
Distancesleeve(35 mm)
5025047-01
Cover plate, inlet port
3:1
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SpecialTools B
45025049-01
1!s Assemblingpliers
(centrifugal clutch)
-01
for elec-
5025051-01
/
Cableclip pliers
@
5025052-01
Fitting sleevefor
sealingring
5025062-01
Fitting tool (manual
pump)
5025066-01 NV 22 mm
U-spannerfor vibration
damper
/
5025069-01
Fitting drift
(piston pin)
5025070-01
Q
o
\6
\/
5025070-01
Pistonmounting set,
compl.
5025081-01
Coverplate, exhaustport
5025082-01
Fitting drift (sealingring)
5025083-01
Hook for oil filter
5025084-01
Electrotester
5025085-01
Oil pump tester,
compl.
5025086-01 NV 3mm
5025087-01 NV 4mm
Allen screwdriverwith
ball
3:2
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SpecialTools El
502
5025090-01
Jet-Pacsprayguncompl.
incl. retouch paint
5025091-01
Retouch paint, orange,
1/8 I
5025092-01
Pressurepack for Jet-Pac
5025101-01
Extractor (sealingring)
5025102-01
Clamping device
5025106-01
Glue, adhesive
5025107-01
Glue, epoxy
5025108-01
Loctite AA (normal locking power)
5025109-01
Loctite AAV (stronglocking power)
5025124-01
SEM electric systemtester
3:3
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2100 Fuelsystem V
Removalofcarlxwettor
Removecarburetor cover, pre-filter, air filter,
cylinder coverand fuel hose.
Removethe throttle pushrod from the plasticle-
ver with apair of flat hosepliers.
Fig 4:3
Drill asmall hole in the welch plugs(aPProx. @2
mm) and priseaway the plugsby meansof a
pointed tool.
Fig 4:1
Loosenthe socket headscrewsthat retain the carbu-
retor (usethe Allen key No. 502501 8-01).
Removescrews,air filter elbow and carburetor.
Clean the carburetor on the outside.
Fig 4:4
IVOTE!
Drill with care in order not to damage the carburetor
housing.
Fig 4:2
Removethe metering diaphragmcoverand the me-
tering diaphragm.
Note that the centre pin of the diaphragmenters
the forked end of the leverof the needlevalve.
Connect the pressuregauge5025038-01 to the
fuel inlet of the carburetor and pump until a
pressureof 0.03 MPa (0.3 kp/cm2 )isreached.
Check for any leakageat the needlevalveor at the
gasketon the pump side.
The easiestway of locating leakagesisto pour
somepetrol where you suspectthe leakagesto be.
Loosenthe screwthat retainsthe bearingshaft of
the leverand remove lever, shaft, springand needle
valve (seefig. 4:3).
Fig 4:5
Unscrewthe two adjustingneedles.Removethe
coverabovethe pump diaphragmand remove
diaphragmand gasket. Lift off the fuel screencare-
fully by meansof apointed tool.
4:1
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nloo G
A
Fuelsystem
Speed governor
The purposeof the governor isto limit the engine
speedin order to protect vital parts Iike the crank-
shaft and ignition systemfrom excessivestresses.We
therefore advisemost strongly againstany inter-
ferencedesignedto render it inoperative.
When the sawisrun under no-loadconditions, the
enginespeedis limited to 10,500 r/rein asthe gover-
nor comesinto operation.
312
wI
4+
4
Fig 4.6 3
1.Steelball. 2. Spring. 3. Fuel inlet. 4. Fueloutlet.
The steel ball and springin the governorare sode-
visedthat vibrations in the carburetor at acertain
enginespeedcausethe steel ball to open the fuel
outlet. An excessivelyrich mixture isthen obtained
and the enginebeginsto four-stroke, the speed
dropsand the vibrations decrease.The steel ball
then closesthe outlet, the enginespeedincreases
and the processisrepeated.
Removalof speedgovernor
Removethe screwfor the choke flap. Pull out the
flap approx. 7mm and pushout the choke shaft
approx. 5mm. Removethe speedgovernorwith a
suitablescrewdriver.
Carburetorcheck
A. Pumping section
Cleanthe fuel screenand -lineswith compressed
air.
Check the gasketand the pump diaphragm for
damageor wear.
B. Metering section
Checkthat the adjustingneedlesare straight and
that their taperedendsare not damaged.Check the
Fig 4:8
gasketand the metering diaphragm for damageor
wear. Checkwith particular carethe wear on the
centre pin of the diaphragm.
Fig 4:9
Check that the needlevalveisnot worn, neither on
itsseat,nor in the groovefor the lever.
Fig 4:7
4:2
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G
A
Fuelsystem
Fig 4:10
Checkthat the needlevalve lever isnot worn,
neither at the connection to the valve, nor to the
metering diaphragm.
Checkthat the filter screennear the main jet is
not dirty or damaged.
C. Mixing section
Cleanall fuel linesand jets with compressedair.
D. Speed governor
The speedgovernor iseasilychecked by meansof
the pressuregaugeNo. 5025038-01.
Fig 4:1 1
Connect the pressuregaugeasshown in fig. 4:11.
Check that the hosedoesnot coverthe two holes
nearthe thread.
The valveshould be tight, which meansno “hiss
sound” at apressurebelow 0.10 MPa (1 kp/cm2).
In caseof leakage,the valveshould be replaced.
4
IThe carburetor sparepart kit hasgot No.
5015467-01. I
Assembly
A. Pumping section
Locatethe fuel screencarefully in its seating(see
fig. 4:5). Locatethe pump diaphragm next to the
carburetor housingand then add gasketand cover.
Tighten the screwsof the coverdiagonally and
evenly. fi—
B. Metering section
Fit new welch plugs.Install them with asuitable
drift: for the big plug: drift 08 mm
for the small plug: drift @4mm
NOTE!
Do not press in the plugs so that they bulge inwards!
Fig 4:13
Mount the needlevalve, lever, springand shaft.
Locatethe springproperly!
4;3
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2noo G
A
Fuelsystem
When properly adjustedthe leverof the needle
valveshall be on alevelwith the carburetor
housingsurrounding it. Adjust if necessary(see
fig. 4:14).
Fig 4:14
If the leverislocated too high, the carburetor will
bevery sensitiveasregardsthe adjustment of the
adjustingneedles.
Atoo low leverinducesbad accelerationqualities.
Check that the levercan move freely.
Make apressuretest of the carburetor. Proceedas
mentioned above.
Then mount gasket,metering diaphragmand cover.
NOTE!
Care should be taken to ensure that the centre pin of the
diaphragm enters the fork in the lever!
Install the adjustingneedlesand screwthem out
to the following basicposition:
H=1.0 turn open
L=1.2 turn open
C. Speed governor
Locatethe sealingwasherin the carburetor hous-
ingand fastenthe speedgovernor, Pushthe choke
shaft into its position and fit the choke flap and
its locking screw.
Adjustmentofcartwrettor
A. Basic setting
Beforeadjustingthe carburetor, proceedas
follows:
Clean the air filter or, if necessary, replace it.
Check the spark plug and its electrodes.
Check that the fuel filter is not clogged.
Fig 4:15
Examine the fuel filter asfollows:
Loosenthe fuel hosefrom the carburetor and lay
the chain sawon the clutch side. Open the tank
cap. If there isenoughfuel in the tank, someof it
ought to run out of the hose(seefig. 4:15).
Fig 4:16
After the abovementionedchecks,make abasic
adjustment of the carburetor needles,i.e. H=1.0
turn open and L=1.2 turn open.
Start the chain sawand warm it up by applying
full throttle and letting it cut into alog.
Aconstantspeed,without fourstroking, for 10-20
sec.when cutting into alog indicatesnot only a
good high speedfunction of the carburetor but
alsoagood condition overall.
4:4
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Fuelsystem ~
The following problemsmay occur when warming the chain sawup:
PROBLEM DAMAGE
Enginefourstroking Speedgovernorfaulty
Bad idling Crack in the insulatingpiece
Badly tightened carburetor screws
Incorrectly assembledor leakinggaskets
Tank breathervalveinoperative
Fuel filter clogged
Low enginepower Leakagein the pumping sectionof the carburetor
NOTE!
Too lean adjustment of the carburetor would causea
considerable lossof power. Adjust the carburetor in
order to obtain maximum power and not maximum
speed.
B. Adjustment of L-needle
Adjust the idling speedby meansof the throttle
adjustingscrew“T” (fig. 4:16). Try to reacha
position where the chain isjust beginningto
rotate, that isat acomparatively high idling speed.
Fig 4:17
Put your right hand on the front handle and make
afine adjustment of the L-needlewith your left
hand. UsescrewdriverNo. 5016002-01.
Fine adjustment ismade asfollows:
1. Screw in the L-needleslowly and the speedwill
increase.Screw in the needlealittle further and
the speedwill slow down againasthe fuel
supply becomestoo “lean”.
Notice the position of the needleat the highest
speed.
2. Open the L-needleagainand notice the highest
speedposition. Note that the speedslowsdown
at “richer” supply.
3, Adjust the L-needleto the highestspeedposi-
tion. Then open it equivalent to 10 min on a
clock-faceto obtain asomewhat “richer” supply
to aid acceleration.
4. By meansof the T-needle adjust the idling speed
to 2,300-2,500 r/rein ensuringthat the chain
doesnot rotate when engineisidling.
5. Give full throttle acouple of times to check that
the engine“responds”. If not, open the L-needle
by abt. 3min. Checkagain.
C. Adjustment of H-needle
Adjust the highspeedneedle (H) asfollows:
Apply full throttle by keepingaconstant graspof
the throttle trigger. At correct adjustment of the
H-needlethe engineshould be fourstroking.
The high idle speedshould be approx. 10,500 r/rein.
Fig 4:18
4:5
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G
A
Fuelsystem
Fig 4:20
Check by meansof e.g. revolution counter No.
5025036-01, that the high idle speedisapprox.
10,500 r/rein. Should the high idle speedof the
enginebe below 10,000 r/rein, check the speed
governorof the carburetor and replaceit, if neces-
sary.
4,6
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G
A
Fuelsystem
Troubleshootingguide
m\ \ v
Irregular idling speed x x
Engine stopswhen accelerated xxx
(chokerequired) x x
“Leaning out” xx x x x x
No fuel supply xx x x
Difficult adjustment xx x
Too “rich” supply xx
No idling speed x
Extreme needle position x x xx
High idle speed not reaching
10,500 r/rein x x
4:7
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nloo E
Electricsystem ~
A.Ignitionsystem,
troubleshooting
In all ignition testingthe plug must be firmly
earthed againstthe cylinder in order to prevent da-
nageto the system.
.Removethe spark plug.
Connect the ignition cableand “earth” the plug
e.g. againstthe cylinder.
Checkfor aspark between the electrodeswhen
Fig 5:3
4. In casethe trouble hasnot beendetected, check
the armature plate by meansof testingdeviceNo.
5025124-01.
Removethe armature plate (seebelow, “Removal,
assembly”)and test it under load.
For test values,seethe instruction suppliedwith
the testingdevice.
2.
3.
—
If no sparkoccurs,try anew plug.
If still no spark,check the connection between
ignition cableand spark plug protector.
Disconnectthe short circuiting cablefrom the
switch.
Check for aspark.
If asparkoccurs,the stop switch isfaulty and
should beexchanged.
Removethe starter and air conductor.
Cablesthat are squeezedor otherwise damaged
should be exchanged.
B.Removal/assembly
Fig 5:4
Removestarter and air conductor. Removecylinder
coverand spark plug and fit piston stop No.
5025033-01 in the spark plug hole. Then loosen
the flywheel nut by meansof abox spanner(17 mm).
5:1
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R
Electricsystem ~
Fig 5:5
Fit holding bar No. 5025060-01 on the flywheel
and puller No. 5025026-01 on the holding bar.
Removethe flywheel.
Changingthe starterpawlsand springs
Placethe flywheel on the working benchwith the
starter pawlsdownwards.
A
.Y
$,
Fig 5.6
Removethe three screwsretaining thearmature
plate. Removethe bracket for the ignition cable
and disconnectthe short circuiting cable from the
stop switch. Then removethe armature plate.
Assemblyismade in reverseorder.
When fitting the armature plate notice the marking
(fig. 5:7), ensuringacorrect advanceignition. The
flywheel nut should be tightened by torque 40-43
Nm.
NOTE!
Before fitting anew flywheel remove every trace of rust
preventive especially on the hub.
Fig 5:8
Pushthe bearingpinsof the starter pawlsout of
the flvwheel with adrift (~ 3mm). Change
starte; pawlsand springs,and pressback t;e bear-
ing pinsfrom the fan side. Use Loctite AA in the
pin holesbefore putting the pins back. Check that
the pinsreachthe bottom and that springsand
pawlswork properly.
To ensureproper connection between contact
springand ignition cable, useassemblingpliers
No. 5025006-01 for fitting the sparkplug protec-
tor on the ignition cable.
We recommendthe useof Lithium greaseNo.
5025042-01 when connectingthe ignition cable
to the sparkplug protector.
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Removalofoilpump
Removethe following parts in order to get at the
oil pump:
Clutch cover, chain and bar, centrifugal clutch
(NOTE! Left-hand threads), clutch drum.
NOTE!
The washer between the oil pump drive gear and the main
bearing seal!
Fig 6:1
Loosenthe three screwsthat retain the pump with
ascrewdriverand removethe oil pump.
Fig 6:2
Check if there isdirt in the suction channel by ro-
tating the pump shaft in both directions.When the
pump works properly and isfilled with oil, the oil
goesalternately through the suction channel (A)
and the pressurechannel (B).
(3
Lubricatingsystem 0
D
c
Fig 6:3
For cleaning, dismantle the pump as follows:
1. Removethe adjustingscrew (A, fig. 6:3).
2. Knock the edgeof the pump housingagainsta
pieceof wood to make the pump piston (B,
fig. 6:3) and its bearingslideout of the casing.
Fig 6:4
3. Check the wear of the adjustingscrewagainst
which the cam curveof the pump piston runs.
Replaceif necessary.
4. Check the oil hosesand their connectionsto
tank and crankcase(fig. 6:5).
Fig 6:5
6:1
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