RedMax CHTZ60 Instruction manual

Workshop manual
CHTZ60
English
1351 - 002 - 25.11.2020

Contents
1 Introduction
1.1 Document description............................................ 3
1.2 Target group...........................................................3
1.3 Revisions................................................................3
1.4 Safety..................................................................... 3
1.5 Servicing tools........................................................3
2 Safety
2.1 Safety definitions....................................................4
2.2 General safety instructions.....................................4
2.3 Symbols on the product......................................... 4
3 Prepare and do servicing on the product
3.1 Maintenance schedule........................................... 5
4 Servicing data
4.1 Servicing data ....................................................... 6
5 Servicing tools
5.1 Servicing tools......................................................10
6 Function overview
6.1 Type plate and product serial number..................12
7 Repair instructions
7.1 Product overview for repair instructions............... 13
7.2 To clean and examine the product parts..............14
7.3 Starter.................................................................. 14
7.4 Muffler.................................................................. 17
7.5 Air filter................................................................. 17
7.6 Flywheel............................................................... 18
7.7 Ignition system..................................................... 20
7.8 Introduction.......................................................... 20
7.9 Carburetor............................................................ 23
7.10 Handles.............................................................. 27
7.11 Cutting unit......................................................... 30
7.12 Clutch, clutch drum and gearbox....................... 30
7.13 Cylinder and piston............................................ 33
7.14 Crankshaft and crankcase................................. 38
7.15 Fuel tank............................................................ 44
8 Troubleshooting
8.1 Troubleshooting................................................... 46
9 Technical data
9.1 Technical data......................................................50
21351 - 002 - 25.11.2020

1 Introduction
1.1 Document description
This manual gives a full description of how to do
maintenance and repair on the product. It also gives
safety instructions that the personnel must obey.
1.2 Target group
This manual is for personnel with a general knowledge
of how to do repair and do servicing. All personnel that
do repair or do servicing on the product must read and
understand the manual.
1.3 Revisions
Changes to the product can cause changes to the
maintenance work and spare parts. Separate
information is sent out for each change.
Read the manual together with all received information
about changes to maintenance and spare parts for the
product.
1.4 Safety
WARNING: All personnel that repair or do
servicing on the product must read and
understand the safety instructions in this
workshop manual.
1.5 Servicing tools
The manual gives information about necessary servicing
tools. Always use original tools from RedMax.
1351 - 002 - 25.11.2020 Introduction - 3

2 Safety
2.1 Safety definitions
Warnings, cautions and notes are used to point out
specially important parts of the manual.
WARNING: Used if there is a risk of injury or
death for the operator or bystanders if the
instructions in the manual are not obeyed.
CAUTION: Used if there is a risk of damage to
the product, other materials or the adjacent area
if the instructions in the manual are not obeyed.
Note: Used to give more information that is necessary in
a given situation.
2.2 General safety instructions
WARNING: Read the warning instructions that
follow before you use the product.
The service center that repairs the product must have
safety devices that obey local regulations. Warnings and
cautions are used to point out specially important parts
of the workshop manual.
2.3 Symbols on the product
WARNING! This product can be
dangerous and cause serious injury or
death to the operator or others. Be careful
and use the product correctly.
Read the operator's manual carefully and
make sure that you understand the
instructions before you use this product.
Stop.
Use a protective helmet in locations where
objects can fall on you. Use approved
hearing protection. Use approved eye
protection.
Always wear approved protective gloves.
Use stable boots with non-slip soles.
Stop the product fully before you touch the
cutting tool.
Keep all parts of your body away from the
hot surfaces.
Fuel.
Choke.
Air purge bulb.
Idle adjustment screw.
High speed needle.
Low speed needle.
This product applies with the applicable
EC Directives.
Noise emissions to the environment
according to European Directive
2000/14/EC and New South Wales
legislation “Protection of the Environment
Operations (Noise Control) Regulation
2017”. Noise emission data can be found
on the machine label and in the Technical
data chapter.
yyyywwxxxxx The rating plate shows the serial number. yyyy is the production year and ww is the
production week.
Note: Other symbols/decals on the product refer to
special certification requirements for some markets.
4 - Safety 1351 - 002 - 25.11.2020

3 Prepare and do servicing on the product
3.1 Maintenance schedule
Maintenance Before
operation After 40 h After 100 h
Clean the external surface. After each operation.
Clean the muffler, exhaust pipe and engine from leaves, dirt and unwanted lubri-
cant. After each operation.
Make sure that the cutting attachment does not move at idle speed. X
Do a check of the stop switch. X
Examine the cutting attachment and the cutting attachment guard for damages
and cracks. Replace if it is damaged. X
Examine the hand guard for damages and cracks. Replace if it is damaged. X
Do a check of the throttle trigger lockout and the throttle trigger. X
Examine the engine, the fuel tank and the fuel lines for leaks. X
Tighten nuts and screws. X
Examine the fuel filter for contamination and the fuel hose for cracks and other
defects. Replace if necessary. X
Examine the starter and the starter rope for damages. X
Clean the air filter. Replace if it is necessary. X
Examine the vibration damping units for damages and cracks. X
Examine the spark plug, refer to To examine the spark plug on page 20 . X
Clean the cooling system. X
Clean the external surface of the carburetor and the area around it. X
Clean or replace the spark arrester mesh. X
Clean the inner surface of the fuel tank. X
Examine the spark plug. X
Make sure that the gear housing is filled with grease. X
1351 - 002 - 25.11.2020 Prepare and do servicing on the
product - 5

4 Servicing data
4.1 Servicing data
▲ Lubricate with 2-stroke oil.
● Lubricate with grease.
T273 - 4 Nm
T27
3 - 4 Nm
T273 - 4 Nm
T275 - 8 Nm
T27
3 - 4.5 Nm
T273 - 4.5 Nm
T271.5 - 2.5 Nm
T272 - 3 Nm
T272 - 3 Nm
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T27
6 - 8 Nm
T27
6 - 9 Nm
10 - 15 Nm
8 mm
6 - 9 Nm
T27
4 - 6 Nm
T27
3 - 5 Nm
1351 - 002 - 25.11.2020 Servicing data - 7

T27
1.5 - 2.5 Nm
T27
4.5 - 5.5 Nm
T27
6 - 8 Nm
TXX
6 - 8 Nm
16 mm
10 - 12 Nm
T27
4 - 6 Nm
T27
8 - 10 Nm
T27
3 - 4 Nm
T273 - 4 Nm
T27
2.5 - 3 Nm
10 - 12 Nm
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T27
6 - 9 Nm
T27
3 - 5 Nm
8 mm
6 - 9 Nm
8 mm
6 - 9 Nm 8 mm
6 - 9 Nm
8 mm
6 - 9 Nm
T27
3 - 5 Nm
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5 Servicing tools
5.1 Servicing tools
0.5 mm
0.3
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15
17 18 19
16
20
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21
Item Description Use Article number
1 Removal tool for
the ball bearing
To remove ball bearings. 502 50 18-01
2 T-handle Torx,
T27
To loosen or remove Torx screws. 502 71 27-02
3 Carburetor ad-
justment tool
To adjust the idle speed screw on the carburetor. 501 60 02-03
4 Carburetor ad-
justment tool
To adjust the high speed needle and low speed needle on the carbu-
retor.
530 03 55-60
5 Removal tool for
the drive gear
To remove the drive gear. 505 38 13-08
6 Assembly pliers To repair the spark plug cable. 502 50 06-01
7 Piston stop To stop the movement of the piston. 522 43 18-01
8 Test spark plug To do a spark test. 502 71 13-01
9 Fuel filter hook To pull the fuel filter out of the fuel tank. 502 50 83-01
10 Removal tool for
the piston pin
To remove the piston pin. 505 38 17-05
11 Air gap gauge,
0.3 mm
To measure the distance between the flywheel and the ignition module. 502 51 34-02
12 Air gap gauge,
0.5 mm
To measure the electrode gap on the spark plug. 502 51 91-01
13 Crankshaft as-
sembly sleeve
To assemble the crankshaft. 577 90 21-01
14 Flywheel remov-
al tool
To remove the flywheel. 577 90 66-01
15 Piston assembly
tool
To assemble the piston. 502 50 70-01
16 Tachometer To measure RPM. 502 71 14-01
17 Pressure tester To do a pressure test. 531 03 06-23
18 Grease To lubricate the gear housing. 503 98 96-03
19 Detergent To clean the air filter. 505 69 85-70
20 Air filter oil To lubricate the air filter. 531 00 60-76
21 UL 21 spray To lubricate the cutting unit. 544 14 21-01
1351 - 002 - 25.11.2020 Servicing tools - 11

6 Function overview
6.1 Type plate and product serial number
RedMax CHTZXXXX
s/n 20XX XXXXXXX
XXX XX XX-XX
Husqvarna AB
Huskvarna, Sweden
12 - Function overview 1351 - 002 - 25.11.2020

7 Repair instructions
7.1 Product overview for repair instructions
5
3
1
6
2
4
9
12
13
7
11
10
8
14
1. Starter unit
2. Muffler
3. Spark plug
4. Flywheel
5. Ignition module
6. Air filter
7. Fuel tank
8. Carburetor
9. Rear handle
10. Gearbox
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11. Cutting equipment
12. Cylinder and piston
13. Crankcase and crankshaft
14. Front handle
7.2 To clean and examine the product parts
• Clean and examine all parts fully. You find more
instructions in the chapter for each part if special
tools or procedures are necessary.
• Replace damaged or defective parts.
• Always use original spare parts.
7.3 Starter
7.3.1 To remove and install the starter unit
1. Remove the 4 screws and the starter unit.
2. Install in the opposite sequence.
7.3.2 To disassemble the starter unit
WARNING: Use protective glasses. The recoil
spring can eject from the starter pulley and
cause injury.
1. Remove the starter unit. Refer to To remove and
install the starter unit on page 14 .
2. Pull out the starter rope approximately 30 cm and
put the starter rope into the notch in the starter
pulley. Hold the starter pulley with your thumb.
3. Decrease the pressure of your thumb. Let the starter
pulley rotate clockwise slowly to decrease the
tension in the recoil spring.
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4. Remove the screw (A), the drive disc (B), and the
drive disc spring (C).
A
B
C
D
E
5. Carefully remove the starter pulley (D) together with
the recoil spring (E).
Note: The recoil spring is installed in the starter
pulley.
7.3.3 To clean and examine the starter unit
• Clean all components.
• Examine the starter rope. Replace the starter rope if
it is damaged.
• Examine the starter pulley. Replace damaged parts.
• Make sure that the start pawls on the starter pawl
assembly are not damaged. Make sure that the
starter pawl springs on the starter pawl assembly
are attached correctly and move freely.
• Lubricate the starter pawls on the starter unit.
• Lubricate the starter spring.
7.3.4 To install the recoil spring in the starter pulley
WARNING: Use protective glasses. The recoil
spring can eject from the starter pulley and
cause injury.
1. Align the flange on the recoil spring with the groove
in the starter pulley.
2. Hold the recoil spring with 2 fingers. Push the recoil
spring down into the starter pulley with a
screwdriver.
3. Hold the recoil spring with 2 fingers. Remove the
plastic strap with a screwdriver.
1351 - 002 - 25.11.2020 Repair instructions - 15

7.3.5 To assemble the starter unit
1. Make sure that the recoil spring is installed in the
starter pulley. Install the recoil spring if it is
necessary. Refer to
To install the recoil spring in the
starter pulley on page 15 .
2. Attach the starter rope to the starter pulley. Install
the knot in the dedicated cut-out in the starter pulley.
3. Wind the starter rope 3 turns counterclockwise
around the starter pulley.
4. Lubricate the recoil spring in the starter pulley with
cold resistant grease.
5. Move the free end of the starter rope through the
starter rope guide (A) in the starter housing.
A
B
6. Carefully put the starter pulley into the starter
housing. Put the free end of the recoil spring into the
dedicated slot (B) on the hub of the starter housing.
7. Install the drive disc spring (C).
E
D
C
8. Lubricate the drive disc spring with cold resistant
grease.
9. Install the drive disc (D).
10. Install the screw (E).
11. Attach the starter rope handle to the starter rope.
12. Pull out the starter rope to its end position and hold
the starter pulley with your thumb.
7-8 r
13. Put the starter rope into the notch in the starter
pulley and turn the starter pulley 7 to 8 turns
clockwise.
14. Remove the starter rope from the notch in the starter
pulley.
15. Decrease the pressure of your thumb and let the
starter pulley rotate clockwise slowly.
16. Make sure that you can turn the starter pulley ½ turn
clockwise with the starter rope fully pulled out.
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7.4 Muffler
7.4.1 To remove and install the muffler
1. Remove the 2 screws and the muffler cover.
2. Remove the 2 screws and remove the muffler.
3. Remove the gasket.
4. Remove the screw and the spark arrester.
5. Install in the opposite sequence.
7.4.2 To clean and examine the muffler
1. Clean all components. Clean the contact surfaces of
the gasket, the heat deflector and the cylinder.
2. Examine the spark arrester for damage.
3. Examine the muffler and the muffler holder for
damage.
4. Examine the gasket for damage.
5. Replace all damaged parts.
7.5 Air filter
7.5.1 To remove and install the air filter
1. Turn the knob counterclockwise and remove the air
filter cover.
2. Remove the air filter.
3. Install in the opposite sequence.
7.5.2 To clean and examine the air filter
WARNING: Use protective gloves.
CAUTION: Do not use compressed air to clean
the air filter.
1. Remove the air filter. Refer to To remove and install
the air filter on page 17 .
2. Clean the air filter with warm water with soap. Use
RedMax cleaning agent. Refer to Servicing tools on
page 10 .
Note: Replace the air filter if it is too dirty to clean
fully. Replace the air filter if it is damaged.
3. Let the air filter dry fully.
4. Put the air filter and 1 tablespoon of air filter oil in a
plastic bag. Use RedMax air filter oil. Refer to
Servicing tools on page 10 .
1351 - 002 - 25.11.2020 Repair instructions - 17

5. Rub the plastic bag to supply the air filter oil equally
across the air filter.
6. Remove unwanted air filter oil from the air filter.
7. Clean the inner surface of the air filter cover. Use
compressed air or a brush.
8. Make sure that the air filter is dry before you install
it.
7.6 Flywheel
7.6.1 To disassemble the flywheel
1. Remove the starter unit. Refer to To remove and
install the starter unit on page 14 .
2. Clean the area around the spark plug.
3. Remove the spark plug.
4. Put a piston stop in the spark plug hole. Refer to
Servicing tools on page 10 .
CAUTION: Make sure that the piston stop
does not go into the exhaust port. There is a
risk of engine damage.
5. Remove the nut.
6. Attach the flywheel removal tool to the crankshaft,
refer to Servicing tools on page 10 . Keep a distance
of approximately 2 mm between the flywheel
removal tool and the flywheel.
7. Hit the flywheel removal tool lightly with a hammer
while you lift the flywheel with your other hand.
8. Remove the 2 lock washers (A) with a screwdriver.
This causes deformation of the lock washers.
Discard the lock washers.
C
B
A
9. Remove the 2 starter pawls (B) and the 2 recoil
springs (C).
7.6.2 To clean and examine the flywheel
• Examine the flywheel for cracks and damage.
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• Make sure that the key in the flywheel and keyway
are not damaged.
• Clean the crankshaft from grease and oil.
7.6.3 To assemble the flywheel
1. Make sure that the key in the flywheel and the
keyway in the crankshaft are not damaged.
2. Install the 2 recoil springs (A) and the 2 starter pawls
(B) on the flywheel. Make sure that the recoil springs
are correctly attached to the flywheel.
A
C
B
3. Install new lock washers (C).
CAUTION: Always use new lock washers.
4. Put the flywheel in position on the crankshaft.
5. Install the piston stop in the spark plug hole. Refer to
Servicing tools on page 10 .
6. Install the nut and tighten the nut with the correct
torque. Refer to Servicing data on page 6 .
7. Remove the piston stop.
8. Use the air gap gauge between the flywheel and the
ignition module for the correct air gap. Refer to
Servicing tools on page 10 .
a) If it is necessary, loosen the 2 screws and adjust
the air gap between the flywheel and the ignition
module.
b) Tighten the screws to the correct torque. Refer
to Servicing data on page 6 .
9. Install the spark plug and the spark plug cap.
1351 - 002 - 25.11.2020 Repair instructions - 19

7.7 Ignition system
7.8 Introduction
The engine has an electronic ignition system fully
without moving parts. A defective component cannot be
repaired, but must be replaced by a new component.
If the engine does not fire, the ignition module can be
damaged. Before you replace the ignition module, do
the tests that follow.
7.8.1 To examine the spark plug
CAUTION: Always use the recommended spark
plug type. Incorrect spark plug type can cause
damage to the product.
• Examine the spark plug if the engine is low on
power, is not easy to start or does not operate
correctly at idle speed.
• To decrease the risk of unwanted material on the
spark plug electrodes, obey these instructions:
a) Make sure that the idle speed is correctly
adjusted.
b) Make sure that the fuel mixture is correct.
c) Make sure that the air filter is clean.
• If the spark plug is dirty, clean it and make sure that
the electrode gap is correct, refer to Technical data
on page 50 .
• Replace the spark plug if it is necessary.
7.8.2 To do a spark test
1. Remove the spark plug from the cylinder.
2. Connect the spark plug to the spark plug cap.
3. Make sure that the stop switch on the throttle handle
is in the start position.
4. Hold the spark plug against the cylinder and pull the
starter rope handle.
a) If a spark occurs between the electrodes on the
spark plug, the ignition operates correctly. The
test is completed.
b) If no spark occurs, continue with the next step.
5. Remove the spark plug and connect the ignition
tester to the spark plug cap. Refer to Servicing tools
on page 10 .
6. Connect the ground cable to the cutting equipment.
7. Use the knob to adjust the distance between the 2
electrodes to 6 mm.
Note: 6 mm is 6 marks on the scale.
8. Pull the starter rope handle.
9. Do 1 of the steps that follow.
a) If a spark occurs between the electrodes on the
ignition tester, replace the spark plug.
b) If there is no spark between the electrodes on
the ignition tester, examine the ignition module.
Refer to To examine the ignition module on page
22 .
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