Stihl 024 User manual

STIHL 024
Instruction Manual
0 Flees Manual
Assembling
Safety Precautions
Operating Instructions
Maintenance
Warning! To reduce risk of kickback injury use STIHL reduced kickback bar
Read and follow all safety precautions and STIHL PM 1 (3/s" Picco) orTM 1 (0.325") chain depending on
in Owner's Manual improper use sprocket pitch or otheravailable low kickback components.
can cause serious or fatal injury. @ Andreas Stihl 1985.
STIHL
STIH

Important Safety Precautions
for Chain Saw Users
A. Kickback Safety Precautions
Warning!
Kickbackmay occurwhen the nose ortip ofthe guide
bar touches an object, orwhen thewood closes in and
pinches the saw chain in the cut. Tip contact in some
cases may cause a lightning fast reverse reaction,
kicking the guide bar up and back towards the
operator. Pinching the saw chain along the top of the
guide bar may push the guide bar rapidly back to-
wards the operator. Either of these reactions may
cause you to lose control of the saw which could re-
sult in serious personal injury.
Section 4.12 of ANSI B 175.1-1985 sets certain perfor-
mance and design criteria related to chain saw kick-
back. STIHL has developed a color code system using
green and yellow to help you select a powerhead, bar
and chain combination thatcomplies with the kickback
requirements ofthe ANSI Standard. See the sections
entitled "Safety Precautions" and "Specifications" of
this Manual.
Do not rely exclusively upon the safety devices built
into your saw. As a chain saw user, you should take
several steps to keep your cutting jobs free from acci-
dentor injury.
1. With a basic understanding of kickback, you can
reduce or eliminate the element of surprise. Sud-
den surprise contributes to accidents.
Keep a good firm grip on the saw with both hands,
the right hand on the rear handle, and the left hand
on the front handle, when the engine is running.
Use a firm grip with thumbs and fingers encircling
the chain saw handles. A firm grip will help you re-
duce kickback and maintain control of the saw.
Don't let go.
Make sure that area in which you are cutting is free
from obstructions. Do not let the nose of the guide
bar contact a log, branch, or any other obstruction
which could be hit while you are operating the saw.
Cut at high engine speeds.
Do not overreach or cut above shoulder height.
Follow manufacturer's sharpening and mainten-
ance instructions for the saw chain.
Only use replacement bars and chains specified
by the manufacturer or the equivalent.
B. Other Safety Precautions
Do not operate a chain saw when you are fatigued.
Use safety footwear; snug-fitting clothing; protec-
tive gloves; and eye, hearing, and head protection
devices.
Use caution when handling fuel. Move the chain
saw at least 10 feet (3 m) from the fueling point
before starting the engine.
continued on the back inside cover

This Manual contains operating and safety instructions for
all STIHL 024 series power saws.
Pay special attention to thesafety precautions outlined on
the inside cover and on pages 4 to 23. Allow only persons
who understand this Manual to operateyour chain saw.
To receive maximum performance and satisfaction from
your STIHL chain saw, it is important that you read and
understand the maintenance and safety precautions be-
fore using your saw. Contact your STIHL dealer or the
STIHL distributor for your area if you do not understand
any of the instructions in this Manual.
Because a chain saw is a high-speed wood-cutting tool,
some special safety precautions must be observed as wi-
thany other power saw to reduce the risk of personal inju-
ries. Careless or improper use may cause serious or even
fatal injury.
STIHI2s philosophy is to continually improve all of its pro-
ducts. As a result, engineering changes and improve-
ments are made from time-to-time. If the operating cha-
racteristics or the appearance of your saw differs from
those described in this Manual, please contact your STIHL
dealerfor information and assistance.
STIHL 024 AV Super electronic Quickstop,
024 WB electronic Quickstop
Andreas Stihl
D-7050 Waiblingen
Operating Instructions
Sharpening and Maintenance ofSaw Chains
Contents
Parts of the Chain Saw 2
Safety Precautions 4
The Operator 4
The Saw 6
The Use of the Saw 6
Maintaining and Storing the Saw 23
Fuel 24
Chain Oil 25
Mounting the Bar and Chain 26
Chain Brake 29
General Notes on Operation 30
Master Control 31
Starting 32
Electrically Heated Handles 35
Winter Operation 36
Guide Bar, Chain and Sprocket 38
Replacing the Chain Sprocket 40
Air Filter 41
Carburetor 42
Rewind Starter 44
Maintenance Chart 46
Specifications 47
Sharpening and Maintenance of Saw Chain 49
Ordering Spare Parts 55
0458 127 3021. Mb. F1. T. Printed in Germany X c 1991 Andreas Stihi,Waiblingen
STIHL®

2
Parts of the Chain'Saw
7 Front handle
8 Shroud fastener
9 Spark plug terminal
10 Handle heating switch
11 Rear handle
12 Rear hand guard /
20 Chain guard
21 Muffler
22 Starter grip
23 Oil filler cap
24 Fuel fillercap
Front hand guard 6
Chain brake 5
Bumper spike 4
Guide bar
nose 3
Guide bar 2
Oilomatic saw chain 1
Chain sprocket 13
Chain catcher 14
Chain sprocket cover 15
Twist lock 16
Throttle trigger interlock 17
Throttle trigger 18
Master Control lever 19

Definitions 14. Chain Catcher. Helps to reduce the risk of operator
contact by a chain when it brakes or comes offthe bar.
Oilomatic Saw Chain. A loop consisting of cutters,
tie straps and drive links.
Guide Bar. Supports and guides the saw chain.
Guide Bar Nose. The exposed end of the guide bar.
Bumper Spike. Toothed stop for holding saw steady
against wood.
Chain Brake.A device to stop the rotation of the chain
if activated in a kickback situation by the operator's
hand or by inertia.
Front Hand Guard. Provides protection against pro-
jecting branches and helps prevent the left hand from
touching the chain if it slips off the handle bar.
Front Handle. Handle bar for the left hand at front of
saw.
Shroud Fastener. For fastening the shroud.
Spark Plug Terminal. Connects the spark plug with
the ignition wire.
Handle Heating Switch. For switching the electric
handle heating on and off.
Rear Handle. The support handle for the right hand,
located at or toward the rear of the saw.
Rear Hand Guard. Gives added protection to
operator's right hand.
Chain Sprocket. The toothed wheel that drives the
saw chain.
Chain Sprocket Cover. Covers the clutch and the
sprocket.
Twist Lock. Lock for carburetor box cover.
Throttle Trigger Interlock. Must be depressed be-
fore the throttle trigger can be activated.
Throttle Trigger. Controls the speed of the engine.
Master Control Lever. Lever for choke control,
starting throttle, run and stop switch, position.
Chain Guard (Scabbard). Covers the bar and the
chain when the saw is not in use.
Muffler. Reduces engine exhaust noise and directs
the exhaust gases.
Starter Grip. The grip of the starter, for starting the
engine.
Oil Filler Cap. For closing the oil tank.
Fuel Filler Cap. For closing the fuel tank.
Clutch. Couples engine to chain sprocket when
engine is accelerated beyond idle speed.
(Not illustrated.)
Anti-Vibration System. The anti-vibration system in-
cludes a number of buffers designed to reduce the
transmission of vibrations created by the engine and
cutting attachment to the operator's hands.
(not illustrated). 3

Safety Precautions
The use ofany chain sawmay be hazardous.The saw chain
has many sharp cutters. If the cutters contact your flesh,
they will cut you, even if the chain is not moving. At full
throttle, the chain speed can reach 45 mph (20 m/s). It is
important that you read, fully understand and observe the
following safety precautions and warnings. Read the
owner's manual and the safety instructions periodically.
Pay special attention to the section on reactive forces,
pages 10 to 16.
Warning!
Reactive forces, including kickback, can be dangerous.
Careless or improper use of any chain saw may cause
serious or fatal injury.
All safety precautions that are generally observed when
working with an axe or a hand saw also apply to the opera-
tion of chain saws. However, because a chain saw is a
highspeed, fast-cutting power tool, special safety pre-
cautions must be observed to reduce the risk of personal
injury.
Have your STIHL dealer show you how to operate your
chain saw. Observe all applicable local safety regulations,
standards and ordinances.
Warning!
Minors should never be allowed to use a chain saw.
Bystanders, especially children and animals should not be
allowed in the area where a chain saw is in use (ill. 1).
Never let the saw run unattended. Store it in a locked place
away from children and empty the fuel tank before storing
for longer than a few days.
Do not lend or rent your chain saw without the Owner's
Manual. Be sure that anyone using your saw reads and
4 understands the information contained in this Manual.
These safety precautions and warningsapply to the use of
all STIHL chain saws. Different models may have different
parts and controls. See the appropriate section of your
Owner's Manual for a description of the controls and
function of the parts of your model saw.
Safe use of a chain saw involves
the operator
the saw
the use of the saw.
THE OPERATOR
Physical Condition
You must be in good physical condition and mental health
and not under the influence of any substance (drugs,
alcohol) which might impair vision, dexterity or judgment.
Do not operate a chain saw when you are fatigued (ill. 2).
Be alert If you get tired while operating your chain saw,
take a break. Tiredness may result in loss ofcontrol. Work-
ing with any chain saw can be strenuous. If you have any

condition that might be aggravated by strenuous work,
check with your doctor before operating a chain saw.
Warning!
Prolonged useof chain saws (or othermachines) exposing
the operator to vibrations may produce whitefinger dis-
ease (Raynaud's phenomenon). This phenomenon re-
duces the hand's ability to feel and regulate temperature,
produces numbness and burning sensations and may
cause nerve and circulation damage and tissue necrosis.
Many STIHL models are available with an anti-vibration
(AV) system designed to reduce engine vibration. An anti-
vibration system is recommended for those using chain
saws on a regular or sustained basis.
Heated handles help to reduce the risk of whitefinger
diseaseand are recommended for cold weather use. Most
STIHL powerheads are available with heated handles.
Anti-vibration systems and heated handles do not gua-
rantee that you will not sustain whitefinger disease. There-
fore, continual and regular users should monitor closely
the condition of their hands and fingers. If any of the above
symptoms appear, seek medical advice immediately.
Proper Clothing
Clothing must be sturdy and snug-fitting, but allow com-
plete freedom of movement. Avoid loose-fitting jackets,
scarfs, neckties, jewelry, flared or cuffed pants, or anything
that could become entangled with the saw or brush. Wear
overallsor jeans with a reinforced cut resistant insert (ill. 3).
Protect your hands with gloves when handling saw and
saw chain. Heavy-duty, nonslip gloves improve your grip
and protect your hands. 5
2

Good footing is most important in chain saw work . Wear
sturdy boots with nonslip soles. Steel-toed safety boots
are recommended.
Proper eye protection is a must. Non-fogging, vonted
goggles or a face screen is recommended. Their use re-
duces the risk of eye injury.
Wear an approved safety hard hat to protect your head.
Chain saw noise may damage your hearing. Always wear
sound barriers (ear plugs or ear mufflers) to protect your
hearing. Continual and regular users should have their
hearing checked regularly.
THE SAW
Parts of the chain saw; for illustrations and definitions of
the parts see pages 2 and 3!
Warning!
Never modify a chain saw in any way. Only attachments
and parts supplied by STIHL or expressly approved by
STIHL for use with the specific STIHL saw models are
authorized. Although certain unauthorized attachments
are useable with the STIHL powerhead, their use may, in
fact, be extremely dangerous.
THE USE OF THE SAW
Transporting thechain saw Preparation forthe use of the saw
Warning!
Always stop the engine before putting a chain saw down
or carrying it. Carrying a chain saw with the engine running
is extremely dangerous. Accidental acceleration of the
6 engine can cause the chain to rotate. During operation,
4
j_19)?r,
the powerhead muffler and the material around it reach
extremely high temperatures. Avoid touching the hot muf-
fler, you could receive serious burns.
By hand: When carrying your saw by hand, the engine
must be stopped and the saw must be in the proper posi-
tion. Grip the front handle and place the muffler away from
the body (ill. 4).
The chain guard (scabbard) should be over the chain and
the guide bar, which should point backwards. When carry-
ing your saw, the bar should be behind you (ill. 4).
By vehicle: When transporting in a vehicle, keep chain
and bar covered with the chain guard. Properly secure
your saw to prevent turnover, fuel spillage and damage to
the saw.
Take off the chain guard and inspect for safety in opera-
tion. For assembly, follow the procedure described in the
chapter "Mounting the Bar and Chain" of your owner's
manual.

STIHL Oilomatic chain, guide bar and sprocket must
match each other in gauge and pitch.
Before replacing any bar and chain, see the sections on
"Specifications", kickback and the ANSI B 175.1-1985
chain saw kickback standard in this manual.
Warning!
Proper tension of the chain is extremely important. In or-
der to avoid improper setting, the tensioning procedure
must be followed as described in your manual. Always
make sure the hexagonal nut(s) for the sprocket cover is
(are) tightened securely after tensioning the chain. Never
start the saw with the sprocket cover loose. Check chain
tension once more after having tightened the nut(s) and
thereafter at regular intervals (whenever the saw is shut
off). If the chain becomes loose while cutting, shut off the
engine and then tighten. Never try to tighten the chain
while the engine is running!
Fueling
Your STIHL chain saw uses an oil-gasoline mixture forfuel
(see chapter "Fuel" of your owner's manual).
Warning!
Gasoline is an extremely flammable fuel. Use extreme
caution when handling gasoline or fuel mix. Do not smoke
or bring any fire or flame near the fuel (ill. 5).
Fueling Instructions
Fuel your chain saw in well-ventilated areas, outdoors
only.
Always shut off the engine and allow it to cool before
refueling. Gasoline vapor pressure may build up inside the
gas tank of a two cycle engine depending on the fuel
used, the weather condition, and the venting system ofthe
tank. In order to reduce the risk of burns or other personal
injury from escaping gas vaporand fumes, remove the gas
cap on the STIHL product carefully so as to allow any
pressure build-up in the tank to release slowly. Never re-
move fuel filler cap while engine is running.
Select bare ground for fueling and move at least 10 feet
(3 m) from fueling spot before starting the engine. Wipe off
any spilled fuel before starting your saw, and check for
leakage.
Check for fuel leakage while refueling and during opera-
tion. If fuel or oil leakage is found, do not start or run the
engine until leak is fixed and spilled fuel has been wiped
away. Tighten the fuel cap after filling to avoid spillage and
risk of fire.
Starting
Warning!
Your chain saw is a one-person saw. Do not allow other
persons to be near the running chain saw. Start and oper-
ate your saw without assistance. For specific starting in-
structions, see the appropriate section of the owner's
manual. Proper starting methods reducethe risk of injury. 7
5

Do not drop start. This method is very dangerous because
you may lose control ofthe saw (ill 6).
There are two recommended methods for starting your
chain saw. With the first method, the chain saw is started
on the ground. Engage the chain brake (see "Chain Brake"
chapter in your owner's manual) and place the chain saw
on firm ground or other solid surface in an open area.
Maintain good balance and secure footing. Grip the front
handlebar of the saw firmly with your left hand and press
down. For saws with a rear handle level with the ground,
put the toe of your rightfoot into the rear handle and press
down. With your right hand pull out the starter grip slowly
until you feel a definite resistance and then give it a brisk,
strong pull.
The second recommended method for starting your
chain saw allows you to start the saw without placing it on
the ground. Engage the chain brake, grip the front handle
of the chain saw firmly with your left hand. Keep the arm
on the front handle in a locked (straight) position. Hold the
rear handle of the sawtightly between your legs just above
the knees. Maintain good balance and secure footing. Pull
the starting grip slowly with your right hand until you feel a
8 definite resistance and then give it a brisk, strong pull.
Warning!
Be sure that the guide bar and chain are clear of you and
all other obstructions and objects, including the ground.
When the engine is started, the engine speed with the
starting throttle lock engaged will be fast enough for the
clutch to engage the sprocket and turn the chain. If the up-
per quadrant of the tip of the bar touches any object, it
may cause kickback to occur (see section on reactive for-
ces on pp. 10-16). To reduce this risk, always engage the
chain brake before starting. Never attempt to start the
chain saw when the guide bar is in a cut or kerf.
When you pull the starter grip, do not wrap the starting
rope around your hands. Do not allow the grip to snap
back, but guide the starter rope slowly back to permit the
rope to rewind properly. Failure to follow this procedure
may result in injury to hand or fingers and maydamagethe
starter mechanism.
Important adjustments
Warning!
At correct idle speed, the chain should not rotate. For di-
rections to adjust idle speed, see the appropriate section
of your owner's manual.
Do not use a saw with incorrect idle speed adjustment.
If you cannot set the correct idle speed, have your STIHL
dealer check your saw and make proper adjustments or
repairs.
After adjusting a chain, start the saw, let the engine run for
a while, then switch engine off and recheck chain tension.
Proper chain tension is very important at all times.
6