Stihl HSE 61 User manual

STIH)
STIHL HSE 61, 71, 81 2008-02

1HSE 61, HSE 71, HSE 81
q
© ANDREAS STIHL AG & Co. KG, 2008
RA_279_00_01_01
1. Introduction 3
2. Safety Precautions 4
3. Electrical System 5
3.1 Replacing the Carbon
Brushes 5
3.1.1 Removing the carbon
Brushes 5
3.1.2 Installing the carbon
brushes 5
3.2 Replacing the
Connecting Cord 6
3.2.1 Removing the
connecting cord 6
3.2.2 Installing the
connecting cord 6
3.3 Replacing the Motor 6
3.3.1 Removing the motor 6
3.3.2 Installing the motor 7
3.4 Wiring – Switch –
Capacitor 8
3.4.1 Removing the blue
connecting wire 8
3.4.2 Installing the blue
connecting wire 8
3.4.3 Removing the wiring
harness with capacitor 9
3.4.4 Installing the wiring
harness with capacitor 9
3.4.5 Removing the blue motor
connecting wire 11
3.4.6 Installing the blue motor
connecting wire 11
3.4.7 Removing
the microswitch 12
3.4.8 Installing
the microswitch 13
4. Cutting Attachment 15
4.1 Replacing the cutting
attachment 15
4.1.1 Disassembling the
cutting attachment 15
4.1.2 Mounting the cutting
attachment 16
4.2 Servicing the Cutting
Attachment 18
4.2.1 Disassembling the
cutting attachment 18
4.2.2 Assembling the
cutting attachment 19
4.3 Sharpening the blades 20
5. Drive Gear 21
5.1 Servicing
the drive gear 21
5.1.1 Exposing
the drive gear 21
5.1.2 Removing
spur gear assembly 21
5.1.3 Removing the carrier 21
5.1.4 Assembling the
drive gear 22
5.1.5 Installing
the drive gear 22
5.2 Servicing
the intermediate gear
(HSE 71, HSE 81) 23
5.2.1 Removing the gear 23
5.2.2 Removing the bearing 23
5.2.3 Installing the bearings 23
5.2.4 Installing the gear 23
5.3 Replacing
the connecting rods 24
5.3.1 Replacing upper
connecting rod 24
5.3.2 Replacing the lower
connecting rod 24
5.4 Replacing the gearbox
plate 25
5.4.1 Removing the gearbox
plate 25
5.4.2 Installing
the gearbox plate 26
5.5 Replacing
the support plate 27
5.5.1 Removing
the support plate 27
5.5.2 Installing
the support plate 27
5.6 Replacing
the bearing plate 28
5.6.1 Removing
the bearing plate 28
5.6.2 Installing
the bearing plate 29
6. Housing and
Handles 30
6.1 Opening the housing 30
6.1.1 Removing
the top cover 30
6.1.2 Removing
the loop handle 30
6.1.3 Removing the cap 30
6.1.4 Removing the motor
housing 31
6.1.5 Removing housing
half 31
6.2 Closing the housing 31
6.2.1 Closing the
housing half 31
6.2.2 Installing
the motor housing 32
6.2.3 Installing the cap 32
6.2.4Fitting the top cover 33
6.2.5 Mounting
the loop handle 33
6.3 Servicing the
Loop Handle and
Hand Guard 34
6.3.1 Disassembling the
loop handle and
hand guard 34
6.3.2 Assembling the loop
handle and hand guard 34
6.4 Servicing
the rear handle 35
6.4.1 Opening
the rear handle 35
6.4.2 Disassembling
the rear handle 35
6.4.3 Assembling
the rear handle 37
6.4.4 Closing
the rear handle 41
6.5 Replacing
the housing 42
6.5.1 Removing
the housing 42
6.5.2 Installing
the housing 43
6.6 Replacing
the quadrant 44
6.6.1 Removing
the quadrant 44
6.6.2 Installing
the quadrant 44
Contents

2HSE 61, HSE 71, HSE 81
Contents
7. Switch
Components 46
7.1 Replacing
the switch lever 46
7.2 Servicing
the control unit 46
7.2.1 Disassembling
the control unit 46
7.2.2 Assembling
the control unit 48
7.2.3 Installing
the switch pin 49
7.2.4 Mounting
the control unit 50
7.3 Replacing the cable 52
7.3.1 Removing the cable 52
7.3.2 Installing the cable 52
7.4 Replacing front
switch rod 53
7.4.1 Removing
the switch rod 53
7.4.2 Installing
the switch rod 53
7.5 Replacing
the switch lever
(loop handle) 54
7.5.1 Removing
the switch lever
(loop handle) 54
7.5.2 Installing
the switch lever
(loop handle) 54
7.6 Replacing the slide 54
7.6.1 Removing the slide 54
7.6.2 Installing the slide 55
8. General 58
8.1 Troubleshooting 58
8.2 Maintenance Chart 58
8.3 Cleaning 59
8.4 Repair kits 59
8.5 Tightening torques 60
8.6 Lubrication 61

3HSE 61, HSE 71, HSE 81
1. Introduction
This service manual contains
detailed descriptions of all the repair
and servicing procedures specific to
this power tool.
As the design concept of model
HSE 61, HSE 71, HSE 81 hedge
trimmers is almost identical, the
descriptions and servicing
procedures in this manual generally
apply to all three models.
Differences are described in detail.
You should make use of the
illustrated parts lists while carrying
out repair work. They show the
installed positions of the individual
components and assemblies.
Refer to the latest edition of the
relevant parts list to check the part
numbers of any replacement parts.
A fault on the machine may have
several causes. To help locate the
fault, consult the troubleshooting
charts for all assemblies and
systems in this manual and the
"STIHL Service Training System".
Refer to the “Technical Information”
bulletins for engineering changes
which have been introduced since
publication of this service manual.
Technical information bulletins also
supplement the parts list until a
revised edition is issued.
Symbols are included in the text and
pictures for greater clarity.
The meanings are as follows:
In the descriptions:
:= Action to be taken as
shown in the illustration above
the text
– = Action to be taken that is
not shown in the illustration
above the text
In the illustrations:
APointer
aDirection of movement
b4.2 = Reference to another
chapter, i.e. chapter 4.2
in this example
Service manuals and all technical
information bulletins are intended
exclusively for the use of properly
equipped repair shops. They must
not be passed to third parties.
Always use original STIHL
replacement parts.
They can be identified by the
STIHL part number,
the STIH) logo and the
STIHL parts symbol (
This symbol may appear alone on
small parts.

4HSE 61, HSE 71, HSE 81
2. Safety Precautions
If the power tool is started up in the
course of repairs or maintenance
work, observe all local and country-
specific safety regulations as well
as the safety precautions and
warnings in the instruction manual.
Warning!
All relevant electrical safety
precautions must be observed
when carrying out repairs on
electrical equipment.
Repairs may only be performed by a
qualified electrician observing all
country-specific safety precautions
and the instruction manual.
Improper handling may result in
serious injuries.

5HSE 61, HSE 71, HSE 81
3. Electrical System
3.1 Replacing the Carbon
Brushes
3.1.1 Removing the carbon
Brushes
– Remove the top cover, b6.1.1.
:Disconnect both wires (red) (1)
from the motor in the direction of
the arrows and take them out of
the openings.
:Remove the screws (1) from the
carbon brushes (2).
1
1
1
1
1
2
2
:Take out the carbon brushes (1)
(pull in direction of arrow).
3.1.2 Installing the carbon
brushes
:Fit the (new) carbon brushes (1)
in the motor.
1
1
1
1
:Secure the carbon brushes (2) in
position with the screws (1).
:Pass the two wires (red) (1)
through the openings and
connect up.
– Fit the cover, b6.2.4.
1
2
2
1
11

6HSE 61, HSE 71, HSE 81
3.2 Replacing the
Connecting Cord
3.2.1 Removing the
connecting cord
– Remove the cap, b6.1.3.
:Lift the connecting cord (1) out of
the housing.
:Loosen the screws (3) on
terminal block (2) to disconnect
the connecting cord (1).
:Remove the connecting cord (1).
1
13
3
2
3.2.2 Installing the connecting
cord
:Secure the connecting cord (1) to
the terminal block (2) by
tightening down the screws (3)
(0.5 Nm).
:Fit the terminal block (2) in the
housing.
:Position the connecting cord (1)
in the strain relief guide as shown
in the illustration.
:Engage the cord protector (4) in
the end of the handle.
– Fit the cap, b6.2.3.
4132
3
3.3 Replacing the Motor
3.3.1 Removing the motor
– Remove the cutting attachment,
b4.1.1.
– Open the housing, b6.1.
– Expose the drive gear, b6.1.1.
:Remove the front switch rod (1).
:Disconnect the blue wire (1) and
black wire (2) from the motor.
1
2
1

7HSE 61, HSE 71, HSE 81
:Take out the motor mounting
screws (1).
:Remove the motor (1) in direction
of arrows.
11
11
1
3.3.2 Installing the motor
:Fit the motor (1) in direction of
arrows.
:Insert the motor mounting screws
(1) and tighten them down firmly
to a torque of 1.5 Nm.
1
11
11
:Connect the blue wire (1) at the
front side of the motor and the
black wire (2) at the rear of the
motor (see illustration).
:Push the blue wire (1) into the
two slots (2) in the housing and
secure in position.
– Install the drive gear, b5.1.5.
– Close the housing, b6.2.
2
1
1
2
2

8HSE 61, HSE 71, HSE 81
3.4 Wiring – Switch –
Capacitor
3.4.1 Removing the blue
connecting wire
– Open the housing, b6.1.
– Open the rear handle, b6.4.1.
:Disconnect the blue wire (1) from
the switch.
:Take the wire out of the slots.
:Loosen the screw (2) and remove
the blue wire from the terminal
block (1).
1
21
:Pull the blue wire (1) out of the
rear handle in the direction of the
arrow.
3.4.2 Installing the blue
connecting wire
:Thread the blue wire (1) through
the rear handle, from front to rear
in the direction of the arrow.
Make sure the blue wire (1) is
positioned as shown in the
illustration.
1
1
1
:Connect the blue wire to the
terminal block (1).
:Pull the blue wire (1) forwards
and push it into the slots (A).
Connect the wire (1) to the
switch.
– Close the rear handle, b6.4.4.
– Close the housing, b6.2.
1
AA
1A

9HSE 61, HSE 71, HSE 81
3.4.3 Removing the wiring
harness with capacitor
– Open the housing, b6.1.
– Open the rear handle, b6.4.1.
– Disassemble the rear handle,
b6.4.2.
:Take the gear housing (1) with its
components out of the motor
housing (2). Pull off the gearbox
housing (1) in the direction of the
arrow.
:Disconnect the black wire (1)
from the motor.
2
1
1
– Disconnect the blue wire from the
switch (2).
:Disconnect the black wire (1)
from the switch (2).
:Remove the capacitor (1) from its
holder in the direction of the
arrow.
1
2
1
3.4.4 Installing the wiring
harness with capacitor
:Connect the black wire (1) to the
motor.
:Connect terminal socket of black
wire (1) to switch (2) and push it
together with wire (3) into the
retaining slots (4) (see
illustration).
1
2
1
3
4
4

10 HSE 61, HSE 71, HSE 81
:Fit the capacitor (1) in its holder
(2).
:Engage both black wires (1) from
the capacitor in the slot.
1
2
1
:Push the black connecting wire
(1) into the slot (2).
– Connect the blue wire to the
switch.
:Push the blue wire (1) into the
two slots (2) in the housing and
secure in position.
2
1
1
2
2
:Place the gear housing (1) with
its components in the motor
housing (2).
– Assemble the rear handle,
b6.4.3.
– Close the rear handle, b6.4.4.
– Close the housing, b6.2.
2
1

11HSE 61, HSE 71, HSE 81
3.4.5 Removing the blue motor
connecting wire
– Open the housing, b6.1.
– Open the rear handle, b6.4.1.
– Disassemble the rear handle,
b6.4.2.
:Take the gear housing (1) with its
components out of the motor
housing (2).
:Disconnect the blue wire (1) from
the motor.
2
1
1
:Disconnect the black wire (1)
from the switch.
(
:Disconnect the blue wire (1) from
the switch.
1
1
3.4.6 Installing the blue motor
connecting wire
:Connect the blue wire (1) to the
motor.
:Connect terminal socket of blue
wire (1) to the switch and push
the wire into the slot (2).
1
1
2

12 HSE 61, HSE 71, HSE 81
:Connect terminal socket of black
wire (1) to the switch and push
the wire into the slots (2).
:Place the gear housing (1) with
its components in the motor
housing (2).
– Assemble the rear handle,
b6.4.3.
– Close the rear handle, b6.4.4.
– Close the housing, b6.2.
– Replace the microswitch.
21
2
2
1
3.4.7 Removing the
microswitch
– Open the housing, b6.1.
– Open the rear handle, b6.4.1.
– Disassemble the rear handle,
b6.4.2.
:Take the gear housing (1) with its
components out of the motor
housing (2).
:Push the blue wire (1) into the
two slots (2) in the housing and
secure in position.
2
1
1
2
2
:Swing the rod (1) up.
:Disconnect all wires (1 – 3) from
the microswitch (4).
1
1
2
4
3

13HSE 61, HSE 71, HSE 81
:Remove the microswitch (1) from
the control unit (pull in direction of
arrow).
3.4.8 Installing the
microswitch
:With the rod (2) upright, fit the
microswitch (1) in the control unit.
1
2
1
:Swing the rod (1) down.
:Connect terminals of the wires (1
– 3) to the microswitch (4).
Wire 1: blue
Wire 2: black
Wire 3: blue
1
1
2
4
3
:Engage the wires in the slots.
:Push the blue wire (1) into the
two slots (2) in the housing and
secure in position.
1
2
2

14 HSE 61, HSE 71, HSE 81
:Place the gear housing (1) with
its components in the motor
housing (2).
– Assemble the rear handle,
b6.4.3.
– Close the rear handle, b6.4.4.
– Close the housing, b6.2.
2
1

15HSE 61, HSE 71, HSE 81
4. Cutting Attachment
4.1 Replacing the cutting
attachment
4.1.1 Disassembling the
cutting attachment
:Take out the screws (1).
:Remove the bottom cover (1).
1
1
1
1
1
Up to serial number 9 72 393 577
:Loosen blade mounting screws
(1).
:Tilt the cutting attachment (1)
slightly (ease it in direction of
arrow) to disengage it from the
connecting rods and pull it away
forwards.
11
1
From serial number 9 72 393 578
:Loosen the screws (1) and (2).
:Remove the circlip (3) (only on
models HSE 71, HSE 81).
:Remove the bearing plate (1) and
washer(2).
:Tilt the cutting attachment (3)
slightly (ease it in direction of
arrow) to disengage it from the
connecting rods and pull it away
forwards.

16 HSE 61, HSE 71, HSE 81
4.1.2 Mounting the cutting
attachment
Up to serial number 9 72 393 577
:Place the cutting attachment (1)
on the gear housing (2).
– Engage the lower blade on the
lower connecting rod (3).
:Line up holes in cutting
attachment with holes in gear
housing (2) and insert the screws
(4) but do not finally tighten yet.
:Engage the upper blade (1) on
the upper connecting rod (2).
1
4
4
3
2
21
:Tighten down the screws (1)
firmly (2.9 Nm).
:Check that the pin (1) is fitted in
the cover (2). If the pin (1) is not
in the cover (2), fit it as shown in
the illustration.
b4.1.1
1
1
1
2
From serial number 9 72 393 578
:Place the cutting attachment (1)
on the gear housing (2).
– Engage the lower blade on the
lower connecting rod (3).
:Line up holes in cutting
attachment with holes in gear
housing (2) and insert the screw
(4) but do not finally tighten yet.
:Engage the upper blade (1) on
the upper connecting rod (2).
21

17HSE 61, HSE 71, HSE 81
:Insert the screw (1) through the
hole in the bearing plate (2).
:Place the washer (3) on the hole.
:Insert the screw (1) (with bearing
plate (2)) through the washer and
tighten it down moderately.
:Fit the screws (4).
:Fit the circlip (1) (only on models
HSE 71, HSE 81).
:Tighten down the screws (2)
firmly (2.9 Nm).
:Tighten down the screws (3)
firmly (2.9 Nm).
b4.1.1
:Fit the bottom cover (1) and
tighten down the self-tapping
screws (2) to a torque of 1.5 Nm.
Now tighten down the screws (3)
to a torque of 2.9 Nm.

18 HSE 61, HSE 71, HSE 81
4.2 Servicing the Cutting
Attachment
4.2.1 Disassembling the
cutting attachment
– Remove the cutting attachment,
b4.1.1.
:Loosen the screws (4).
:Loosen the screws (9) and
remove the tip guard (6).
Only one screw (9) needs to be
removed on units up to serial
number 9 72 318 871
(TI 09.2006).
:Remove the guide (5).
:Lift away the blade (7) and blade
(8) separately.
:Remove the sliders (1), (2) and
(3) (for quantities of sliders (1),
(2) and (3) see table).
:Take out the screws (12) and
remove the cutter guard (11)
(HSE 81).
4
5
2
3
3
3
3
3
3
99
6
1
1
7
8
10
11
12
12
12
10mm
8mm
7mm
A
B
C12
1234
HSE 61 2xA 1xC 4xB 5x
HSE 71 2xA 1xC 5xC 6x
HSE 71 2xA 1xC 6xC 7x
HSE 81 2xA 1xC 5xC 6x
HSE 81 2xA 1xC 6xC 7x

19HSE 61, HSE 71, HSE 81
4.2.2 Assembling the cutting
attachment
:Mount the cutter guard (11)
(HSE 81) with the screws (12).
:Position the blades (7 + 8)
correctly (see illustration D) on
the aluminum guide (10).
:Fit the sliders (3) in the slots of
the blades (7 + 8) and line them
up with the tapped holes in the
guide.
:Fit the sliders (1), collar facing up,
on the blade mounting holes.
:Place the guide (5) on the blade.
4
5
2
3
3
3
3
3
3
99
6
1
1
7
8
10
11
12
12
10mm
8mm
7mm
A
B
C12
D
1234
HSE 61 2xA 1xC 4xB 5x
HSE 71 2xA 1xC 5xC 6x
HSE 71 2xA 1xC 6xC 7x
HSE 81 2xA 1xC 5xC 6x
HSE 81 2xA 1xC 6xC 7x