Hitachi CS 51EA User manual

Brand: Hitachi

Model: CS 51EA

Category: Power chainsaws

Type: User manual

This manual is also suitable for

CS51EAP

PRODUCT NAME

Hitachi Engine Chain Saw

Models CS 51EAP

CS 51EA

International Sales Division

䌃

TROUBLESHOOTING GUIDE ---------------------------------------------------------------------------------------------- 1

1. Troubleshooting and correction ------------------------------------------------------------------------------- 1

REPAIR GUIDE ----------------------------------------------------------------------------------------------------------------- 3

1. Precaution on maintenance, inspection and repair ------------------------------------------------------ 3

2. Inspection criteria for each section and consumable parts -------------------------------------------- 3

CONTENTS

Page

LIST Nos.

CS 51EAP: F009

CS 51EA: F008

Feb. 2012

-1-

1. Troubleshooting and correction

Trouble Cause Corrective action

Starter

handle

cannot be

pulled.

The crank shaft does

not rotate.

Faulty piston ring

Disassembly and parts

replacement

Seized piston and cylinder

Faulty crank shaft bearings

Magneto rotor contact with

ignition coil

The recoil starter does

not rotate.

Broken recoil starter

Inspection and replacement

Faulty starter pawl

Startup is

impossible.

No compression

Faulty piston ring

Parts replacement

Worn piston

Expired oil seal service life

Worn cylinder

Defective sealing of the packing

Faulty decompression valve Cleaning or replacement

Short-circuited due to foreign matter between the spark plug

electrodes.

Removal of foreign matter: In

case of frequent occurrence,

disassemble and clean the

engine.

No spark

Stop switch not at startup position Adjust to startup position.

Dirty or faulty spark plug

Cleaning or replacement

Improperly connected plug cap Inspection and replacement

Disconnected or improperly

connected high voltage cord

Repair or replacement

Ground connection of high

voltage cord

Repair

Disconnected or faulty ignition

coil ass’y

Replacement

Large gap between the magneto

rotor circumference and ignition

coil ass’y

Adjustment

The spark plug does

not become wet with

fuel after repeated

starting operation.

No fuel in the fuel tank

Add properly mixed fuel

(25:1 to 50:1).

Clogged fuel filter Cleaning or replacement

Faulty fuel pipe

Adjustment, replacement or

connection

Faulty vent hole (inner cap) on

the fuel tank

Replacement

Faulty carburetor ass’y

Adjustment, cleaning or

replacement

The spark plug is wet

due to excessive fuel

supplied.

Starter handle pulled repeatedly

with choke button pulled out (set

at “startup”)

Dry the spark plug.

Remove excessive fuel.

Idling stops

although

startup is

possible.

Weak spark

Dirty or faulty spark plug Cleaning or replacement

Improper air gap Adjustment

Low compression

Worn piston ring

Replacement

Expired oil seal service life

Faulty decompression valve Cleaning or replacement

Good spark and

compression

Revolutions too low for idling

Adjustment

Poorly adjusted carburetor ass’y

TROUBLESHOOTING GUIDE

-2-

Trouble Cause Corrective action

Starts, but

when

accelerating

…

The engine stalls.

Clogged fuel filter Cleaning or replacement

Insufficient warm-up Warm-up

Poorly adjusted carburetor ass’y Adjustment

Poor acceleration; no

increase in revolutions

Clogged cylinder vent passage,

exhaust port and/or

carbon-clogged muffler

Cleaning

Clogged air cleaner

Chain brake set on Release

Poorly adjusted carburetor ass’y

Adjustment, cleaning or

replacement

Starts, but

…

Fluctuating revolutions

at high speed

Dirt-clogged high-speed fuel line Cleaning

Defective sealing of the packing Replacement

Faulty carburetor ass’y

Adjustment, cleaning or

replacement

Excessive fuel

consumption

Clogged air cleaner Cleaning

Poorly adjusted carburetor ass’y Adjustment

Chain oil is not discharged.

Insufficient amount of chain oil in

the oil tank

Insufficient chain oil in the oil

tank

Clogged chain oil discharge port

Cleaning

Clogged oil filler port on the guide

bar

Clogged oil filter

Poor adjustment of chain oil

discharge amount

Poorly adjusted chain oil

discharge amount

Faulty oil pump Faulty oil pump

-3-

This section describes repair, focusing on portions requiring frequent repair. See TROUBLESHOOTING

GUIDE in the previous section as the context for the following descriptions.

1. Precautions on maintenance, inspection and repair

• The fuel used readily ignites; therefore, never bring the product near a flame.

• Use new gaskets at reassembly.

• Prior to disassembly for repair, remove the fuel and chain oil into separate containers, and allow the engine

to cool down.

• During repair, startup or running, use adequate care for portions posing the risk of burn injury or electric

shock, such as hot areas including the muffler, high voltage cord, and spark plug.

• Before running the product with the guide bar and saw chain attached, make sure that there are no other

people nearby.

• Ensure proper ventilation when performing repair in a small room or other poorly ventilated space.

2. Inspection criteria for each section and consumable parts

Model

Item

CS 51EAP CS 51EA

Idling revolutions 3,000 ± 200 min

-1

(rev./min.)

No-load maximum revolutions

(with guide bar and saw chain)

13,500 min

-1

(rev./min.)

Clutch engagement 3,900 to 4,600 min

-1

(rev./min.)

Accelerating performance Smooth acceleration

Gap between magneto rotor and

ignition coil ass’y

0.2 to 0.4 mm

Spark plug NGK BPM7A or NGK BPMR7A

Gap between spark plug electrodes 0.6 to 0.7 mm

Saw chain type OREGON 95VPX, 20BPX

Saw chain pitch x gauge 8.26 mm (0.325 in.) x 1.27 mm (0.05 in.)

No. of saw chain drive links 56, 64, 66, 72, 78

REPAIR GUIDE

-4-

Seized or broken piston ring Replacement

Seized piston or cylinder Replacement

Seized or broken needle bearing of the crank

shaft

Replacement

Seized ball bearing Replacement

Magneto rotor contact with ignition coil Adjustment

Broken recoil starter Inspection/replacement

Faulty starter pawl Inspection/replacement

Faulty piston ring Cleaning/replacement

Worn piston ring Replacement

Worn piston Replacement

Worn or damaged oil seal Replacement

Worn cylinder Replacement

Defective sealing of the packing Replacement

Defective decompression valve Replacement

Remove foreign matter. Disassembly/cleaning

Stop switch not at startup position

Setting to startup

position

Dirty or faulty spark plug Cleaning/inspection

Improperly connected plug cap Inspection/replacement

Disconnected or improperly connected high

voltage cord and other wiring

Inspection/replacement

Ground connection of high voltage cord and

other wiring

Inspection

Disconnected or faulty ignition coil

Replacement

Excessive gap between magneto rotor

circumference and ignition coil

Adjustment

No fuel in fuel tank or improper mixing ratio

Add properly mixed fuel

(25:1 to 50:1).

Clogged fuel filter Cleaning/replacement

Bent fuel pipe Adjustment

Cracked fuel pipe Replacement

Fallen fuel pipe Connection

Faulty tank vent hole (inner cap) Replacement

Faulty pump diaphragm of carburetor ass’y Replacement

Dirt-clogged carburetor ass’y Cleaning

Poorly adjusted carburetor ass’y Adjustment

Starter handle pulled repeatedly with choke

button pulled out (set at “startup”)

Dry the spark plug.

Remove excessive fuel.

air flowchart

Pull the starter handle.

Is pulling possible?

Remove the spark plug to

check for sparks.

Sparks are generated.

Dry

There is compression.

Return the spark plug

and plug cap to the

original positions, and

then perform proper

startup operation.

Confirm that the tip of the

spark plug becomes wet

with fuel.

Wet spark plug due to

excessive supply of fuel

Is the spark plug

contaminated with foreign

matter?

Contaminated

No spark

Impossible to pull

No compression

Wet

-5-

Dirty or faulty spark plug Cleaning/replacement

Defective air gap

Adjustment

Worn piston ring

Replacement

Expired oil seal service life

Replacement

Defective decompression valve

Cleaning/replacement

Revolutions too low for idling Adjustment

Poorly adjusted carburetor ass’y Adjustment

Revolutions too low for idling Adjustment

Poorly adjusted carburetor ass’y Adjustment

Defective sealing of the packing Replacement

Revolutions too high for idling Adjustment

Worn or faulty clutch Inspection/replacement

Poorly adjusted carburetor ass’y Adjustment

Clogged fuel filter

Cleaning/replacement

Inadequate warm-up, especially in cold

weather

Warm-up

Poorly adjusted carburetor ass’y

Adjustment

Clogged cylinder vent passage, exhaust port

or carbon-clogged muffler

Cleaning

Clogged air cleaner

Cleaning

Chain brake set on

Release

Poorly adjusted carburetor ass’y

Adjustment

Faulty carburetor ass’y pump diaphragm

Replacement

Dirt-clogged carburetor ass’y

Cleaning

Dirt-clogged high-speed fuel line of the

carburetor ass’y

Cleaning

Air intake from the packing section Inspection

Faulty carburetor ass’y pump diaphragm Replacement

Poorly adjusted carburetor ass’y Adjustment

Revolutions too low for idling Adjustment

Poorly adjusted carburetor ass’y Adjustment

Clogged air cleaner Cleaning

Poorly adjusted carburetor ass’y Adjustment

Insufficient chain oil in the oil tank Supply oil.

Clogged chain oil discharge port Cleaning

Clogged guide bar oil feed port Cleaning

Clogged oil filter Cleaning

Poorly adjusted chain oil discharge amount Adjustment

Defective oil pump Replacement

When the speed rapidly

decelerates from high speed…

Revolutions fluctuate

The engine stalls

The engine starts, but when

the throttle lever is pulled…

High speed unavailable

Pulling the throttle lever

increases the speed.

When the revolutions

increase…

When the product is tilted

during idling…

The engine stalls

The saw chain starts

rotating during idling.

Starts rotating

The engine stalls

Starts up, and when idling

mode is set…

Is fuel consumption excessive?

Excessive

Is chain oil discharged?

No discharge

-6-

Ɣ Spark plug

High voltage cord

Ignited sparks

Spark Plug [46]

Plug cap

Ɣ Checking for sparks

Metallic portion of the engine

[Bold] numbers in the descriptions below correspond to item numbers in the Parts List and exploded

assembly diagram for the Models CS 51EAP and CS 51EA.

Always stop the engine prior to disassembly or when replacing the saw chain.

1. Checking the spark of the spark plug

CAUTION:

Ɣ Be careful not to touch the metallic portion of the Spark Plug

[46] when pulling the starter handle; otherwise, you run the

risk of electric shock.

Ɣ Carefully wipe off any fuel around the plug to avoid a

sudden flash of fire.

(1) Remove the Spark Plug [46] from the Cylinder [73].

Use a wire brush to clean off carbon deposits on the Spark

Plug [46] electrodes, as needed. Adjust the gap between the

electrodes if necessary. Use a cloth to wipe off any fuel on

the electrodes. Remove fuel left in the Engine Case (A)

Ass’y [87] and Engine Case (B) Ass’y [80] by following the

procedure below.

(a) With the Spark Plug [46] removed from the Cylinder [73]:

(b) Open the Choke Button [93] (by pushing it in), and then

set the Stop Switch [95] to the stop position.

(d) Pull the starter handle several times.

(2) Insert the Spark Plug [46] into the Plug Cap [162], and then

place the electrodes in contact with the metallic portion of

the engine. Under these conditions, set the Stop Switch [95]

to the startup position and pull the starter handle.

(3) When all the above are normal, the Spark Plug [46]

electrodes make a snapping sound to generate sparks.

2. Adjustment of the carburetor

(1) Use the Idle Adjust Screw [63] to adjust the carburetor.

Ɣ Idle Adjust Screw [63]

Use this screw to adjust revolutions at idling. Turning the

screw clockwise increases engine revolutions; turning it

counterclockwise decreases engine revolutions.

(2) Standard setting of the carburetor

Ɣ 3,000 ± 200 min

-1

(rev./min)

(3) Fine adjustment

Ɣ Idling adjustment

(a) Use the Idle Adjust Screw [63] to set revolutions so that

the Saw Chain [115] does not start rotating while the

engine runs stably.

(b) Set idling revolutions to 2,800 to 3,200 min

-1

(rev./min) by using the Idle Adjust Screw [63].

(Adjust to approx. 3,000 min

-1

(rev./min).)

Adjust the idling revolutions after the engine is fully warmed up.

(Tip on warm-up: Let the engine idle for one minute with the engine in half-throttled status.)

Inspection and repair procedures

Ɣ Idle adjust screw

Idle Adjust Screw [63]

Revolutions

decrease.

Revolutions

increase.

Gap between

electrodes

(0.6 to 0.7 mm)

Remove carbon here.

-7-

Cleaner Knob [6]

Knob Packing [7]

Cleaner Cover [2]

Cleaner Element (B) [8]

Cleaner Element (A) [9]

Cover Set Bolt [4]

Carburetor Insulator (C51) [50]

Carburetor Ass’y [52]

Cleaner Support [71]

Hex. Socket Hd. Bolt

M5 x 12 (Precote) [38]

Cylinder Cover [5]

Clip [31]

Fuel Pipe [68]

Hex. Socket Hd. Bolt M5 x 45 [70]

Operation Plate [94]

Choke Rod Rubber [92]

Choke Button [93]

Fuel Pipe (FKM) [51]

Fuel Pipe [72]

Shutter Plate [3]

Washer 5 [69]

Ɣ Cleaner and carburetor

1. Disassembly and reassembly of the cleaner and carburetor

[Tools required]

Ɣ Phillips screwdriver

Ɣ Hex. bar wrench (4mm)

(1) Disassembly

Ɣ Loosen the Cleaner Knob [6] and remove the Cleaner Cover [2].

Use a Phillips screwdriver to loosen the three Cover Set Bolts

[4]

, and then remove the Cylinder Cover

[5]

Ɣ Pull out Cleaner Element (A) [9] and Cleaner Element (B) [8].

Ɣ Remove the Clip [31] and pull out the Fuel Pipes [68] [51] [72] from the Carburetor Ass’y [52]. Use a

hex. bar wrench (4 mm) to remove the Hex. Socket Hd. Bolt M5 x 12 (Precote) [38] and two Hex.

Socket Hd. Bolts M5 x 45 [70]. Then remove the Cleaner Support [71] and Carburetor Ass’y [52].

(2) Reassembly

Reassembly can be conducted by reversing the disassembly procedure. However, special attention

should be given to the following items.

Ɣ Do not bend the Fuel Pipes [68][51][72]. (See “2. Connecting the fuel pipes” for details.)

Ɣ Apply 0.1 to 0.2 gram of Alvania Grease RL3 to the sliding portion of the Choke Rod Rubber [92] for

the Choke Button [93]. Pull out the Choke Button [93] and then turn the throttle of the carburetor.

Make sure that the Choke Button [93] returns automatically and the carburetor’s choke valve opens to

its initial position.

Ɣ Apply 0.1 to 0.2 gram of Alvania Grease RL3 to the lug portions (to be fitted in the grooves of the

Engine Case (A) Ass’y [87] and Engine Case (B) Ass’y [80])) of the Operation Plate [94].

Ɣ Be careful not to get Cord (A) [163] and Cord (B) [164] caught in the Cylinder Cover [5].

Disassembly and reassembly

-8-

2. Connecting the fuel pipes

Make the connections as shown in the illustration below.

(1) Fully insert the pipes down to their roots.

(2) Do not bend or twist the pipes.

(3) Be careful not to get pipes in the respective portions caught in other parts.

(4) The end faces of the Fuel Pipe 2.5 x 4 x 90 [43] and Fuel Pipe [68] should protrude from the edge of the

Fuel Grommet [152] by 55 to 60 mm and 167 to 172 mm, respectively.

CAUTION: Never mix up fuel pipes inserted into the Priming Pump Comp. [44].

Ɣ Fuel pipe connection chart

Priming Pump Comp. [44]

Fuel Pipe [72]

Carburetor Ass’y [52]

Fuel Pipe 2.5 x 4 x 90 [43]

Fuel Pipe [68]

Cleaner Support [71]

Clip [31]

Fuel Pipe (FKM) [51]

Clip [31]

Fuel Grommet (A) [41]

Grommet [42]

7 mm or more

Color: Black

Color:

Transparent

CAUTION: Check the positional

relation of the Fuel

Pipes [68] and [72].

7 mm or more

Fuel Pipe 2.5 x 4 x 90 [43]

Fuel Pipe [68]

Fuel Grommet [152]

-9-

ၥၷှျၱၑၥ[162]

Ɣ Recoil starter

Air Deflector [175]

Recoil Starter [176]

Cover Set Bolt [4]

Air Deflector [175]

Cord (A) [163]

Cord (B) [164]

High voltage cord

CAUTION: Place Cord (A) [163] and Cord (B)

[164] into the groove of the Air

Deflector [175] for assembly.

CAUTION: Move the excess cords

here to take up the

slack of Cord (A) [163]

and Cord (B) [164].

3. Disassembly and reassembly of the recoil starter

[Tool required]

Ɣ Phillips screwdriver

(1) Disassembly

Ɣ Pull out the Plug Cap [162] from the Spark Plug [46].

Ɣ Use a Phillips screwdriver to loosen the four Cover Set Bolts [4], and then remove the Recoil Starter

[176] and Air Deflector [175].

(2) Reassembly

Reassembly can be conducted by reversing the disassembly procedure. However, special attention

should be given to the following items.

Ɣ Place Cord (A) [163] and Cord (B) [164] into the groove of the Air Deflector [175] for assembly.

Ɣ Place the high voltage cord of the ignition coil into the groove of the Air Deflector [175] for assembly.

Ɣ Apply 0.05 to 0.1 g of Chemiseal L-391 (manufactured by Chemitech Inc.) on the female threads of the

Cover Set Bolt [4] before mounting the Recoil Starter [176].

Ɣ Assembling the Recoil Starter [176] is made easier by first pulling the starter handle, and then

returning it a little.

-10-

Damper [124]

Damper Set Bolt [15]

Nut M6 [10]

Rear handle ass’y

Spring Holder [155]

Antivibration Spring [157]

Engine case ass’y

Fuel Pipe [68]

Rear Damper [88]

Ɣ Rear handle and engine case

4. Disassembly and reassembly of the rear handle and engine case

[Tools required]

Ɣ Flat-blade screwdriver

Ɣ Box end wrench 10 x 19 mm

(1) Disassembly

Ɣ Remove the Fuel Pipe 2.5 x 4 x 90 [43] from the

Priming Pump Comp. [44].

Ɣ Secure the Spring Holders [155] [12] by inserting a

flat-blade screwdriver into the groove of the bolt,

and then use a box end wrench 10 x 19 mm to

remove Nut M6 [10].

Ɣ Remove the Damper [124], and then use a

flat-blade screwdriver to remove the two Damper

Set Bolts [15]. Also remove the Rear Handle [146].

(2) Reassembly

Reassembly can be conducted by reversing the

disassembly procedure. However, special attention

should be given to the following items.

Ɣ Insert the Antivibration Springs [157] [14] so that their first coils do

not protrude from the first coils of the Spring Holders [155] [12].

(See the illustration above.)

Ɣ Apply 0.1 to 0.3 g of Chemiseal L-391 (manufactured by Chemitech

Inc.) to the bolts of the Spring Holders [155] [12] or on the female

threads of Nut M6 [10].

Ɣ Secure the Spring Holders [155] [12] by inserting a flat-blade

screwdriver into the groove of the bolt as illustrated on the right,

and then tighten Nut M6 [10] so that the Spring Holders [155] [12]

do not rotate when you turn the screwdriver by using a box end

wrench 10 x 19 mm.

Ɣ Use the box end wrench 10 x 19 mm to hold Nut M6 [10] in place, and then use a torque wrench with a

flat bit to tighten the bolts of the Spring Holders [155] [12] at the specified torque of 5.5 ± 0.5 N•m (56 ±

5 kgf•cm).

CAUTION: Do not twist the Fuel Pipe [68] between the rear handle and engine case.

Ɣ Tightening Nut M6 [10]

Nut M6 [10]

Ɣ Assembling the antivibration structure of coil spring

1 mm or less

The Antivibration Springs [157] [14] should not protrude

from this surface of the Spring Holders [155] [12].

Rear Handle [146]

Flanged Tapping

Screw D6 [156]

ntivibration

Springs [157] [14]

Spring Holders [155] [12]

-11-

Clutch [131]

Clutch Washer (B) [132]

Clutch Housing [133]

Needle Bearing [134]

Rim Sprocket [135]

Clutch Washer [136]

Seal Lock Screws M4 x 10 [16]

Oil Pump Cover [137]

Worm [138]

Oil Pump [30]

Oil Pipe [29]

Clip [31]

Machine Screw M4 x 16 [28]

Air Vent Valve (B) [140]

Ɣ Clutch and oil pump

Air Vent Sponge [139]

5. Disassembly and reassembly of the clutch and oil pump

[Tools required]

Ɣ J-361 jig (No.6698723) (clutch puller)

Ɣ Phillips screwdriver

(1) Disassembly

Ɣ Align the pawl of the J-361 jig (clutch puller) with the Clutch [131],

and then use an impact driver to turn it in the arrow direction as

shown in the illustration on the right to remove the Clutch [131].

Remove Clutch Washer (B) [132], the Clutch Housing [133], Needle

Bearing [134], Rim Sprocket [135], and Clutch Washer [136].

CAUTION: Note that the Clutch [131] is screwed into the Crank

Shaft [83] with left-hand threads. Do not remove Spark

Plug BPM-7A/BPMR7A [46] from the Cylinder [73]. Turn

off the Decomp. [45] (by pulling it toward you).

Ɣ Remove the three Seal Lock Screws M4 x 10 and [16] Oil Pump Cover [137].

CAUTION: The threads of the Seal Lock Screws M4 x 10 [16] may be easily broken. Therefore,

do not tighten the screws too much.

Ɣ Remove the Machine Screw M4 x 16 [28] and Clip [31], and then remove the Oil Pipe [29] from the Oil

Pump [30]. Finally, remove the Oil Pump [30] from the main body.

(2) Reassembly

Reassembly can be conducted by reversing the disassembly procedure. However, special attention

should be given to the following items.

Ɣ Before mounting the Worm [138], apply 0.1 to 0.3 gram of Alvania Grease RL3 to its inner diameter.

Ɣ Before mounting the Oil Pump

[30]

, apply 0.6 to 1.0 gram of Alvania RL3 on the gear portion of the Worm

[138]

Ɣ Securely engage the Oil Pump [30] with the gears of the Worm [138].

Ɣ Place the Clutch Washer [136] on the protrusions of the Worm [138] for assembly. (See the illustration

titled “Mounting the clutch washer” on the next page for details.)

Ɣ Before mounting the Clutch [131], degrease the female threads of the Clutch [131] and the threads of

the Crank Shaft [83].

Ɣ Use the Hitachi 14.4V impact driver to tighten the Clutch [131] for about one second, in order to obtain

the specified torque.

CAUTION: Ɣ Never tighten excessively. Otherwise, the flange of the Worm [138] may break and

thus inhibit removal.

Ɣ Run the assembled chain saw and make sure the Clutch [131] is firmly tightened.

Ɣ Removing the clutch

J-361 jig (clutch puller)

Clutch [131]

-12-

Ɣ Mounting the clutch washer

Clutch Washer [136]

Worm [138]

Rim Sprocket [135]

Needle Bearing [134]

Clutch Housing [133]

Clutch [131]

Clutch Washer (B) [132]

Crank Shaft [83]

Clutch Washer [136]

Worm [138]

Place the Clutch Washer [136] on the protrusion

of the Worm [138] before assembly.

Protrusions

6. Disassembly and reassembly of the magneto rotor

[Tools required]

Ɣ J-363 jig (No.6694822) (8 x 120 handle)

Ɣ J-357 (No.6695737) (center bolt)

Ɣ J-356 jig (No.6695736) (complete rotor extraction tool)

Ɣ J-365 jig (No.6695739) (stepped bolt 5 mm)

Ɣ Socket wrenches (10 mm and 13 mm)

Ɣ M8 nut

(1) Disassembly

Ɣ Use a 10-mm socket wrench to remove the two Step Bolts [174]. Then remove the two Shims [173],

two Starter Pawls [172], two Starter Pawl Springs [170], and two Washers 0.8 [171].

Ɣ Use a 13-mm socket wrench to remove Flange Nut M8 [112].

Ɣ With the screw end face of the Crank Shaft [83] made

flush with the upper face of a commercially available

M8 nut, rotate the J-363 jig (8 x 120 handle) in the

arrow direction and tighten the J-357 jig (center bolt)

as shown in the illustration on the right. Then remove

the Magneto Rotor [169].

(2) Reassembly

Reassembly can be conducted by reversing the

disassembly procedure. However, special attention

should be given to the following items.

Ɣ Before mounting the Magneto Rotor [169], degrease

the tapered section of the Magneto Rotor [169], as

well as the threads and tapered section of the Crank

Shaft [83].

Ɣ When removing the Magneto Rotor [169] or Ignition

Coil [166], adjust the clearance between the Magneto

Rotor [169] and Ignition Coil [166] as per “7.

Adjustment of clearance between the magneto rotor

and ignition coil.”

Ɣ After reassembly, check the operation of the Starter Pawl [172].

J-363 jig (8 x 120 handle)

J-357 (center bolt)

Magneto Rotor [169]

J-356 jig

(complete rotor

extraction tool

)

J-365 jig

(stepped bolt 5 mm)

Ɣ Removing the magneto rotor

-13-

Ɣ Magneto rotor

Magneto Rotor [169]

Starter Pawl Spring [170]

Washer 0.8 [171]

Starter Pawl [172]

Shim [173]

Step Bolt [174]

Flange Nut M8 [112]

Crank Shaft [83]

7. Adjustment of clearance between the magneto rotor and ignition coil

(1) Loosen the Hex. Socket Hd. Bolt (W/Flange)

M4 x 18 [167] so as to temporarily secure

the Ignition Coil [166].

(2) Insert a 0.3-mm thickness gauge between

the Ignition Coil [166] and the perimeter of

the Magneto Rotor [169].

(3) Under this condition, firmly tighten the Hex.

Socket Hd. Bolt (W/Flange) M4 x 18 [167].

Ɣ Adjustment of clearance between the magneto rotor and

ignition coil

Magneto Rotor [169]

0.2 to 0.4 mm

Hex. Socket Hd. Bolt

(W/Flange) M4 x 18 [167]

Ignition Coil [166]

-14-

• Wiring diagram

Spark Plug BPM-7A/BPMR7A [46]

Cord (A)[163]

Ignition Coil [166]

Cord (B) [164]

Hex. Socket Hd. Bolt (W/Flange) M4 x 18 [167]

Plug Cap [162]

Cable Tie [161]

Stop Switch [95]

Operation Plate [94]

Connecto

(Silve

)

Connecto

(Brass color)

• Cable tie securing position

Cord (B) [164]

Cord (A)[163]

Cut off the surplus end of the Cable Tie [161] with

2 to 5 mm of strap projecting from its locking head.

Cable Tie [161]

Concave portion of Cord (A) [163] and Cord (B) [164]

Cord (B) [164]

Cord (A)[163]

Cable Tie [161]

8. Wiring diagram

The following diagram shows the wiring.

(1) Connect the connector (silver) of Cord (A) [163] to the Ignition Coil [166].

(2) Fix Cord (B) [164] to the Ignition Coil [166] with the Hex. Socket Hd. Bolt (W/Flange) M4 x 18 [167].

(3) Fit the Stop Switch [95] into the Operation Plate [94] so that indication “1” faces up.

(4) Connect the connectors (brass color) of Cord (A) [163] and Cord (B) [164] to the connectors of the Stop

Switch [95].

(5) Bundle together Cord (A) [163] and Cord (B) [164], and then secure the concave portion of the bundle

with the Cable Tie [161].

CAUTION: Do not get Cord (A) [163] and Cord (B) [164] caught in other parts.

-15-

• Muffler

Muffler Packing [40]

Muffler [39]

Hex. Socket Hd. Bolt M5 x 12 (Precote) [38]

Seal Lock Hex. Socket Hd. Bolt M6 x 20 [37]

Muffler Cap [36]

Muffler Protector [26]

Muffler Protector Gauze [27]

Muffler Gauze [20]

Exhaust Pipe [19]

Hex. Socket Hd. Bolts

M4 x 10 [24]

Bolt Washers M4 [25]

9. Disassembly and reassembly of the muffler

[Tools required]

Ɣ Hex. bar wrenches (3 mm, 4 mm and 5 mm)

Ɣ Flat-blade screwdriver

(1) Disassembly

Ɣ Use a flat-blade screwdriver to remove the two Muffler Caps [36]. Use a 5-mm hex. bar wrench to

remove the two Seal Lock Hex. Socket Hd. Bolts M6 x 20 [37]. Use a 4-mm hex. bar wrench to remove

the two Hex. Socket Hd. Bolts M5 x 12 (Precote) [38]. Then remove the Muffler [39].

Ɣ Use a 3-mm hex. bar wrench to remove the five Hex. Socket Hd. Bolts M4 x 10 [24] and five Bolt

Washers M4 [25]. Then remove the Muffler Protector [26], Muffler Protector Gauze [27], Exhaust Pipe

[19], and Muffler Gauze [20].

(2) Reassembly

Reassembly can be conducted by reversing the disassembly procedure. However, special attention

should be given to the following items.

Ɣ Do not reuse the Seal Lock Hex. Socket Hd. Bolts M6 x 20 [37], Hex. Socket Hd. Bolts M5 x 12

(Precote) [38], and Muffler Caps [36].

Ɣ Before mounting the Muffler [39], degrease the screw holes of the Cylinder [73], Engine Case (A) Ass’y

[87], and Engine Case (B) Ass’y [80].

Ɣ Mount the Muffler [39] by temporarily securing the two Seal Lock Hex. Socket Hd. Bolts M6 x 20 [37]

and the two Hex. Socket Hd. Bolts M5 x 12 (Precote) [38], and then firmly tighten all four bolts.

-16-

10. Disassembly and reassembly of the cylinder and scavenging cover

[Tools required]

Ɣ Hex. bar wrenches (4 mm and 5 mm)

Ɣ Phillips screwdriver

Ɣ Socket wrenches (13 mm and 19 mm)

(1) Disassembly

Ɣ Use a 19-mm socket wrench to remove Spark Plug BPM-7A/BPMR7A [46].

Ɣ Use a 5-mm hex. bar wrench to remove the four Seal Lock Hex. Socket Hd. Bolts M6 x 20 [37]. Then

remove the Cylinder [73].

Ɣ Use a Phillips screwdriver to remove the eight Seal Lock Screws M4 x 10 [16]. Then remove

Scavenging Cover (A) [74] and Scavenging Cover (B) [17].

CAUTION: The threads of the Seal Lock Screws M4 x 10 [16] may be easily broken. Therefore,

do not tighten the screws too much.

Ɣ Use a 13-mm socket wrench to remove the Decomp. [45].

(2) Reassembly

Reassembly can be conducted by reversing the disassembly procedure. However, special attention

should be given to the following items.

Ɣ Do not reuse the Cylinder Packing (C51) [75], Cover Packing [18], and Intake Packing (C51) [47].

Ɣ Do not reuse the Seal Lock Screws M4 x 10 [16], Seal Lock Hex. Socket Hd. Bolts M6 x 20 [37], and

Hex. Socket Hd. Bolts M5 x 12 (Precote) [38].

Ɣ Before mounting the Cylinder [73], degrease the screw holes of the Engine Case (A) Ass’y [87] and

Engine Case (B) Ass’y [80].

Ɣ Before mounting Scavenging Cover (A) [74] and Scavenging Cover (B) [17], degrease the screw holes

of the Cylinder [73].

Ɣ Before mounting the Intake (CS51) [48], degrease the screw holes of the Cylinder [73].

Ɣ Reassemble the packings by ensuring the proper alignment of the holes.

Ɣ Pay attention to the directional property of the Cylinder Packing (C51) [75]. (At reassembly, match it

with the shape of the vent port.)

Ɣ Pay attention to the directional property of the Cover Packing (C51) [18]. (Assemble so that the lower

part of the Cover Packing (C51) [18] protrudes between Scavenging Cover (A)

[74] and Scavenging

Cover (B) [17].)

Ɣ When removing the Cylinder [73], remove all carbon deposits on the exhaust port and combustion

chamber by being careful not to scratch the cylindrical surface, and then carefully clean these parts by

using gasoline.

Ɣ Prevent the entry of foreign matter through the respective ports of the Cylinder [73] at reassembly.

Ɣ Before mounting the Cylinder [73], lightly apply 2-cycle oil to the cylindrical surface of the Cylinder [73]

and the periphery of the Piston (44) (M) [77].

Ɣ Fit the lip portion of the Intake (CS51) [48] into the groove of the Carburetor Insulator (C51) [50] when

mounting the Intake (CS51) [48] to the Carburetor Insulator (C51) [50].

-17-

• Cylinder and scavenging cover

Lip portion

Scavenging Cover (A) [74]

Intake (CS51) [48]

Intake Packing (C51) [47]

Cover Packing (C51) [18]

Scavenging Cover (B) [17]

Cover Packing (C51) [18]

Decomp. [45]

Cylinder [73]

Cylinder Packing (C51) [75]

Hex. Socket Hd. Bolt

M5 x 12 (Precote) [38]

Seal Lock Screw M4 x 10 [16]

Seal Lock Hex. Socket Hd. Bolt

M6 x 20 [37]

Spark Plug BPM-7A/BPMR7A [46]

Seal Lock Screw M4 x 10 [16]

Cab. Insulator Rubber [49]

Carburetor Insulator (C51) [50]

11. Disassembly and reassembly of the piston and piston ring

[Tools required]

Ɣ Long-nose pliers

Ɣ J-359 jig (No.6695741) (piston pin extraction tool ass’y)

Ɣ Hex. socket hd. bolt M5 x 12

Ɣ Round bar 9.8 mm in diameter (e.g., borer 10 mm in diameter)

(1) Disassembly

Ɣ Remove the two Circlips [78] with long-nose pliers.

Ɣ Insert a hex. socket hd. bolt M5 x 12 into the

pushing side of the Piston Pin [85], and then turn

the pin pullout bolt of the J-359 jig (piston pin

extraction tool ass’y) clockwise to pull out the

Piston Pin [85].

CAUTION: Do not scratch the Piston (44) (M) [77].

(2) Reassembly

Ɣ Do not reuse the Circlips [78].

Ɣ When removing the Piston (44) (M) [77], remove

carbon deposits on top of the Piston (44) (M) [77]

by being careful not to scratch the piston surface,

and then carefully clean the Piston (44) (M) [77] by

using gasoline.

Ɣ If the Piston Ring [76] does not move smoothly, remove carbon deposits on the ring groove of the

Piston (44) (M) [77] and Piston Ring [76], and then carefully clean these parts by using gasoline.

• Removing the piston

Hex. socket hd.

bolt M5 x 12

Pin pullout bolt

J-359 jig

(piston pin extraction tool ass’y)

-18-

Ɣ Mounting the piston

Piston (44) (M) [77]

Pin pullout bolt

Piston Pin [85]

Hex. socket hd. bolt

M5 x 12

Round bar 9.8 mm in diameter

(

., borer 10 mm in diameter

)

Piston Pin Collar (C51) [79] Needle Bearing (A) [86]

Circlip mounting groove

Connecting rod small end

Ɣ Piston and piston ring

Piston Ring [76]

Piston (44) (M) [77]

Piston Pin [85]

Needle Bearing (A) [86]

Piston Pin Collar (C51) [79]

Circlip [78]

Connecting rod small end

Ɣ Insert the Piston Pin [85] by following the procedure below. (See “Mounting the piston.”)

(1) Insert the Piston Pin [85] into the Piston (44) (M) [77] by about 7 mm.

CAUTION: Be sure to support the flat portion (casting surface) of the Piston (44) (M) [77]

when using a hand press. Do not tilt the Piston Pin [85].

(2) Set the J-359 jig (piston pin extraction tool ass’y) to the Piston (44) (M) [77], and then set a hex.

socket hd. bolt M5 x 12 into the pushing side of the Piston Pin [85].

(3) Set Needle Bearing (A) [86] and the two Piston Pin Collars (C51) [79] to the connecting rod small

end, and then cover it with the Piston (44) (M) [77]. (Align the triangular arrow on top of the Piston

(44) (M) [77] with the direction of the exhaust port of the Cylinder [73].) Insert a round bar about

9.8 mm in diameter (e.g., borer 10 mm in diameter) into the Piston (44) (M) [77] opposite the side

where the Piston Pin [85] is inserted, in order to prevent Needle Bearing (A) [86] and the two

Piston Pin Collars (C51) [79] from becoming misaligned.

CAUTION: Mount the Piston Pin Collar (C51) [79] with its concave portion facing Needle

Bearing (A) [86].

(4) With the round bar 9.8 mm in diameter inserted, turn the pin pullout bolt of the J-359 jig (piston pin

extraction tool ass’y) clockwise, and then push in the Piston Pin [85] just before the circlip

mounting groove of the Piston (44) (M) [77].

CAUTION: Do not get the Piston Pin Collars (C51) [79] caught in other parts.

Ɣ Use long-nose pliers to fit the tip of the Circlip [78] (2 pcs.) into the groove of the Piston (44) (M) [77],

and then turn it until the Circlip [78] is completely mounted.

Ɣ Align the opening of the Piston Ring [76] (2 pcs.) with the knock pin of the Piston (44) (M) [77].

Ɣ After mounting the Piston (44) (M) [77], lightly apply 2-cycle oil to Needle Bearing (A) [86].

-19-

Engine Case (B) Ass’y [80]

Oil Seal [81]

Ball Bearing 6202C3 [82]

Crank Shaft [83]

Crank Case Packing (C51) [84]

Engine Case (A) Ass’y [87]

Rear Damper (C51) [88]

Seal Lock Hex.

Socket Hd. Bolt

M5 [32]

Seal Lock Hex.

Socket Hd. Bolt

M5 x 45 [35]

Seal Lock

Screw

M5 x 12 [33]

Spike [34]

Ɣ Engine case

12. Disassembly and reassembly of the engine case

[Tools required]

Ɣ Hex. bar wrench (5 mm)

Ɣ Phillips screwdriver

Ɣ Long-nose pliers

(1) Disassembly

Ɣ Use long-nose pliers to pull out the Rear Damper (C51) [88].

Ɣ Use a Phillips screwdriver to remove the two Seal Lock Screws M5 x 12

[33]

, and then remove the Spike

[34]

CAUTION: The threads of the Seal Lock Screws M5 x 12 [33] may be easily broken. Therefore, do not

tighten the screws too much.

Ɣ Use a 5-mm hex. bar wrench to remove the four Seal Lock Hex. Socket Hd. Bolts M5 [32] and two Seal

Lock Hex. Socket Hd. Bolts M5 x 45 [35]. Then remove the Engine Case (A) Ass’y [87], Engine Case

(B) Ass’y [80], and Crank Shaft [83].

Ɣ Remove Ball Bearing 6202C3 [82] and the Oil Seal [81] by pushing it out on the Oil Seal [81] side.

(2) Reassembly

Reassembly can be conducted by reversing the disassembly procedure. However, special attention

should be given to the following items.

Ɣ Do not reuse the Oil Seal [81] and Ball Bearing 6202C3 [82] removed from the Engine Case (A) Ass’y

[87] and Engine Case (B) Ass’y [80].

Ɣ Do not reuse the Crank Case Packing (C51) [84].

Ɣ Do not reuse the Seal Lock Hex. Socket Hd. Bolts M5

[32]

and Seal Lock Hex. Socket Hd. Bolts M5 x 45

[35]

Ɣ Apply 50 to 100 mg of Piloknock Universal No. 0 of JX Nippon Oil & Energy between the lips of the Oil

Seal [81].

Ɣ Carefully clean the Crank Shaft [83] by using gasoline before mounting.

Ɣ Degrease the screw holes of the Engine Case (A) Ass’y [87] and Engine Case (B) Ass’y [80] before

mounting. Do not get the Fuel Pipe [119] caught between the Engine Case (A) Ass’y [87] and Engine

Case (B) Ass’y [80] when mounting.

Ɣ Check the hole position of the Crank Case Packing (C51) [84] and mount it without misalignment.

(When mating the Engine Case (A) Ass’y [87] and Engine Case (B) Ass’y [80], confirm that the Crank

Case Packing (C51) [84] is properly mounted along the circumference of the engine case.)

Ɣ Cut off the protrusion of the Crank Case Packing (C51) [84] at the mating surface of the Cylinder [73]

after mounting.

CAUTION: Do not break the Crank Case Packing (C51) [84] when cutting it.

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Hitachi CS 51EA User manual

Brand: Hitachi

Model: CS 51EA

Category: Power chainsaws

Type: User manual

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Hitachi CS 51EA User manual

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