STIH) STIHL CombiTools

Transcription

1 STIH) STIHL CombiTools FS-KM, FS, FS 38, FS 45, FS 46, FS 55, FS 73, FS 75, FS 80, FS 83, FS 85, FS 87, FS 90, FS 00, FS 0, FS 0, FS 30, FS 00, FS 50, FSE 60, FSE 65 FR 85, FR 30, FR 0, FR 350, FR 450, FR 480 FCS-KM, FCB-KM, FCS, FC 73, FC 75, FC 83, FC 85, FC 90, FC 95, FC 00, FC 0, FCE 60 FH-KM, FH, FH 75 HL-KM, HL, HL 75, HL 00 HT-KM, HT, HT 70, HT 73, HT 75, HT 00, HT 0, HT 30, HT 3, HT 50, HTE 60 KW-KM (460), KW (460), KW 85 BC-KM, BC 35

2 Contents RA_7_00_0_0. Introduction. Safety Precautions 3 3. Assignment of Gearboxes to Models 4 4. Specifications 5 4. Tightening Torques 5 4. Chain Lubrication (HT) Gearbox Grease Capacities 7 5. Troubleshooting 8 5. Mowing Heads Polymatic/TrimCut AutoCut SuperCut PolyCut 5. Chain Lubrication (HT) 5.3 FH-KM/ HL-KM Drive Tube (Boom) 4 7. Gearbox 6 7. Removing and Installing All Gearboxes (not FCS, HT, KW) FCS only KW (460) only HT only 7 7. FC, FCB, FS FCS HT Checking Clutch Slip Torque BC Cutter Bar HL HL HL Cutting Blades HL/FH Angle Drive 38 CombiTools 8. Gearbox (new versions) Removing and Installing HL HL Disassembling the HL 0 Gearbox Disassembling the Input Pinion Disassembling the Output Pinion Blade Drive Gear Disassembling HL 35 Gearbox Input Pinion Output Pinion in Angle Drive Output Pinion in Blade Drive Gear Blade Drive Gear Blade Drive Gear Lock Lock Mechanism Quadrant Lubricating the Gearbox HL HL Cutting Attachment Removing and Installing HL Removing and Installing HL-KM Disassembly the Cutting Attachment Other Components 6 9. FS Deflector 6 9. BC Deflector FCS Wear Guard Skirt Gearbox Wheel Depth Wheel Deflector FC, FCB FC Deflector (wheel adjustment on segment) FC Deflector (wheel adjustment on deflector) Skirt Depth Wheel Depth Wheel (wheel adjustment on segment) KW (460) Sweeper Drums Sweeper Belts Axle Sleeve on Drive Tube Sleeve on Gearbox HT Oil Tank (up to 00) Oil Tank (from 00) Oil Pump (up to 00) Oil Pump (from 00) Chain Tensioner 7 0. Special Servicing Tools 7. Servicing Aids 73 q ANDREAS STIHL AG & Co. KG, 007

3 . Introduction This service manual contains detailed descriptions of all typical repair and servicing procedures for CombiTools. If there is no specific reference to individual machines, the procedure is the same for all machines. There may be minor differences in the illustrations, depending on the machine, but the methods used and the sequence of operations are identical. You will find detailed descriptions of repair procedures on engine components in the separate manuals covering the basic engine and components. 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. 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 and this service manual until a revised edition is issued. The special servicing tools mentioned in the descriptions are listed in the chapter "Special Servicing Tools" of this manual. Use the part numbers to identify the tools in the "STIHL Special Tools manual. The manual lists all special servicing tools currently available from STIHL. 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) b 4. Reference to another chapter, i.e. chapter 4. in this example. In the illustrations: A Pointer adirection of movement If a procedure applies to all machines in a series, e.g. HT 70, 75, the machines are not listed separately, i.e. they are only referred to as HT. However, if only one specific machine or assembly is concerned, it is mentioned by name, e.g. HT 75. Service manuals and 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. CombiTools

4 . Safety Precautions If the engine is started up in the course of repairs or maintenance work, observe all local and countryspecific safety regulations as well as the safety precautions and warnings in the instruction manual. Gasoline is an extremely flammable fuel and can be explosive in certain conditions. Improper handling may result in burns or other serious injuries. Warning! Do not smoke or bring any fire, flame or other source of heat near the fuel. All work with fuel must be performed outdoors only. Spilled fuel must be wiped away immediately. Always wear protective gloves when working on power tool attachments. CombiTools 3

5 3. Assignment of Gearboxes to Models Gearbox Gearbox Type Installed in Model Remarks BC WG BC, BC-KM, BC 35 FC AG FC 44, 7, 75, EC 70 ) FC/FCB AG FC, FCB, FCB-KM, ) FC 55, 73, 75, 90, 00, FCE 60 FCS AG FCS, FCS-KM, FC 83, 85, 95, 0 FS AG FS, FS-KM, FS 5-4, FS 55, FS 55 T, FS 65-4, FS 80 (from 996), FS 83, FS 83 T, FS 85, FS 85 T, FS 85 RX, FS 87, FS 90, FS 00, FS 0, FS 0 RX, FS 0, FS 30, FS 00, FS 50, FR 85, 85 T, 30 T, 350, 450, 480, 0 HL BG HL 0, HL 30, HL 0 90, HL 35, HL-KM 0, HL-KM 30, HL-KM 0 90, HL-KM 35, HL 45, HL 73 0, HL 73 30, HL , HL 75 0, HL 75 30, HL , HL 75 35, HL 00 35, HLR 85 0, HLR 85 30, HLR HL 0 AG HL 0, HL-KM 0, HL 75 0, HL 00 0 HL 30 AG HL 30, HL-KM 30, HL HL 0 90 AG HL 0 90, HL-KM 0 90, HL , HL HL 35 AG HL 35, HL-KM 35, HL 75 35, HL FH MG FH 0 90, FH 35, FH-KM 0 90, FH-KM 35, FH , FH FH 0 90 AG FH 0 90, FH-KM 0 90, FH FH 35 AG FH 35, FH-KM 35, FH HT AG HT, HT-KM HT 70, HT 73, HT 75, HT 00, HT 0, HT 30, HT 3, HTE 60, HTR 85 KW (460) WG KW, KW-KM, KW 85 Remarks ) Height adjustment of depth wheel on deflector ) Height adjustment of depth wheel on segment WG = Worm gear AG = Angle gear BG = Blade drive gear 4 CombiTools

6 4. Specifications 4. Tightening Torques DG and P (Plastoform) screws are used in polymer and lightmetal components. These screws form a permanent thread when they are installed for the first time. They can be removed and installed as often as necessary without impairing the strength of the screwed assembly, providing the specified tightening torque is observed. For this reason it is essential to use a torque wrench. Fastener Thread size For component Torque Remarks Nm Collar screw IS-M5x6LI Friction clutch/gearbox 8.0 )3) Screw IS-DG5x0 Oil tank/gearbox housing 5.5 0)) Screw IS-P6x4 Line limiter blade/deflector.5 4)5)6) Screw IS-M5x8 Cutting tool deflector 4.3 6)7) Screw IS-P5x4 Line limiter blade/deflector.5 6)7) Locknut M0x LI Cutting tool 5.0 5)7) Screw IS-M5x6 Cutting tool deflector/gearbox housing 4.3 5)7) Screw IS-Mx0 Screw plug, gearbox 9.5 7) Screw IS-M6x0 Gearbox housing/drive tube 9.0 ) Screw IS-M6x0 Gearbox housing/drive tube 0.0 3)8) Screw IS-M6x5 Deflector/gearbox housing/clamp/ 5.0 ) locknut Screw IS-DG5x Skirt/deflector (with washer) 5.5 ) Hex head screw M0x8 Segment/deflector 5.0 ) Screw IS-Mx0 Screw plug/gearbox 0.0 )5) Screw IS-M5x0 Guide/blade/gearbox housing 9.5 4)8)9) Screw IS-M4x6 Gearbox cover/gearbox housing 3.5 3)8)9) Screw IS-M5x0 FS gearbox housing/ 7.0 3)8)9) HS gearbox housing Nut M5 DS550 mm blade/screw 9.5 3)8)9) Screw IS-Mx8 Screw plug/gearbox cover 5.5 3)8)9) Screw IS-Mx8 Screw plug/gear housing 5.5 3)8)9) Screw IS-M6x30 Gearbox housing/drive tube/nut 8.0 ) Screw IS-M5x5 Gearbox cover/gear housing 6.5 0)) Screw IS-M5x84 Gearbox housing, left/right.5 3)8) Locknut M5 Gearbox housing, left/right (locknut) 6.0 3)8) Nut M5 DS70 mm blade/screw 9.5 3) Screw IS-M5x0 Quadrant/gear housing 8.0 3) Screw IS-M4x6 Guard plate/gearbox cover 3.5 3) Screw M8x5L Blade 5.0 ) CombiTools 5

7 Fastener Thread size For component Torque Remarks Screw M6x30 Cutting tool deflector/clamp 5.0 4) Screw DG 6x8 Gearbox/drive tube clamp.0 5) Screw IS-DG5x60 Clamp, deflector/drive tube.0 ) Screw IS-M5x8 Bearing plate/gearbox 9.0 ) Screw IS-M5x8 Deflector/gearbox 9.0 ) Hex head screw M8x4 Blade 5.0 ) Hex head screw M8x0 Segment/deflector 5.0 ) Screw M5x Quadrant/gear housing 8.0 9) Screw M4x0 Guard plate/gearbox cover 3.5 9) Grub screw M6x8 Grub screw/gear housing 4.5 9) Screw M5x Adjusting lever/gear housing 8.0 9) Remarks ) FC 75 8) HL 45 ) FC 85 9) HL 75 3) FH 75 0) HT 70 4) FS 45 ) HT 75 5) FS 55 ) KW 85 6) FS 75 3) High-strength Loctite 7 7) FS 80, 85 Note: Use the following procedure when refitting a DG or P screw in an existing thread: Place the screw in the hole and rotate it counterclockwise until it drops down slightly. Tighten the screw clockwise to the specified torque. This procedure ensures that the screw engages properly in the existing thread and does not form a new thread and weaken the assembly. Note: Screws secured with adhesive should be heated with a hot air blower before releasing. Take special care with plastic components. Power screwdriver setting for polymer components: P screws max. 500 rpm 4. Chain Lubrication (HT) Fully automatic speed-controlled oil pump with rotary piston Oil delivery rate 7.5 ±,5 cm 3 /min 6 CombiTools

8 4.3 Gearbox Grease Capacities Gearbox Type of Grease Amount of Grease for Initial Filling (g) Amount of Grease for Re-lubrication (g) Remarks BC A 45 max. 5 FC, FC/FCB A 5 max. 5 FCS A 8 max. 5 FS 440 A 5 max. 5 ) FS 437 A 9 max. 5 ) HL/FH blade drive gear B 7 max. 5 HL/FH blade drive gear B max. 5 3) HL 0 angle drive A max. 5 HL 30 angle drive A max. 5 HL 0 90 angle drive A 0 max. 5 HL 35 angle drive A max. 5 3) HT, HT 75 A 8 4) KW (460) 5) Remarks A STIHL gear lubricant for brushcutters B STIHL gear lubricant for hedge trimmers ) Gearboxes for FS 55, 55 T ) Gearboxes for FS, FS-KM, FS 5-4, 65-4, 80 (from model year 996), 83, 83 T, 85 T, 85 RX, 87, 90, 00, 0, 0 RX, 0, 30, 00, 50 FR 85, 85 T, 30 T, 350, 450, 480, 0 3) New version 4) Lubricated for life 5) Faulty gearboxes are replaced CombiTools 7

9 5. Troubleshooting 5. Mowing Heads 5.. Polymatic/TrimCut Condition Cause Remedy Poor cutting performance Line too short Readjust line by bumping the rotating mowing head* on the ground Automatic feed mechanism only operates sporadically Automatic feed mechanism worn Always open throttle wide and then bump mowing head on the ground Install new mowing head Head does not cut Line broken off at spool housing Open the mowing head and pull line out of housing Spool empty Wind fresh line onto spool Lines fused together or jammed Open the mowing head, correct the fault (cut off fused lines), pull line out of the housing Automatic feed mechanism worn Install new mowing head Line wound onto spool in wrong direction Rewind spool correctly Line wears rapidly Line stored in dry condition for too long Store new line in water bath for several days in a cool place until it is used for the first time. Place line that has not been used for a long period in water bath for several days in a cool place. This increases the toughness and durability of the line * not TrimCut 8 CombiTools

10 5.. AutoCut Condition Cause Remedy Poor cutting performance Line too short Readjust line by bumping the rotating mowing head on the ground Automatic feed mechanism only operates sporadically Automatic feed mechanism worn Always open throttle wide and then bump mowing head on the ground Install new mowing head Head does not cut Line broken off at spool housing Open the mowing head and pull line out of housing Spool empty Wind fresh line onto spool Lines fused together or jammed Open the mowing head, correct the fault (cut off fused lines), pull line out of the housing Automatic feed mechanism worn Install new mowing head Line wound onto spool in wrong direction Rewind spool correctly Line wears rapidly Line stored in dry condition for too long Store new line in water bath for several days in a cool place until it is used for the first time. Place line that has not been used for a long period in water bath for several days in a cool place. This increases the toughness and durability of the line CombiTools 9

11 5..3 SuperCut Condition Cause Remedy Poor cutting performance Line too short Open throttle wide, lift mowing head out of cut if necessary Automatic feed mechanism only operates sporadically Automatic feed mechanism worn Pawl bearings dry SuperCut -, -, 40- only: Automatic line feed mechanism not properly adjusted Operate the mowing head at full throttle Install new mowing head Lubricate pawl bearings with oil, see instructions Adjust automatic line feed mechanism correctly Head does not cut Line broken off at spool housing Open the mowing head and pull line out of housing Spool empty Wind fresh line onto spool Lines fused together or jammed Open the mowing head, correct the fault (cut off fused lines), pull line out of the housing Automatic feed mechanism worn Install new mowing head Line wound onto spool in wrong direction Rewind spool correctly SuperCut 0 and 0 only: High line consumption Line diameter too small Use.4 mm diameter line instead of.0 mm Line wears rapidly Line stored in dry condition for too long Store new line in water bath for several days in a cool place until it is used for the first time. Place line that has not been used for a long period in water bath for several days in a cool place. This increases the toughness and durability of the line 0 CombiTools

12 5..4 PolyCut Condition Cause Remedy Poor cutting performance Blades worn, blades broken Replace all blades Line too short Collar screw bearing bushings too stiff Head operated with nylon line and blades at the same time Fit new line Clean and dry the bearing bushings and collar screws, lubricate with STIHL gear lubricant for hedge trimmers Operate mowing head with either nylon line or blades Head does not cut All blades broken Replace all blades Line broken off at spool housing Fit new line Line or blades wear rapidly Line or blades stored in dry condition for too long Store new line or blades in water bath for several days in a cool place before use. Place line or blades that have not been used for a long period in water bath for several days in a cool place. This increases the toughness and durability of the line and blades PolyCut 0, 0, 40 only: Line wears rapidly Line diameter too small Use.7 mm or 3.0 mm diameter line instead of.4 mm CombiTools

13 5. Chain Lubrication (HT) Important! In the event of trouble with the chain lubrication system, always investigate the other possible sources of faults before disassembling the oil pump. Condition Cause Remedy Saw chain receives no oil Oil tank empty Fill up with oil Oil inlet hole in guide bar is blocked Strainer in gear housing is blocked Flanks on pump piston and/or shaft worn Clean the oil inlet hole Clean or replace the strainer Install new oil pump and/or new shaft Machine losing chain oil Bore in pump housing worn Install new oil pump and/or new shaft Oil pump delivers too little oil Control screw and/or control edge on pump piston worn Fit new control screw and/or oil pump Bore in pump housing worn Install new oil pump Vent hole is blocked Clean the vent hole CombiTools

14 5.3 FH-KM/ HL-KM 35 Condition Cause Remedy Cutting attachment or blade drive gear jammed Angle drive set outside operating range (35 ) Readjust angle drive within normal range on quadrant Thrust pin missing Install thrust pin Cam lobe on pin broken Install new pin Cutting attachment or blade drive gear does not lock in transport position Cam lobe on pin broken Install new pin Thrust pin in angle drive is stuck Free off or replace the thrust pin Torsion spring on pin broken or fatigued Install new torsion spring Torsion spring not installed or not attached Install or re-attach the torsion spring CombiTools 3

15 6. Drive Tube (Boom) The drive tube is installed on machines with a split drive tube (boom) and CombiTools. The drive shaft is supported inside the drive tube in a flexible liner. The upper end of the drive tube is sealed with a sleeve and the lower end with a plug. Remove the gearbox, b 7.. or b : Pull the rigid drive shaft out of the drive tube. 7RA99 : On flexible drive shaft, check that clamp (arrow) is firmly seated; replace the drive shaft if necessary. 7RA0 : Loosen the wing screw () and pull the drive tube () out of the coupling sleeve (3). 7RA97 : On machines with a curved drive tube, pull the flexible drive shaft out of the drive tube. 7RA00 : Pull the plug () out of the drive tube (). 7RA98 7RA0 : Press down the lug () and hold it there. : Pull the drive shaft and sleeve () out of the drive tube. This operation is easier if you push the other end of the drive shaft. : If sleeve (arrow) is fitted, heat it with a hot air blower. Remove the sleeve. If the drive shaft has turned blue, always install a new one. : Pull the flexible liner out of the drive tube. If necessary, mark the position of the handle hose on the drive tube, carefully cut it open and remove it. 7RA08 4 CombiTools

16 Assembling : Push flexible liner into the drive tube (end with plug) until it is recessed "a" = 0±0.5 mm. Fit the plug. 3 7RA05 : Heat the sleeve () to about 50 C, push in on to the drive shaft () and press it on to the knurling (3). Coat the drive shaft with STIHL gear lubricant for hedge trimmers, b, before installing it in the drive tube. Apply the lubricant uniformly to the drive shaft. Do not pump lubricant directly into drive tube. Push the drive shaft into the drive tube. 7RA04 Coat inside of handle hose (where applicable) with a little STIHL Press Fluid, b. : Push the handle hose (arrow) on to the drive tube and line it up with the mark. 7RA07 : Press down the lug () and push home the sleeve () as far as stop. The lug must engage properly, turn the sleeve back and forth if necessary. Install the gearbox, b 7.. or b 7..3 CombiTools 5

17 7. Gearbox 7. Removing and Installing 7.. All Gearboxes (not FCS, HT, KW) Removing 7.. FCS only 7..3 KW (460) only Loosen the clamp screw and pull the gearbox off the drive tube turn the gearbox back and forth at the same time. : Degrease the drive tube in the area of the clamp before installing the gearbox. Machines with sleeve on drive tube Remove tools and deflector as necessary. 7RA000 Remove the deflector, b 9.4. or b 9.4. : Take out the fixing screw (). : Loosen the clamp screw (). : Loosen the screws (arrows). Pull the gearbox off the drive tube. Installing Degrease clamp mounting area. : Pull the gearbox (3) off the drive tube. : If necessary, remove the gearbox wheel (4), b Reassemble in the reverse sequence. : Slide the gearbox () onto the drive tube () until the end of the tube is no longer visible in the slot (arrow). Push gearbox on as far as stop. 7RA05 Slide the gearbox onto the drive tube turn the output shaft back and forth at the same time so that the square end of the drive shaft engages the square socket in the drive pinion. Push the gearbox on as far as stop and line it up. Tighten down the screws firmly, b 4. On FC and FCB: Mount the deflector, b 9.4. or b 9.4. On FC and FCB: Mount the gearbox wheel, b : Push home the drive tube until the holes (arrows) are in alignment. Tighten down the fixing screw and clamp screw firmly, b 4. Remove the shafts, b RA4 Turn the gearbox back and forth while pushing it into position. Machines with sleeve on gearbox 3 : If the end of the drive tube end is visible in the clamp () (check by pushing the rubber sleeve () to one side), push home the gearbox (3) as far as stop. 7RA053 6 CombiTools

18 HT only Removing A 3 7RA RA093 : Line up the gearbox () on the drive tube so that the machine support (3) on the engine faces down and the output shafts (4) are horizontal. Tighten down the clamp screw (). : Loosen the screws (arrows) on the gearbox. Pull the gearbox or 30 angle drive (special accessory) off the drive tube. 936RA93 : Mark the drive tube at distance A = 50 mm. 3 Installing 3 936RA09 With the output shafts () horizontal, line up the drive tube () so that the fixing lug (arrow) on the drive tube points up. Tighten down the clamp screw firmly. Reassemble in the reverse sequence. 7RA059 : Check dimension a, it must not be more than mm. If necessary, rotate shaft slowly until it can be pushed in to the right length. a 936RA65 : Push the gearbox () on to the drive tube as far as stop. Turn the gearbox back and forth during this process until the square end of the shaft is properly engaged. The gearbox is correctly positioned when the end of the housing reaches or covers the mark (arrow). Make sure the screws (3) face up and the chain sprocket cover is exactly vertical when the engine is resting on the machine support. : Moderately tighten the screws (3) alternately first, then finally tighten to the specified torque, b 4. CombiTools 7

19 7. FC, FCB, FS Remove the deflector on FC and FCB, b 9.4. or b Assembling Remove the gearbox wheel on FC and FCB, b Disassembling Remove the gearbox, b 7.. : Pull the ball bearing () and bevel gear () off the drive shaft (3). 7RA063 The drive pinion and bevel gear are available only as a matching pinion set. 3 : Take the circlip out of the input end of the housing. 7RA060 : Remove the circlip from the drive pinion. 7RA064 : Heat the ball bearings to about 50 C and push them onto the drive pinion. 7RA067 The open ball bearing () must be against the pinion () and the closed bearing (3) at the end with the groove for the circlip. : Take the circlip out of the groove in the output end of the housing. : Heat the gearbox housing to about 0 40 C and remove the gearbox components from input end first then the output end by knocking the gearbox against a wooden base. 7RA06 : Press the drive pinion out of the ball bearings. Clean all parts and inspect them for serviceability. 7RA065 The FS 55 has only one ball bearing. Fit the circlip in the groove. 8 CombiTools

20 7RA068 : Heat ball bearing to about 50 C and push it onto the input shaft as far as stop. : Place the preassembled output shaft in position and press it home as far as stop. : Fit the circlip in the groove at the output end of the housing. 7RA074 : Push the bevel gear, teeth first, onto the input shaft. 7RA069 : Place the preassembled drive pinion in position and push it home as far as stop. Check that the teeth of the pinion and bevel gear mesh properly. : Remove the screw plug (arrow) from the gearbox housing and the fill the housing with grease. Use STIHL gear lubricant for brushcutters for lubrication of the gearbox, b. Screw the tube of grease into the hole. 7RA075 : To install the ball bearing and pinion set, heat the gearbox housing to about 40 C. Press ball bearing into the housing as far as stop. : Fit the circlip in the groove at the input end of housing. 7RA073 Fill the gearbox housing with grease, b 4.3 Top up with grease during maintenance work only if no grease is visible on the inside of the screw plug, b 4.3. CombiTools 9

21 Use a hot air blow to heat the center of the gearbox cover until the ball bearing falls off with the output shaft and bevel gear. : Unscrew the tube of grease. Fit the screw plug and tighten it down firmly, b 4. : Take out the screws () and remove the bearing plate (). 7RA8 3 7RA Assemble all other parts in the reverse sequence 7.3 FCS Disassembling Remove the gearbox, b 7.. Remove the gearbox wheel, b : Drive the output shaft () out of the ball bearing by knocking it on a wooden base and then pull it out of the housing together with the bevel gear () and gearbox cover (3). Remove the O-ring from the gearbox cover. 3 7RA9 : Heat the ball bearing () a little and pull it off the output shaft (3) together with the bevel gear (). : Remove the circlip from the groove at the output end of the housing. 7RA Free off the oil seal by tapping it with a suitable tube or punch. 7RA7 : Apply puller () with jaws (with No. profile). Tension the arms. Pull out the oil seal (). : Place the gearbox cover (), output shaft facing down, on a tube () with an inside diameter of 55 mm and a length of 80 mm. 7RA0 : Use press arbor () to remove the ball bearing. 7RA3 0 CombiTools

22 The drive pinion and bevel gear are available only as a matching pinion set. Assembling 3 7RA4 : Remove the circlip from the input end of the housing. Heat the input end of the gearbox housing to about 0 40 C and remove the gearbox components from input end by knocking the gearbox against a wooden base. : Heat the ball bearing at the input end to about 50 C and push it onto the drive pinion. 7RA067 The open ball bearing () must be against the pinion () and the closed bearing (3) at the end with the groove for the circlip. Fit the circlip in the groove. : Remove the circlip from the drive pinion. 7RA064 7RA5 7RA6 : Fit the circlip in the groove at the input end of the housing. : Fit the circlip in the groove at the output end of the housing. 7RA7 7RA8 7RA065 Heat input end of gearbox housing to about 0 40 C. : Place preassembled drive pinion in position and press it home as far as stop. : Use press arbor () to press home the ball bearing until it butts against the circlip. : Press the drive pinion out of the ball bearings. Clean all parts and inspect them for serviceability. CombiTools

23 7RA9 Lubricate sealing lips of oil seal with grease, b. 7RA34 : Use press arbor () to press home the oil seal (), open side facing ball bearing, until it butts against the ball bearing. : Heat the gearbox cover () to about 40 C and push home the ball bearing () (on drive shaft) as far as stop. : Unscrew the screw plug (arrow) from the gearbox housing and fill the housing with grease. The initial series of gearboxes was produced with a grease nipple. Use a standard grease gun to pump grease into the gearbox housing of versions with a grease nipple. 7RA3 Use STIHL gear lubricant for brushcutters for lubrication of the bevel gear gearbox, b. Screw the tube of grease into the filler hole. : Push the bevel gear () onto the output shaft (). : Heat the ball bearing (3) to about 50 C and push it onto the output shaft as far as stop. : Wait for the gearbox cover to cool down and then fit a new O-ring (). : Push the preassembled output shaft () into the ball bearing (). Fit the bearing plate, insert the screws and tighten them down firmly, b 4. 7RA33 Fill gearbox housing with grease, b 4.3 Top up with grease during maintenance work only if no grease is visible on the inside of the screw plug, b 4.3. Unscrew the tube of grease. Refit the screw plug and tighten it down firmly, b 4. Fit the gearbox wheel, b Install the gearbox, b 7.. Assemble all other parts in the reverse sequence. CombiTools

24 7.4 HT Disassembling Remove the cutting head from the drive tube, b 7..4 Remove the chain sprocket cover. : Loosen and unscrew the collar screw clockwise. : Remove the cup springs, washers and chain sprocket. Make sure cup springs are installed in correct sequence. Replace damaged cup springs. HT from /00 The following illustrations show the versions from December 00. The only difference is that the oil tank can be left on the gearbox housing on the new versions. : Pry the ring () off the shaft (). Remove the bar and chain. HT gearbox without friction clutch HT gearbox with friction clutch 3 936RA87 : Shorten a standard T-handle, 5 mm square section screwdriver or STIHL T-handle Allen key (5 mm hex section) to the length shown above. : Pry the E-clip () off the shaft and remove the washers () and chain sprocket (3). : Modify the hexagon cross section as shown. On machines up to December 00, remove the oil tank, b RA88 936RA89 : Remove all the screws () from the gearbox cover (). : Remove the gearbox cover (). 936RA90 7RA : Take the pinion () out of the gearbox housing (). : Clamp the gearbox in a vise. : Insert modified T-handle screwdriver as far as stop in the pinion s square socket in the gearbox. CombiTools 3

25 Assembling 3 3 : Use pliers () to remove the circlip (). : Remove the ball bearings (3). 7RA08 : Press ball bearing ball 609 () on to the pinion end of the shaft (3). : Press ball bearing 600 () on to the shaft (3). 7RA0 : Fill recess for pinion in gearbox housing with STIHL gear lubricant for brushcutters, b. : Place the pinion () in the gearbox housing (). 936RA93 : Take the shaft () out of the gearbox housing () RA9 : Place the shaft () in the gearbox housing (). 936RA9 : Apply thin coating of Dirko sealant, b, to mating surface of gearbox housing (marked black in illustration). 936RA94 7RA00 : Pull the ball bearings (+) off the shaft (3). 7RA03 936RA95 : Press on the ball bearings (). : Fit the circlip (). : Fit gearbox cover () in position. : Insert screws () in gearbox cover () and, with the exception of the clamp screws (arrows), tighten them down firmly, b 4. 4 CombiTools

26 HT gearbox with friction clutch Fit the bar and chain. Fit the chain sprocket cover. Mount the gearbox on the drive tube, b 7..4 : Press ring () on to the shaft (). 7RA RA Checking Clutch Slip Torque On machines up to December 00, install the oil tank, b 9.6. HT gearbox without friction clutch 3 : Slip the washers () and chain sprocket () over the shaft. : Fit the cup springs (3). Note assembly sequence. : Fit collar screw (4) with Loctite 7, b. 3 7RA07 : Screw home the collar screw counterclockwise and tighten it down firmly, b 4. Remove the gearbox from the drive tube, b 7..4 Clamp gearbox s hook in vise. : Fit washers (), chain sprocket (3) and E-clip () on the shaft. Fit the bar and chain. Fit the chain sprocket cover. Mount the gearbox on the drive tube, b RA87 Clamp the gearbox in a vise. : Insert modified T-handle screwdriver as far as stop in the pinion s square socket in the gearbox. : Tighten down the collar screw counterclockwise, b 4. Check clutch slip torque, b RA97 Remove the complete chain tensioner, b : Place the guide bar () against the gearbox, slide it in the direction in of the chain sprocket so that the top part of its tail engages between two teeth (arrows). : Fit several washers () with an inside diameter of 8.4 mm (total thickness 6 mm) or the ring for the chain sprocket cover on the bar stud. : Fit the nut (3) and tighten it down firmly (the chain sprocket is now locked in position). CombiTools 5

27 936RA98 7RA78 : Use a standard 5 mm square section bit for a torque wrench or STIHL bit () (5 mm hex section) and torque wrench () to check that clutch slip torque is between 5 and 4 Nm. : Take out the screws (arrows) and remove the housing cover (). : Pull the oil seals (), ball bearings (), thrust washers (3) and worm wheel (4) off the output shaft (5). Remove the key from the shaft. : Modify the hexagon cross section as shown. In case of deviations from these torque values, replace the washers, chain sprocket and cup springs. Reassemble in the reverse sequence 7.5 BC Disassembling Use hot air blower to heat the housing cover in area of ball bearing to about 80 C. : Remove the ball bearing (arrow) by knocking the housing cover against a wooden base. 7RA79 : Pull or lift the worm () out of the ball bearing (). 7RA83 7RA8 Remove the gearbox, b 7.. Remove the rotor blades. : Lift the complete output shaft out of the gearbox housing. Use a hot air blower to heat the gearbox housing in the area of the ball bearing to about 80 C. : Take the washers () off the output shaft (). 6 CombiTools

28 : Remove the ball bearing (arrow) by knocking the gearbox housing against a wooden base. Take out the washer. Clean all parts and inspect them for serviceability. Worm wheel and worm are available only as a matching set. Assembling : Press worm () into ball bearing () as far as stop. Lubricate the sealing lips of the oil seal with grease, b. : Push the oil seal (), open side facing the ball bearing, on to the output shaft. Fit the thrust washer, ball bearing and oil seal on the other end of the output shaft. : Place washer, convex side first, in the gearbox housing. : Heat the gearbox housing to about 00 C and fit the ball bearing () or, if necessary, use press arbor () to press it home as far as stop. 7RA85 : Fit the key () in the slot in the output shaft (). : Fit the worm wheel (3) and push it over the key. : Slip the thrust washers () and ball bearing () over the output shaft. Place the preassembled output shaft in position in the gearbox housing. : Push the oil seals up against the ribs (arrows). CombiTools 7

29 7.6 Cutter Bar 7.6. HL 0 Disassembling 7RA9 : Heat the gearbox cover to about 00 C and fit the ball bearing () or, if necessary, use press arbor () to press it home as far as stop. : Fit the sleeves () in the gearbox housing. : Apply thin bead of Dirko gray sealant, b, to the gearbox housing mating face (). Follow maker s instructions. Fit the gearbox cover, insert the screws and tighten down firmly, b 4. : Slip the washers () over the right and left-hand ends of the output shaft (). : Remove the screw plug (3) from the gearbox housing. Use STIHL gear lubricant for brushcutters, b, for lubrication of the gearbox. Screw the tube of grease into the hole. Fill the gearbox housing with grease, b 4.3 Top up with grease during maintenance work only if no grease is visible on the inside of the screw plug, b 4.3. Unscrew the tube of grease. Fit the screw plug and tighten it down firmly, b 4. Assemble all other parts in the reverse sequence. Remove the gearbox, b 7.. : Take out the screws (arrows). Remove the angle drive gearbox. : Use pliers () to remove the circlip. 7RA00 7RA003 : Pull off the pinion. 8 CombiTools

30 The open ball bearing () must be against the pinion () and the closed bearing (3) at the end with the groove for the circlip. Fit hookless retaining ring in the groove. 7RA35 7RA065 : Take circlip out of the groove in the input end of the housing. : Press the drive pinion out of the ball bearings. 7RA38 : Heat ball bearings () at output end to about 50 C and push them on to the output pinion (). : Take circlip out of the groove in the output end of the housing. eat the gearbox housing to about 0 40 C and remove the gearbox components from input end first by knocking the gearbox against a wooden base. 7RA36 : Press the output pinion out of the ball bearings. Clean all parts and inspect them for serviceability. The drive pinion and output pinion are available only as a matching set of pinions. Assembling 7RA37 The open sides of the ball bearings must face each other Heat the gearbox housing to about 40 C to install the pinion. 3 7RA064 : Place the preassembled output pinion in position and push it home as far as stop. : Remove the hookless retaining ring from the drive pinion. Heat ball bearings for input end to about 50 C and push them on to the drive pinion. 7RA067 CombiTools 9

31 Assemble all other parts in the reverse sequence 7.6. HL 30 7RA43 Disassemble the angle drive gearbox, b 7. : Place the preassembled drive pinion in position and push it home as far as stop. Check that the teeth of the pinions mesh properly. : Fit the circlip in the groove at the input end of the housing. 7RA4 : Unscrew the screw plug (arrow) from the gearbox housing. Screw the tube of grease into the hole. Use STIHL gear lubricant for brushcutters for lubrication of the gearbox, b. Fill the gearbox housing with grease, b 4.3 Top up with grease during maintenance work only if no grease is visible on the inside of the screw plug, b 4.3 Unscrew the tube of grease. Fit the screw plug and tighten it down firmly, b 4. A strengthened ball bearing (0x6x8) for the drive shaft was installed as part of a line modification. The drive shaft and gearbox housing were modified accordingly. Reassemble in the reverse sequence, b HL 0-90 Disassembling 3 : Fit the circlip on the output end of the housing. 7RA4 : Push on the pinion () and secure it with the circlip (). : Place the angle drive gearbox in position, insert the screws and tighten them down firmly, b 4. 7RA44 Remove the gearbox, b 7.. Pry away the plug (), take out the screw () and remove the adjusting lever (3). Unscrew the nut exposed after removing the plug (). 7RA45 30 CombiTools

32 7RA46 : Pry the cap off the screw. : Loosen the screw and pull it out. Remove the O-ring, washer and cup springs. : Pull the double pinion off the bearing bushing. : Place double pinion on press sleeve () and use drift () to press the needle sleeves out of the pinion. 7RA53 : Take the circlip out of the groove at the input end of the housing. Remove the washer. Heat the gearbox housing to about 0 40 C and remove the components from the input end by knocking the housing against a wooden base. 7RA064 7RA56 : Remove the hookless retaining ring from the drive pinion. : Pull back the lock housing () and remove the gearbox housing () sideways from the blade drive gear. : Unscrew the screw sleeve () from the gearbox housing () and pull it out together with the lock housing (3). CombiTools 3

33 7RA065 7RA50 : Press the drive pinion out of the ball bearings. Remove the washer (if fitted). : Take out the screws (arrows). Remove the gearbox housing. : Use pliers to remove the circlip () from the housing groove. Take out the washer. Heat the gearbox housing to about 0 40 C and remove the gearbox components by knocking the gearbox against a wooden base. : Take O-ring () out of the groove in the gearbox housing (). : Use pliers to remove the circlip (). If necessary, pull the bearing bushing out of the heated gearbox housing. 7RA37 : Take out the screws () and remove the quadrant (). 7RA49 : Pull off the pinion (). : Press the output pinion out of the ball bearings. Clean all parts and inspect them for serviceability. Drive pinion, double pinion and output pinion are available only as a matching set of pinions. 3 CombiTools

34 Assembling : Heat ball bearings () at output end to about 50 C and push them on to the output pinion (). The open sides of the ball bearings must face each other. Heat the gearbox housing to about 40 C. 7RA60 : Fit the washer (). : Install circlip () in the housing groove. 7RA63 : Press home needle sleeves () at both ends of the double pinions () until they are recessed about mm from the edge. : Push on the pinion () and secure it with the circlip (). 7RA64 : Push the double pinion (), large pinion () first, on to the bearing bushing (3). 7RA : If the bearing bushing () was removed, press it home as far as stop. 5 : Place the preassembled output pinion in position and push it home as far as stop. 3 : Fit a new O-ring () in the housing groove. : Place the gearbox housing () in position, insert all screws (3) and tighten them down firmly, b 4. : Fit the quadrant (4), insert and tighten down the screws (5) firmly, b 4. 7RA65 : Slip the washer (4), if fitted, over the pinion. Washer is not required on a new set of pinions. : Heat ball bearings at input end to about 50 C and push them onto the drive pinion. 7RA73 CombiTools 33

35 The open ball bearing () must be against the pinion () and the closed bearing (3) at the end with the groove for the circlip. Fit the circlip in the groove. 4 Heat the gearbox housing to about 40 C to install the drive pinion RA70 : If required, push the screw sleeve (), spring () and washer (3) on to the locking pin on the lock housing (4) and secure with the snap ring (5). : Pull back the lock housing () and push home the gearbox housing () as far as stop. : Place the preassembled drive pinion in position and press it home as far as stop. Check that the teeth of the pinions mesh properly. Use 3. snap ring (DIN 6799) on original version of locking pin () and 5x0.8 snap ring (DIN 7993) on new version of locking pin (). 7RA : Fit cup springs () (convex side against screw head), washer (3) and new O-ring (4) over the screw (). 7RA7 : Fit the washer (). 7RA4 : Fit the circlip () in the housing groove. : Push the locking pin (on lock housing (3) into the gearbox housing () and screw home the screw sleeve (). : Push the screw () into the gearbox housing and secure hand-tight. 34 CombiTools

36 Remove the wear guard (FH only). Remove the gearbox cover. If necessary, pull the needle sleeve out of the gearbox cover. : Tighten down the screw () firmly, b 4. Check that gearbox housing (5) is still adjustable. 7RA76 : Fit the nut on the other end of the screw and tighten it down firmly (while counterholding the screw), b 4. Fit the cap on the screw head. : Remove the screw plug (arrow) from the gearbox housing and the fill the housing with grease. Use STIHL gear lubricant for brushcutters for lubrication of the bevel gear drive, b. Screw the tube of grease into the hole. Fill the gearbox housing with grease, b 4.3 : Remove the gasket. 3 Top up with grease during maintenance work only if no grease is visible on the inside of the screw plug, b 4.3 Unscrew the tube of grease. : Install original version of adjusting lever () with M5x40 screw () or new version of adjusting lever (3) with M6x50 screw (4). 4 7RA75 Fit the screw plug, b 4. Install the gearbox, b Cutting Blades : Remove the thrust plate from the shaft. The new adjusting lever and the new gearbox housing have a flat mating surface. Fit the plug on the screw head. 7RA008 7RA005 : Take out the seal. Remove the gearbox, b 7.. : Take out the screws (arrows). CombiTools 35

37 : Fit the flat spring (3) (pockets facing up) on the screws. : Put both blades (4) together with their cutting edges facing each other and locate them on the pockets. 7RA083 : Place the sliders (5) in the pockets. : Take the connecting rod off the spur gear and the pin on the blade. : Unscrew the nuts (). : Remove guard, guides () and flat spring, if fitted. : Fit the second guide (6). : Fit new locknuts (7) and tighten down firmly, b 4. The guide (8), flat spring (9) and screws (0) are only installed in older type cutting attachments. 7 : Remove the screws (arrows) from the gearbox housing. 7RA00 : Take out the sliders (arrows). Separate the blades. 7RA RA04 Reassemble in the reverse sequence Assemble cutting blades for FH machines in the same way. 7 4 : Remove the cutting attachment. 7RA374 TG : Place the guide () on the workbench with the screw heads () facing down. 7RA03 3 : The pin () must engage the bore () in the connecting rod. : The peg (3) must engage the hole (4). 7RA CombiTools

38 7.6.5 HL/FH Remove the cutting blades, b RA08 7RA087 : Fit the connecting rod so that the marking (see arrow) faces the spur gear. Fit screws (arrows) in gearbox cover and tighten them down firmly, b 4. : Remove the screw plug () from the gearbox cover. : Take the spur gear out of the gearbox housing : Fit the thrust plate so that its bent corners face the connecting rod. Use a new gasket. : Push home the new needle sleeve (arrow) as far as stop. Note that a replacement gearbox cover comes with the needle sleeve already installed. 7RA0 Use STIHL gear lubricant for hedge trimmers for lubrication of the bevel gear drive, b. : Screw the tube of grease into the hole. Fill the gearbox housing with grease, b 4.3 Top up with grease during maintenance work only if no grease is visible on the inside of the screw plug, b 4.3 Unscrew the tube of grease. Fit the screw plug, b 4. Install the gearbox, b 7.. : Take the connecting rod out of the gearbox housing : Take the thrust plate out of the gearbox housing. CombiTools 37

39 Fit the spur gear with the chamfered side of the teeth facing the connecting rod. Assemble all other parts in the reverse sequence. : Pull the needle sleeve (arrow) out of the gearbox housing. Push home the new needle sleeve as far as stop. 7RA Angle Drive Removing : Remove the screws (). : Separate the two halves of the gearbox housing (). 7RA0 Note that a replacement gearbox housing comes with the needle sleeve already installed. Reassemble in the reverse sequence : Fit the thrust plate so that its bent corners face the gearbox housing. Remove the cutting head, if fitted, b 7..4 Remove the HL gearhead, if fitted, b 7.. : Loosen the screws (). : Pull the angle drive off the drive tube. Disassembling 7RA8 : Pry the pinions with ball bearings out of the gearbox housing. Replacement pinions are only supplied as a matching pair with preassembled ball bearings. Assembling 7RA 7RA9 7RA7 7RA08 : Loosen the screws (). Clean the two halves of the gearbox housing, b. : Fit the connecting rod with the marking (see arrow) facing up. : Pull the drive tube () out of the angle drive. Clean the vent channel (arrow) in both halves of the gearbox housing, b. 38 CombiTools

40 Use STIHL gear lubricant for brushcutters for lubrication of the angle drive, b. A 7RA4 936RA093 Fill recesses in the gearbox housing (arrows) with gear lubricant for brushcutters, b 4.3 Note that the large pinion (), with shaft and ball bearings, must be installed at the side with the vent channel. Fit the pinions in the gearbox housing. Check that the ball bearings are properly seated in the gearbox housing. : Coat mating faces () with Dirko sealant, b. 7RA 7RA3 Marry up the two halves of the angle drive housing. : Fit screws (), without washers, and tighten down firmly in crosswise pattern, b 4. : Push short drive tube () into angle drive housing as far as stop. : Fit screws () with washers and tighten down in alternate pattern, b 4. : Fit screws (3) with washers but do not finally tighten yet. 3 7RA5 Installing : Apply a mark to the end of the drive tube (from powerhead) at distance "A", 50 mm. : Push the 30 angle drive on to the drive tube as far as stop. Turn the angle drive back and forth during the process until the square shaft engages properly. The 30 angle drive is correctly fitted when the edge of the housing reaches or covers the mark. : Tighten the screws () moderately in an alternate pattern, then tighten them down firmly, b 4. Install the cutting head, b RA6 CombiTools 39

41 8. Gearbox (new versions) 8. Removing and Installing 8.. HL 0 Removing Installing 8.. HL 35 Removing Fit the blade guard over the cutting attachment. 7RA7 TG : Push the gearbox () onto the drive tube () turn the gearbox () back and forth at the same time so that the square end of the drive shaft (arrow) engages the square socket in the gearbox. 7RA9 TG Fit the blade guard over the cutting attachment. : Loosen the screws (arrows). 7RA3 TG : Loosen the screws (arrows). : Pull the gearbox () off the drive tube (). Degrease clamp mounting areas (arrows), b. 7RA8 TG Push the gearbox () on as far as stop and line it up. The end of the tube must not be visible in the clamp s slot (arrow). : Tighten down the screws () firmly. Tightening torques, b 4. 7RA30 TG : Pull the gearbox () off the drive tube (). 7RA3 TG 7RA33 TG : Turn the sleeve () to one side. Degrease clamp mounting areas (arrows), b. 40 CombiTools

42 Installing 3 Line up bore in sleeve () with gearbox bore. : Push the gearbox () onto the drive tube (3) through the sleeve (). Pull back the sleeve () a little at the same time and position the gearbox on the drive tube (arrow). 7RA34 TG Push the gearbox () on as far as stop and line it up. The end of the tube must not be visible in the clamp s slot (arrow). : Tighten down the screws () firmly. Tightening torques, b 4. 7RA36 TG : Heat the gearbox housing to about 0 40 C and remove the components () from the input end by knocking the housing against a wooden base. This operation must be carried out quickly because the outer bearing races will otherwise absorb heat and expand. 7RA38 TG 3 8. Disassembling the HL 0 Gearbox 8.. Disassembling the Input Pinion : Push the gearbox () onto the drive tube () turn the gearbox () back and forth at the same time so that the square end of the drive shaft (arrow) engages the square socket in the gearbox. 7RA35 TG Remove the gearbox, b 7. 7RA37 TG Inspect the pinion, if damaged, replace the input and output pinions. New pinions come preassembled. : Remove the circlip (). 7RA39 TG : Take out the grub screw (). Wear work gloves to protect your hands. CombiTools 4

43 I 7RA40 TG 7RA4 TG 7RA44 TG : Support the input pinion () by way of the bearing race of the ball bearings and press it out of the ball bearings. Assembling 3 The closed side of the ball bearing must face the circlip. : Fit the circlip () and make sure it is properly seated in the groove (arrow). : Insert the grub screw () in bore (arrow) and tighten it down as far as stop. Assemble all other parts in the reverse sequence Tightening torques, b 4. Lubricate the gearbox, b Disassembling the Output Pinion Heat the new ball bearings to about 50 C and push them onto the input pinion. : Push the open ball bearing () onto the input pinion () as far as stop first, then push on the closed ball bearing (3), open side facing the pinion, until it butts against the first bearing. 7RA4 TG : Heat the gearbox housing to about 0 40 C and push preassembled input pinion () into the bore (arrow) as far as stop. This operation must be carried out quickly because the outer bearing races will otherwise absorb heat and expand. 7RA43 TG Remove the blade drive gear, b RA45 TG This operation must be carried out quickly because the inner bearing races will otherwise absorb heat and expand. : Take out the lock screw (arrow) and remove the washer. 4 CombiTools