FE 35, 40, 55, EC 70 1 Service Manual FE 35, FE 40, FE 55 Electric Trimmers, EC 70 Electric Edger As the design concept of the FE 35 and FE 40 trimmers is almost identical, the descriptions and servicing procedures generally apply to both. Differences are described in detail. The motors of the FE 55 trimmer and EC 70 edger are identical. The shafts and drives are different and are described separately. 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. Microfilmed parts list are always more up to date than printed lists. Warning: When carrying out repairs to electric power tools it is essential to observe all relevant national safety regulations and ordinances. Important notes: - Every time you open the housing, clean the motor with a soft brush. - Always use the mounting screws specified in the parts list - other screws must not be used. - Parts of the motor must neither be repaired nor modified in any way. - Always use original STIHL replacement parts. - Original STIHL parts can be identified by the STIHL part number, the STIHl logo and the STIHL parts symbol ( The symbol may appear alone on small parts. A fault on the machine may have several causes. Consult the "Troubleshooting Chart" when tracing faults. Refer to the "Technical Information Bulletins" for engineering changes which have been introduced since publication of this service manual. Service manuals and technical information bulletins are intended exclusively for the use of STIHL servicing dealers and staff and must not be passed to third parties. The STIHL Special Tools manual lists all special servicing tools currently available from STIHL. STIHl
FE 35, 40, 55, EC 70 2 CONTENTS 1. Specifications 3 1.1 Motor 3 1.2 Cutting Tool 4 1.3 Gearhead 4 1.4 Special Accessories 5 1.4.1 For User 5 1.5 Tightening Torques 5 2. Troubleshooting Chart 6 2.1 Motor 6 2.2 Mowing Head 6 3. Electrical Circuit 7 3.1 Wiring Diagrams 7 3.2 Power Cable (FE 35, FE 40) 8 3.3 On/Off Switch (FE 35, FE 40) 9 3.4 Power Cable (FE 55, EC 70) 9 3.5 Trigger / On/Off Switch / Capacitor (FE 55, EC 70) 10 3.6 Motor (FE 35, FE 40) 11 3.7 Carbon Brushes (FE 35, FE 40) 13 3.8 Switch Unit of Automatic Feed Mechanism (FE 40) 14 3.9 Adjusting Automatic Feed Mechanism (FE 40) 15 3.10 Motor (FE 55, EC 70) 15 3.11 Fanwheel 16 3.12 Adapter 16 3.13 Strain Relief Flap 16 4. Shaft 17 4.1 Line Feed Lever/ Activating Cord (FE 35) 17 4.2 Connecting Tube / Loop Handle 17 4.3 Drive Tube (FE 55, EC 70) 18 4.4 Drive Shaft (FE 55, EC 70) 19 4.5 Loop Handle (FE 55, EC 70) 20 5. Cutting Tool Drive 21 5.1 Bearing Housing (FE 55) 21 5.2 Gearhead (EC 70) 23 5.2.1 Disassembly 23 5.2.2 Assembly 26 5.3 Mowing Head / Motor Mounting Plate (FE 35, FE 40) 28 6. Special Servicing Tools and Aids 30 6.1 Special Servicing Tools 30 6.2 Servicing Aids 31
FE 35, 40, 55, EC 70 3 1. SPECIFICATIONS 1.1 Motor FE 35 FE 40 Rating: Rated current: Voltage: Frequency: Maximum speed (without nylon line): Fuse: Insulation: Radio interference suppression: Type of enclosure: 350 W 1.6 A 220-240 V 50 Hz 11,700 rpm 10A Class II VIDE Level "N" VIDE 0875 IP 20 to DIN 40050 400 W 1.8 A 220-240 V 50 Hz 11,700 rpm 10A Class II VIDE Level "N" VIDE 0875 IP 20 to DIN 40050 FE 55/EC70 Rating: Rated current: Voltage: Frequency: Rated speed at width of cut, 350 mm (14 in) 1) Maximum speed (without nylon line): Fuse: Insulation: Radio interference suppression: 600 W 2.6 A 230 V 50 Hz 8,500 rpm 13,500 rpm 10A Class II VDE Conforms to EEC directive 76/885 and DIN 57 875 650 W 2.7 A 240 V 50 Hz 8,500 rpm 13,500 rpm 10A Class II VIDE Conforms to EEC directive 76/885 and DIN 57 875 660 W 5.5 A 120 V 60 Hz 8,500 rpm 13,500 rpm 15A Class II VDE Conforms to EEC directive 76/885 and DIN 57 875 1) with cutting blade on EC 70
FE 35, 40, 55, EC 70 4 1.2 Cutting Tool FE 35 FE 40 FE 55 Mowing head: with two nylon lines with two nylon lines with two nylon lines Line diameter: 1.6 mm (0.065 in) 1.6 mm (0.065 in) 2.0 mm (0.080 in) Width of cut: 300 mm (12 in) 300 mm (12 in) 350 mm (14 in) Nylon line in spool: 10 m (33 ft) 10 m (33 ft) 2x3.75m(2x12.3ft) Line feed: semi-automatic fully automatic semi-automatic EC 70 Cutting blade 4133 713 4101 1.3 Gearhead EC 70 Type: Spiral-tooth bevel gear drive Gear ratio: 1.24 Bearings: Deep-groove ball bearings Lubrication: STIHL gear lubricant 0781 120 1117
FE 35, 40, 55, EC 70 5 1.4 Special Accessories 1.4.1 For User Spool with nylon line (10 m/33 ft) 4802 710 4300 1 ) Replacement nylon line (15.2 m/50 ft reel) 0000 930 2515 2 ) Replacement nylon line (spool) (FE 55) 4004 710 4304 4 ) Shoulder strap 4130 710 9000 2 ) Goggles 5 ) 1.5 Tightening Torques Fastener Thread size For component Torque Nm lbf.ft Remarks Tapping screw IS-P4x19 Handle 1.2 0.9 1) Tapping screw IS-P4x19 Housing 1.1 0.8 1) Tapping screw IS-P4x35 Housing 1.2 0.9 1) Pan head screw M4x8 Mounting screw 1.8 1.3 1) Tapping screw IS-P6x19 Housing 5.5 4.0 2) 3) Tapping screw B3.5x9.5 Bearing housing 3.0 2.2 2) Spline screw IS-M5x18 Clamp on bearing housing 6.5 4. 8 2) Spline screw IS-M 6x20 Clamp screw in gearhead 7.5 5. 5 1) FE 35, FE 40 2) FE 55 3) EC 70 4) Not available in Europe 5) Standard equipment in some markets
FE 35, 40, 55, EC 70 6 2. TROUBLESHOOTING CHART 2.1 Motor Condition Cause Remedy Motor does not run Plug not in power outlet Connect plug to power outlet Carbon brushes worn (FE 35, FE 40) Switch unit faulty (FE 40) Motor faulty Fit new carbon brushes Replace switch unit Replace motor 2.2 Mowing Head Condition Poor cutting performance Does not cut Cause Cutting line too short Automatic feed mechanism not properly adjusted Spool empty Remedy Readjust nylon line (FE 35, FE 55) Adjust automatic feed mechanism correctly Fit new spool FE 35, FE 55: Line is not advanced when line feed lever is operated Spool empty Line sticking in spool Activating cord broken Fit new spool Grip ends of line and pull firmly outward Fit new activating cord FE 40: Line is not advanced even though feed process is audible, or no click is heard Ends of line not projecting from spool Pull ends of line about 10 cm (4") out of spool FE 40: Line is advanced too late or too often and cut off by line limiting blade on deflector Automatic feed mechanism not properly adjusted Adjust automatic feed mechanism correctly
FE 35, 40, 55, EC 70 7 3. ELECTRICAL CIRCUIT 3.1 Wiring Diagrams 1 = Power cable 2 = Switch with capacitor 3 = Wires with flat connectors 4 = Brush holder with carbon brush 1 = Power cable 2 = Capacitor 1 1 3 = Switch 4 = Wires from motor 1 = Power cable 2 = Switch 3 = Wires with right-angle connectors 4 = Brush holder with carbon brush 5 = Switch unit (electronic) 6 = Solenoid 1) Capacitor not installed in all countries
FE 35, 40, 55, EC 70 8 3.2 Power Cable (FE 35, FE 40) Handle mounting screws Removing on/off switch 1 = Screws Cable protector Correct position of power cable 1 = Cable protector 1 = Line feed lever 2 = Activating cord Caution: The power cable must positioned as shown so that it is not pinched when the handle is assembled. Make sure all wires are reconnected to their original terminals - see 3.1. - On FE 35, check that the activating ord is attached to line feed lever. Make sure that line feed lever is properly seated in the handle molding. - Tighten handle mounting screws to 1.2 Nm (0.9 Ibf.ft). Warning! Always unplug the unit from the power supply before performing any servicing or repair work. - Take out the handle mounting screws. Remove the two halves of the handle from the connecting tube. - Lift the on/off switch out of its seat, remove the screws and pull the wires out of the switch. - Take the power cable out of the handle molding and slip the cable protector off the end of the cable. Installation is a reversal of the removal sequence. Note: Pay special attention to the following points. - The cable protector must be properly engaged and the power cable correctly positioned in the handle molding. Warning! Always use only the handle molding mounting screws specified in the parts list. - On FE 35, check smooth action of line feed lever.
FE 35, 40, 55, EC 70 9 3.3 On/Off Switch (FE 35, FE 40) 3.4 Power Cable (FE 55, EC 70) Removing wires (FE 40) On/off switch (FE 35) 1 = Capacitor Housing mounting screws Removing on/off switch 1 = Connector tabs Correct position of on/off switch Correct position of connecting wires - Disconnect the power cable from the on/off switch - see 3.2. - Use a thin pointed tool (e.g. scriber) to push back the clamping springs in the switch and then pull the wires out of the switch. Installation is a reversal of the removal sequence. Note: Fit wires by pushing them into the openings in the switch. - Take out housing mounting crews and remove the righthand housing molding. - Pull the on/off switch out of its seat in the left-hand housing molding and pull the two wires off the connector tabs. - Remove wires of power cable from the left-hand housing molding. Installation is a reversal of the removal sequence. - Fit on/off switch in its seat and check that it is properly located. - Position connecting wires correctly in housing molding.
FE 35, 40, 55, EC 70 10 3.5 Trigger / On/Off Switch / Capacitor (FE 55, EC 70) Cable protector Removing trigger Connectors on switch 1 = On/off switch 2 = Push-on distributor 3 = Capacitor Caution: The power cable must positioned as shown so that it is not pinched when the handle is assembled. Make sure both wires are reconnected to their original terminals - see 3.1. - The cable protector The cable protector must be properly engaged in the housing recess. - Tighten housing molding mounting screws to 5.5 Nm (4.0 Ibf.ft). - Pull the push-on distributors off the connector tabs on the switch and remove the capacitor. Installation is a reversal of the removal sequence. Important: All wires must be reconnected to their original terminals - see 3.1. Warning! Always use only the housing molding mounting screws specified in the parts list. - Remove the right-hand housing molding - see 3.4. - Remove the trigger. - Pull the on/off switch out of its seat in the left-hand housing molding and disconnect all wires from the connector tabs and the push-on distributors.
FE 35, 40, 55, EC 70 11 3.6 Motor (FE 35, FE 40) 1 = Retaining lug 2 = Deflector shield Clamp nut Housing mounting screws Activating cord on line feed lever (FS 35) Removing the solenoid 1 = Actuating pin 2 = Iron core Removing the iron core - Use a screwdriver to lift the retaining lug on the deflector shield a little and then pull off the deflector shield. - Unscrew the clamp nut from the housing. - Remove housing mounting screws and lift away the upper housing molding. - Disconnect the activating cord from the adjusting lever. - On FE 40, remove the solenoid from the mounting plate and pull the actuating pin out of the iron core at the same time. - Pull the iron core out of the solenoid and put solenoid to one side.
FE 35, 40, 55, EC 70 12 1 = Adjusting lever 2 = Actuating pin Lifting motor out of housing Connections on motor Housing slots Correct position of cable (FE 35) Correct position of wiring (FE 40) - Pull the actuating pin out of the adjusting lever. - Lift the motor with mowing head out of the housing. - Pull the connectors off the motor. Note: The mowing head and mounting plate have to be removed to replace the motor -see 5.3. Installation is a reversal of the removal sequence. - The mounting plate must engage the housing slots. - Position wires in the notches in the housing web. - Fit the connecting tube - see 4.2. Note: Pay special attention to the following points.
FE 35, 40, 55, EC 70 13 3.7 Carbon Brushes (FE 35, FE 40) 1 = Tab 2 = Spring Correctly positioned activating cord Opening cover 1 = Carbon brush 2 = Retaining tag - On FE 35, hook activating cord onto adjusting lever and position it behind the pin. - Place the upper housing molding in position. Screw on the clamp nut. Insert mounting screws and tighten down to 1.2 Nm (0.9 Ibf.ft). The commutator is subject to normal wear. The friction generated by the carbon brushes causes the commutator surface to wear gradually and eventually leaves deep scores. The scores cause an increase in sparking between the carbon brushes and commutator. Therefore, before installing new carbon brushes, inspect the commutator for wear and replace the complete motor if necessary. - Remove the motor - see 3.6. - Use a small screwdriver to remove the cover. - Bend open the tab on the brush holder and remove the spring. - Push the retaining rings in the brush holder slightly toward the mowing head so that the worn carbon brush can slip out of the brush holder. Note: Carbon brushes must always be replaced in pairs. - Fit new carbon brush, push the spring into the brush holder and bend the tab back to the horizontal position. - Close the cover. - Install the motor - see 3.6.
FE 35, 40, 55, EC 70 14 3.8 Switch Unit of Automatic Feed Mechanism (FE 40) Solenoid mounting plate Removing switch unit Right angle connectors on switch unit Switch unit assembly (original version) 1 = Thermistor Switch unit assembly (new version) 1 = Solenoid 2 = Solenoid mounting plate 3 = Switch unit 4 = Iron core 5 = Actuating pin The complete switch unit has to be replaced if any one of its components is faulty. The new and original parts cannot be combined. The new switch unit assembly can be identified as follows: The connecting wires between the switch unit and solenoid are yellow instead of red. No thermi- is fitted. - Fit the iron core, cross hole facing outward, in the solenoid. - Remove the motor - see 3.6. - Take the solenoid mounting plate out of its seat in the housing. - Remove the switch unit from the housing molding. - Pull the right angle connectors off the switch unit. Installation is a reversal of the removal sequence. Note: A modified switch unit is installed to avoid the need to solder the switch unit's sensitive printed circuit board. Important: All wires must be reconnected to their original terminals - see 3.1.
FE 35, 40, 55, EC 70 15 3.9 Adjusting Automatic Feed Mechanism (FE 40) 3.10 Motor (FE 55, EC 70) Potentiometer Switch Wires from motor Lifting motor out of housing Correct position of wiring If the automatic feed mechanism malfunctions, its tripping point can be corrected on the potentiometer. - Remove upper housing molding see 3.6. - Use a small screwdriver to rotate the potentiometer on the switch unit. Note: Turn clockwise = feed is activated when cutting line is shorter (later). Turn counterclockwise = feed is activated when cutting line is longer (earlier). - Refit upper housing molding. - Pull the drive tube off the adapter see 4.3. - Remove the on/off switch from its seat in the left-hand housing molding. - Pull the wires from the motor off the switch terminals. - Remove the motor from the lefthand housing molding. Installation is a reversal of the removal sequence. Note: Reconnect both wires to the original terminals - see 3.1. Position the wires in the slot in the housing molding.
FE 35, 40, 55, EC 70 16 3.11 Fanwheel 3.12 Adapter 3.13 Strain Relief Flap Removing the fanwheel Press-fitted fanwheel a = 3.5 mm (0.14 in) Prying adapter off shaft Installing the adapters Removing strain relief flap Torsion spring - Remove the motor - see 3.10. - Rest fanwheel on bench and use a piece of round stock (6 mm/ 1/4" dia.) to press it off the shaft. - Press the fanwheel, blades first, onto the shaft until distance "a" is obtained. - Install the motor - see 3.10. - Remove the motor - see 3.10. - Use a hot air blower (e.g. hair dryer) to heat the adapter and then pry it off the shaft with two screwdrivers. - Press adapter on to shaft as far as stop. - Install the motor - see 3.10. - Separate the two halves of the housing - see 3.4. - Take the strain relief flap out of the left-hand half of the housing. - Remove the torsion spring from the flap. - When refitting the flap, make sure that torsion spring is properly seated.
FE 35, 40, 55, EC 70 17 4. SHAFT 4.1 Line Feed Lever/ 4.2 Connecting Tube / Loop Handle Activating cord on adjusting lever Activating cord on line feed lever Correctly positioned activating cord Removing the connecting tube 1 = Cable Cylindrical pin - Tie a piece of string (about 1000 mm/39 in long) to the activating cord. - Pull the activating cord out of the connecting tube so that the string is still inside the tube and can be used to fit the new activating cord. Installation is a reversal of the removal sequence. - Remove upper housing molding see 3.6. - Unhook activating cord from adjusting lever. - Remove the handle - see 3.2. - Unhook the activating cord from the line feed lever. Note: After fitting the new activating cord, pass it behind the pin the connecting tube and around the pin in the housing molding. - Remove the activating cord - see 4.1. - Remove the on/off switch - see 3.3. - Remove the connecting tube and pull out the cable at the same time. - Pull the cylindrical pin out of the connecting tube.
FE 35, 40, 55, EC 70 18 4.3 Drive Tube (FE 55, EC 70) Removing clamp nut 1 = Clamp nut 2 = Loop handle Installing connecting tube (FE 35) 1 = Hole at end of slot Installing connecting tube (FE 40) 1 = Slot Housing mounting screws Removing the drive tube - Slip the clamp nut off the connecting tube. - Release clamp nut on loop handle and pull the loop handle off the connecting tube. Installation is a reversal of the removal sequence. Note: Pay special attention to the following points: - On FE 35, fit connecting tube so that the cylindrical pin engages the hole at the end of the slot. - On FE 40, fit connecting tube so that the cylindrical pin engages the slot. - Take out the housing mounting screws and remove the righthand housing molding. - Raise the drive tube until the retaining block is clear of the recess in the left-hand housing molding. - Pull the drive tube off the adapter.
FE 35, 40, 55, EC 70 19 4.4 Drive Shaft (FE 55, EC 70) 1 = Retaining block 2 = Peg 3 = Recess in housing molding Withdrawing flexible shaft (FE 55, EC 70) Drive shaft must project a = 15 mm (0.6 in) on FE 55 20 mm (0.8 in) on EC 70 - To replace the drive tube, remove the bearing housing on the FE 55 or the gearhead on the EC 70 see 5.1 or 5.2. Pull out the drive shaft, see 4.4, and remove the loop handle, see 4.5. Reassemble in the reverse sequence. Note: Push the drive tube onto the adapter. Fit peg of retaining block into hole in drive tube and engage retaining block in recess in housing molding. Torque down housing mounting screws to 5.5 Nm (4.0 Ibf.ft). The drive shaft is supported inside the drive tube in bearing bushes. It is not possible to replace the bearing bushes, i.e. a new drive tube has to be installed in the event of a fault or damage. - On FE 55, remove the bearing housing, see 5.1. On EC 70, remove the gearhead, see 5.2. - Pull the drive shaft out of the drive tube. - Coat the drive shaft with STIHL multipurpose grease, see 6.2, before installation. Important: Apply the grease uniformly and thinly to the whole drive shaft. Do not pump grease directly into the drive tube. - Push the drive shaft into the drive tube. Note: Push the drive shaft into the drive tube until dimension "a" is obtained (see illustration). If necessary, apply slight pressure to the shaft and rotate it slowly until it can be pushed in to the specified dimension. - Fit the bearing housing or gearhead.
FE 35, 40, 55, EC 70 20 4.5 Loop Handle (FE 55, EC 70) Clamp screw on loop handle Removing the fixing Pulling off handle hose 1 = Loop handle 2 = Clamping block 1 = Clamp screw 2 = Square nut - Place the square nut in position and insert the clamp screw from the other side. Line up the loop handle and tighten down clamp screw firmly. - Take the clamp screw out of the loop handle. Remove the loop handle and clamping block from the drive tube. - To replace the handle hose, unscrew the fixing screw from the loop handle. - Turn the loop handle to one side and pull off the handle hose. - Refit the loop handle on the drive tube. Place the clamping block against the drive tube and slide it sideways into the loop handle (see illustration).
FE 35, 40, 55, EC 70 21 5. CUTTING TOOL DRIVE 5.1 Bearing Housing (FE 55) 1 = Clamp 2 = Deflector shield 1 = Bearing housing 2 = Clamp Fixing screw Pliers 0811 611 8200 Removing the circlip Removing the washer - Remove the mowing head (if fitted). - Release screw on clamp and pull deflector shield off the bearing housing. - Release screw on bearing housing clamp and slip the clamp off the bearing housing. - Take the fixing screw out of the bearing housing and pull bearing housing off the drive tube. - Remove the circlip from the output shaft. - Remove the washer from the output shaft.
FE 35, 40, 55, EC 70 22 Removing the output shaft Press arbor 4119 893 7200 Pressing home plain bearing Pressing home plain bearing Lining up holes in bearing housing and drive tube Correct position of deflector shield in relation to bearing housing - Pull the output shaft out of the bearing housing. - Carefully drive the two plain bearings out of the bearing housing. Assembly is a reversal of the disassembly sequence. Note: Pay special attention to the following points: - Use press arbor to install the two plain bearings until they butt against shoulder on bearing housing. - Push bearing housing onto drive tube so that the holes line up. - Insert the fixing screw and tighten down to 3 Nm (2.2 Ibf.ft). - Line up recess in neck of deflector shield with peg on bearing housing. Push deflector onto bearing housing as far as stop. - Torque down bearing housing clamp screw to 6.5 Nm (4.8 Ibf.ft).
FE 35, 40, 55, EC 70 23 5.2 Gearhead (EC 70) 5.2.1 Disassembly Unscrewing flanged nut 1 = Thrust plate 2 = Cutting blade Removing thrust plate 1 = Clamp 2 = Clamp screw 3 = Star knob screw Removing deflector shield 1 = Washer 2 = Retainer 3 = Mounting screws 4 = Star knob screw - Use 5 mm (0.2 in) drift to block the output shaft and unscrew the flanged nut. Note: Flanged nut has left-hand thread. - Take the thrust plate and cutting blade off the output shaft. - Take the thrust plate off the output shaft. - Unscrew the clamp screw and star knob screw from the clamp and then remove the clamp. - Remove the deflector shield from the gearhead. Note: The following three operations must be performed to replace the deflector shield: - Take the mounting screws out of the retainer, pull the star knob screw out of the bore and remove the washer.
FE 35, 40, 55, EC 70 24 Removing bearing bolt from depth wheel 1 = Rubber flap 2 = Fastening screw Clamp screw Pliers 0811 641 8380 Removing circlip from input end of gearhead Removing circlip from output end of gearhead - Unscrew the bearing bolt from the depth wheel and remove the wheel. - Take out the fastening screw and remove the rubber flap. - Release clamp screw on gearhead and pull the gearhead off the drive tube. - Remove the circlip from groove in input end of the gearhead. - Remove the circlip from groove in output end of the gearhead. - Heat the gearhead housing to about 110 to 140 C (230-280 F). Remove the gearhead components from the input end first and then the output end by knocking the gearhead against a wooden base.
FE 35, 40, 55, EC 70 25 Removing output shaft 1 = Bevel gear 2 = Ball bearing Pliers 0811 611 8200 Removing the circlip from the drive pinion Pressing drive pinion out of ball bearings Pinion set - Press the output shaft out of the ball bearing. - Pull the ball bearing and bevel gear off the output shaft. - Remove the circlip from the drive pinion. - Press the drive pinion out of the ball bearings. - Clean all parts and inspect them for signs of wear or damage. Note: The drive pinion and bevel gear are only available as matched pairs, i.e. as a pinion set.
FE 35, 40, 55, EC 70 26 5.2.2 Assembly 1 = Drive pinion 2 = Open ball bearing 3 = Sealed ball bearing Ball bearing on output shaft Pushing bevel gear onto the output shaft Fitting the sealed ball bearing in gearhead housing Fitting the output shaft Fitting the drive pinion - Heat the ball bearings for input end to about 50 C (120 F) and push them onto the drive pinion so that the open bearing locates against the pinion. - Fit the circlip in the groove. - Heat ball bearing for output end to about 50 C (120 F and push it onto the output shaft as far as stop. - Push the bevel gear (teeth first) onto the output shaft. - To install the bearing and pinion set, heat the gearhead housing to about 140 C (285 F), e.g. on a heating plate or with a hot air blower. - Push the sealed ball bearing into the housing as far as stop. - Place the preassembled output shaft in position and press it home as far as stop. - Place the preassembled drive pinion in position and press it home as far as stop. Note: Make sure the teeth of the drive pinion and bevel gear mesh properly during installation.
FE 35, 40, 55, EC 70 27 Screw plug for gear lubricant Fitting gearhead on drive tube Washers Fitting the clamp 1 = Deflector shield 2 = Washer - Fit the circlips in their respective grooves at the input and output ends of the gearhead housing. - Remove the screw plug from the gearhead, screw the tube of grease into position and fill the gearhead with grease. Note: Use STIHL gear lubricant, see 6.2, for lubrication of the bevel gear drive. Important: Fill the gearhead with approx. 20 g (3/4 oz) grease. Service note: Top up gearhead with grease (max. 5...10 g / 1/4-3/8 oz) only if no grease is visible on the inside of the screw plug. - Unscrew the tube of grease, refit the screw plug and tighten it down firmly. - Slide the gearhead 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 gearhead as far as stop and line it up. Tighten down the two clamp screws to 7.5 Nm (5.5 Ibf.ft). - Refit the rubber flap. - To fit the depth wheel, slip washer over the bearing bolt. Push the bearing bolt through the depth wheel, fit a washer at the other side and screw the bearing bolt into the deflector shield. - Position the deflector shield against the gearhead. Fit a washer on the clamp screw and place the clamp in position. - Fit a new self-locking nut and tighten it down firmly. - Refit the cutting blade by reversing the removal sequence.
FE 35, 40, 55, EC 70 28 5.3 Mowing Head / Motor Mounting Plate (FE 35, FE 40) Removing cap Prying off the driver Removing mowing head housing Prying out support roller Mounting screws of motor mounting plate The mowing head housing and driver should be installed with the motor removed. This avoids excessive bearing loads when pressing on the driver. - Remove the motor - see 3.6. - Clamp the motor, with the mowing head facing up, in a vise. Important: Use protective jaws. Take care not to damage winding. - Hold the mowing head housing steady. - Press the cap downward, turn it counterclockwise as far as stop and lift it away. -Take the spool out of the mowing head housing. - Heat the driver (e.g. with hot air blower or hair dryer) and use two screwdrivers to lever it off (see illustration). - Remove the mowing head housing. - To replace the motor mounting plate, perform the following operations: - Carefully pry the support roller (above the mounting screw) out of its seat. - Take the mounting screws out of the motor mounting plate and remove the mounting plate.
FE 35, 40, 55, EC 70 29 Adapter sleeve Mowing head housing with retrofitted sleeves Mowing head housing with aluminum sleeves 1 = Slot in mowing head housing 2 = Adapter sleeve Pressing on the driver - If necessary, use a 2.5 mm (0.10 in) punch to drive the adapter sleeve out of the rotor shaft. Assembly is a reversal of the disassembly sequence. Note: Pay special attention to the following points: - Torque down mounting screws of motor mounting plate to 1.8 Nm (1.3 Ibf.ft). - Carefully press the support roller (shorter bearing pin must face rotor shaft) into its seat. Note: Mowing head housings with aluminum sleeves (for nylon line) are installed from machine numbers X 19 966 870 (FE 35) and X 19 971 252 (FE 40). If the trimmer still has a mowing head housing with retrofitted sleeves, it is advisable to install a mowing head housing with aluminum sleeves for improved nylon line control and better heat dissipation. - Fit the mowing head housing so that the adapter sleeve engages the slot. - Press the driver onto the rotor shaft as far as it will go. - Fit the spool, projecting edge facing up, so that the nylon lines locate in the sleeves. - Hold the mowing head housing steady. - Fit the cap in position, press it downward and turn it clockwise as far as stop. - Install the motor - see 3.6.
FE 35, 40, 55, EC 70 30 6. Special Servicing Tools and Aids 6.1 Special Servicing Tools No. Part Name Part No. Application 1 Crimping tool 5910 890 8210 Attaching connectors to electric wires 2 Pliers A 10 0811 611 8200 External circlip on bearing housing and drive pinion 3 Press arbor 4119 893 7200 Installing plain bearings in bearing housing 4 Pliers A 19 0811 641 8380 Internal circlip on gearhead
FE 35, 40, 55, EC 70 31 6.2 Servicing Aids No. Part Name Part No. Application 1 Electrician's repair kit 0000 007 1013 2 STIHL multipurpose grease 0781 120 1109 Lubricating drive shaft (FE 55, EC 70) 3 STIHL gear lubricant 0781 120 1117 Lubricating gearhead (EC 70)