Zenoah CHTZ2401, Workshop Manual

Page 1: ...HEDGE TRIMMER Workshop Manual February 2010 USA models CHTZ2401 2460 and HTZ2401 2460 EU models CHTZ6000 7500 HTZ7500 and eHT602D 752S China models HTZ7510 CHTZ6010 and eHT603D 753S...

Page 2: ...re also included in this manual However many cases need rich maintenance experience and informed judgment Please refer to this manual for maintenance support NOTES 1 The contents of this manual are ba...

Page 3: ...11 Insulator Assembly 14 4 12 Connecting of Fuel Pipes 14 5 Carburetor Specifications 15 6 Carburetor Construction Maintenance Specifications 16 7 Carburetor Service Guide 7 1 Recommended Tools 17 7...

Page 4: ...eight without attachment kg lb 5 67 12 5 5 58 12 3 5 9 13 0 1 6 1 13 4 2 5 8 12 8 3 4 7 10 4 5 8 12 8 1 5 9 13 0 2 4 7 10 4 Fuel Tank Capacity 15 9 fl oz US 470 cc 470 cc 400 cc 470 cc 400 cc Operatin...

Page 5: ...82 N m 90 kgf cm Tighten the bolts again after operation inspection Bolt M4x L10 T27 4 0 98 0 96 N m 10 20 kgf cm TARGET 1 47 N m 15 kgf cm Cover 2 Gasket 2 Cylinder Gasket Insulator Bolt M5x L20 T27...

Page 6: ...0 60 kgf cm Plate Crankshaft Comp Key Gasket case Crankcase Bearing Spring Tube Cord Comp Coil Engine Cover Cap Grommet Bolt M5x L16 T27 2 2 94 5 88 N m 30 60 kgf cm Bolt M4x L16 T27 2 2 45 3 92 N m 2...

Page 7: ...Muffler Cover Screw M4x L12 1 47 1 96 N m 15 20 kgf cm Screw TP M4x L16 1 96 2 94 N m 20 30 kgf cm Clip Pipe Comp Clip Filter Cushion Tank Cap Assy Absorber 2 Screw M5x L16 2 45 3 43 N m 25 35 kgf cm...

Page 8: ...case Pin Case Gasket Oil Seal Bearing Crankshaft Comp Bearing Ring Oil Seal Snap Ring 2 Piston Pin Washer 2 Bearing Piston Piston Ring Crankcase Rotor Coil Spacer 2 Cord Comp Bolt M4x L20 2 2 45 3 92...

Page 9: ...uller Assy 2890 96100 520 76 93 01 To remove rotor Piston Stopper 4810 96220 521 34 51 01 To hold crankshaft when disassembling assembling clutch shoe and rotor Piston Stopper 2670 96220 516 84 93 01...

Page 10: ...hen remove the clutch shoes G20LH Remove the clutch shoe with the wrench 2841 96110 516 95 87 01 3 GZ23N If necessary remove the clutch plate with the puller assembly 2890 96100 520 76 93 01 by turnin...

Page 11: ...n the rotor nut 2 Hold the rotor in your hand and place the aluminum block on the rotor nut 3 Tap the aluminum block with a hummer then remove the rotor G20LH 1 Remove the rotor nut 2 Remove the rotor...

Page 12: ...nce tester measurement A resistance value is within the normal range shows no internal leakage or any other defect We supply the measurement equipment gap tester that can measure spark energy while th...

Page 13: ...muffler gasket Liquid gasket ThreeBond 1207C 4 7 Throttle Wire Adjustment Adjust the throttle lever to the position at the lowest velocity and pull the wire sleeve lightly The normal play of the throt...

Page 14: ...s firmly in the correct direction Turn the snap ring using thin tipped tool and check that it moves smoothly in its groove If the snap ring is improperly installed it will not move smoothly in its gro...

Page 15: ...ace of the bearing and crank case ID at bearing area Apply grease to the lip area of the oil seal and degrease the outer surfaces of the oil seal 2T 2 cycle Engine Oil Degrease MAG side Snap Ring Pist...

Page 16: ...of the insulator to the pulse hole of the cylinder 4 12 Connecting of Fuel Pipes When connecting the fuel pipes connect the suction pipe black and return pipe clear properly Elongate Hole Insulator P...

Page 17: ...Mixture Air 9 0 0 354 Mixture Air 9 0 0 354 9 0 0 354 Mixture Air 9 0 0 354 9 0 0 354 Choke Bore 13 2 0 520 13 2 0 520 12 0 0 472 13 2 0 520 12 0 0 472 Standard Engine Speed rpm Idling 3 000 Clutch en...

Page 18: ...et Pump Diaphragm Screen Body Assembly Inlet Valve Spring Metering Lever Pin Screw Gasket Main Diaphragm Body Pump Pump Cover Screw USA model only Throttle Valve Assembly Swivel Carburetor Body O Ring...

Page 19: ...ecute a correct adjustment according to page 21 7 6 Carburetor Adjustment A limiter cap closes the L needle adjustment hole of the throttle valve Carburetor adjustments with caps removed must be condu...

Page 20: ...vailable screw driver tip width 2 5mm Clockwise CW Fuel mixture becomes lean Speed increases Counterclockwise CCW Fuel mixture becomes rich Speed decreases Limiter cap insertion side Limiter cap tool...

Page 21: ...or diaphragm contacting areas If wear exists replace it with a new one Remove the inlet valve and check for dirt sludge rusting and or step wear Replace the inlet valve if a step is found on the rubb...

Page 22: ...ase fuel is not supplied though the priming pump is operated c Throttle valve normality check Check that no wear exists in the throttle valve slide Carefully slide a screw driver tip along the plunger...

Page 23: ...intake Required Tools and Parts Carburetor adjustment screw driver 2 5mm flat tip Electronic digital tachometer Limiter cap removal tool New Limiter cap Adjustment when engine activated 1 Start the en...

Page 24: ...When the needle screw completely loosens a click tone can be heard Turn the idling limiter clockwise CW from this position until the regulated angle is attained Refer to page 15 5 Carburetor Specific...

Page 25: ...ate and full throttle within the regulated number of revolutions Refer to page 15 5 Carburetor Specifications Standard Engine Speed Confirmation after adjustment For some models After adjustment is co...

Page 26: ...7 72 Dry Weight no fuel without grease and blade cover kg lb 5 9 13 0 5 8 12 8 6 1 13 4 4 6 10 1 4 5 9 9 Type Single side Double side Single side Double side Size mm in 750 30 600 24 750 30 710 28 57...

Page 27: ...Left hand thread Bolt M5x L16 6 2 9 4 41 N m 30 45 kgf cm Wave Washer Thrust Washer Clutch Drum Spacer Fitting Upper Gear Case Guide Plate Upper Blade Lower Blade Felt Bearing 2 Ring Drive Gear Upper...

Page 28: ...T4531 94110 521 85 55 01 To hold drive gear when disassembling assembling clutch drum Puller T1666 96110 512 35 94 01 To remove clutch drum 11 1 Engine Removal 1 Remove the three mounting bolts then...

Page 29: ...ers When assembling the connecting rods turn the mark of GEAR SIDE to the driven gear side without fail and assemble them 11 3 Clutch Drum Replacement 1 Fix the gear wrench T4531 94110 521 85 55 01 to...

Page 30: ...se Set the grease gun to the grease fitting and supply grease from the tip of the gear case to beginning see Specified grease Grease for lithium heatproof system 2 NOTE When using Husqvarna Zenoah gen...

Page 31: ...1001 SY NZ003...