Zenoah GZ3500T, Workshop Manual

Page 1: ...Workshop Manual English GZ3500T...

Page 2: ......

Page 3: ...ical data 10 Service tools 12 Service data 14 Safety equipment 16 Repair instructions 26 Carburettor 35 Trouble shooting 53 List of contents Husqvarna AB has a policy of continuous product development...

Page 4: ...he ignition module 29 Intake system 44 Assembling the intake system 45 Cleaning and checking 44 Dismantling the intake system 44 Introduction and safety regulations 7 General information 7 General ins...

Page 5: ...tle and spring 23 Assembling the throttle lockout throttle and spring 24 Cleaning and checking 23 Dismantling the throttle lockout throttle and spring 23 Trouble shooting 54 Trouble shooting technique...

Page 6: ...y regulations List of contents 2 1 General information 7 2 2 Safety 7 2 3 Target group 7 2 4 Modifications 7 2 5 Tools 7 2 6 Structure 7 2 7 Numbering 7 2 8 General instructions 8 2 9 Special instruct...

Page 7: ...stion 2 5 Tools Special tools are required for some stages All service tools are listed in the Workshop Manual Usage is evident from the respective section Always use Husqvarna s original Spare parts...

Page 8: ...o not start the chain saw unless the bar chain and clutch cover chain brake are fitted otherwise the clutch may come loose and cause personal injury Insufficient chain lubrication can result in chain...

Page 9: ...2 10 Symbols on the saw The symbols below are embedded in the chain saw Choke control Refuelling Stop button Filling up saw chain oil 2 11 Symbols in the Workshop Manual This symbol warns of personal...

Page 10: ...28 1 10 1 5 2 0 9 500 Electrode gap Ignition system Air gap Carburettor type mm inches mm inches GZ3500T 0 5 0 02 Ikeda Denso 0 3 0 012 Walbro WT 804 Usable cutting length Chain speed at Chain pitch...

Page 11: ...olume fuel tank Capacity oil pump at Volume oil tank Automatic oil pump Litres US pint 9 500 rpm Litres US pint ml min GZ3500T 0 26 0 55 3 9 0 17 0 36 No Weight without bar and chain Weight with bar a...

Page 12: ...12 English 4 Service tools Service tools 11 4 6 9 1 3 7 8 10 5 2...

Page 13: ...01 7 Fitting cone Assembling the intake system 522 63 97 01 8 Assembly fixture Securing the chain saw 502 51 02 01 9 Pressure gauge Pressure testing 531 03 06 23 10 Test spark plug Checking the ignit...

Page 14: ...Key The numbers by the components to be assembled with screws state the tightening torque in Nm s Lubricate with two stroke oil n Lubricate with engine oil l Lubricate with grease q Glued using 2 com...

Page 15: ...English 15 Service data...

Page 16: ...3 Dismantling the muffler 20 6 4 Assembling the muffler 20 6 5 Replacing the chain catcher 20 6 6 Dismantling the start stop switch 21 6 7 Assembling the start stop control 21 6 8 Resistance test sto...

Page 17: ...tling the chain brake 2 Release the brake by pushing the kickback guard forwards 4 Loosen the screws and hold the cover in place with one hand Insert a screwdriver as illustrated over the spring to pr...

Page 18: ...the spring C use pliers to tension the spring behind the plastic plug see figure 10 Safety equipment Fig 6 Fig 8 Fig 9 Fig 10 6 Loosen the nut E washer D spring C sleeve B and screw A To remove the kn...

Page 19: ...d remove the screwdriver Insert the screwdriver straight from above and press down until the spring catches against the cut out edge Fig 12 6 Bend the screwdriver away from the spring so that the spri...

Page 20: ...uffler 1 Assemble the muffler as shown in figure 20 tighte ning torque 12 14 Nm The square screws should be slided in the slot on the cylinder Assemble the chain bar and clutch cover 3 Warm up the saw...

Page 21: ...ng Clean and check carefully all components If there are cracks or other defects these details should be replaced with new ones Always use original spare parts Fig 22 6 7 Assembling the start stop swi...

Page 22: ...the cold air wire make sure that the ignition cable is fitted into the slot Clean the contact areas and check the resistance as follows Test the resistance by connecting a multimeter to the ignition...

Page 23: ...the air filter holder and the filter Dismantle the handle part by loo sening screws A Remove the throttle lockout B Remove the throttle C and the spring D Loosen the carburettor screw E Remove the gu...

Page 24: ...throttle and spring 1 Put the electrical cables J back in the cable slot as shown in figure 32 Fig 32 3 Fold the throttle actuator rod forwards so that it can be placed in the handle part 4 Push the c...

Page 25: ...gure 36 Fig 37 Fig 38 Fig 39 6 Place the throttle as shown in figure 37 Put the handle bar in the handle unit 7 The handle part is fastened with the screws A see figure 39 Note Hold the throttle locko...

Page 26: ...fugal clutch 33 7 11 Dismantling the oil pump and screen 33 7 12 Assembling the oil pump and screen 34 7 13 Carburettor 35 7 14 Dismantling the intake system 44 7 15 Assembling the intake system 45 7...

Page 27: ...he cord out about 30 cm and lift it into the notch on the starter pulley s outer edge Release the tension in the return spring by allowing the star ter pulley to rotate slowly backwards see figures 2...

Page 28: ...ring must be released 1 Pull the cord out about 30 cm and lift it into the notch on the outside of the starter pulley Release the tension in the return spring by letting the starter pulley slowly rota...

Page 29: ...ken return spring and replace it with a new one 3 Fit the screw into the centre of the starter pulley tightening torque 2 3 Nm Load the return spring see Loading the return spring Fig 8 7 6 Testing th...

Page 30: ...E and the earthing cable F from the ignition module C Fig 12 3 Unscrew the spark plug and screw in the piston stop G Fig 13 4 Loosen flywheel nut H with a suitable socket span ner and then remove the...

Page 31: ...arthing cable F in screw D as shown in figure 15 Tighten the screw D tightening torque 4 5 6 Nm Remove the plastic feeler gauge Fit the ignition cable E on ignition module C Set the distance 0 3 0 1 m...

Page 32: ...tch using a suitable socket spanner or combination spanner Turn the clutch clockwise to loosen it 7 9 Dismantling the centrifugal clutch 1 Release the brake by moving the kickback guard backwards Loos...

Page 33: ...ckwise 3 Reinstall the spark plug 4 Assemble the clutch cover chain and bar Repair instructions Fig 23 Fig 24 7 11 Dismantling the oil pump and screen 1 Dismantle the centrifugal clutch as in the chap...

Page 34: ...to press nipple G upwards through the rubber grommet to the oil tank 3 Slide the washer F on the crankshaft Refit the cover and the pump drive wheel Screw the chain guide plate into place using screw...

Page 35: ...unit In the pump unit C fuel is pumped from the fuel tank to the carburettor s metering unit One side of the pump diaphragm is connected to the crank case and pulses in time with the pressure changes...

Page 36: ...rottle valve H is partly open Full throttle mode In full throttle mode both valves are open and fuel is supplied through all three diffuser jets E F and G Part throttle mode In part throttle mode the...

Page 37: ...dle part by loose ning screws A Remove the throttle lockout B Remove throttle C and spring D Loosen carburet tor screw E Remove guide F see figure 40 Fig 40 Fig 42 2 Remove the carburettor and remove...

Page 38: ...lift off cover B and carefully remove gasket D and control diaphragm C 8 Unscrew screw J and remove needle valve G with lever arm F shaft E and spring H 9 Use a needle or similar and carefully lift u...

Page 39: ...arburettor Observe cleanliness when assembling the car burettor The slightest contamination can cause malfunctions 1 If throttle and choke valves with shafts lever arms and springs are removed these s...

Page 40: ...40 English Repair instructions 7 Assemble control diaphragm C gasket D cover B and tighten screw A 8 Assemble the valve housing S and lever arm T with accompanying details 9 Do a pressure test Fig 47...

Page 41: ...one after the carburettor has been repaired but can also be carried out as trouble shooting before the carburettor is taken apart See figure 48 and check as follows 1 Adjust the high and low speed scr...

Page 42: ...and fit the fuel hose J as shown in figure 50 3 Fold the throttle actuator rod K forwards so that it can be placed in the handle part 4 Push the carburettor into place and make sure the nipple is secu...

Page 43: ...not be tightened more than that about 0 5 cm remain to the bar See figure 54 Replacing the H needle or entire carburettor 1 Screw the new H needle to the bottom and turn it A revolutions anticlockwis...

Page 44: ...shown in figures 55 and 56 Cleaning and checking Clean and check all parts carefully Parts must be replaced if cracked or showing signs of other defects Always use original spare parts 2 Gently press...

Page 45: ...61 3 Refit the tank unit Insert the fitting cone as shown in figure 62 Use pliers with a shrinkable tube to insert the air intake bellows B and C see figures 57 and 62 Pull off the fitting cone and m...

Page 46: ...g the fuel tank Remove the air filter cover air filter holder and the air filter Use pliers with a shrinkable tube to remove the tank venting valve Test Opening pressure outwards 1 Open the tank lock...

Page 47: ...a flat screwdriver to snap the fuel pump loose see figure 67 3 Split the suction hose C at the shaft Replace hoses if necessary see figure 68 NOTE Fluted pliers may not be used with the fuel hose The...

Page 48: ...ote Springs with greater resistance are available but must only be used together with longer bars See the spare parts list for spare part number 2 Assemble the following parts Handle unit Chain and ba...

Page 49: ...ig 76 3 Loosen the heat shield A see figure 74 4 Loosen the four screws as shown in figures 75 and 76 Fig 74 5 Remove the cylinder cover see figure 77 Lift out the engine body Fig 77 Fig 78 6 Screw ap...

Page 50: ...is not welded to its track Remove the piston ring from the piston to mea sure the wear Use the bottom of the piston to press down the piston ring into the cylinder The opening of the ring must not ex...

Page 51: ...sten the circlips D see figure 81 Note Use new circlips 3 Oil the piston and piston ring with two stroke oil Fit the piston with the arrow pointing towards the exhaust port S see figure 87 4 Compress...

Page 52: ...eplacing the crankshaft bearing Remove the crankshaft completely from the crankcase 1 Pull out the crankshaft bearing from the crankshaft see figure 88 Fig 89 2 Fit the new bearing on the crankshaft u...

Page 53: ...English 53 Trouble shooting 8 Trouble shooting List of contents 8 1 Trouble shooting 54 8 2 Trouble shooting techniques 55...

Page 54: ...mping screws carburettor Worn throttle valve shaft The throttle valve screw is loose The throttle valve is worn Control system is binding Leaking control system air or fuel The control system s centre...

Page 55: ...Pressure testing the cylinder High speed Does not run at full throttle Low on power Will not four stroke Adjust the H screw Blocked air filter Tank venting clogged The fuel filter is clogged The fuel...

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