STIH)
STIHL KombiTools
2013-08
SP-KM, SP-10,
SP 90, SP 92
FH-KM, FH,
FH 75
HL-KM, HL, HL 45,
HL 75, HL 90, HL 95,
HL 100
HT-KM, HT,
HT 56, HT 70, HT 73,
HT 75, HT 100, HT 101,
HT 130, HT 131,
HTE 60
KW-KM (4602),
KW (4602),
KW 85
BC-KM,
BC 35
FS-KM, FS,
FS 38, FS 40, FS 45,
FS 46, FS 50, FS 55,
FS 56, FS 70, FS 73,
FS 75, FS 80, FS 83,
FS 85, FS 87, FS 90,
FS 100, FS 110, FS 120,
FS 130, FS 200, FS 240,
FS 250, FS 260 R,
FS 460 R,
FSE 60, FSE 65
FR 85, FR 130, FR 220,
FR 350, FR 410, FR 450,
FR 460, FR 480
FCS-KM, FCB-KM, FCS,
FC 56, FC 73, FC 75,
FC 83, FC 85, FC 100,
FC 110,
FCE 60
FBD-KM
1 KombiTools
q
© ANDREAS STIHL AG & Co. KG, 2013
RA_227_00_01_04
1. Introduction 3
1.1 Safety Precautions 4
2. Assignment of
Gearboxes to Models 5
3. Specifications 6
3.1 Tightening Torques 6
3.2 HT, HT-KM Chain
Lubrication 8
3.3 Gearbox Grease
Capacities 9
4. Troubleshooting 10
4.1 Mowing Heads 10
4.1.1 Polymatic / TrimCut 10
4.1.2 AutoCut 11
4.1.3 SuperCut 12
4.1.4 PolyCut 13
4.2 HT Chain Lubrication 14
4.3 FH-KM/ HL-KM 135° 15
5. Drive Tube (Boom) 16
6. Gearbox 18
6.1 Removing and
Installing 18
6.1.1 All Gearboxes 18
6.1.2 FCS only 18
6.1.3 KW (4602) only 18
6.1.4 HT only 19
6.2 FC, FCB, FS 20
6.3 FS 56, FS 70 22
6.3.1 Removing and
Installing 22
6.3.2 Disassembling 22
6.4 FCS 25
6.5 Disassembling HT 28
6.5.1 Checking Clutch
Slip Torque 31
6.6 BC 32
6.7 Cutter Bar 34
6.7.1 HL 0° 34
6.7.2 HL 30° 36
6.7.3 HL 0-90° 37
6.7.4 Cutting Blades 42
6.7.5 HL/FH 44
6.7.6 Angle Drive (special
accessory for
HT, HL) 45
7. Gearbox
(new versions) 48
7.1 Removing and
Installing 48
7.1.1 HL 0° 48
7.1.2 HL 135° 48
7.2 Disassembling
the HL 0° Gearbox 49
7.2.1 Disassembling
the Input Pinion 49
7.2.2 Disassembling
the Output Pinion 50
7.2.3 Blade Drive Gear 52
7.3 Disassembling
HL 135° Gearbox 53
7.3.1 Input Pinion 53
7.3.2 Output Pinion
in Angle Drive 53
7.3.3 Output Pinion
in Blade Drive Gear 56
7.3.4 Blade Drive Gear 57
7.3.5 Blade Drive
Gear Lock 59
7.3.6 Lock Mechanism 61
7.3.7 Quadrant 62
7.4 Lubricating
the Gearbox 62
7.4.1 HL 0° 62
7.4.2 HL 135° 63
7.5 Cutting Attachment 64
7.5.1 Removing and
Installing H 0° 64
7.5.2 Removing and
Installing HL-KM 135° 65
7.5.3 Disassembling
the Cutting Attachment 68
8. SP-KM, SP 10, SP 92 71
8.1 Tines on Rakes 71
8.1.1 Protective Tubes
on Tines 71
8.2 Rake Drive
Removing and
Installing 71
8.3 Rakes 72
8.3.1 Connecting Arm 73
8.4 Drive Tube (Boom)
Removing and
Installing 74
8.4.1 Disassembling the
Drive Tube (SP 92) 75
8.4.2 Disassembling
Drive Tube (SP-KM) 76
8.4.3 Carrying Ring – pivot-
mounted (SP 92) 76
8.5 Gear Housing 76
8.5.1 Bearings / Bushings 78
8.5.2 Drive Pinion 80
8.5.3 Forkhead 81
8.5.4 Ring Gear 82
9. FBD-KM 83
9.1 Blade 83
9.2 Deflector / Mud Flap 83
9.2.1 Depth Wheel 84
9.3 Drive Tube (Boom)
Removing and
Installing 84
9.4 Gearbox 84
9.4.1 Wear Guard 87
10. New HT, HT-KM 88
10.1 Drive Tube (Boom)
Removing and
Installing 88
10.1.1 Disassembling
the Drive Shaft 88
10.2 Saw Chain 88
10.3 Chain Tensioner 89
10.3.1 Bar Stud 89
10.4 Chain Sprocket 89
10.4.1 Testing Chain
Sprocket Friction
Clutch 91
10.5 Oil Tank 91
10.5.1 Oil Pump 92
10.5.2 Oil Tank Vent Valve 93
10.6 Disassembling
Gearbox 93
11. Other Components 96
11.1 FS Deflector 96
11.1.1 Deflector for
Machines without
Gearbox
FS 40, FS 50 96
11.1.2 Deflector for
Machines
with Gearbox – FS 56 97
11.2 BC Deflector 97
11.3 FCS 98
11.3.1 Wear Guard 98
11.3.2 Mud Flap 98
11.3.3 Gearbox Wheel 100
11.4 Depth Wheel 100
11.4.1 Deflector 100
11.5 FC, FCB 101
Contents
2 KombiTools
Contents
11.5.1 FC Deflector
(Wheel Adjustment
on Segment) 101
11.5.2 FC Deflector
(Wheel Adjustment
on Deflector) 101
11.5.3 Mud Flap 102
11.5.4 Depth Wheel 102
11.5.5 Depth Wheel
(Wheel Adustment
on Segment) 103
11.6 KW (4602) 103
11.6.1 Sweeper Drums 103
11.6.2 Sweeper Belts 103
11.6.3 Axle 104
11.6.4 Sleeve
on Drive Tube 104
11.6.5 Sleeve
on Gearbox 105
11.7 HT 105
11.7.1 Oil Tank
(up to 2002) 105
11.7.2 Oil Tank
(from 2002) 105
11.7.3 Oil Pump
(up to 2002) 106
11.7.4 Oil Pump
(from 2002) 106
11.7.5 Chain Tensioner 107
12. Special Servicing
Tools 109
13. Servicing Aids 110
3 KombiTools
1. Introduction
This service manual contains
detailed descriptions of all typical
repair and servicing procedures for
KombiTools.
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.
verwenden.
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 until a
revised edition is issued.
The special tools mentioned in the
descriptions are listed in the chapter
on "Special Servicing Tools" in 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 that is
shown in the illustration
(above the text)
– = Action to be taken that is
not shown in the illustration
(above the text)
b 4.2
Reference to another chapter, i.e.
chapter 4.2 in this example
In the illustrations:
A Pointer (short arrow)
aDirection of movement
If a procedure applies to all
machines in a series, e.g. HT 75,
80, 85, 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 all 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.
Storing and disposing of fuels
Collect fuel in a clean container and
dispose of it properly in accordance
with local environmental
regulations.
4 KombiTools
1.1 Safety Precautions
If the machine is started up in the
course of repairs or maintenance
work, observe all local and country-
specific safety regulations as well
as the safety precautions and
warnings in the instruction manual.
Fuel is extremely flammable and
can be explosive in certain
conditions.
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 perform leakage test after
working on the fuel system and the
engine.
Always wear suitable protective
gloves for operations in which
components are heated for
assembly or disassembly.
Improper handling may result in
burns or other serious injuries.
Always replace damaged parts.
Check disassembled parts for wear
or damage before re-installing –
replace as necessary.
The chapter on tightening torques
lists all machine components that
have to be tightened to a specific
torque or coated with threadlocking
adhesive. The specifications must
be maintained when tightening
down screws, nuts and other
fasteners in all the procedures
described in this service manual.
5 KombiTools
2. Assignment of Gearboxes to Models
Gearbox Gearbox
Type
Installed in Model Remarks
BC WG BC, BC-KM, BC 35
FC AG FC 44, 72, 75, EC 70 1)
FC/FCB AG FC, FCB, FCB-KM,
FC 55, FC 56, FC 73, FC 75, FC 100,
FCE 60
2)
FCS AG FCS, FCS-KM,
FC 83, 85, 110
FS AG FS, FS-KM,
FS 25-4, FS 55, FS 55 T, FS 56, FS 65-4, FS 70,
FS 80 (from 1996), FS 83, FS 85, FS 87, FS 90, FS
100, FS 110, FS 110 RX, FS 120, FS 130, FS 200, FS
240, FS 250, FS 260 R, FS 460 R
FR 85, FR 130, FR 220, FR 350, FR 410, FR 450,
FR 460, FR 480
HL BG HL 0°, HL 30°, HL 0–90°, HL 135°,
HL-KM 0°, HL-KM 30°, HL-KM 0–90°, HL-KM 135°,
HL 45,
HL 73, HL 75, HL 90, HL 95, HL 100,
HLR 85
HL 0° AG HL 0°, HL-KM 0°,
HL 75 0°, HL 90 0°, HL 95 0°, HL 100 0°
HL 30° AG HL 30°, HL-KM 30°, HL 75 30°
HL 0–90° AG HL 0–90°, HL-KM 0–90°,
HL 73 0–90°, HL 75 0–90°
HL 135° AG HL 135°, HL-KM 135°,
HL 75 135°, HL 95 135°, HL 100 135°
FH BG FH 0–90°, FH 135°,
FH-KM 0–90°, FH-KM 135°,
FH 75 0–90°, FH 75 135°
FH 0–90° AG FH 0–90°, FH-KM 0–90°,
FH 75 0–90°
FH 135° AG FH 135°, FH-KM 135°,
FH 75 135°
HT, HT-KM AG HT, HT-KM
HT 56, HT 70, HT 73, HT 75, HT 100, HT 101, HT 130,
HT 131,
HTE 60, HTR 85
KW (4602) WG KW, KW-KM, KW 85
FBD-KM AG FBD-KM 2)
SP BG SP-KM, SP 10, SP 90, SP 92 2)
Remarks
1) Height adjustment of depth wheel on deflector
2) Height adjustment of depth wheel on segment
WG = Worm gear
AG = Angle gear
BG = Blade drive gear
6 KombiTools
3. Specifications
3.1 Tightening Torques
DG and P (Plastoform) screws are used in polymer and light metal 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.
Use the following procedure when refitting a DG or P screw in an existing thread:
Insert the screw in the hole and rotate it counterclockwise until it drops down slightly and engages in the existing
thread. 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.
Micro-encapsulated screws and screws coated with threadlocking adhesive:
Before re-installing, clean both threads (screw tap into female thread by hand and then blow out with
compressed air; clean male thread with brush), coat micro-encapsulated screws with medium-strength Loctite
242 or 243, and screws previously coated with threadlocking adhesive with Loctite (see list of screws below).
Important
Use a hot air blower to heat and release screws that have been secured with adhesive. Be careful with polymer
components.
Power screwdriver setting for polymer: P and DG screws max. 500 rpm.
Do not use an impact wrench for releasing or tightening screws.
Do not mix up screws with and without binding heads.
Fastener Thread size For component Torque
Nm
Remarks
Collar screw IS-M5x6 LH Friction clutch / gearbox 8.0 14), 18)
Screw IS-DG5x20 Oil tank / gearbox housing 5.5 14)
Screw IS-P4x14 Line limiting blade / deflector 2.5 6), 7), 9)
Screw IS-M5x18 Cutting attachment deflector 4.3 9), 10)
Screw IS-P5x14 Line limiting blade / deflector 2.5 9), 10)
Locknut M10x1 LH Cutting attachment 25.0 7), 10)
Screw IS-M5x16 Cutting attachment deflector / gearbox
housing
4.3 7), 10)
Screw IS-M11x10 Screw plug / gearbox 9.5 10)
Screw IS-M6x20 Gearbox housing / drive tube 9.0 2)
Screw IS-M6x20 Gearbox housing / drive tube 10.0 4), 12)
Screw IS-M6x25 Deflector / gearbox housing / clamp /
locknut
5.0 2)
Screw IS-M6x30 Deflector / gearbox housing / clamp /
locknut
5)
Screw IS-M5x8 Clamp / deflector 5)
7 KombiTools
Fastener Thread size For component Torque
Nm
Remarks
Screw IS-DG5x12 Skirt / deflector (with washer) 5.5 2)
Hex head screw M10x18 Segment / deflector 15.0 2)
Screw IS-M11x10 Screw plug / gearbox 10.0 2), 7)
Screw IS-M5x20 Guide / blade / gearbox housing 9.5 6), 12), 13)
Screw IS-M4x16 Gearbox cover / gearbox housing 3.5 4), 12), 13)
Screw IS-M5x20 FS gearbox housing /
HS gearbox housing
7.0 4), 12), 13)
Nut M5 DS550 mm blade / screw 9.5 4), 12), 13)
Screw IS-M11x8 Screw plug / gearbox cover 5.5 4), 12), 13)
Screw IS-M11x8 Screw plug / gearbox housing 5.5 4), 12), 13)
Screw IS-M6x30 Gearbox housing / drive tube / nut 8.0 3)
Screw IS-M5x25 Gearbox cover / gearbox housing 6.5 14)
Screw IS-M5x84 Gearbox housing, left / right 1.5 4), 12)
Locknut M5 Gearbox housing, left / right (locknut) 6.0 4), 12)
Nut M5 DS270 mm blade / screw 9.5 4)
Screw IS-M5x10 Quadrant / gearbox housing 8.0 4)
Screw IS-M4x16 Guard plate / gearbox cover 3.5 4)
Screw M8x25L Blades 25.0 2)
Screw M5x14 Deflector / gearbox 8)
Screw M6x25 Clamp / coupling sleeve / locknut 11)
Screw M5x23 Clamp / loop handle 11)
Screw M6x30 Cutting attachment deflector / clamp 5.0 6)
Screw DG 6x28 Gearbox / drive tube clamp 12.0 7), 8)
Screw IS-DG5x60 Clamp, deflector / drive tube 2.0 3)
Screw IS-M5x18 Bearing plate / gearbox 9.0 3)
Screw IS-M5x18 Deflector / gearbox 9.0 3)
Hex head screw M8x24 Blades 25.0 3)
Hex head screw M8x20 Segment / deflector 15.0 3)
Screw M5x12 Quadrant / gearbox housing 8.0 13)
Screw M4x10 Guard plate / gearbox cover 3.5 13)
Stud M6x8 Stud / gearbox housing 4.5 13)
Screw M5x12 Adjusting lever / gearbox housing 8.0 13)
Tines M12 Tines / rake 4.0 16)
Locknut M6 Gearbox housing / rake axle 9.0 16)
Screw D 5x20 Gearbox housing halves 6.0 16), 19), 20)
Screw M 6x20 Gearbox housing halves / drive tube
clamp
10.0 16), 19), 20)
Screw D 5x12 Sleeve 10.0 16), 19), 20)
Nut M 8x20 LH Thrust washer / attachment / gearbox 20.0 17)
Wing nut M 8 Screw / depth wheel / wing nut 3.0 17)
Screw D 6x28 Gearbox / drive tube clamp 12.0 17), 19)
Grub screw M 6x8 Grub screw / gearbox 4.0 17), 21)
Screw P 5x20 Mud flap / deflector 4.0 17)
8 KombiTools
Fastener Thread size For component Torque
Nm
Remarks
Screw M 5x18 Deflector / gearbox housing 8.0 17), 19), 20)
Screw M 4x10 Deflector / gearbox housing 3.0 17), 21)
Screw M 5x10 Deflector / segment 8.0 17), 19), 20)
Remarks
1) FC 56 12) HL 45
2) FC 75 13) HL 75
3) FC 85 14) HT, HT-KM
4) FH 75 15) KW 85
5) FS 40, FS 50 16) SP-KM, SP 10, SP 92
6) FS 45 17) FBD-KM
7) FS 55 18) Loctite 272, high strength
8) FS 56 19) Screws with binding head
9) FS 75 20) Waxed screws
10) FS 80, 85 21) Micro-encapsulated screws
11) KM 56
3.2 HT, HT-KM Chain
Lubrication
Fully-automatic speed-controlled oil pump with rotary piston
Oil delivery rate 7.5 ± 2.5 cc/min
9 KombiTools
3.3 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 15 max. 5
FCS A 28 max. 5
FS 4140, FS 4144 A 15 max. 5 1)
FS 4137 A 9 max. 5 2)
HL/FH - blade drive gear B 27 max. 5
HL/FH - blade drive gear B 21 max. 5 3)
HL 0° - angle drive gear A 11 max. 5
HL 30° - angle drive gear A 11 max. 5
HL 0–90° - angle drive gear A 20 max. 5
HL 135° - angle drive gear A 11 max. 5 3)
HT, HT-KM A 8 — 4)
HT, HT-KM A 11 — 3), 4)
KW (4602) — — — 5)
SP-KM, SP 10, SP 92 B 20 — 4)
FBD-KM A 25 — 4)
Remarks
A STIHL gear lubricant
B STIHL multipurpose grease
1) Gearbox for FS 55
2) Gearbox for FS, FS-KM, FS 25-4, 65-4, 80 (from model year 1996), 87, 90,
100, 110, 120, 130, 200, 240, 250, 260 R, 460 R
FR 85, 130 T, 350, 450, 480, 220
3) New version
4) Lubricated for life
5) Faulty gearbox is replaced
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STIHL KombiTools Service Repair Workshop Manual
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This Service Manual for the STIHL KOMBITOOLS is a comprehensive guide for immediate repairs. It contains technical data, diagrams, and a complete list of parts, making it essential for professional mechanics and DIY enthusiasts alike.
- Introduction
- Specifications
- Clutch, Chain Drive, Chain Brake And Chain Tensioner
- Engine
- Ignition System
- Rewind Starter
- AV Handle System
- Master Control / Handle System
- Chain Lubrication
- Fuel System
- Special Servicing Tools And Aids
This manual is available in PDF format and is compatible with all versions of Windows and Mac. It is a valuable resource for on-the-go repairs in the garage, enabling cost-effective DIY repairs. The step-by-step instructions make it suitable for all skill levels.
