STIHL KombiTools Service Repair Workshop Manual

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

STIHL KombiTools Service Repair Workshop Manual

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