Poulan Chainsaw PP5020AV Owners Manual

The Poulan PP5020AV is a 50cc, 20-inch gas-powered chainsaw featuring an anti-vibration system, automatic oiler, and a professional-grade engine. Designed for demanding cutting tasks, it includes safety features like a chain brake, throttle lockout, and a right-hand guard. Below are key sections covering safety, assembly, operation, maintenance, troubleshooting, and specifications.

1. Safety Information 2. Assembly & Setup 3. Controls & Features 4. Starting & Operation 5. Maintenance Schedule 6. Chain Sharpening & Tensioning 7. Fuel & Lubrication 8. Storage Guidelines 9. Troubleshooting 10. Specifications 11. Warranty & Support

Safety Information

Critical safety rules to prevent injury. Always wear protective gear: safety glasses, hearing protection, gloves, chainsaw chaps, and sturdy boots.

Hazard	Precaution
Kickback	Hold saw firmly with both hands; keep chain sharp; avoid tip contact.
Cutting hazards	Clear work area; plan escape path; never cut above shoulder height.
Fuel handling	Refuel outdoors, engine off and cool; use approved fuel container.
Electrical lines	Assume all lines are energized; keep saw and body away.
Chain brake	Test before each use; engage for carrying or if kickback occurs.

WARNING! Failure to follow safety instructions can result in serious injury or death. Read manual completely before use.

Assembly & Setup

Unpack and inspect all parts. Assemble on a clean, flat surface.

Attach guide bar and chain: Place bar over studs, align chain with drive sprocket, adjust tension.
Install chain brake handle: Ensure it moves freely and engages brake band.
Fill oil reservoir: Use bar and chain oil; check for leaks.
Fuel mix: Prepare 50:1 gas/oil mixture (87 octane minimum, 2-cycle oil).
Final check: Verify all fasteners are tight, chain moves freely.

CAUTION! Do not operate with loose components. Ensure chain is properly tensioned.

Controls & Features

Key components: Throttle trigger, Throttle lockout, Chain brake, Choke control, Primer bulb, Decompression valve, Master control lever, Front and rear handles.

Master Control Lever: Combines choke, start, and run positions.

Chain Brake: Stops chain instantly if activated manually or by inertia.

Automatic Oiler: Delivers oil to bar and chain during operation; adjustable via screw.

Anti-Vibration System: Reduces operator fatigue through rubber mounts.

Starting & Operation

Starting procedure (cold engine):

Place saw on firm ground, clear of debris.
Engage chain brake by pulling handle forward.
Set master control to choke (full up).
Press primer bulb 5-6 times.
Pull starter rope briskly until engine fires.
Move control to half-choke, pull until engine runs.
Allow to warm up, then squeeze throttle to disengage fast idle.

Cutting Techniques: Use lower quadrant of bar; let saw do the work; maintain steady speed.

WARNING! Never drop-start or start above waist height. Keep bystanders at least 15 feet away.

Maintenance Schedule

Before each use: Check chain tension, sharpness, brake function, fasteners, fuel/oil levels.
Every 10 hours: Clean air filter, check spark plug, inspect guide bar for wear.
Every 20 hours: Clean cooling fins, check fuel filter, lubricate clutch bearing.
Every 50 hours: Replace spark plug, clean muffler screen, check anti-vibration mounts.
Seasonally: Replace fuel filter, inspect clutch and sprocket, full system check.

Note: Maintenance intervals vary with operating conditions. Increase frequency in dusty environments.

Chain Sharpening & Tensioning

Proper chain maintenance ensures safe, efficient cutting.

Tensioning: Loosen bar nuts, adjust tensioning screw until chain snaps back when pulled from bar.
Sharpening: Use round file matching chain pitch (typically 3/8"). Maintain 30° filing angle.
Depth gauges: File down to maintain proper height (0.025" below cutter).
Bar maintenance: Flip bar regularly; clean oil holes; dress rails with flat file.

CAUTION! Always wear gloves when handling chain. Ensure engine is off and cool.

Fuel & Lubrication

Fuel Mix: 50:1 ratio. Use 2.6 oz of 2-cycle oil per gallon of fresh unleaded gasoline (87 octane minimum).

Bar & Chain Oil: Use quality lubricant with tackifiers; adjust oiler for cutting conditions.

Storage: For long-term storage, run engine dry or add fuel stabilizer. Empty oil tank.

WARNING! Never use automotive oil or straight gasoline. Mix fuel in approved container outdoors.

Storage Guidelines

Proper storage prevents fuel system issues and corrosion.

Clean saw thoroughly, removing sawdust and debris.
Drain fuel tank or add stabilizer and run for 5 minutes.
Remove chain, clean and soak in oil; store separately.
Store in dry, cool place, protected from dust and moisture.
Cover bar and engine to prevent dust accumulation.

CAUTION! Store fuel separately in approved container. Keep away from heat sources and open flame.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine won't start	Old fuel, clogged filter, flooded engine	Use fresh fuel mix; clean/replace filter; wait 15 minutes and restart with choke off.
Engine runs poorly	Dirty air filter, spark arrestor clogged	Clean air filter; remove and clean spark arrestor screen.
Chain doesn't turn	Clutch worn, drive sprocket damaged	Inspect clutch shoes and springs; replace drive sprocket if worn.
Excessive vibration	Loose fasteners, worn AV mounts	Tighten all nuts/bolts; replace anti-vibration mounts.
Chain throws oil	Oiler over-adjusted, wrong oil type	Reduce oil flow; use proper bar and chain oil.

Specifications

Engine Displacement: 50cc, 2-cycle
Guide Bar Length: 20 inches (50 cm)
Chain Pitch: 3/8"
Fuel Capacity: 16.9 fl oz (500 ml)
Oil Capacity: 8.5 fl oz (250 ml)
Dry Weight: 12.8 lbs (5.8 kg)
Ignition System: Electronic
Sound Power Level: 112 dB(A)
Vibration Levels: Front handle 4.5 m/s², Rear handle 5.5 m/s²

Warranty & Support

Poulan PP5020AV comes with a 2-year consumer warranty covering defects in materials and workmanship. Proof of purchase required. Warranty does not cover normal wear, misuse, or improper maintenance.

Customer Support: For technical assistance, parts, or service locations:

Phone: 1-800-554-6723
Website: www.poulanpro.com
Email: [email protected]

Safety Recall Information: Check website regularly for any safety notices or recalls.