Poulan Pro Chainsaw PP5020AV Manual

The Poulan Pro PP5020AV is a 50cc, 20-inch gas-powered chainsaw featuring an anti-vibration system, automatic oiler, side-access chain tensioner, and a QuickStart system for easier pull starts. Designed for demanding cutting tasks like felling trees and bucking logs. Below are key sections for safety, features, assembly, operation, maintenance, and troubleshooting.

Features at a Glance

Key components: 50cc 2-cycle engine, 20-inch Oregon bar and chain, anti-vibration handles, automatic chain oiler, side-access chain tensioner, QuickStart system, chain brake, and decompression valve.

Assembly & Setup

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

1. Attach the guide bar and chain: Place bar over studs, loop chain over sprocket and bar, adjust tension.
2. Fill oil reservoir: Use bar and chain oil only.
3. Mix fuel: Use fresh unleaded gasoline (87 octane min.) with 2-cycle oil at 40:1 ratio.
4. Check all fasteners: Ensure bar nuts, handles, and covers are secure.

WARNING! Always wear cut-resistant gloves during assembly. Do not attempt to start the saw until fully assembled.

Safety Instructions

Read and understand all safety warnings before operation.

1. Personal Protective Equipment (PPE): Always wear safety glasses, hearing protection, gloves, steel-toe boots, and chainsaw chaps.
2. Clear work area: Ensure no bystanders, pets, or obstacles within 15 feet.
3. Check chain brake: Verify it engages properly before each use.
4. Carry properly: Always carry with engine off, bar pointed backward, and hand guard covering chain.

CAUTION! Kickback is a major cause of injury. Keep firm grip, do not cut with tip, and always use chain brake.

Specifications

• Engine Displacement: 50cc.
• Power Output: 3.2 HP.
• Guide Bar: 20 inches, Oregon.
• Chain Pitch: 0.325 inches.
• Chain Gauge: 0.050 inches.
• Fuel Capacity: 16.9 fl oz (500 ml).
• Oil Capacity: 8.5 fl oz (250 ml).
• Weight (dry): 12.8 lbs (5.8 kg).
• Sound Power Level: 112 dB(A).
• Vibration Level: Front handle 4.2 m/s², Rear handle 5.8 m/s².

Controls and Components

Main Controls: Throttle trigger, throttle lockout, choke control, ON/OFF switch, primer bulb, decompression valve, chain brake lever.

Components: Front handle with hand guard, rear handle, fuel tank cap, oil tank cap, air filter cover, spark plug, muffler, and chain catcher.

Operation: Set ON/OFF to ON, pull choke, press primer bulb 5 times, pull starter rope until engine fires, push choke in, pull again to start. Engage throttle to run. Activate chain brake by pushing lever forward.

Fuel & Oil

Fuel: Mix fresh unleaded gasoline (minimum 87 octane, ethanol content under 10%) with high-quality 2-cycle engine oil at 40:1 ratio. Use measuring bottle for accuracy.

1. Never use straight gasoline or automotive oil.
2. Never use fuel older than 30 days.
3. Oil: Use only bar and chain oil in oil reservoir. Do not use waste oil.
4. Check oil level before each use and refill as needed.

Tip: Store fuel mix in an approved container labeled "2-Cycle Mix".

Starting & Operation

Starting Procedure (Cold Engine):

1. Place saw on flat ground, clear of debris.
2. Activate chain brake by pushing lever forward.
3. Set ON/OFF switch to ON.
4. Pull choke control out fully.
5. Press primer bulb 5-7 times.
6. Press decompression valve (if equipped).
7. Hold front handle with left hand, place right foot in rear handle.
8. Pull starter rope briskly until engine fires (usually 3-5 pulls).
9. Push choke control in halfway.
10. Pull starter rope again until engine starts.
11. Allow to warm up at idle for 30 seconds before cutting.

WARNING! Never drop-start or start above waist height. Always engage chain brake when starting.

Chain Maintenance

Chain Sharpening: Use round file (5/32" or 4.0mm) and file guide. Maintain 30° cutting angle. File each cutter evenly. Check depth gauges with gauge tool.

Chain Tension: Adjust when chain sags from bar. Loosen bar nuts, turn tensioning screw until chain fits snug against bar (can be pulled by hand), tighten bar nuts. Chain should move freely when cool.

Storage

Long-Term Storage (over 30 days):

1. Drain all fuel from tank and run engine until it stops.
2. Remove spark plug, add 1 teaspoon of 2-cycle oil into cylinder, pull starter 2-3 times, reinstall plug.
3. Clean entire saw, especially air filter and cooling fins.
4. Remove chain, clean, and soak in oil. Loosen chain tension.
5. Store in dry, cool place, away from ignition sources.

CAUTION! Fuel left in carburetor will degrade and cause starting problems.

Warranty Information

Poulan Pro 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, improper fuel, or lack of maintenance. For warranty service, contact authorized service center or call 1-800-554-6723. Keep this manual as proof of purchase date.

Troubleshooting

Service: For repairs, use only Poulan Pro authorized service centers. Customer Support: 1-800-554-6723 or www.poulanpro.com