Husqvarna 550XP, 545, 550XPG User Manual

Oper ator ′ s manual

545, 545 TrioBrake

550XP, 550XP TrioBrake

550XPG, 550XPG TrioBrake

Please r ead the operator’s manual carefully and make sure you understand the instructions before using the machine.

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Symbols on the mac hine:

ARNING! Chain saws can be dangerous! Careless or incorrect use can result in serious or fatal injury to the operator or others.

Please read the operator’s manual carefully and make sure you understand the instructions before using the machine.

Always wear:

• Approved protective helmet

• Approved hearing protection

• Protective goggles or a visor

This product is in accordance with applicable EC directives.

Noise emission to the environment according to the European Community’s Directive. The machine’s emission is speciﬁed in chapter Technical data and on label.

Both of the operator ′ s hands must be used to operate the chain saw.

Never operate a chain saw holding it with one hand only.

Never let the guide bar tip come in contact with any object.

KEY T O SYMBOLS

Ignition; choke: Set the choke control

in the choke position. This should automatically set the stop switch to the start position.

Air purge.

Refuelling.

Chain oil ﬁll.

Adjustment of the oil pump.

If your machine bears this symbol it is equipped with heated handles.

Always use the recommended spark plug type! Use of the wrong spark plug can damage the piston/cylinder. Check that the spark plug is ﬁtted with a suppressor.

Other symbols/decals on the mac hine refer to special certiﬁcation requirements for certain markets.

WARNING! Kickback may occur when the nose or tip of the guide bar touches an object, and cause a lightning fast reverse reaction, kicking the guide bar up and towards the operator. May cause serious personal injury.

Chain brake, activated (right) Chain brake, not activated (left)

Decompression v alve: The

valve is to reduce the pressure in the cylinder and make starting easier. You should always use the decompression valve when starting the machine.

– English

Symbols in the operator’ s manual:

Switch off the engine b y moving the stop switch to the STOP position before carrying out any checks or maintenance. CAUTION! The start/ stop switch automatically returns to run position. In order to prevent unintentional starting, the spark plug cap must be removed from the spark plug when assembling, checking and/or performing maintenance.

Always wear approved protective gloves.

Regular cleaning is required.

KEY T O SYMBOLS

Visual check.

Protective goggles or a visor must be worn.

Refuelling.

Filling with oil and adjusting oil ﬂow.

The chain brake must be engaged when the chain saw is started.

English

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Contents

KEY TO SYMBOLS

Symbols on the machine: ...................................... 2

Symbols in the operator’s manual: ........................ 3

CONTENTS

Contents ............................................................... 4

INTR ODUCTION

Dear Customer , ..................................................... 5

WHA T IS WHAT?

What is what on the chain sa w? ........................... 6

GENERAL SAFETY PRECA UTIONS

Bef ore using a new chain saw .............................. 7

Important .............................................................. 7

Always use common sense .................................. 8

Personal protective equipment ............................. 8

Machine ′ s safety equipment ................................. 8

Cutting equipment ................................................. 11

ASSEMBL Y

Fitting the bar and chain ....................................... 17

FUEL HANDLING

Fuel ....................................................................... 18

Fueling .................................................................. 19

Fuel safety ............................................................ 19

ARTING AND STOPPING

Star ting and stopping ............................................ 20

ORKING TECHNIQUES

Bef ore use: ............................................................ 22

General working instructions ................................ 22

How to avoid kickback ........................................... 28

MAINTENANCE

Gener al ................................................................. 29

Carburettor adjustment ......................................... 29

Checking, maintaining and servicing chain saw

safety equipment ..................................................

Mufﬂer ................................................................... 31

Starter ................................................................... 32

Air ﬁlter .................................................................. 33

Spark plug ............................................................. 33

Lubricating the bar tip sprocket ............................. 34

Needle bearing lubrication .................................... 34

Adjustment of the oil pump. ................................... 34

Cooling system ..................................................... 34

”Air Injection” centrifugal cleaning ......................... 35

Winter use ............................................................. 35

Heated handles ..................................................... 35

Maintenance schedule .......................................... 36

TECHNICAL D ATA

echnical data ....................................................... 37

Guide bar and chain combinations ....................... 39

Saw chain ﬁling and ﬁle gauges ............................ 39

EC-declaration of conformity ................................. 40

– English

′

INTR ODUCTION

Dear Customer ,

Cong ratulations on your choice to buy a Husqvarna product! Husqvarna is based on a tradition that dates back to 1689, when the Swedish King Karl XI ordered the construction of a factory on the banks of the Husqvarna River, for production of muskets. The location was logical, since water power was harnessed from the Huskvarna River to create the waterpowered plant. During the more than 300 years of beeing, the Husqvarna factory has produced a lot of different products, from wood stoves to modern kitchen appliances, sewing machines, bicycles, motorcycles etc. In 1956, the ﬁrst motor driven lawn mowers appeared, followed by chain saws in 1959, and it is within this area Husqvarna is working today.

Today Husqvarna is one of the leading manufacturers in the world of forest and garden products, with quality as our highest priority. The business concept is to develop, manufacture and market motor driven products for forestry and gardening as well as for building and construction industry. Husqvarna ergonomics, usability, security and environmental protection. That is the reason why we have developed many different features to provide our products within these areas.

We are convinced that you will appreciate with great satisfaction the quality and performance of our product for a very long time to come. The purchase of one of our products gives you access to professional help with repairs and service whenever this may be necessary. If the retailer who sells your machine is not one of our authorised dealers, ask for the address of your nearest service workshop.

It is our wish that you will be satisﬁed with your product and that it will be your companion for a long time. Think of this operator

s manual as a valuable document. By following its ′ content (using, service, maintenance etc) the life span and the second-hand value of the machine can be extended. If you will sell this machine, make sure that the buyer will get the operator

Thank you for using a Husqvarna product.

Husqvarna AB has a policy of continuous product development and therefore reserves the right to modify the design and appearance of products without prior notice.

s manual.

s aim is also to be in the front edge according to

English – 5

WHA T IS WHA T?

What is what on the c hain saw?

Cylinder cover

2 Air purge

3 Throttle lockout

4 Rear handle

5 Information and warning decal

6 Combined start and stop switch

7 Fuel tank

8 Starter handle

9 Starter

10 Chain oil tank

11 Bar tip sprocket

12 Guide bar

13 Saw chain

14 Mufﬂer

15 Chain brake and front hand guard

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16 Front handle

17 Decompression valve

18 Switch for heated handle (550XPG, 550XPG

TrioBrake)

19 Right-hand brake trigger (545 TrioBrake, 550XP

TrioBrake, 550XPG TrioBrake)

20 Rear handle with right hand guard

21 Throttle trigger

22 Product and serial number plate

23 Oil pump adjustment screw

24 Clutch cover

25 Chain catcher

26 Spike bumper

27 Combination spanner

28 Guide bar cover

29 Operator ′ s manual

•

GENERAL SAFETY PRECA UTIONS

Bef ore using a new chain saw

Please read this manual carefully.

• Check that the cutting equipment is correctly ﬁtted and

adjusted. See instructions under the heading Assembly.

• Refuel and start the chain saw. See the instructions

under the headings Fuel Handling and Starting and Stopping.

• Do not use the chain saw until sufﬁcient chain oil has

reached the chain. See instructions under the heading Lubricating cutting equipment.

• Long-term exposure to noise can result in permanent

hearing impairment. So always use approved hearing protection.

ARNING! Under no circumstances may

the design of the machine be modiﬁed

without the permission of the manufacturer. Always use genuine accessories. Non-authorized modiﬁcations and/or accessories can result in serious personal injury or the death of the operator or others.

ARNING! A chain saw is a dangerous

tool if used carelessly or incorrectly and

can cause serious, even fatal injuries. It is very important that you read and understand the contents of this operator’s manual.

ARNING! The inside of the mufﬂer

contain chemicals that may be

carcinogenic. Avoid contact with these elements in the event of a damaged mufﬂer.

ARNING! Long term inhalation of the

engine’s exhaust fumes, chain oil mist

and dust from sawdust can represent a health risk.

ARNING! This machine produces an

electromagnetic ﬁeld during operation.

This ﬁeld may under some circumstances interfere with active or passive medical implants. To reduce the risk of serious or fatal injury, we recommend persons with medical implants to consult their physician and the medical implant manufacturer before operating this machine.

ARNING! Never allow children to use or be in the vicinity of the machine. As the machine is equipped with a springloaded stop switch and can be started by low speed and force on the starter handle, even small children under some circumstances can produce the force necessary to start the machine. This can mean a risk of serious personal injury. Therefore remove the spark plug cap when the machine is not under close supervision.

Impor tant

IMPOR TANT!

This chain saw for forest service is designed for forest work such as felling, limbing and cutting.

You should only use the saw with the bar and chain combinations we recommend in the chapter Technical data.

Never use the machine if you are fatigued, while under the inﬂuence of alcohol or drugs, medication or anything that could affect your vision, alertness, coordination or judgement.

Wear personal protective equipment. See instructions under the heading ”Personal protective equipment”.

Do not modify this product or use it if it appears to have been modiﬁed by others.

Never use a machine that is faulty. Carry out the checks, maintenance and service instructions described in this manual. Some maintenance and service measures must be carried out by trained and qualiﬁed specialists. See instructions under the heading Maintenance.

Never use any accessories other than those recommended in this manual. See instructions under the headings Cutting equipment and Technical data.

CAUTION! Always wear protective glasses or a face visor to reduce the risk of injury from thrown objects. A chain saw is capable of throwing objects, such as wood chips, small pieces of wood, etc, at great force. This can result in serious injury, especially to the eyes.

ARNING! Running an engine in a conﬁned or badly ventilated area can result in death due to asphyxiation or carbon monoxide poisoning.

ARNING! Faulty cutting equipment or the wrong combination of bar and saw chain increases the risk of kickback! Only use the bar/saw chain combinations we recommend, and follow the ﬁling instructions. See instructions under the heading Technical data.

English

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GENERAL SAFETY PRECA UTIONS

ways use common sense

It is not possib le to cover every conceivable situation you can face when using a chain saw. Always exercise care and use your common sense. Avoid all situations which you consider to be beyond your capability. If you still feel uncertain about operating procedures after reading these instructions, you should consult an expert before continuing. Do not hesitate to contact your dealer or us if you have any questions about the use of the chain saw. We will willingly be of service and provide you with advice as well as help you to use your chain saw both efﬁciently and safely. Attend a training course in chain saw usage if possible. Your dealer, forestry school or your library can provide information about which training materials and courses are available.

Work is constantly in progress to improve the design and technology - improvements that increase your safety and efﬁciency. Visit your dealer regularly to see whether you can beneﬁt from new features that have been introduced.

ersonal protective equipment

WARNING! Most chain saw accidents happen when the chain touches the

operator. You must use approved personal protective equipment whenever you use the machine. Personal protective equipment cannot eliminate the risk of injury but it will reduce the degree of injury if an accident does happen. Ask your dealer for help in choosing the right equipment.

• Boots with saw protection, steel toe-cap and non-slip sole

• Always have a ﬁrst aid kit nearby.

• Fire Extinguisher and Shovel

Generally clothes should be close-ﬁtting without restricting your freedom of movement.

IMPORTANT! Sparks can come from the mufﬂer, the bar and chain or other sources. Always have ﬁre extinguishing tools available if you should need them. Help prevent forest ﬁres.

Mac hine′′′′s safety equipment

In this section the machine’s safety features and their function are explained. For inspection and maintenance see instructions under the heading Checking, maintaining and servicing chain saw safety equipment. See instructions under the heading, What is what?, to ﬁnd where these parts are located on your machine.

The life span of the machine can be reduced and the risk of accidents can increase if machine maintenance is not carried out correctly and if service and/or repairs are not carried out professionally. If you need further information please contact your nearest service workshop.

WARNING! Never use a machine with defective safety components. Safety equipment must be inspected and maintained. See instructions under the heading Checking, maintaining and servicing chain saw safety equipment. If your machine does not pass all the checks, take the saw to a servicing dealer for repair.

Chain brake and front hand guard

Your chain saw is equipped with a chain brake that is designed to stop the chain if you get a kickback. The chain brake reduces the risk of accidents, but only you can prevent them.

Alw ays wear:

• Approved protective helmet

• Hearing protection

• Protective goggles or a visor

• Gloves with saw protection

• Trousers with saw protection

– English

Take care when using your saw and make sure the kickback zone of the bar never touches any object.

GENERAL SAFETY PRECAUTIONS

• The chain brake (A) can either be activated manually (by your left hand) or automatically by the inertia release mechanism.

• To release the chain brake pull the front hand guard backwards, towards the front handle.

• The brake is applied when the front hand guard (B) is pushed forwards or when the right-hand brake trigger (E) is pushed up and forwards.

• This movement activates a spring-loaded mechanism that tightens the brake band (C) around the engine drive system (D) (clutch drum).

• The front hand guard is not designed solely to activate the chain brake. Another important feature is that it reduces the risk of your left hand hitting the chain if you lose grip of the front handle.

• The chain brake must be engaged when the chain saw is started to prevent the saw chain from rotating.

• Kickback can be very sudden and violent. Most kickbacks are minor and do not always activate the chain brake. If this happens you should hold the chain saw ﬁrmly and not let go.

• The way the chain brake is activated, either manually or automatically by the inertia release mechanism, depends on the force of the kickback and the position of the chain saw in relation to the object that the kickback zone of the bar strikes.

If you get a violent kickback while the kickback zone of the bar is farthest away from you the chain brake is designed to be activated by the inertia in the kickback direction.

If the kickback is less violent or the kickback zone of the bar is closer to you the chain brake will be activated manually by the movement of your left hand.

• Use the chain brake as a ”parking brake” when starting and when moving over short distances, to reduce the risk of moving chain accidentally hitting your leg or anyone or anything close by.

• In the felling position the left hand is in a position that makes manual activation of the chain brake impossible. With this type of grip, that is when the left hand is placed so that it cannot affect the movement

English – 9

GENERAL SAFETY PRECAUTIONS

of the front hand guard, the chain brake can only be activated by the inertia action.

Will my hand always activate the chain brake during a kickback?

No. It takes a certain force to move the hand guard forward. If your hand only lightly touches the front guard or slips over it, the force may not be enough to trigger the chain brake. You should also maintain a ﬁrm grip of the chain saw handles while working. If you do and experience a kickback, your hand may never leave the front handle and will not activate the chain brake, or the chain brake will only activate after the saw has swung around a considerable distance. In such instances, the chain brake might not have enough time to stop the saw chain before it touches you.

There are also certain positions in which your hand cannot reach the front hand guard to activate the chain brake; for example, when the saw chain is held in felling position.

Will my inertia activated chain brake always activate during kickback in the event of a kickback?

No. First your brake must be in working order. Testing the brake is simple, see instructions under the heading Checking, maintaining and servicing chain saw safety equipment. We recommend you do before you begin each work session. Second the kickback must be strong enough to activate the chain brake. If the chain brake is too sensitive it would activate all the time which would be a nuisance.

Will my chain brake always protect me from injury in the event of a kickback?

No. First, the chain brake must be in working order to provide the intended protection. Second, it must be activated during the kickback as described above to stop the saw chain. Third, the chain brake may be activated but if the bar is too close to you the brake might not have enough time to slow down and stop the chain before the chain saw hits you.

Only you and proper working technique can eliminate kickback and its danger.

Throttle lockout

The throttle lockout is designed to prevent accidental operation of the throttle control. When you press the lock (A) (i.e. when you grasp the handle) it releases the throttle

control (B). When you release the handle the throttle control and the throttle lockout both move back to their original positions. This arrangement means that the throttle control is automatically locked at the idle setting.

Chain catcher

The chain catcher is designed to catch the chain if it snaps or jumps off. This should not happen if the chain is properly tensioned (see instructions under the heading Assembly) and if the bar and chain are properly serviced and maintained (see instructions under the heading General working instructions).

Right hand guard

Apart from protecting your hand if the chain jumps or snaps, the right hand guard stops branches and twigs from interfering with your grip on the rear handle.

Vibration damping system

Your machine is equipped with a vibration damping system that is designed to minimize vibration and make operation easier.

The machine′s vibration damping system reduces the transfer of vibration between the engine unit/cutting equipment and the machine chain saw, including the cutting equipment, is insulated from the handles by vibration damping units.

Cutting hardwoods (most broadleaf trees) creates more vibration than cutting softwoods (most conifers). Cutting with cutting equipment that is blunt or faulty (wrong type or badly sharpened) will increase the vibration level.

′s handle unit. The body of the

10 – English

GENERAL SAFETY PRECAUTIONS

WARNING! Overexposure to vibration can lead to circulatory damage or nerve

damage in people who have impaired circulation. Contact your doctor if you experience symptoms of overexposure to vibration. Such symptoms include numbness, loss of feeling, tingling, pricking, pain, loss of strength, changes in skin colour or condition. These symptoms normally appear in the ﬁngers, hands or wrists. These symptoms may be increased in cold temperatures.

Stop switch

Use the stop switch to switch off the engine.

Mufﬂer

The mufﬂer is designed to keep noise levels to a minimum and to direct exhaust fumes away from the user.

WARNING! The exhaust fumes from the engine are hot and may contain sparks

which can start a ﬁre. Never start the machine indoors or near combustible material!

WARNING! Never use a saw without a mufﬂer, or with a damaged mufﬂer. A damaged mufﬂer may substantially increase the noise level and the ﬁre hazard. Keep ﬁre ﬁghting equipment handy. If a spark arrestor screen is required in your area, never use the saw without or with a broken spark arrestor screen.

Cutting equipment

This section describes how to choose and maintain your cutting equipment in order to:

• Reduce the risk of kickback.

• Reduce the risk of the saw chain breaking or jumping off the bar.

• Obtain optimal cutting performance.

• Extend the life of cutting equipment.

• Avoid increasing vibration levels.

General rules

• Only use cutting equipment recommended by us! See instructions under the heading Technical data.

• Keep the chain’s cutting teeth properly

sharpened! Follow our instructions and use the recommended ﬁle gauge.

sharpened chain increases the risk of accidents.

• Maintain the correct depth gauge setting! Follow

our instructions and use the recommended depth gauge clearance.

the risk of kickback.

A damaged or badly

Too large a clearance increases

In areas with a hot, dry climate there is a high risk of ﬁres. These areas are sometimes subject to government rules requiring among other things the mufﬂer must be equipped with an approved type of spark arrestor mesh.

CAUTION! The mufﬂer gets very hot during and after use. This also applies during idling. Be aware of the ﬁre hazard, especially when working near ﬂammable substances and/or vapours.

• Keep the chain properly tensioned! If the chain is slack it is more likely to jump off and lead to increased wear on the bar, chain and drive sprocket.

• Keep cutting equipment well lubricated and

properly maintained!

more likely to break and lead to increased wear on the bar, chain and drive sprocket.

A poorly lubricated chain is

English – 11

GENERAL SAFETY PRECAUTIONS

Cutting equipment designed to reduce kickback

WARNING! Faulty cutting equipment or the wrong combination of bar and saw

chain increases the risk of kickback! Only use the bar/saw chain combinations we recommend, and follow the ﬁling instructions. See instructions under the heading Technical data.

The only way to avoid kickback is to make sure that the kickback zone of the bar never touches anything.

By using cutting equipment with ”built-in” kickback reduction and keeping the chain sharp and wellmaintained you can reduce the effects of kickback.

Guide bar

The smaller the tip radius the lower the chance of kickback.

Saw chain

A chain is made up of a number of links, which are available in standard and low-kickback versions.

IMPORTANT! No saw chain design eliminates the danger of kickback.

WARNING! Any contact with a rotating saw chain can cause extremely serious

injuries.

• Chain pitch (inches). The spacing between the drive links of the chain must match the spacing of the teeth on the bar tip sprocket and drive sprocket.

• Number of drive links. The number of drive links is determined by the length of the bar, the chain pitch and the number of teeth on the bar tip sprocket.

• Bar groove width (inches/mm). The groove in the bar must match the width of the chain drive links.

• Chain oil hole and hole for chain tensioner. The bar must be matched to the chain saw design.

Some terms that describe the bar and chain

To maintain the safety features of the cutting equipment, you should replace a worn or damaged bar or chain with a bar and chain combinations recommended by Husqvarna. See instructions under the heading Technical Data for a list of replacement bar and chain combinations we recommend.

Guide bar

• Length (inches/cm)

• Number of teeth on bar tip sprocket (T).

12 – English

Saw chain

• Chain pitch (inches)

• Drive link width (mm/inches)

• Number of drive links.

GENERAL SAFETY PRECAUTIONS

Sharpening your chain and adjusting depth gauge setting

General information on sharpening cutting teeth

• Never use a blunt chain. When the chain is blunt you have to exert more pressure to force the bar through the wood and the chips will be very small. If the chain is very blunt it will produce wood powder and no chips or shavings.

• A sharp chain eats its way through the wood and produces long, thick chips or shavings.

• The cutting part of the chain is called the cutter and consists of a cutting tooth (A) and the depth gauge (B). The cutters cutting depth is determined by the difference in height between the two (depth gauge setting).

When you sharpen a cutting tooth there are four important factors to remember.

1 Filing angle

2 Cutting angle

Sharpening cutting teeth

To sharpen cutting teeth you will need a round ﬁle and a ﬁle gauge. See instructions under the heading Technical data for information on the size of ﬁle and gauge that are recommended for the chain ﬁtted to your chain saw.

• Check that the chain is correctly tensioned. A slack chain will move sideways, making it more difﬁcult to sharpen correctly.

• Always ﬁle cutting teeth from the inside face. Reduce the pressure on the return stroke. File all the teeth on one side ﬁrst, then turn the chain saw over and ﬁle the teeth on the other side.

3 File position

4 Round ﬁle diameter

It is very difﬁcult to sharpen a chain correctly without the right equipment. We recommend that you use our ﬁle gauge. This will help you obtain the maximum kickback reduction and cutting performance from your chain.

See instructions under the heading Technical data for information about sharpening your chain.

WARNING! Departure from the sharpening instructions considerably

increases the risk of kickback.

• File all the teeth to the same length. When the length of the cutting teeth is reduced to 4 mm (5/32") the chain is worn out and should be replaced.

min 4 mm

(5/32")

General advice on adjusting depth gauge setting

• When you sharpen the cutting tooth (A) the depth gauge setting (C) will decrease. To maintain optimal cutting performance the depth gauge (B) has to be ﬁled down to achieve the recommended depth gauge setting. See instructions under the heading Technical data to ﬁnd the correct depth gauge setting for your particular chain.

WARNING! The risk of kickback is increased if the depth gauge setting is too large!

English – 13

GENERAL SAFETY PRECAUTIONS

Adjustment of depth gauge setting

• The cutting teeth should be newly sharpened before adjusting the depth gauge setting. We recommend that you adjust the depth gauge setting every third time you sharpen the cutting teeth. NOTE! This recommendation assumes that the length of the cutting teeth is not reduced excessively.

• You will need a ﬂat ﬁle and a depth gauge tool. We recommend that you use our depth gauge tool to acheive the correct depth gauge setting and bevel for the depth gauge.

• Place the depth gauge tool over the chain. Detailed information regarding the use of the depth gauge tool, will be found on the package for the depth gauge tool. Use the ﬂat ﬁle to ﬁle off the tip of the depth gauge that protrudes through the depth gauge tool. The depth gauge setting is correct when you no longer feel resistance as you draw the ﬁle along the depth gauge tool.

Tension the chain as tightly as possible, but not so tight that you cannot pull it round freely by hand.

• Undo the bar nuts that hold the clutch cover/chain brake. Use the combination spanner. Then tighten the bar nuts by hand as tight as you can.

• Raise the tip of the bar and stretch the chain by tightening the chain tensioning screw using the combination spanner. Tighten the chain until it does not sag from the underside of the bar.

• Use the combination spanner to tighten the bar nuts while lifting the tip of the bar at the same time. Check that you can pull the chain round freely by hand and that it does not sag from the underside of the bar.

Tensioning the chain

WARNING! A slack chain may jump off and cause serious or even fatal injury.

The more you use a chain the longer it becomes. It is therefore important to adjust the chain regularly to take up the slack.

Check the chain tension every time you refuel. NOTE! A new chain has a running-in period during which you should check the tension more frequently.

14 – English

The position of the chain tensioning screw on our chain saws varies from model to model. See instructions under the heading What is what? to ﬁnd out where it is on your model.

Lubricating cutting equipment

WARNING! Poor lubrication of cutting equipment may cause the chain to snap, which could lead to serious, even fatal injuries.

Chain oil

Chain oil must demonstrate good adhesion to the chain and also maintain its ﬂow characteristics regardless of whether it is warm summer or cold winter weather.

As a chain saw manufacturer we have developed an optimal chain oil which, with its vegetable oil base, is also biodegradable. We recommend the use of our own oil for both maximum chain life and to minimise environmental damage. If our own chain oil is not available, standard chain oil is recommended.

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