Husqvarna 966451906 User Manual

Workshop Manual

555 560XP/XPG

562XP/XPG

English

Contents

Workshop Manual

Husqvarna 555, 560XP, 560XPG, 562XP and

562XPG

Contents

Index ...................................................................... 4

Introduction and safety instructions .................. 6

Technical data ......................................................10

Service tools ....................................................... 12

Service data .........................................................14

Safety equipment ................................................ 16

Repair instructions .............................................. 24

Carburettor .......................................................... 34

Troubleshooting ...................................................56

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.

English - 3

Index

Bar bolt 54

Replacing the bar bolt 53

Carburettor 34

Assembly 38 Cleaning and inspection 38 Design 34 Dismantling 36 Function 35 Pressure testing the carburettor 40

Centrifugal clutch 30

Assembly of centrifugal clutch 31 Cleaning and inspection 30 Dismantling the centrifugal clutch 30

Chain brake 17

Assembling the chain brake 18 Cleaning and inspection 17 Dismantling the chain brake 17

Chain catcher 20

Replacing the chain catcher 20

Crankshaft and crankcase 49

Assembling a complete crankshaft 54 Dismantling the crankcase and crankshaft 49

Fuel system 44

Replacing the fuel lter 44 Replacing the fuel hose 44

Ignition module and ﬂywheel 28

Assembling the ignition module and ywheel 29 Cleaning and inspection 28 Dismantling the ignition module and ywheel 28

Intake system 32

Assembling the intake system 33 Cleaning and inspection 33 Dismantling the intake system 32

Introduction and safety instructions 7

General 7 General Instructions 8 Modications 7 Numbering 7 Safety 7 Special Instructions 8 Structure 7 Target group 7 Tools 7

Mufﬂer 19

Assembling the mufer 19 Dismantling the mufer 19

Oil pump and screen 31

Assembling the oil pump and screen 32 Cleaning and inspection 31 Dismantling the oil pump and screen 31

Piston and cylinder 45

Assembling the piston and cylinder 47 Dismantling the piston and cylinder 45 Faults and causes 47 Pressure testing the cylinder 48

Service data 14 Service tools 12 Starter 25, 26

Cleaning and inspection 25 Cleaning and inspection: 26 Dismantling the starter 25 Replacing a broken or worn starter cord 26 Replacing a broken return spring 27 Starter assembly 27

Stop control 20

Dismantling the stop control 20, 21

Stop function 21

Resistance test - stop function 21

Symbols

Symbols in the Workshop Manual 9 Symbols on the saw 9

Tank unit 42

Assembly 43 Dismantling 42

Tank valve 42 Technical Data 10 Threads 54

Repairing damaged threads 54

Throttle control lock, throttle lock and spring 22

Assembling the throttle lockout, throttle control

and spring 23 Cleaning and inspection 22 Dismantling the throttle control lock, throttle

control and spring 22

Troubleshooting 57

Troubleshooting methods 58

4 - English

Vibration damping system 43

Assembly 43 Cleaning and inspection 43 Dismantling 43

Index

English - 5

Introduction and safety instructions

2 Introduction and safety regulations

Contents

2.1 General ...........................................................................................................................7

2.2 Safety .............................................................................................................................7

2.3 Target group ...................................................................................................................7

2.4 Modications....................................................................................................................7

2.5 Tools ...............................................................................................................................7

2.6 Structure .........................................................................................................................7

2.7 Numbering ......................................................................................................................7

2.8 General instructions ........................................................................................................8

2.9 Special instructions .........................................................................................................8

2.10 Symbols on the saw .......................................................................................................9

2.11 Symbols in the Workshop Manual ..................................................................................9

6 - English

Introduction and safety instructions

2 Introduction and safety instructions

2.1 General

This Workshop Manual describes in detail how to be troubleshoot, repair and test the chain saw. A description of different safety steps that must be taken during repair work is also given.

2.2 Safety

Note: The section dealing with safety must be read and understood by all those carrying out repair work or service on the chain saw.

Warning symbols can be found in this Workshop Manual and on the chain saw. See “Symbols on the saw” and “Symbols in the Workshop Manual”. A new warning symbol decal must be applied as soon as possible if a warning symbol on the chain saw has been damaged or is missing so that the greatest level of safety can be maintained when using the chain saw.

2.3 Target group

This Workshop Manual is written for personnel who are assumed to have general knowledge of repairing and servicing chain saws.

The Workshop Manual must be read and understood by personnel who will carry out repair work and service on the chain saw. The Manual is also suitable for use when training new employees.

2.4 Modiﬁcations

Any modications to the chain saw will be gradually introduced into ongoing production. As these modications affect service and/or spare parts, specic service information will be sent out on each occasion. This means that in time this Workshop Manual will become out of date. In order to prevent this, the Manual should be read together with all service information concerning the chain saw in question.

2.5 Tools

Special tools are required for some stages. All service tools are listed in the Workshop Manual. Usage is made apparent in each section.

Always use Husqvarna’s original:

• Spare parts

• Service tools

• Accessories

2.6 Structure

This Workshop Manual can be used in two different

ways:

• Repair of a specic system on the chain saw.

Dismantling and assembly of the entire chain saw.

•

Repair of a speciﬁc system

When a particular system on the chain saw is to be

repaired, proceed as follows:

1. Look up the page for the system in question.

2. Carry out the following steps: Dismantling

Cleaning and inspection

Assembly

Dismantling and assembling the chain saw.

Proceed as follows when the chain saw is to be dismantled and assembled:

1. Open the “Repair instructions” chapter which

deals with the Starter and carry out the instructions outlined under the Dismantling

heading.

2. Work forward in the Manual and carry out Dis- mantling in the order set out in the sections.

3. Go back to the Starter and carry out the instructions under Cleaning and Inspection.

4. Work forward in the Manual and carry out

Cleaning and Inspection in the order set out

in the sections.

5. Order or collect all requisite spare parts from the stores.

6. Look up the “Repair instructions” chapter which

deals with the Crankcase and carry out the instructions outlined in Assembling.

7. Work back in the Manual and carry out Assem- bling in the order set out in the sections.

Some sections include an introductory Descrip- tion of the actual unit in order to increase the basic

understanding.

2.7 Numbering

Position references to components inside the gures are designated A, B, etc. The gures are numbered 1, 2 etc. The position references and gure numbers restart

English - 7

Introduction and safety instructions

2.8 General Instructions

The workshop where the chain saw is to be repaired must be equipped with safety equipment in accordance with local regulations.

No one may repair the chain saw unless they have read and understood the content of this Workshop Manual.

This workshop manual contains the following warning boxes in relevant places.

WARNING! The warning box warns of the risk of personal injury if the instructions are not followed.

NOTE! This box warns of material damage if the

instructions are not followed.

2.9 Special Instructions

The fuel used in the chain saw has the following hazardous properties:

• The uid and its vapour are poisonous.

• Can cause eye and skin irritation.

• Can cause breathing problems.

• Is highly inammable.

When using compressed air, do not direct the jet towards your body. Air can penetrate into the blood stream, which can endanger life.

Wear protective earplugs or earmuffs when test running.

After test running, do not touch the mufer until it has cooled down. Risk of burns. Use protective gloves when working with the mufer.

Do not start the chain saw unless the bar, chain and clutch cover (chain brake) are tted, otherwise the clutch may loosen and cause personal injury.

Insufcient chain lubrication can result in chain breakage, which can cause serious or even lifethreatening injury.

Exercise care to ensure the starter spring does not y out and cause personal injury. Wear protective glasses. If the spring tension is activated on the starter pulley when it is to be taken up, the spring can y out and cause personal injury.

Check that the brake is applied when removing the pressure spring on the chain brake. Otherwise the pressure spring can y out and cause personal injury.

After repairing, check the chain brake, see “Assembling chain brake \ Function check”.

Keep in mind the re risk. The chain saw may emit sparks, which cause ignition.

Check the chain catcher and replace it if it is damaged.

8 - English

Introduction and safety instructions

2.10 Symbols on the saw

The symbols below are embedded on the chain saw.

Choke Lever

Refuelling

Stop button

2.11 Symbols in the Workshop Manual

This symbol warns of personal injury when the instructions are not followed.

Chain oil ll.

Chain brake

Decompression valve

Fuel pump

Adjusting the oil pump

English - 9

Technical data

3 Technical data

Displacement Cylinder diameter Stroke length Max. output/speed cm3/cubic inch Ø mm/Ø inch mm/inch kW/hp/ rpm

555: 59,8 / 3.65 46 / 1.81 36 / 1.42 3.1 / 4.2 / 9600 560XP/XPG: 59,8 / 3.65 46 / 1.81 36 / 1.42 3.5 / 4.8 / 9600 562XP/XPG: 59,8 / 3.65 46 / 1.81 36 / 1.42 3.5 / 4.8 / 9600

Electrode gap Ignition system Air gap Carburettor type mm/inch mm/inch

555: 0,5 / 0.02 SEM 0,3 / 0.012 Zama 560XP/XPG: 0,5 / 0.02 SEM 0,3 / 0.012 Zama 562XP/XPG: 0,5 / 0.02 SEM 0,3 / 0.012 Zama

Usable cutting length Chain speed at Chain pitch Drive link cm/inch max. output - speed mm/inch mm/inch m/s - rpm

555: 33-61 / 13-24 21,3 / 9600 8.25 / 0.325 9,53 / 0.375 1.3 / 0.050 - 1,5 / 0.058 560XP/XPG: 33-61 / 13-24 21,3 / 9600 8,25 / 0.325 9,53 / 0.375 1,3 / 0.050 - 1,5 / 0.058 562XP/XPG: 38-71 / 15-28 21,3 / 9600 9,53 / 0.375 1,3 / 0.050 - 1,5 / 0.058

10 - English



GAS

OIL

Technical data

Engage speed Spark plug Automatic oil pump rpm

555: 3800 NGK CMR6H Yes 560XP/XPG: 3800 NGK CMR6H Yes 562XP/XPG: 3800 NGK CMR6H Yes

Volume fuel tank Capacity oil pump at Volume oil tank Litre/US. pint 9,000 rpm, Litre/US. pint ml/min

555: 0,65 / 1.37 6-15 0.33 / 0.70 560XP/XPG: 0,65 / 1,37 6-15 0,33 / 0.70 562XP/XPG: 0,65 / 1.37 8-18 0,35 / 0.74

Weight without bar and chain Weight with bar and chain kg/lbs kg/lbs

555: 5,6 / 12.3 Weight depending on selected cutting equipment 560XP/XPG: 5,6 / 12.3 562XP/XPG: 5,7 / 12.6

English - 11

Service tools

4 Service tools

1 2

3 5

4 mm

4 mm 5 mm

12 - English

12a

12b

Service tools

13c

13a13d

13b

Pos Description Used for Order No.

1 Piston stop Locking the crankshaft 575 29 36-01

2 Hook for fuel lter Suspending the fuel lter 502 50 83-01 3 Allen key, 4 mm For M5 bolts 502 50 87-01 4 Allen key, 4 mm For M5 bolts 502 50 18-01

4 Allen key, 5 mm For M6 bolts 502 50 64-01 5 Air gap tool Setting, ignition module 502 51 34-02 6 Clutch tool Centrifugal clutch 575 25 14-01

7 Assembly xture Securing the chain saw 502 51 02-01 8 Pressure gauge Pressure testing 531 03 06-23

9 Test spark plug Checking the ignition module 501 97 64-01

10 Assembly pliers Fitting the spark plug guard 502 50 06-01 11 Dismantling device Dismantling the crankcase 575 28 69-01

12a Assembly tool Assembling the sealring 575 34 70-01

12b Guide sleeve Assembling the sealring 575 34 69-01

13a Cover plate, outlet Closure of outlet 574 71 14-01

13b Cover plate, inlet Closure of inlet 575 29 81-01

13c Cover plug, inlet Closure of inlet 574 70 12-01

13d Pressure tester Pressure testing the cylinder 503 84 40-03

14 Mandrel Dismantling the ywheel 502 51 94-01

15 Assembly tool Assembling the crankshaft 502 50 30-23

16 Puller Dismantling the crankshaft 531 00 48-67

17 Engine Diagnostic Tool Diagnosis and troubleshooting 576 69 23-01

English - 13

Service data

18-20Nm 16mm

5 Service data

12-14Nm 13mm

12-15 Nm 5mm

1-2Nm

8-10Nm 4mm

1,5-2Nm 4mm

1-2Nm

5-6Nm 4mm

1-2Nm

Min. 15Nm 13mm

1-2Nm

Key

The numbers by the components to be assembled with screws state the tightening torque in Nm.

4-5Nm 4mm

Min. 25Nm

s = Lubricate using two-stroke oil. n = Lubricate using chain oil. l = Lubricate using grease.

14 - English

Service data

9-11Nm 4mm

1-2Nm

3-4Nm 4mm

22-25Nm 13mm

6-8Nm 4mm

7-9Nm 4mm

3-4Nm 4mm

6-8Nm 4mm

4-5Nm 4mm

2-3Nm 4mm

3-4Nm 4mm

7-9Nm 4mm

8-10Nm 4mm

3,5-4,5Nm 4mm

English - 15

Safety equipment

6 Safety equipment

Contents

6.1 Dismantling the chain brake ...........................................................................................17

6.2 Assembling the chain brake ............................................................................................18

6.3 Dismantling the mufer ...................................................................................................19

6.4 Assembling the mufer ...................................................................................................19

6.5 Replacing the chain catcher ...........................................................................................20

6.6 Dismantling the start/stop control ...................................................................................20

6.7 Assembling the start/stop control ....................................................................................21

6.8 Resistance test - stop function .......................................................................................21

6.9 Dismantling the throttle control lock, throttle control and spring ..................................... 22

6.10 Assembling the throttle control lock, throttle control and spring .....................................23

16 - English

6 Safety equipment

6.1 Dismantling the chain brake

Remove the cylinder cover. Release the brake by moving the front hand guard backward. Loosen the bar nuts and remove the clutch cover, bar and chain, see g. 1.

Unscrew the kickback guard and remove it. NOTE! Make sure that the spring and rocker do not y out. Carefully tighten the clutch housing in a vice. Release the brake by using the saw’s hand guard as a tool. Mesh with the brake and tighten anti-clockwise until the brake is activated, see g. 2.

Safety equipment

Fig 1

Alt. 1

Alt. 2

Loosen the screws and insert a screwdriver to maintain pressure on the spring, and then carefully remove the cover over the brake spring, see g. 3.

WARNING! Exercise care to ensure the spring does not ﬂy out and cause personal injury. Wear protective goggles.

Hold one hand on top of the brake spring and press in a small screwdriver into the spring. Carefully bend upwards until the spring is released and it slides onto the screwdriver, see g. 4.

Cleaning and inspection

• Clean and check carefully all components. Parts must be replaced if cracked or show signs of other defects. Always use original spare parts.

Fig 2

Fig 3

Fig 4

• Measure the thickness of the chain brake band.

It must not be less than 0.6 mm in any place. See gure 5.

• Lubricate the knee joint with grease.

Fig 5

English - 17

Safety equipment

6.2 Assembling the chain brake

Screw the knee joint and the brake band together (see gure 5) using a tightening torque of 1-1.5 Nm. Place the knee joint with the tted chain brake band in the opening in the clutch cover. The space for the spring in the cover must be lubricated with grease. See gure 6.

Compress the spring with a wide screwdriver and press it down with your thumb. See gure 7.

WARNING! Exercise care to ensure the spring does not ﬂy out and cause personal injury. Wear protective goggles.

Fig 6

Fig 7

Fit the cover over the brake spring using 1-1.5 Nm tightening torque. See gure 8.

Tighten the brake by using the saw’s hand guard as a tool. Mesh with the brake and tighten clockwise until the brake is in the off position. See gure 9.

NOTE! Make sure the bushings in the kickback guard’s attachments are kept in place from the inside. See gure 9.

Screw the kickback guard in place and put the rocket in position. Position the spring (B) in the plastic housing (C) (see gure 10) and press the spring against the rocker and then press the plastic housing into its groove. Tighten the chain guide plate in place.

Fig 8

Fig 9

Fit the:

• bar

• chain

• clutch shoe

• cylinder cover

18 - English

A B

Fig 10

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