Husqvarna Chainsaw 966451906 User Manual

Workshop Manual  
555 560XP/XPG  
562XP/XPG  
English  
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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  
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Index  
Index  
M
B
Muffler 19  
Bar bolt 54  
Assembling the muffler 19  
Dismantling the muffler 19  
Replacing the bar bolt 53  
C
O
Carburettor 34  
Assembly 38  
Oil pump and screen 31  
Assembling the oil pump and screen 32  
Cleaning and inspection 38  
Design 34  
Dismantling 36  
Cleaning and inspection 31  
Dismantling the oil pump and screen 31  
Function 35  
Pressure testing the carburettor 40  
P
Piston and cylinder 45  
Centrifugal clutch 30  
Assembling the piston and cylinder 47  
Dismantling the piston and cylinder 45  
Faults and causes 47  
Assembly of centrifugal clutch 31  
Cleaning and inspection 30  
Dismantling the centrifugal clutch 30  
Pressure testing the cylinder 48  
Chain brake 17  
Assembling the chain brake 18  
Cleaning and inspection 17  
Dismantling the chain brake 17  
S
Service data 14  
Service tools 12  
Chain catcher 20  
Starter 25, 26  
Replacing the chain catcher 20  
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  
Crankshaft and crankcase 49  
Assembling a complete crankshaft 54  
Dismantling the crankcase and crankshaft 49  
F
Fuel system 44  
Replacing the fuel filter 44  
Replacing the fuel hose 44  
Stop control 20  
Dismantling the stop control 20, 21  
Stop function 21  
Resistance test - stop function 21  
I
Ignition module and flywheel 28  
Assembling the ignition module and flywheel 29  
Symbols  
Symbols in the Workshop Manual 9  
Symbols on the saw 9  
Cleaning and inspection 28  
Dismantling the ignition module and flywheel 28  
T
Intake system 32  
Assembling the intake system 33  
Cleaning and inspection 33  
Dismantling the intake system 32  
Tank unit 42  
Assembly 43  
Dismantling 42  
Introduction and safety instructions 7  
General 7  
Tank valve 42  
Technical Data 10  
General Instructions 8  
Modifications 7  
Numbering 7  
Threads 54  
Repairing damaged threads 54  
Throttle control lock, throttle lock and spring 22  
Assembling the throttle lockout, throttle control  
and spring 23  
Safety 7  
Special Instructions 8  
Structure 7  
Target group 7  
Cleaning and inspection 22  
Dismantling the throttle control lock, throttle  
control and spring 22  
Tools 7  
Troubleshooting 57  
Troubleshooting methods 58  
4 - English  
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Index  
V
Vibration damping system 43  
Assembly 43  
Cleaning and inspection 43  
Dismantling 43  
English - 5  
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Introduction and safety instructions  
2 Introduction and safety regulations  
Contents  
2.1  
2.2  
2.3  
2.4  
2.5  
2.6  
2.7  
2.8  
2.9  
General ...........................................................................................................................7  
Safety .............................................................................................................................7  
Target group ...................................................................................................................7  
Modifications....................................................................................................................7  
Tools ...............................................................................................................................7  
Structure .........................................................................................................................7  
Numbering ......................................................................................................................7  
General instructions ........................................................................................................8  
Special instructions .........................................................................................................8  
2.10 Symbols on the saw .......................................................................................................9  
2.11 Symbols in the Workshop Manual ..................................................................................9  
6 - English  
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Introduction and safety instructions  
2 Introduction and safety instructions  
2.1 General  
2.6 Structure  
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.  
This Workshop Manual can be used in two different  
ways:  
Repair of a specific system on the chain saw.  
Dismantling and assembly of the entire chain saw.  
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.  
Repair of a specific system  
When a particular system on the chain saw is to be  
repaired, proceed as follows:  
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.  
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:  
2.3 Target group  
This Workshop Manual is written for personnel who  
are assumed to have general knowledge of repair-  
ing and servicing chain saws.  
1. Open the “Repair instructions” chapter which  
deals with the Starter and carry out the in-  
structions outlined under the Dismantling  
heading.  
The Workshop Manual must be read and under-  
stood 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. 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 in-  
structions under Cleaning and Inspection.  
2.4 Modifications  
Any modifications to the chain saw will be gradually  
introduced into ongoing production. As these modi-  
fications affect service and/or spare parts, specific  
service information will be sent out on each occa-  
sion. This means that in time this Workshop Manu-  
al 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.  
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.  
2.5 Tools  
7. Work back in the Manual and carry out Assem-  
bling in the order set out in the sections.  
Special tools are required for some stages. All  
service tools are listed in the Workshop Manual.  
Usage is made apparent in each section.  
Some sections include an introductory Descrip-  
tion of the actual unit in order to increase the basic  
understanding.  
Always use Husqvarna’s original:  
• Spare parts  
2.7 Numbering  
• Service tools  
• Accessories  
Position references to components inside the fig-  
ures are designated A, B, etc.  
The figures are numbered 1, 2 etc.  
The position references and figure numbers restart  
English - 7  
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Introduction and safety instructions  
2.8 General Instructions  
2.9 Special Instructions  
The workshop where the chain saw is to be re-  
paired must be equipped with safety equipment in  
accordance with local regulations.  
The fuel used in the chain saw has the following  
hazardous properties:  
The fluid and its vapour are poisonous.  
Can cause eye and skin irritation.  
Can cause breathing problems.  
Is highly inflammable.  
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 warn-  
ing boxes in relevant places.  
When using compressed air, do not direct the jet  
towards your body. Air can penetrate into the blood  
stream, which can endanger life.  
WARNING!  
The warning box warns of the risk  
of personal injury if the instruc-  
tions are not followed.  
Wear protective earplugs or earmuffs when test  
running.  
After test running, do not touch the muffler until  
it has cooled down. Risk of burns. Use protective  
gloves when working with the muffler.  
NOTE!  
This box warns of material damage if the  
instructions are not followed.  
Do not start the chain saw unless the bar, chain  
and clutch cover (chain brake) are fitted, otherwise  
the clutch may loosen and cause personal injury.  
Insufficient chain lubrication can result in chain  
breakage, which can cause serious or even life-  
threatening injury.  
Exercise care to ensure the starter spring does not  
fly 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 fly 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 fly out and cause personal  
injury.  
After repairing, check the chain brake, see “Assem-  
bling chain brake \ Function check”.  
Keep in mind the fire risk. The chain saw may emit  
sparks, which cause ignition.  
Check the chain catcher and replace it if it is dam-  
aged.  
8 - English  
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Introduction and safety instructions  
2.10 Symbols on the saw  
2.11 Symbols in the Workshop Manual  
The symbols below are embedded on the chain  
saw.  
This symbol warns of personal injury  
when the instructions are not followed.  
Choke Lever  
Refuelling  
Stop button  
Chain oil fill.  
Chain brake  
Decompression valve  
Fuel pump  
Adjusting the oil pump  
English - 9  
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Technical data  
3 Technical data  
Displacement  
cm3/cubic inch  
Cylinder diameter  
Ø mm/Ø inch  
Stroke length  
mm/inch  
Max. output/speed  
kW/hp/ rpm  
555:  
560XP/XPG:  
562XP/XPG:  
59,8 / 3.65  
59,8 / 3.65  
59,8 / 3.65  
46 / 1.81  
46 / 1.81  
46 / 1.81  
36 / 1.42  
36 / 1.42  
36 / 1.42  
3.1 / 4.2 / 9600  
3.5 / 4.8 / 9600  
3.5 / 4.8 / 9600  
Electrode gap  
mm/inch  
Ignition system  
Air gap  
mm/inch  
Carburettor type  
555:  
0,5 / 0.02  
SEM  
SEM  
SEM  
0,3 / 0.012  
0,3 / 0.012  
0,3 / 0.012  
Zama  
Zama  
Zama  
560XP/XPG: 0,5 / 0.02  
562XP/XPG: 0,5 / 0.02  
Usable cutting length  
cm/inch  
Chain speed at  
max. output - speed  
m/s - rpm  
Chain pitch  
mm/inch  
Drive link  
mm/inch  
555:  
33-61 / 13-24  
21,3 / 9600  
21,3 / 9600  
21,3 / 9600  
8.25 / 0.325 9,53 / 0.375 1.3 / 0.050 - 1,5 / 0.058  
8,25 / 0.325 9,53 / 0.375 1,3 / 0.050 - 1,5 / 0.058  
560XP/XPG: 33-61 / 13-24  
562XP/XPG: 38-71 / 15-28  
9,53 / 0.375  
1,3 / 0.050 - 1,5 / 0.058  
10 - English  
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Technical data  
Engage speed  
rpm  
Spark plug  
Automatic oil pump  
555:  
560XP/XPG:  
562XP/XPG:  
3800  
3800  
3800  
NGK CMR6H  
NGK CMR6H  
NGK CMR6H  
Yes  
Yes  
Yes  
GAS  
OIL  
Volume fuel tank  
Litre/US. pint  
Capacity oil pump at  
9,000 rpm,  
ml/min  
Volume oil tank  
Litre/US. pint  
555:  
560XP/XPG:  
562XP/XPG:  
0,65 / 1.37  
0,65 / 1,37  
0,65 / 1.37  
6-15  
6-15  
8-18  
0.33 / 0.70  
0,33 / 0.70  
0,35 / 0.74  
Weight without bar and chain  
kg/lbs  
Weight with bar and chain  
kg/lbs  
555:  
560XP/XPG:  
562XP/XPG:  
5,6 / 12.3  
5,6 / 12.3  
5,7 / 12.6  
Weight depending on selected cutting equipment  
English - 11  
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Service tools  
4 Service tools  
1
2
3
4
5
6
4 mm  
5 mm  
4 mm  
8
7
9
10  
12a  
11  
12b  
12 - English  
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Service tools  
14  
16  
13d  
13a  
13b  
13c  
15  
17  
Pos Description  
Used for  
Order No.  
1
Piston stop  
Locking the crankshaft  
575 29 36-01  
2
3
4
Hook for fuel filter  
Allen key, 4 mm  
Allen key, 4 mm  
Suspending the fuel filter  
For M5 bolts  
For M5 bolts  
502 50 83-01  
502 50 87-01  
502 50 18-01  
4
5
6
Allen key, 5 mm  
Air gap tool  
Clutch tool  
For M6 bolts  
Setting, ignition module  
Centrifugal clutch  
502 50 64-01  
502 51 34-02  
575 25 14-01  
7
8
Assembly fixture  
Pressure gauge  
Securing the chain saw  
Pressure testing  
502 51 02-01  
531 03 06-23  
9
Test spark plug  
Checking the ignition module  
501 97 64-01  
10 Assembly pliers  
11 Dismantling device  
Fitting the spark plug guard  
Dismantling the crankcase  
502 50 06-01  
575 28 69-01  
12a Assembly tool  
12b Guide sleeve  
13a Cover plate, outlet  
13b Cover plate, inlet  
13c Cover plug, inlet  
13d Pressure tester  
14 Mandrel  
Assembling the sealring  
Assembling the sealring  
Closure of outlet  
575 34 70-01  
575 34 69-01  
574 71 14-01  
575 29 81-01  
574 70 12-01  
503 84 40-03  
502 51 94-01  
502 50 30-23  
531 00 48-67  
Closure of inlet  
Closure of inlet  
Pressure testing the cylinder  
Dismantling the flywheel  
Assembling the crankshaft  
Dismantling the crankshaft  
15 Assembly tool  
16 Puller  
17 Engine Diagnostic Tool Diagnosis and troubleshooting 576 69 23-01  
English - 13  
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Service data  
5 Service data  
18-20Nm 16mm  
12-14Nm 13mm  
8-10Nm 4mm  
1,5-2Nm 4mm  
1-2Nm  
12-15 Nm 5mm  
1-2Nm  
12-15 Nm 5mm  
5-6Nm 4mm  
4-5Nm 4mm  
1-2Nm  
Min. 15Nm 13mm  
Min. 25Nm  
1-2Nm  
Key  
The numbers by the components to be assembled with  
screws state the tightening torque in Nm.  
s = Lubricate using two-stroke oil.  
n = Lubricate using chain oil.  
l = Lubricate using grease.  
14 - English  
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