Husqvarna 966451906 manual

Workshop Manual English 555 560XP/XPG 562XP/XPG[...]

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English - 3 W orkshop Manual Husqv arna 555, 560XP , 560XPG, 562XP and 562XPG Contents Index ...................................................................... 4 Introduction and saf ety instructions .................. 6 T echnical data ...................................................... 10 Service tools .....................................[...]

4 - English Index Inde x B Bar bolt 54 Replacing the bar bolt 53 C Carburettor 34 Assembly 38 Cleaning and inspection 38 Design 34 Dismantling 36 Function 35 Pressure testing the carburettor 40 Centrifugal clutc h 30 Assembly of centrifugal clutch 31 Cleaning and inspection 30 Dismantling the centrifugal clutch 30 Chain brake 17 Assembling the chai[...]

English - 5 Index V Vibration damping system 43 Assembly 43 Cleaning and inspection 43 Dismantling 43[...]

6 - English Introduction and safety instructions 2 Intr oduction and safety regulations Contents 2.1 General ........................................................................................................................... 7 2.2 Safety ........................................................................................................[...]

English - 7 2 Intr oduction and safety instructions 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 re[...]

8 - English 2.8 General Instructions The workshop where the chain saw is to be re- paired 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 warn- ing boxes in relevant place[...]

English - 9 Introduction and safety instructions 2.10 Symbols on the saw The symbols below are embedded on the chain saw . Choke Lever Refuelling Stop button Chain oil ll. Chain brake Decompression valve Fuel pump Adjusting the oil pump 2.11 Symbols in the W orkshop Manual This symbol warns of personal injury when the instructions are not follow[...]

10 - English 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 ty[...]

English - 1 1 Engage speed Spark plug Automatic oil pump rpm 555: 3800 NGK CMR6H Y es 560XP/XPG: 3800 NGK CMR6H Y es 562XP/XPG: 3800 NGK CMR6H Y es V olume fuel tank Capacity oil pump at V olume 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[...]

12 - English 6 10 11 4 Service tools Service tools 3 5 8 1 2 7 9 4 mm 5 mm 4 4 mm 12a 12b[...]

English - 13 Service tools 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 modul[...]

14 - English 5 Service data Service data 12-15 Nm 5mm 1,5-2Nm 4mm 5-6Nm 4mm Min. 25Nm 1-2Nm 8-10Nm 4mm 4-5Nm 4mm 18-20Nm 16mm 12-15 Nm 5mm Min. 15Nm 13mm 12-14Nm 13mm 1-2Nm 1-2Nm 1-2Nm s = Lubricate using two-stroke oil. n = Lubricate using chain oil. l = Lubricate using grease. The numbers by the components to be assembled with screws state the ti[...]

English - 15 Service data 3,5-4,5Nm 4mm 3,5-4,5Nm 4mm 4-5Nm 4mm 6-8Nm 4mm 7-9Nm 4mm 6-8Nm 4mm 22-25Nm 13mm 9-11Nm 4mm 3-4Nm 4mm 7-9Nm 4mm 3-4Nm 4mm 3-4Nm 4mm 2-3Nm 4mm 1-2Nm 3-4Nm 4mm 9-11Nm 4mm 8-10Nm 4mm[...]

16 - English 6 Safety equipment Safety equipment Contents 6.1 Dismantling the chain brake ........................................................................................... 17 6.2 Assembling the chain brake ............................................................................................ 18 6.3 Dismantling the mufer .........[...]

English - 17 3 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. W ARNING! Exer cise care to ensure the spring doe s no t fly out and cau se p er sona l injury . W ear protective goggles. 6.1 Dismantling the chain brake 2 Unscrew the kickback guard[...]

18 - English 6.2 Assembling the chain brake 1 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. 2 Compress the spring w[...]

English - 19 NO TE! Aft er r epai ring , th e c hain bra ke m us t be in- spe cted in line wit h th e in stru ctio n be low . Functional inspection: Do not turn on the motor when carrying out this inspection. Bar length Height 38 cm/15” 50 cm/20" • Hold the chain saw over a stable surface. The distance between the bar and the surface is sh[...]

20 - English 6.5 Replacing the chain catcher A worn chain catcher must always be replaced with a new one. Always use original spare parts. 1 Release the brake by moving the front hand guard backward. Loosen the bar nuts and remove the clutch cover , chain and bar . 2 Remove the chain catcher and replace it with a new one. Make sure that the vibrati[...]

English - 21 Safety equipment 6.8 Resistance test - stop function Dismantle the ignition module as outlined in “7.7 Dismantling the ignition module and ywheel”. Cut open the shrink tube covering both cables and shrink tubing that encloses the cable ends. Clean the contact areas and check resistance in the following way: T est the resistance [...]

22 - English Safety equipment 3 Press out the throttle control pin (C) with the help of a punch. See gure 21. 4 Loosen the throttle cable (D) and lift out the throttle control and the spring. See gure 22. 5 6.9 Dismantling the throttle contr ol lock, throttle contr ol and spring 1 Loosen the screw on the rear handle. Remove the handle insert [...]

English - 23 6.10 Assembling the thr ottle control lock, throttle contr ol and spring 1 Lubricate the pin and joined surfaces with a light oil. Hook on the throttle cable (D). Slide in the throttle control and make sure the spring is tted as outlined in gure 24. NOTE! Make sure that the rear end of the throttle control is correctly aligned in[...]

24 - English 7 Repair instructions Repair Instructions Contents 7.1 Dismantling the starter .................................................................................................... 25 7.2 Replacing a broken or worn starter cord ........................................................................ 26 7.3 T ensioning the return spring [...]

English - 25 Repair Instructions W ARNING! If the spring tension is activated on the starter pulley , the spring can fly out and cause personal injury . W ear protective glasses. 7.1 Dismantling the starter 1 Loosen the four screws, which hold the starter against the crankcase and remove the starter . 3 Loosen the screw in the centre of the pulley[...]

26 - English Repair instructions 7.2 Replacing a broken or w orn starter cord Wh en t he s ta rt er c or d is w or n an d mu st b e re pl ac ed , th e te ns io n in t he r et ur n sp ri ng m us t be r el ea se d. 1 Pull the cord out about 30 cm and lift it into the notch on the outside of the starter pulley . Release the tension on the return sprin[...]

English - 27 Repair Instructions W ARNING! Ex e r ci se c ar e to e ns ur e th e sp ri ng do es n ot fl y ou t an d ca us e pe r so n- al i nj ur y . W ea r pr o te ct iv e go gg le s. 7.4 Replacing a broken return spring 1 Loosen the screw at the centre of the starter pulley and loosen the screws on the cassette. Remove the starter pulley with th[...]

28 - English Repair Instructions 7.6 Dismantling the ignition module and flywheel 1 Remove the cylinder cover . Remove the starter . Snap off the ignition cable from the guide rail and remove the guide rail. See gure 7. 4 Thread the mandrel on the crank pin. Screw in until 1-2 threads are left to the ywheel. Knock on the mandrel with a suita[...]

English - 29 Repair Instructions 7.7 Assembling the ignition module and flywheel 1 Run the cables through the opening in the crank- case. Screw the earth cable in place. See gure 1 1. Fit the cabling to the stop button. 2 Position the cable channel as outlined in gure 10. NOTE! T ake care that the cable channel is posi- tioned correctly unde[...]

30 - English Repair Instructions 4 Secure the clutch in a vice as shown in gure 16. Carefully remove the clutch springs. Remove the clutch shoe springs from the side that does not have text. NO TE! Be careful with the clutc h springs, as opening them too muc h can result in material damage. Cleaning and inspection • Clean and check all parts c[...]

English - 31 7.9 Assembl y of centrifugal clutc h 1 Insert the clutch springs on the side of the shoes without text. See gure 17. 2 Screw in the clutch (anti-clockwise) until it stops. Then tighten the clutch using tool 575 25 14-01 and a suitable socket wrench or combination span- ner . T ightening torque of at least 25 Nm. 3 Remove the piston [...]

32 - English D D D D E Repair Instructions 7. 1 1 A ss em b li n g th e o il pu mp an d s cr e en 1 Low er t he o il  lter in plac e an d re plac e th e oi l pu mp as outl ined in gur e 19 and tig hten the scr ews. 2 Fit the pump drive wheel, the needle bearing, the drive sprocket, the clutch drum and the clutch, us- ing a tightening torque o[...]

English - 33 Repair Instructions 7.13 Assembling the intake system 1 Assemble the intake system. 2 Fit the lower screws of the intake system using the POP-out hole and the fuel hose hole. Fit the other screws. Fit the fuel hose and the throttle cable to their attachments. See gure 24. Fit the rubber grommet to the throttle cable. Push the tank b[...]

34 - English Repair Instructions W ARNING! The fue l us ed i n th e c hain sa w h as the f ollo win g h azar do us p ro pertie s: 1. The fluid and its vapour are poisonous. 2. Can cause skin irritation. 3. Is highly inflammable. 7.14 Carburettor Description The gures accompanying this description do not correspond with the carburettor on the c[...]

English - 35 Repair Instructions Function The carburettor operates differently in the following modes: • Cold start mode • Idling mode • Part throttle mode • Full throttle mode In cold start mode the choke valve H is completely shut. This increases the vacuum in the carburettor and fuel is easier to suck from all the diffuser jets D, E, and[...]

36 - English Repair Instructions Dismantling the carburettor 1 Dismantle the cylinder cover and the air lter . 2 Loosen the screws, F . Unhook the rubber attach- ment G on both sides. See Figure 35. Fig 35 Fig 34 6 Use a small at screwdriver to snap open the con- nector from the black attachment. Separate the connector by pressing down the ca[...]

English - 37 H J K Q R L M P Repair Instructions 7 Dismantle the pump cover H and carefully remove the control diaphragm J and gasket K. 8 Unscrew screw P and remove needle valve M with lever arm Q, shaft L and spring R. 9 Use a needle or similar device and carefully pull up the fuel screen (W). See gure 39. 10 If necessary , dismantle throttle [...]

38 - English Repair Instructions Assembl y Observe cleanliness when assembling the car- burettor . The slightest contamination can result in downtime. 1. If throttle and choke valves with shafts, lever arms and springs are removed, these must be assembled. The spring is tensioned 1-2 turns. Lubricate the shaft bearings using a light oil. 2. Fit the[...]

English - 39 Repair Instructions 4. Assemble needle valve M with lever arm Q, shaft L and spring R, and tighten screw P . (Fit the expansion washer). See gure 40. 5. Check using a ruler or the like that the lever is level with the assembly plane on the cover . If necessary , the lever arm can be bent, see gure 41. 7. Fit gasket K, the control[...]

40 - English Fitting on the saw 1 Press the connector together as outlined in gure 44 and push it into place in the holder . Repair Instructions Leak in Fault with Dif fuser jets Needle valve Leak in the impulse pipe Pump membrane V entilation hole on the Control membrane metering unit. Pressure testing the carburettor Pressure testing should be[...]

English - 41 D E Repair Instructions Fig 48 Fig 46 Fig 49 2 Make sure the cabling is tted to its mounting on the intake ange. Press the fuel hose (D) in place in the collar on the intake bellows. Hook on the throttle cable (E) in its mounting on the intake bellows. See gure 46. Make sure the lug on the carburettor hooks in place on its mou[...]

42 - English 7.15 T ank unit Dismantling 1. Drain the fuel from the tank. 2. Remove the cylinder cover , the clutch cover , the chain and the bar . See the Operator’s Manual. Dismantle the carburettor as outlined in “Dis- mantling the carburettor”. 3. Loosen the hoses A to D. See gure 50. 4. Loosen the screws F . See gure 51. 5. Loosen [...]

English - 43 Assembly 1. Thread the throttle cables in the connection M as outlined in gure 55. NOTE! The gure is shown from underneath. 2. Run the fuel hose D through hole K and hoses B and C in hole L. See gure 55. Pull the hoses so that the collars are on each side of the bot- tom on the carburettor compartment. 3. T ighten the chain ca[...]

44 - English 1 When replacing the fuel lter , the old fuel lter must be taken out of the tank unit using special tool 502 50 83-01. 2 Pull out fuel hose B from the tank unit and pull away the lter A. See gure 58. 3 Fit the new fuel lter A and press the fuel hose back into place. 7.1 9 R epl acin g t he fuel ho se/ retu rn hos e The f[...]

English - 45 Repair Instructions 7.2 1 D ism antl ing th e pi sto n a nd c yl ind er 1 Dismantle: • The cylinder cover • The carburettor (see “Dismantling the carburettor”) • The mufer • The vibration element • The spark plug cap • The intake system 2 Unscrew the cylinder’s four screws and carefully lift away the cylinder and t[...]

46 - English Repair Instructions Check the following: • That the cylinder’s surface coating is not worn. Especially the upper part of the cylinder . • That the cylinder does not have any chafe or cutting marks. • That the piston is free of score marks. Minor scratches can be polished off using ne emery paper . • That the piston ring is[...]

English - 47 Faults and causes Score marks on the piston (A) 1. Leakage, check not carried out. 2. T oo low octane fuel. 3. T oo low or incorrect oil in the fuel. Carbon build-up (B) 1. T oo much or incorrect oil in the fuel. See Figure 63. Piston ring breakage 1. Piston ring worn out. 2. Oversized piston ring groove. 7.2 2 A sse mbl ing th e pi st[...]

48 - English Repair Instructions W ARNING! Once the cylinder has been pressure tested, make sure the inlet manifold is fitted correctl y . Otherwise the chainsa w can be damaged. 7.23 Pressure testing the cylinder 1 Loosen • The cylinder cover • The carburettor 2 Attach the cover plate 574 71 14-01 and plug 574 70 12-01. See gure 66. 3 Loos[...]

English - 49 Repair Instructions 7.24 Dismantling the crankshaft and crankcase 1 Dismantle the following: • The clutch cover • The chain and bar . • The centrifugal clutch * • The cylinder cover • The starter * • The ywheel * • The carburettor * • The bottom of the carburettor * • The hand guard * • The mufer * • The han[...]

50 - English Fig 72 Fig 73 7. If required, remove the crankshaft bearing from the crankcase. Proceed as follows: A. Remove the oil rell cap. B. Heat up the crankcase half in question to 200°C. C. Use protective gloves. Press the bearing out of the crankcase half. 8. If the crankshaft bearings are still attached to the crankshaft when dismantlin[...]

English - 51 Fig 76 Fig 77 Fig 78 x4 Assembl y W ARNING! Beware of burn injuries as the crankcase halves are hot. W ear protective glo ves. 1 Proceed as follows if a bearing must be tted: A. Heat up the crankcase half in question to 200°C. B. Use protective gloves. Fit the bearing in the ywheel side of the crankcase half. When tting the b[...]

52 - English Fig 80 Fig 81 8 Assemble the following parts: A. T ank unit. See page 43. B. Piston and cylinder . See page 47. C. Mufer . See page 19. D. Carburettor . See page 40. E. Centrifugal clutch. See page 31. F . Electrical System. See page 29. G. Starter . See page 25. H. Bar and chain. See the Operator’s Manual. Sealing rings 1 T o rep[...]

English - 53 Repair Instructions 7.25 Assembling a complete crankshaft 1 Fit the complete crankshaft in the crankcase. Fit the following parts: • The piston and cylinder * • The fuel unit * • The handle system * • The mufer * • The hand guard * • The bottom of the carburettor * • The carburettor * • The ywheel * • The starte[...]

54 - English Repair Instructions 7.26 Replacing the bar bolt Replacing a bar bolt with intact crankcase 1 Empty the oil tank. 2 Knock in the old bar bolts from the outside so that they end up in the oil tank. 3 Remove the bolts from the oil tank. 4 Attach a wire to the head of the bar bolt, lower the wire through the oil tank and out through the bo[...]

English - 55[...]

56 - English T roubleshooting 8 T r oubleshooting Contents 8.1 T roubleshooting .............................................................................................................. 57 8.2 T roubleshooting methods ............................................................................................... 58[...]

English - 57 T roubleshooting Starting Idling (low speed) Idling (low speed) (contin ued) Leaking inlet hose (rubber) Loose carburettor mounting Loose or faulty fuel pipe Blocked fuel lter Blocked fuel line T ank ventilator blocked The thr ottl e va lve shaf t is ine rt Throttle stay is binding De fe ct iv e th ro tt le r et ur n sp ri ng Bent v[...]

58 - English T roubleshooting Acceleration and retardation Does not accelerate The engine stops when releasing the throttle Blocked air lter T ank venting clogged Blocked fuel lter Blocked fuel line Loose or faulty fuel pipe Blocked impulse channel The cover on the carburettor pump side is loose Faulty pump diaphragm Leaking inlet hose (rubbe[...]

2011W31 • 115 26 56-26[...]