Husqvarna 555 Workshop Manual

Husqvarna 555 Manual

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  • Husqvarna 555 | Workshop Manual - Page 1
    Workshop Manual 555 560XP/XPG 562XP/XPG English
  • Husqvarna 555 | Workshop Manual - Page 2
  • Husqvarna 555 | Workshop Manual - Page 3
    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
  • Husqvarna 555 | Workshop Manual - Page 4
    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 F Fuel system 44 Replacing the fuel filter 44 Replacing the fuel hose 44 I Ignition module and flywheel 28 Assembling
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    V Vibration damping system 43 Assembly 43 Cleaning and inspection 43 Dismantling 43 Index English - 5
  • Husqvarna 555 | Workshop Manual - Page 6
    safety regulations Contents 2.1 General ...7 2.2 Safety ...7 2.3 Target group ...7 2.4 Modifications...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
  • Husqvarna 555 | Workshop Manual - Page 7
    work and service on the chain saw. The Manual is also suitable for use when training new employees. 2.4 Modifications Any modifications to the chain saw will be gradually introduced into ongoing production. As these modifications affect service and/or spare parts, specific service information will
  • Husqvarna 555 | Workshop Manual - Page 8
    material damage if the instructions are not followed. After test running, do not touch the muffler until it has cooled down. Risk of burns. Use protective gloves when working with the muffler. Do not start the chain saw unless the bar, chain and clutch cover (chain brake) are fitted, otherwise the
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    below are embedded on the chain saw. Choke Lever Introduction and safety instructions 2.11 Symbols in the Workshop Manual This symbol warns of personal injury when the instructions are not followed. Refuelling Stop button Chain oil fill. Chain brake Decompression valve Fuel pump Adjusting
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    SEM SEM Air gap Carburettor type mm/inch 0,3 / 0.012 0,3 / 0.012 0,3 / 0.012 Zama Zama Zama Usable cutting length Chain speed at cm/inch max. output - speed m/s - rpm Chain pitch mm/inch Drive link mm/inch 555: 33-61 / 13-24 560XP/XPG: 33-61 / 13-24 562XP/XPG: 38-71 / 15-28 21
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    / 1.37 0,65 / 1,37 0,65 / 1.37 Capacity oil pump at 9,000 rpm, ml/min 6-15 6-15 8-18 OIL Volume oil tank Litre/US. pint 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
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    Service tools 1 4 Service tools 2 3 4 5 6 4 mm 4 mm 5 mm 7 8 9 10 12 - English 11 12a 12b
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    13d 13a 13b 14 16 13c 15 17 Service tools Pos Description Used for Order No. 1 Piston stop 2 Hook for fuel filter 3 Allen key, 4 mm 4 Allen key, 4 mm Locking the crankshaft Suspending the fuel filter For M5 bolts For M5 bolts 575 29 36-01 502 50 83-01 502 50 87-01 502 50
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    Service data 18-20Nm 16mm 12-14Nm 13mm 8-10Nm 4mm 1,5-2Nm 4mm 1-2Nm 12-15 Nm 5mm Min. 15Nm 13mm 1-2Nm 4-5Nm 4mm 5-6Nm 4mm Min. 25Nm Key 1-2Nm 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
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    9-11Nm 4mm 1-2Nm 7-9Nm 4mm 3-4Nm 4mm 22-25Nm 13mm Service data 3-4Nm 4mm 6-8Nm 4mm 4-5Nm 4mm 9-11Nm 4mm 6-8Nm 4mm 3-4Nm 4mm 2-3Nm 4mm 3,5-4,5Nm 4mm 3-4Nm 4mm 7-9Nm 4mm 8-10Nm 4mm 3,5-4,5Nm 4mm English - 15
  • Husqvarna 555 | Workshop Manual - Page 16
    equipment 6 Safety equipment Contents 6.1 Dismantling the chain brake 17 6.2 Assembling the chain brake 18 6.3 Dismantling the muffler 19 6.4 Assembling the muffler ...19 6.5 Replacing the chain catcher 20 6.6 Dismantling the start/stop control 20 6.7 Assembling the start/stop control 21
  • Husqvarna 555 | Workshop Manual - Page 17
    screwdriver, see fig. 4. Cleaning and inspection • Clean and check carefully all components. Parts Fig 4 must be replaced if cracked or show signs of other defects. Always use original spare parts. • Measure the thickness of the chain brake band. It must not be less than 0.6 mm in any place. See
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    brake spring using 1-1.5 Nm tightening torque. See figure 8. Fig 8 4 Tighten the brake by using the saw's hand guard as a tool. Mesh with the brake and tighten clockwise until the brake its groove. Tighten the chain guide plate in place. Fit the: • bar • chain • clutch shoe • cylinder cover Fig 10 18 -
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    spare parts. The spark arrestor mesh is best cleaned with a wire brush. The mesh must be replaced, if damaged. The saw will overheat if the mesh is clogged resulting in damage to the cylinder and piston. Never use a saw with a clogged or defective muffler. 6.4 Assembling the muffler 1 If the saw is
  • Husqvarna 555 | Workshop Manual - Page 20
    the air filter holder. See the "Dismantling the carburettor" chapter. 2 Loosen screw B and dismantle the stop control A. See figure 14. Unhook the rubber collar around the control from the guide plugs. Cleaning and inspection Clean and check carefully all components. Parts must be replaced if
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    in the rubber sleeve C and hook the sleeve on the guide taps. See figure 15. Safety equipment Fig 15 2 Attach the cables as outlined in figure 16. 3 Attach the air filter holder. See the "Assembling the carburettor" chapter. 4 Fit air filter and cylinder cover. 6.8 Resistance test - stop function
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    Fig 20 4 Loosen the throttle cable (D) and lift out the throttle control and the spring. See figure 22. Fig 21 5 Cleaning and inspection • Carefully clean and check all parts. See figure 13. Parts must be replaced if cracked or show signs of other defects. Always use original spare parts. • Check
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    a light oil. Hook on the throttle cable (D). Slide in the throttle control and make sure the spring is fitted as outlined in figure 24. NOTE! Fig 24 2 Fit the throttle control's pin (C) using a punch. See figure 25. 3 Fit the throttle control lock (B) by sliding it on the shaft in the handle. See
  • Husqvarna 555 | Workshop Manual - Page 24
    damping system 43 7.18 Replacing the fuel filter ...44 7.19 Replacing the fuel hose/return hose 44 7.20 Replacing the fuel pump 44 7.21 Dismantling the piston and cylinder 45 7.22 Assembling the piston and cylinder 47 7.23 Pressure testing the cylinder 48 7.24 Dismantling the crankshaft and
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    hold the starter against the crankcase and remove the starter. Repair Instructions 2 Pull the cord out about 30 cm and lift it into on the cassette and remove the cassette and spring. Cleaning and inspection Clean the parts and check: • The starter cord. • That the starter pawls on the flywheel
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    instructions 7.2 Replacing a broken or worn starter cord When the starter cord is worn and must be replaced through the hole in the starter housing and starter handle and tie a double knot on the cord. Worn or damaged parts must be replaced. Lubricate the return spring with a light oil. Fig 3b 7.3
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    on the cassette. Remove the starter pulley with the cassette and spring. 2 Remove the broken cassette and replace it with a new one. 3 Tighten the screw at the centre of the starter pulley, at a crankcase and tighten the screws at a tightening torque of 3-4 Nm. Repair Instructions English - 27
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    comes off the shaft. Remove mandrel and flywheel. See figure 9. Unscrew the air nozzle to replace the ignition module. Loosen the screws on the ignition module. See figure 10. Dismantle the air filter, air filter holder and carburet- tor. See the "Dismantling the carburettor" chapter. Fig
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    system", the tank unit as outlined in "7.16 tank unit", and the air filter as outlined in "Assembling the carburettor". 6 Press the ignition lead into the holder on the partition wall. 7 Then fit: • The air nozzle • The guide rail and press the cable in place • the spark plug hat by unscrewing
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    Repair Instructions 7.8 Dismantling the centrifugal clutch 1 Remove the cylinder cover. Release the brake by moving the kickback guard backwards. Loosen the bar nuts and remove the clutch cover, chain and bar. See figure 14. Fig 14 2 Loosen the spark plug hat and remove the spark plug, and insert
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    the oil pressure hose. See figure 20. Cleaning and inspection • Clean and check all parts carefully. Parts must be replaced if cracked or showing signs of other defects. Always use original spare parts. • Lubricate all moving parts with chain oil. Fig 18 Fig 19 Fig 20 Repair Instructions English
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    Repair Instructions 7.11 Assembling the oil pump and screen 1 Lower the oil filter in place and replace the oil pump as outlined in figure 19 and tighten the screws. 2 Fit the pump drive wheel, the needle bearing, the drive sprocket, the clutch drum and the clutch, using a tightening torque of 25
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    and check all parts carefully. Parts must be replaced if cracked or showing signs of other defects. Always use original spare parts. 7.13 Assembling 24. Fit the carburettor, the filter holder and the air filter as outlined in "Assembling the carburettor". Fig 25b Fig 26 Repair Instructions English
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    Repair Instructions 7.14 Carburettor WARNING! The fuel used in the chain saw has the following hazardous properties: 1. The valve and the diffuser jets. Here air is mixed with B the fuel to give a fuel/air mixture that can be ignited by the ignition spark. See figure 28. In the pump unit C,
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    I and J are closed and the choke valve H is open. Air is sucked in through an aperture in the throttle valve and a partly open and the choke valve H is fully open. Fuel is supplied through the diffuser jets D and E. The throttle valve, J, starts to open. See figure 32. Fig 31 Repair Instructions
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    Instructions Dismantling the carburettor 1 Dismantle the cylinder cover and the air filter. 2 Loosen the screws, F. Unhook the rubber attachment G on both sides. See Figure 35. 3 Loosen the suction hose A, the return hose B, and the tank bleeding hose C. See figure 34. Fig 34 4 Remove the air Use a
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    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 air valve S, and remove the shafts with lever arms and springs (see figure 39). 11 If necessary, dismantle the AutoTune AB unit. See figure 39. L M P Repair Instructions
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    light oil. 2. Fit the fuel screen W using the handle of a small screwdriver. See figure 39. 3. Fit the gasket X in the carburettor as well as the holder Y. Screw in place screw Z as outlined in figure 39. 4. See figure 39 on how to assemble the AutoTune AB unit with gasket. Note! When replacing the
  • Husqvarna 555 | Workshop Manual - Page 39
    4. Assemble needle valve M with lever arm Q, shaft L and spring R, and tighten screw P. (Fit the expansion washer). See figure 40. Repair Instructions Fig 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,
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    even it if is difficult. Try and identify where the spray is absorbed. It can be used to show leakages in main jets, idling needles, measuring cover gaskets and measuring diaphragms, and autotune gaskets. Fig 43 Leak in Fault with Diffuser jets Leak in the impulse pipe Ventilation hole on the
  • Husqvarna 555 | Workshop Manual - Page 41
    47. • NOTE! Make sure that the fuel and return hoses are not crushed. Fig 46 3 Position the guide taps on the air filter holder in the rubber grommets, G. See figure 48. Fig 47 Repair Instructions D E 4 Hook on the throttle cable, E. See figure 46. Fasten the return hose B and secure it in its
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    Repair Instructions 7.15 Tank unit WARNING! The fuel used in the chain saw has the following hazardous properties: 1. The fluid and its vapour are poisonous. 2. Can cause skin irritation. 3. Is highly inflammable. Dismantling 1. Drain the fuel from the
  • Husqvarna 555 | Workshop Manual - Page 43
    "Assembling the carburettor". Assemble the air filter and cylinder cover. Fig 54 7.17 Vibration damping system Dismantling 1. Dismantle the following parts: •Bar and chain. See the Operator's Manual. •Cylinder cover. See the Operator's Manual. •Tank unit and handle. See "Dismantling the tank unit
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    the return hose when required. Tighten the fuel hose on the filter side with your fingers. Fig 58 7.20 Replacing the fuel pump (Purge) Dismantle 1. Dismantle the cylinder cover and the air filter. 2. Loosen suction hose C and return hose from the fuel pump. See figure 59. 3. Snap off the fuel
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    carburettor (see "Dismantling the carburettor") • The muffler • The vibration element • The spark plug gudgeon pin bearing (the needle bearing) using a pliers. See figure 61. Replace with a new bearing. Fig 61 port • The base of the cylinder and/or crankcase Repair Instructions English - 45
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    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 fine emery paper.
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    63 Repair Instructions B 7.22 Assembling the piston and cylinder 1 Oil the gudgeon pin bearing with two-stroke oil and insert it into the crank rod. See figure 64. 2 Replace the piston with the arrow facing the exhaust port, and slide in the gudgeon pin and fit the circlips. NOTE! Use new circlips
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    . Tighten the screws for the muffler. See figure 66. Use the plastic piston stop 575 29 36-01. 4 Screw the pressure test connection 503 84 40-02 in place. Connect tool 531 03 06-23 to the nipple. Fig 66b 5 Pump the pressure up to 80 kPa (0.8 bar). Wait 30 seconds. The pressure
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    The muffler * • The handle system * • The fuel unit * • The piston and cylinder * • The ignition module • Cabling • The oil pump * See specific instruction. Fig 28 69-01 as outlined in figure 71. Remove the flywheel side's crankcase half. 6. Carefully pull the crankcase halves apart. Two guide pins
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    Repair Instructions 7. If required, remove the crankshaft bearing from the crankcase. Proceed as follows: A. Remove the oil refill cap. B. Heat up the crankcase half in question to 200°C. C. Use protective gloves. Press the bearing out of the crankcase half. Fig 72 8. If the crankshaft bearings
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    200°C. B. Use protective gloves. work. NOTE! Take care to prevent any dirt and foreign particles from entering the bearings. D. Fit the oil guide pin in the crankcase half on the clutch side, apply grease and fit the gasket(C). See Figure 77. 5 Use screws. Tighten the screws using 5 Nm of torque.
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    25. H. Bar and chain. See the Operator's Manual. Sealing rings 1 To replace the crankshaft's sealing rings, first dismantle the following parts: On the flywheel side: • Starter. See page 25. • Flywheel. See page 28. On the clutch side: • Bar and chain. See the Operator's Manual. • Chain guide plate
  • Husqvarna 555 | Workshop Manual - Page 53
    * • The handle system * • The muffler * • The hand guard * • The bottom of the carburettor * • The carburettor * • The flywheel * • The starter * • The cylinder cover • The centrifugal clutch * • The chain and bar. • The clutch cover * See specific instruction. Repair Instructions English - 53
  • Husqvarna 555 | Workshop Manual - Page 54
    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
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    English - 55
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    Troubleshooting 8 Troubleshooting Contents 8.1 Troubleshooting ...57 8.2 Troubleshooting methods 58 56 - English
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    likely fault is listed first, etc. See separate instruction for Autotune troubleshooting. Starting Idling (low speed) (continued) Difficult to start Air filter blocked Choke does not work Worn choke axle Worn choke valve Blocked fuel filter Blocked fuel line Piston ring is stuck Blocked impulse
  • Husqvarna 555 | Workshop Manual - Page 58
    system sticking Faulty diffuser jet Blocked air filter Faulty pump diaphragm Faulty diffuser jet 8.2 Troubleshooting methods In addition to faults given in the above schematic, troubleshooting can be carried out on a specific component or specific chain saw system. The different procedures are
  • Husqvarna 555 | Workshop Manual - Page 59
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Workshop Manual
English
555 560XP/XPG
562XP/XPG