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Husqvarna 555 Workshop Manual
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Husqvarna 555 Workshop Manual

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Workshop Manual
555 560XP/XPG
562XP/XPG
English

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Summary of Contents for Husqvarna 555

  • Page 1 Workshop Manual 555 560XP/XPG 562XP/XPG English...
  • 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 ............
  • Page 4 Index Muffler 19 Bar bolt 54 Assembling the muf er 19 Replacing the bar bolt 53 ismantling the muf er 19 Carburettor 34 Assembly 38 Oil pump and screen 31 Cleaning and inspection 38 Assembling the oil pump and screen 32 Cleaning and inspection 31 esign 34 ismantling the oil pump and screen 31...
  • Page 5 Vibration damping system 43 Assembly 43 Cleaning and inspection 43 ismantling 43 English -...
  • Page 6 ntroduction and safety instructions 2 Introduction and safety regulations Contents General ...........................7 Safety ..........................7 Target group ........................7 Modi cations........................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 - English...
  • Page 7 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 Always use Husqvarna’s original: understanding. • Spare parts 2.7 Numbering •...
  • Page 8 ntroduction and safety instructions 2.8 General Instructions 2.9 Special Instructions The workshop where the chain saw is to be re- The fuel used in the chain saw has the following paired must be equipped with safety equipment in ha ardous properties: accordance with local regulations.
  • Page 9 ntroduction 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 in ury Choke Le er when the instructions are not followed. Refuelling Stop button Chain oil ll.
  • Page 10 3 Technical data isplacement Cylinder diameter Stroke length Ma . output/speed cm3/cubic inch 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...
  • Page 11 Technical data Engage speed Spark plug Automatic oil pump 555: 3800 NGK CMR6H 560XP/XPG: 3800 NGK CMR6H 562XP/XPG: 3800 NGK CMR6H 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...
  • Page 12 Ser ice tools 4 Service tools 4 mm 4 mm 5 mm - English...
  • Page 13 Ser ice tools escription Used for rder No. Piston stop Locking the crankshaft 575 29 36-01 Hook for fuel lter Suspending the fuel lter 502 50 83-01 Allen key, 4 mm or M5 bolts 502 50 87-01 Allen key, 4 mm or M5 bolts 502 50 18-01 Allen key, 5 mm...
  • Page 14 Ser ice 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 The numbers by the components to be assembled with screws state the tightening torque in Nm.
  • Page 15 Ser ice data 1-2Nm 7-9Nm 4mm 3-4Nm 4mm 9-11Nm 4mm 3-4Nm 4mm 22-25Nm 13mm 9-11Nm 4mm 6-8Nm 4mm 3-4Nm 4mm 6-8Nm 4mm 2-3Nm 4mm 4-5Nm 4mm 3-4Nm 4mm 7-9Nm 4mm 8-10Nm 4mm 3,5-4,5Nm 4mm 3,5-4,5Nm 4mm English -...

  • Page 16: Table Of Contents

    Safety equipment 6 Safety equipment Contents ismantling the chain brake ...................17 Assembling the chain brake ....................18 ismantling the muf er ....................19 Assembling the muf er ....................19 Replacing the chain catcher ...................20 ismantling the start/stop control ...................20 Assembling the start/stop control ..................21 Resistance test - stop function ..................21 ismantling the throttle control lock, throttle control and spring ........22 6.10...

  • Page 17: Ismantling The Chain Brake

    Safety equipment 6 Safety equipment 6.1 Dismantling the chain brake Remo e the cylinder co er. Release the brake by mo ing the front hand guard backward. Loosen the bar nuts and remo e the clutch co er, ig 1 bar and chain, see g.

  • Page 18: Assembling The Chain Brake

    Safety equipment 6.2 Assembling the chain brake Screw the knee oint and the brake band together see gure 5 using a tightening torque of 1-1.5 Nm. Place the knee oint with the tted chain brake band in the opening in the clutch co er. The space for the spring in the co er must be lubricated with grease.

  • Page 19: Ismantling The Muf Er

    Safety equipment NOTE! After repairing, the chain brake must be in- spected in line with the instruction below. Functional inspection: o not turn on the motor when carrying out this inspection. ar length Height 38 cm/15 50 cm/20 Hold the chain saw o er a stable surface. The distance between the bar and the surface is shown in the table abo e.

  • Page 20: Replacing The Chain Catcher

    Safety equipment 6.5 Replacing the chain catcher A worn chain catcher must always be replaced with a new one. Always use original spare parts. Release the brake by mo ing the front hand guard backward. Loosen the bar nuts and remo e the clutch co er, chain and bar.

  • Page 21: Assembling The Start/Stop Control

    Safety equipment 6.7 Assembling the start/stop control it the new stop control A and tighten screw place at a torque of 1 Nm. Slide in the stop control in the rubber slee e C and hook the slee e on the guide taps.

  • Page 22: Ismantling The Throttle Control Lock, Throttle Control And Spring

    Safety equipment 6.9 Dismantling the throttle control lock, throttle control and spring Loosen the screw on the rear handle. Remo e the handle insert A . See gure 19. ig 19 Loosen the throttle control lock as shown in the gure using a screwdri er or similar tool.

  • Page 23: Assembling The Throttle Control Lock, Throttle Control And Spring

    Safety equipment 6.10 Assembling the throttle control lock, throttle control and spring Lubricate the pin and oined surfaces with a light oil. Hook on the throttle cable . Slide in the throttle control and make sure the spring is tted as outlined in gure 24.
  • Page 24 Repair nstructions 7 Repair instructions Contents ismantling the starter ....................25 Replacing a broken or worn starter cord ................26 Tensioning the return spring ...................26 Replacing a broken return spring ...................27 Starter assembly......................27 ismantling the ignition module and ywheel ..............28 Assembling the ignition module and ywheel ..............29 ismantling the centrifugal clutch ...................30 Assemby of centrifugal clutch ..................31 7.10...

  • Page 25: Repair Instructions

    Repair nstructions 7 Repair instructions 7.1 Dismantling the starter Loosen the four screws, which hold the starter against the crankcase and remo e the starter. Pull the cord out about 30 cm and lift it into the notch on the outside of the starter pulley. Release the tension in the return spring by letting the starter pulley rotate anti-clockwise.

  • Page 26: Replacing A Broken Or Worn Starter Cord

    Repair instructions 7.2 Replacing a broken or worn starter cord When the starter cord is worn and must be replaced, the tension in the return spring must be released. Pull the cord out about 30 cm and lift it into the notch on the outside of the starter pulley.

  • Page 27: Replacing A Broken Return Spring

    Repair nstructions 7.4 Replacing a broken return spring WARNING! Exercise care to ensure the spring does not fly out and cause person- al injury. Wear protective goggles. Loosen the screw at the centre of the starter pulley and loosen the screws on the cassette. Remo e the starter pulley with the cassette and spring.

  • Page 28: Ismantling The Ignition Module And Ywheel

    Repair nstructions 7.6 Dismantling the ignition module and flywheel Remo e the cylinder co er. Remo e the starter. Snap off the ignition cable from the guide rail and remo e the guide rail. See gure 7. ig 7 Knock out a few of the pins in the tool if it does not match up with the ywheel.

  • Page 29: Assembling The Ignition Module And Ywheel

    Repair nstructions 7.7 Assembling the ignition module and flywheel Run the cables through the opening in the crank- case. Screw the earth cable in place. See gure 11. it the cabling to the stop button. Position the cable channel as outlined in gure 10. N TE Take care that the cable channel is posi- tioned correctly under the ignition module so that the cables are not crushed.

  • Page 30: Ismantling The Centrifugal Clutch

    Repair nstructions 7.8 Dismantling the centrifugal clutch Remo e the cylinder co er. Release the brake by mo ing the kickback guard backwards. Loosen the bar nuts and remo e the clutch co er, chain and bar. See gure 14. ig 14 Loosen the spark plug hat and remo e the spark plug, and insert the plastic piston stop...

  • Page 31: Assemby Of Centrifugal Clutch

    Repair nstructions 7.9 Assembly of centrifugal clutch nsert the clutch springs on the side of the shoes without te t. See gure 17. Screw in the clutch anti-clockwise until it stops. Then tighten the clutch using tool 575 25 14-01 ig 17 and a suitable socket wrench or combination span- ner.

  • Page 32: Assembling The Oil Pump And Screen

    Repair nstructions 7.11 Assembling the oil pump and screen Lower the oil lter in place and replace the oil pump as outlined in gure 19 and tighten the screws. it the pump dri e wheel, the needle bearing, the dri e sprocket, the clutch drum and the clutch, us- ing a tightening torque of 25 Nm.
  • Page 33 Repair nstructions ismantle the air lter, the lter holder, the cable from the intake ange holder and the carburettor and the throttle cable as outlined in ismantling the carburettor . N TE The lug on the carburettor sits on the bracket on the partition wall. ig 24 Hook off the cabling from the holder on the intake system...

  • Page 34: Carburettor

    Repair nstructions 7.14 Carburettor 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. Description The gures accompanying this description do not correspond with the carburettor on the chain saw.
  • Page 35 Repair nstructions Function The carburettor operates differently in the following modes: Cold start mode dling mode Part throttle mode ull throttle mode n cold start mode the choke al e H is completely shut. This increases the acuum in the carburettor and fuel is easier to suck from all the diffuser ets , E, and .
  • Page 36 Repair nstructions Dismantling the carburettor ismantle the cylinder co er and the air lter. Loosen the screws, . Unhook the rubber attach- ment G on both sides. See igure 35. Loosen the suction hose A, the return hose , and the tank bleeding hose C.
  • Page 37 Repair nstructions ismantle the pump co er H and carefully remo e the control diaphragm and gasket K. Unscrew screw P and remo e needle al e M with le er arm , shaft L and spring R. Use a needle or similar de ice and carefully pull up the fuel screen W .
  • Page 38 Repair nstructions Assembly Cleaning and inspection bser e cleanliness when assembling the car- Clean all units in clean petrol. burettor. The slightest contamination can result in downtime. Use compressed air to dry the petrol on the com- ponents. irect the air through all channels in the 1.
  • Page 39 Repair nstructions 4. Assemble needle al e M with le er arm shaft L and spring R, and tighten screw P. it the e pansion washer . See gure 40. ig 40 5. Check using a ruler or the like that the le er is le el with the assembly plane on the co er.
  • Page 40 Repair nstructions Pressure testing the carburettor Pressure testing should be carried out with the car- burettor fully assembled. Testing should always be carried out after the carburettor has been repaired, but a test can also be made for troubleshooting before dismantling. ption 1 See the gure and carry out the check as follows: Connect pressure tester to the carburettor fuel inlet.
  • Page 41 Repair nstructions Make sure the cabling is tted to its mounting on the intake ange. Press the fuel hose 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 mounting on the intake system.

  • Page 42: Tank Unit

    Repair nstructions 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. Can cause skin irritation. Is highly inflammable. Dismantling rain the fuel from the tank. 2.

  • Page 43: Vibration Damping System

    Repair nstructions Assembly 1. Thread the throttle cables in the connection M as outlined in gure 55. N TE The gure is shown from underneath. 2. Run the fuel hose through hole K and hoses 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.

  • Page 44: Replacing The Fuel Lter

    Repair nstructions 7.18 Replacing the fuel filter NOTE! Fluted pliers may not be used with the fuel hose. They can cause material damage resulting in damage to the fuel hose. When replacing the fuel lter, the old fuel lter must be taken out of the tank unit using special tool 502 50 83-01.

  • Page 45: Ismantling The Piston And Cylinder

    Repair nstructions 7.21 Dismantling the piston and cylinder ismantle: The cylinder co er The carburettor see ismantling the carburettor The muf er The ibration element The spark plug cap The intake system Unscrew the cylinder s four screws and carefully lift away the cylinder and the gasket. See gure 60.
  • Page 46 Repair nstructions Check the following: That the cylinder s surface coating is not worn. Especially the upper part of the cylinder. That the cylinder does not ha e any chafe or cutting marks. That the piston is free of score marks. Minor scratches can be polished off using ne emery paper.

  • Page 47: Assembling The Piston And Cylinder

    Repair nstructions Faults and causes Score marks on the piston (A) 1. Leakage, check not carried out. 2. Too low octane fuel. 3. Too low or incorrect oil in the fuel. Carbon build-up (B) 1. Too much or incorrect oil in the fuel. See igure 63.

  • Page 48: Pressure Testing The Cylinder

    Repair nstructions 7.23 Pressure testing the cylinder Loosen The cylinder co er The carburettor Attach the co er plate 574 71 14-01 and plug 574 70 12-01. See gure 66. ig 66a Loosen the screws on the muf er and press the co er plate 575 29 05-01 between the muf er and cylinder.

  • Page 49: Ismantling The Crankshaft And Crankcase

    Repair nstructions 7.24 Dismantling the crankshaft and crankcase ismantle the following: The clutch co er The chain and bar. The centrifugal clutch The cylinder co er The starter The ywheel The carburettor The bottom of the carburettor The hand guard The muf er The handle system The fuel unit...
  • Page 50 Repair nstructions f required, remo e the crankshaft bearing from the crankcase. Proceed as follows: A. Remo e the oil re ll cap. . Heat up the crankcase half in question to 200 C. C. Use protecti e glo es. Press the bearing out of the crankcase half.
  • Page 51 Repair nstructions Assembly WARNING! Beware of burn injuries as the crankcase halves are hot. Wear protective gloves. Proceed as follows if a bearing must be tted: A. Heat up the crankcase half in question to 200 C. . Use protecti e glo es. it the bearing in the ig 76 ywheel side of the crankcase half.
  • Page 52 Repair nstructions Assemble the following parts: A. Tank unit. See page 43. . Piston and cylinder. See page 47. C. Muf er. See page 19. . Carburettor. See page 40. E. Centrifugal clutch. See page 31. . Electrical System. See page 29. G.

  • Page 53: Assembling The Complete Crankshaft

    Repair nstructions 7.25 Assembling a complete crankshaft it the complete crankshaft in the crankcase. it 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 starter The cylinder co er...

  • Page 54: Replacing The Bar Bolt

    Repair nstructions 7.26 Replacing the bar bolt Replacing a bar bolt with intact crankcase Empty the oil tank. Knock in the old bar bolts from the outside so that they end up in the oil tank. Remo e the bolts from the oil tank. Attach a wire to the head of the bar bolt, lower the wire through the oil tank and out through the bolt opening in the crankcase.
  • Page 55 English -...
  • Page 56 Troubleshooting 8 Troubleshooting Contents Troubleshooting ......................57 Troubleshooting methods ....................58 - English...
  • Page 57 Troubleshooting 8.1 Troubleshooting The different faults which may occur on the chain saw are di ided into four groups. Within each group possible operating faults are listed to the left while the probable fault alternati es are listed to the right. The most likely fault is listed rst, etc.
  • Page 58 Troubleshooting High speed Acceleration and retardation oes not locked air lter Will not run locked air lter at full throttle Tank enting clogged accelerate Tank enting clogged locked fuel lter locked fuel lter locked fuel line locked fuel line Loose or faulty fuel pipe Loose or faulty fuel pipe locked impulse channel mpulse channel leaking...
  • Page 59 • 115 26 56-26 2011W31...

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