Husqvarna 122 HD60 Workshop Manual
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Husqvarna 122 HD60 Workshop Manual

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See also: Operator's Manual
Workshop manual
122 HD45, 122 HD60
English

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Summary of Contents for Husqvarna 122 HD60

  • Page 1 Workshop manual 122 HD45, 122 HD60 English...

  • Page 3: Table Of Contents

    Starter Workshop Manual Hedge trimmer Model 122 HD45, 122 HD60 Contents General recommendations ___________________ 2 1. Starter _________________________________ 3 2. Electrical system _________________________ 7 3. Fuel system ____________________________ 13 4. Centrifugal clutch ________________________ 25 5. Cutting deck ___________________________ 29 6. Cylinder and piston ______________________ 33 7.

  • Page 4: Special Tools

    Operator’s Manual. The assembly of other equipment or accessories or spare parts not approved by Husqvarna can Special tools result in the failure to meet these safety demands and that Some of the work described in the Workshop Manual the person carrying out assembly bears responsibility for this.
  • Page 5 Starter Starter Contents Dismantling ___________________________________ 4 Assembly ____________________________________ 5 Replacing the drive _____________________________ 6...
  • Page 6 Starter WARNING! Protective glasses should be worn when working on the starter to avoid injury to the eyes if, for some reason, the return spring should fl y out. Dismantling Dismantling Remove the 4 bolts and lift off the starter. Loosen the four screws and remove the starter.
  • Page 7 Starter Assembly Assembly Fit the recoil spring in the starter pulley. If the return spring has, despite all the precautions, fl own out or if you intend to fi t Place the extension spring exactly above a new spring proceed as follows: the groove in the starter pulley.

  • Page 8: Starter

    Starter Lubricate the recoil spring and the starter Lubricate the return spring and the starter pulley’s stub axle with cold resistant pulley’s stub axle with cold resistant grease or thin oil. grease or thin oil. Insert the starter pulley in position. Move the starter cord through the guide in the starter housing (A).

  • Page 9: Electrical System

    Electrical system Electrical system Contents Checking the ignition spark _____________________ Dismantling _________________________________ 11 Drive dogs __________________________________ 12 Assembly ___________________________________ 12...

  • Page 10: Checking The Ignition Spark

    Electrical system The engine is equipped with an electronic ignition system completely without moving parts. Consequently, a faulty component cannot be repaired, but must be replaced by a new component. The spark in an electronic ignition system has a very short burn time and can therefore be interpreted as weak and can be diffi...
  • Page 11 Electrical system If there is no spark, disconnect the short- If there is still no spark, separate the circuit contact . short-circuit cable located in the cable holder under the fuel tank on the left hand Replace the contact if required. side.
  • Page 12 Electrical system Still no spark? Still no spark? Dismantle the cylinder cover and guard Dismantle the cylinder cover and guard over the muffl er. over the muffl er. 502 71 27-02 Check other cables and connections. Check other cables and connections for poor contacts (dirt, corrosion, cable brea- kage and damaged insulation).

  • Page 13: Dismantling

    Electrical system Dismantling Dismantling First dismantle the following: Dismantle the following parts to access the ignition system: The starter cover, the spark plug and the protective cover over the muffl er. The starter cover, the spark plug and the protective cover over the muffl er. Prise off the cable (A) from the ignition module.

  • Page 14: Drive Dogs

    Electrical system Drive dogs Drive dogs Dismantle the lock washer (A) with the The fl ywheel must fi rst be dismantled from help of a screwdriver. the crankshaft to replace the drive dogs. This deforms the washer and must Remove the locking washer (A) using a be replaced with a new one when screwdriver.
  • Page 15 Fuel system Fuel system Contents Air fi lter _____________________________________ 14 Tank venting _________________________________ 14 Fuel fi lter ____________________________________ 15 Carburettor __________________________________ 16 Assembly ____________________________________ 19 Carburettor settings ____________________________ 19 Throttle handle ________________________________ 20 Trouble Shooting Guide _________________________ 23...

  • Page 16: Air Fi Lter

    Do not clean not the fi lter with petrol. Hazardous! TIP! 505 69 85-70 Use Husqvarna’s cleaning agent Active Cleaning no. 505 69 85-70. Impregnate the fi lter with air fi lter oil. Impregnate the fi lter with air fi lter oil.

  • Page 17: Fuel Fi Lter

    Fuel system The fuel cap can be taken apart for cleaning. Use a screwdriver and prise off the housing (A). Remove the nipple (B) using a small fl at nosed pliers. Blow the bleeding opening in the house (A) clean with compressed air. Blow clean both sintered fi...

  • Page 18: Carburettor

    Fuel system Carburettor Carburettor Dismantling Dismantling Remove the air fi lter cover and the air fi lter 1. Remove the air fi lter cover and the air as well as the return fuel hose from the fi lter. carburettor. 2. Remove the return fuel hose (A). Remove the screws (B) and the air fi...
  • Page 19 Fuel system Remove the 4 screws (A). Dismantle the fuel pump’s diaphragm and the valve housing. Now lift off the fuel pump’s diaphragm (B) and the valve housing (C). NOTE! Make note of the location of both short screws to avoid the locking of the throttle and the choke shafts.

  • Page 20: Fuel System

    Fuel system Lift up the non-return valve (C) and check Carefully lift up non-return valve (A) using that the seals are intact. your nails. Clean the valve housing. Clean the valve housing and check that the channels are open. Check that the non return valve’s seals (B) are undamaged by carefully squeezing the short sides together.

  • Page 21: Assembly

    Fuel system Assembly Assembly Check the distance piece for cracks. Inspect the distance piece (A) for cracks that can cause starting problems and A defective distance piece must be negative idling. Check also that the replaced. impulse channel (B) is open and not Make sure that the impulse channel is completely or partly blocked with grease, entirely open.

  • Page 22: Throttle Handle

    Fuel system Throttle handle Gashandtag Remove the cover over the throttle cable 1. Remove the cover over the throttle guide by the carburettor. cable guide by the carburettor. Dismantle the throttle cable. 2. Dismantle the throttle cable from the carburettor. Separate the short-circuit cables and remove the screws (A).
  • Page 23 Fuel system Prise up the locking tab (D) using a small Prise up the locking tab and pull off the screwdriver. handle. Then pull off the twistable handle from the handle mounting. Inspect the rubber sleeves (E) and the Inspect the rubber sleeves (E) and the O-ring (F) for wear and damage.
  • Page 24 Fuel system Lift off the lock preventing unintentional full throttle (A). Remove the catch (B) for the twistable handle and its spring (C). Remove the throttle lever (D). Note how this recoil spring is tensioned. Prise off the ignition switch (E) using a small screwdriver.

  • Page 25: Trouble Shooting Guide

    Fuel system Trouble Shooting Guide Symptom Starting Low speed Acceleration/ Deceleration Probable causes Stop screw for the throttle not working ● ● ● ● Fuel tank/hose Fuel fi lter blocked ● ● ● ● ● ● ● ● ● ● ●...
  • Page 26 Fuel system...

  • Page 27: Centrifugal Clutch

    Centrifugal clutch Centrifugal clutch Contents Centrifugal clutch, dismantling ___________________ 26 Centrifugal clutch, assembling ___________________ 27 Clutch drum _________________________________ 27...
  • Page 28 Centrifugal clutch The centrifugal clutch has the task of transferring the power from the engine to the cutting equipment’s drive axle. As the name implies, it works according to a centrifugal principle. This means the clutch’s friction shoes are thrown outwards towards the clutch drum at a certain engine speed.
  • Page 29 Centrifugal clutch Dismantle the clutch shoes from the hub. Dismantle the clutch shoes from the hub using a small screwdriver or a pointed tool by fi rst unhooking the clutch springs. Assembly Check that the clutch springs are not Assembly damaged, e.g.
  • Page 30 Centrifugal clutch Check the inside diameter of the clutch Check the clutch drum for wear. drum. If it exceeds 55,0 mm it should be The diameter must not exceed 55,0 mm. If replaced. this is the case replace the clutch drum. Assemble the different components in the Assemble the different components in the reverse order as set out for dismantling.
  • Page 31 Cutting deck Cutting deck Contents Cutting deck, disassembly _____________________ 30 Cutting deck, assembly ________________________ 31...
  • Page 32 Cutting deck Cutting deck Dismantling Unscrew the spark plug. Unhook the throttle cable from the carburettor and separate the connections to the short-circuit cable. Remove the 2 screws holding the front handle. Lift out the engine and the fi tted cutting deck.
  • Page 33 Cutting deck Lift off the following parts: 1. Wear plate (A). 2. Connecting rod (B). 3. Sprocket (C). 4. Screws (D). 5. Bracket (E). 6. Cutting knives (F). 505 38 13-08 Continue removing the following parts: 7. Lower connecting rod (G). 8.
  • Page 34 Cutting deck...
  • Page 35 Cylinder and piston Cylinder and piston Contents Dismantling __________________________________ 34 Cleaning, inspection ___________________________ 35 Analysis and actions __________________________ 36 Service tips _________________________________ 40 Wear tolerances _____________________________ 41 Assembly __________________________________ 41...

  • Page 36: Dismantling

    Cylinder and piston The cylinder and the piston are two of the components exposed to most strain in the engine. They must withstand, for example, high speeds, large temperature swings and high pressure. Moreover, they must be resistant to wear. Despite these tough working conditions, major piston and cylinder failure is relatively uncommon.

  • Page 37: Cleaning, Inspection

    Cylinder and piston Remove the circlips from the gudgeon pin. Remove the circlips on the gudgeon pin using a small fl at nosed pliers. Keep your thumb over the circlip to prevent it from fl ying out. Dismantle the piston from the connecting Push the gudgeon pin from the piston rod.

  • Page 38: Analysis And Actions

    Blocked spark arrestor mesh in the Clean or replace the spark arrestor mesh. muffl er. For the best results we recommend Husqvarna two-stroke oil or ready-mixed fuel that is specially developed for air-cooled two-stroke engines. Mixing ratio: 1:50 (2%). If Husqvarna two-stroke oil is not available another good quality two-stroke oil can be used.
  • Page 39 Cylinder and piston Piston scoring caused by heavy carbon deposits Too heavy carbon depositing can cause damage similar to that caused by insuffi cient lubrication. However, the piston skirt has a darker colour caused by the hot combustion gases that are blown past the piston. This type of piston damage starts at the exhaust port where carbon deposits can become loose and get trapped between the piston and the cylinder wall.

  • Page 40: Cylinder And Piston

    Cylinder and piston The guide pin for the piston ring has been Deep, irregular grooves caused by a loose Irregular grooves on the piston’s inlet side pushed up through the top of piston. circlip. Shown here on the piston’s inlet side. caused by a broken roller retainer.
  • Page 41 Cylinder and piston Cause: Action: • Faulty air fi lter. Small dust particles Fit a fi ner grade fi lter. pass through the fi lter. • The fi lter is worn out due to too much Check the fi lter carefully for holes and cleaning, whereby small holes have damage after cleaning.

  • Page 42: Service Tips

    Cylinder and piston Larger, harder particles that enter the engine cause serious damage to the underside of the piston skirt. Cause: Action: • Air fi lter damaged or missing. Fit a new air fi lter. • Parts from the carburettor or intake Regular service and inspection.

  • Page 43: Wear Tolerances

    Cylinder and piston Wear tolerances Piston ring gap Piston ring groove Piston ring play Cylinder bore When the surface coating is Max. 1.0 mm with the piston Max. 1.6 mm. Clean the Max. 0.15 mm. Clean the worn and aluminium appears. ring inserted in the lower part of groove before checking the groove before checking the...
  • Page 44 Cylinder and piston...
  • Page 45 Crankshaft and crankcase Crankshaft and crankcase Contents Dismantling ________________________________ 44 Inspecting the crankshaft ______________________ 45 Assembly _________________________________ 46...

  • Page 46: Crankshaft And Crankcase

    Crankshaft and crankcase The task of the crankshaft is to transform the reciprocating motion of the piston to rotation. This requires a stable design withstanding immense pressure and rotational and bending strain, as well as high rotational speed. In addition the connecting rod is exposed to large acceleration and retardation forces as it moves between the top and bottom dead centres.
  • Page 47 Crankshaft and crankcase Knock the crankcase half against a Knock the crankcase half against a wooden block so that the ball-bearing falls wooden block so that the ball-bearing falls out. out. Use a suitable punch and hammer if required. Dismantle the sealing rings from the crankcase halves.
  • Page 48 Crankshaft and crankcase Check the crank bearing. Check the crank bearing. The connecting rod shall not have any radial play (up and down). It should, however, have axial play, in order to ensure good lubrication of the crank bearing among other things. Assembly Assembly Mount the bearings in the crankcase...
  • Page 49 Crankshaft and crankcase Assemble the piston. Put the cylinder base gasket in place either in the crankcase or cylinder base. Attach the fl ywheel. Assemble the piston on the connecting rod. Tip! Fit both spacer washers between the piston and the needle bearing with a little grease to facilitate assembling.

  • Page 50: Crankshaft And Crankcase

    Crankshaft and crankcase...

  • Page 51: Tools

    List of tools Tools Contents Starter __________________________________ 50 Electrical system __________________________ 50 Fuel system ______________________________ 50 Centrifugal clutch __________________________ 51 Cutting deck _____________________________ 51 Cylinder and piston ________________________ 51 Crankshaft and crankcase ___________________ 51 Workshop equipment _______________________ 51...
  • Page 52 List of tools 502 50 18-01 521 54 83-01 505 69 85-70 502 51 91-01 501 60 02-03 502 71 27-02 502 71 13-01 531 00 60-76 530 03 55-60 502 50 06-01 531 03 06-23 502 50 83-01 502 71 27-02 502 71 27-02 502 51 34-02 502 71 14-01...
  • Page 53 List of tools 502 71 27-02 502 71 27-02 531 00 92-05 502 71 27-02 544 13 05-01 577 90 21-01 505 38 17-05 544 13 08-01 521 54 83-01 505 38 13-08 502 50 70-01 505 38 13-08 502 50 70-01 544 13 09-01 544 13 10-01 544 34 87-01...
  • Page 54 List of tools...

  • Page 55: Technical Data

    Technicel data Technical data Contents Engine __________________________________ 54 Ignition system ____________________________ 54 Carburettor ______________________________ 54 Clutch __________________________________ 54 Cutting equipment _________________________ 54 Dimensions ______________________________ 54...
  • Page 56 Technicel data Engine 122 HD45 122 HD60 Displacement, cm 21.7 21.7 Cylinder bore, mm 32.0 32.0 Stroke, mm 27.0 27.0 Engine output, kW / speed, rpm 0.6/6000 0.6/6000 Catalytic converter muffl er Ignition system Spark plug NGK BPMR 6Y NGK BPMR 6Y...
  • Page 58 115 43 47-26 2011W20...

This manual is also suitable for:

122 hd45

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