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Husqvarna 560XPG Workshop Manual

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Workshop Manual
555 556 560XP/XPG
562XP/XPG
English

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Summary of Contents for Husqvarna 560XPG

  • Page 1 Workshop Manual 555 556 560XP/XPG 562XP/XPG English...

  • Page 2: Table Of Contents

    7.36.1 Dismantle .................40 6.3.1 Functional inspection: ............14 7.36.2 Assembling ................40 6.4 Dismantling the muffler ..............14 7.38 Handle heater and carburettor heater (560XPG, 562XPG) 41 6.5 Cleaning and inspection ..............14 7.39 Troubleshooting ................41 6.6 Assembling the muffler ..............14 7.40.2 Troubleshooting the heating element, rear handle .43 7.40.1 Troubleshooting the heating element, front handle 43...

  • Page 3: Introduction And Safety Instructions

    Assembling in the order set out in the sections. service tools are listed in the Workshop Manual. Usage is made apparent in each section. Some sections include an introductory Description Always use Husqvarna’s original: of the actual unit in order to increase the basic • Spare parts understanding.

  • Page 4: General Instructions

    Introduction and safety instructions 1.8 General Instructions 1.9 Special Instructions The workshop where the chain saw is to be repaired The fuel used in the chain saw has the following must be equipped with safety equipment in hazardous properties: accordance with local regulations. No one may repair the chain saw unless they have •...

  • Page 5: Symbols

    Introduction and safety instructions 2 Symbols 2.2 Symbols in the Workshop Manual 2.1 Symbols on the saw The symbols below are embedded on the chain saw. Choke Lever This symbol warns of personal injury when the instructions are not followed. Use protective gloves.

  • Page 6: Technical Data

    Technical data 3 Technical data 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 / 9 600 556: 59,8 / 3.65 46 / 1.81 36 / 1.42 3.1 / 4.2 / 9 600...
  • Page 7 Technical data Engage speed Spark plug Automatic oil pump 555: 4 300 NGK CMR6H 556: 4 300 NGK CMR6H 560XP/XPG: 4 300 NGK CMR6H 562XP/XPG: 4 300 NGK CMR6H Volume fuel tank Capacity oil pump at Volume oil tank Litre/US. pint 9,000 rpm, Litre/US.

  • Page 8: Service Tools

    Service tools 4 Service tools 4 mm 4 mm 5 mm - English...
  • Page 9 Service tools Description Used for Order No. Piston stop Locking the crankshaft 575 29 36-01 Hook for fuel filter Suspending the fuel filter 502 50 83-01 Allen key, 4 mm For M5 bolts 502 50 87-01 Allen key, 4 mm For M5 bolts 502 50 18-01 Allen key, 5 mm...

  • Page 10: Service Data

    Service data 5 Service data 18-20Nm 16mm 12-14Nm 13mm 8-10Nm 4mm 1,5-2Nm 4mm 1-2Nm 16-20Nm 5mm 1-2Nm 14-16Nm 5mm 5-6Nm 4mm 4-5Nm 4mm 1-2Nm 11-13Nm 13mm The numbers by the components to be assembled with screws state the tightening torque in Nm. s = Lubricate using two-stroke oil.
  • Page 11 Service data 1-2Nm 7-9Nm 4mm 3-4Nm 4mm 9-11Nm 4mm 3-4Nm 4mm 22-25Nm 13mm 3-4Nm 4mm 9-11Nm 4mm 6-8Nm 4mm 3-4Nm 4mm 6-8Nm 4mm 2-3Nm 4mm 5-6Nm 4mm 3-4Nm 4mm 7-9Nm 4mm 8-10Nm 4mm 3,5-4Nm 4mm 5-6Nm 4mm English -...

  • Page 12: Safety Equipment

    Safety equipment 6 Safety equipment 6.1 Dismantling the chain brake Remove the cylinder cover. Release the brake by moving the front hand guard backward. Fig 1 Alt. 1 Loosen the bar nuts and remove the clutch cover, bar and chain, see fig. 1. Unscrew the kickback guard and remove it.

  • Page 13: Assembling The Chain Brake

    Safety equipment 6.3 Assembling the chain brake Screw the knee joint and the brake band together (see figure 5) using a tightening torque of 1-2 Nm. Place the knee joint with the fitted chain brake band in the opening in the clutch cover.

  • Page 14: Functional Inspection

    Safety equipment NOTE! After repairing, the chain brake must be inspected in line with the instruction below. 6.3.1 Functional inspection: Do not turn on the motor when carrying out this inspection. Bar length Height 15-20” 50 cm 21-28” 70 cm •...

  • Page 15: Replacing The Chain Catcher

    Safety equipment 6.7 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 moving the front hand guard backward. Loosen the bar nuts and remove the clutch cover, chain and bar.

  • Page 16: Assembling The Start/Stop Control

    Safety equipment 6.10 Assembling the start/stop control Fit the new stop control (A) and tighten screw (B) in place at a torque of 1 Nm. Slide in the stop control in the rubber sleeve C and hook the sleeve on the guide taps. See figure 15. Attach the cables as outlined in figure 16.

  • Page 17: Dismantling The Throttle Control Lock, Throttle Control And Spring

    Safety equipment 6.11 Dismantling the throttle control lock, throttle control and spring Loosen the screw on the rear handle. Remove the handle insert (A). See figure 19. Fig 19 Loosen the throttle control lock (B) as shown in the figure using a screwdriver or similar tool. Remove it then from the shaft in the handle.

  • Page 18: Assembling The Throttle Control Lock, Throttle Control And Spring

    Safety equipment 6.13 Assembling the throttle control lock, throttle control and spring 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 fitted as outlined in figure 24. NOTE! Make sure that the rear end of the throttle control is correctly aligned inside the cut-out edging before the pin is pressed in...

  • Page 19: Repair Instructions

    Repair Instructions 7 Repair instructions 7.1 Dismantling the starter Loosen the four screws, which hold the starter against the crankcase and remove 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 20: Replacing A Broken Or Worn Starter Cord

    Repair instructions 7.3 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 21: Replacing A Broken Return Spring

    Repair Instructions 7.6 Replacing a broken return spring WARNING! Exercise care to ensure the spring does not fly out and cause personal injury. Wear protective goggles. Loosen the screw at the centre of the starter pulley and loosen the screws on the cassette. Remove the starter pulley with the cassette and spring.

  • Page 22: Dismantling The Ignition Module And Flywheel

    Repair Instructions 7.8 Dismantling the ignition module and flywheel Remove the cylinder cover. Remove the starter. Snap off the ignition cable from the guide rail and remove the guide rail. See figure 7. Knock out a few of the pins in the tool if it does not match up with the flywheel.

  • Page 23: Assembling The Ignition Module And Flywheel

    Repair Instructions 7.10 Assembling the ignition module and flywheel Run the cables through the opening in the crankcase. Screw the earth cable in place. See figure 11. Fit the cabling to the stop button. Position the cable channel as outlined in figure 10.

  • Page 24: Dismantling The Centrifugal Clutch

    If the chainsaw is equipped with the Fig 15 previous style clutch, 574 23 61-04, Husqvarna recommends to change to the current style clutch, 587 89 92-01. Secure the clutch in a vice as shown in figure 16. Carefully remove the clutch springs.

  • Page 25: Assembly Of Centrifugal Clutch

    See chapter Service data. If the chainsaw is equipped with the previous style clutch, 574 23 61-04, Husqvarna recommends to change to the current style clutch, 587 89 92-01. Fig 18 Remove the piston stop and fit the spark plug using a tightening torque of 18-20 Nm and the spark plug hat.

  • Page 26: Assembling The Oil Pump And Screen

    Repair Instructions 7.16 Assembling the oil pump and screen Lower the oil filter in place and replace the oil pump as outlined in figure 19 and tighten the screws. Fit the pump drive wheel, the needle bearing, the drive sprocket, the clutch drum and the clutch, using a tightening torque of 25 Nm.
  • Page 27 Repair Instructions Dismantle the air filter, the filter holder, the cable from the intake flange holder and the carburettor and the throttle cable as outlined in “Dismantling the carburettor”. NOTE! The lug on the carburettor sits on the bracket on the partition wall. Fig 24 Hook off the cabling H from the holder on the intake system.

  • Page 28: Cleaning And Inspection

    5. Dismantle the intake system. Pull up and then outward. See figure 26. 7.19 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. 7.18 Assembling the intake system Assemble the intake system.

  • Page 29: Carburettor

    7.20 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. 7.20.1 Description The figures accompanying this description do not correspond with the carburettor on the chain saw.

  • Page 30: Function

    Repair Instructions 7.20.3 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 F.

  • Page 31: Dismantling The Carburettor

    Repair Instructions 7.21 Dismantling the carburettor Dismantle the cylinder cover and the air filter Loosen the screws, E Unhook the rubber attachment F on both sides. See Figure 35. Loosen the suction hose A and the return hose B. See figure 34. NOTE! Do not use any sharp tools to loosen the hoses.
  • Page 32 Repair Instructions Use a small flat screwdriver to snap open the connector from the black attachment. Separate the connector by pressing down the catch with a flat screwdriver and then pulling the unit apart. See figure 37 Fig 37 .Dismantle the metering cover G and carefully remove the control diaphragm H and gasket I.

  • Page 33: Cleaning And Inspection

    Repair Instructions 7.23 Assembly 7.22 Cleaning and inspection Observe cleanliness when assembling the Clean all units in clean petrol. carburettor. The slightest contamination can result in downtime. Use compressed air to dry the petrol on the 1. If throttle and choke valves with shafts, lever arms components.
  • Page 34 Repair Instructions 5. Assemble needle valve K with lever arm M, shaft J and spring N, and tighten screw L. (Fit the expansion washer). See figure 40. Fig 40 6. Check, using a ruler or the like. that the lever arm M is 0.05-0.25 mm under the plane of the gasket surface .

  • Page 35: Adjustment Of Autotune At Change Of Carburettor

    Repair Instructions 7.24 Adjustment of AutoTune at change of carburettor The chainsaw will be completely adjusted automatically after a few fuellings at normal running. - The high speed part is set during loaded running, such as cutting and felling. -The idle part is set when the chain saw idles for some time.

  • Page 36: Fitting On The Saw

    Repair Instructions 7.26 Fitting on the saw Press the connector together as outlined in figure 44 and push it into place in the holder.2 Fig 44 Fig 45 Make sure the cabling is fitted to its mounting on the intake flange. Press the fuel hose C in place in the collar on the intake bellows.
  • Page 37 Repair Instructions Position the guide taps on the air filter holder in the rubber grommets, G. See figure 48. Fig 47 Hook on the throttle cable, D. See figure 46. Fig 48 Fasten the return hose B and secure it in its mountings on the air filter holder.

  • Page 38: Tank Unit

    Repair Instructions 7.27 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. 7.28 Dismantling 1. Drain the fuel from the tank. 2.

  • Page 39: Assembly

    Repair Instructions 7.30 Assembly 1. Thread the throttle cables in the connection K as outlined in figure 55. NOTE! The figure is shown from underneath. 2. Run the fuel hose C through hole I and hoses B in hole J. See figure 55. Pull the hoses so that the collars are on each side of the bottom on the carburettor compartment.

  • Page 40: Replacing The Fuel Filter

    Repair Instructions 7.37 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 filter, the old fuel filter must be taken out of the tank unit using special tool 502 50 83-01.

  • Page 41: Handle Heater And Carburettor Heater (560Xpg, 562Xpg)

    Repair Instructions 7.38 Handle heater and carburettor heater (560XPG, 562XPG) Certain chain saw models can be fitted with a handle heater and a carburettor heater and comprise the following: • Generator • Power switch • Heating element in the rear handle •...
  • Page 42 Repair Instructions Carefully remove the power switch using a flat screwdriver or similar tool. See Figure Fig 4 Check that the contact plate in the power switch is intact and free of dirt and oxidation. See Figure 5. Clean and assemble the power switch.

  • Page 43: Troubleshooting The Heating Element, Rear Handle

    Repair Instructions 7.40.2 Troubleshooting the heating element, rear handle Connect the multimeter as outlined in Figure 7 and measure the resistance in rear handle’s heating element. The multimeter reading should indicate between 0.5 and 1.2 Ohm. Replace the heating element if you get another reading. 0.5 - 1.2 Fig 7 7.40.1 Troubleshooting the heating element,...

  • Page 44: Replacing The Front Handle

    Repair Instructions 7.39.2 Troubleshooting the carburettor’s heating element and thermostat Connect the multimeter as outlined in Figure 10. The measurement should be carried out at normal room temperature (20°C/68°F) and should indicate in that case 0 A. Cool the thermostat for instance with a coolant spray or a similar agent.

  • Page 45: Replacing The Generator

    Repair Instructions 7.42 Replacing the generator Dismantle the following parts: • Clutch cover • Bar and chain • Cylinder cover • Starter • Flywheel * * See the chapter “Dismantling the ignition module and flywheel.” Loosen the screws to the generator without Fig 13 removing it.

  • Page 46: Replacing The Carburettor's Heating Element And Thermostat

    Repair Instructions 7.43 Replacing the carburettor’s heating element and thermostat Remove the cylinder cover and air filter. Loosen the thermostat cable from the air filter holder as well as from the cabling in the front handle. Loosen the two screws holding the thermostat’s attachment bar and remove the thermostat.See Figure 15.
  • Page 47 Repair Instructions Fit the new heating element and make sure that no cables are pinched. See Figure 19. Connect the cable to the carburettor’s heating element as outlined in Figure 18. Fit the filter holder as outlined in Figure 17 and tighten screws F.

  • Page 48: Dismantling The Piston And Cylinder

    Repair Instructions 7.44 Dismantling the piston and cylinder Dismantle: • The cylinder cover • The carburettor (see “Dismantling the carburettor”) • The muffler • The vibration element • The spark plug cap • The intake system Unscrew the cylinder’s four screws and carefully lift away the cylinder and the gasket.
  • Page 49 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.

  • Page 50: Assembling The Piston And Cylinder

    Repair Instructions 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 Figure 63.

  • Page 51: Pressure Testing The Cylinder

    Repair Instructions 7.47 Pressure testing the cylinder Loosen • The cylinder cover • The carburettor Attach the cover plate 574 71 14-01 and plug 574 70 12-01. See figure 66. Fig 66a Loosen the screws on the muffler and press the cover plate 575 29 05-01 between the muffler and cylinder.

  • Page 52: Dismantling The Crankshaft And Crankcase

    Repair Instructions 7.48 Dismantling the crankshaft and crankcase Dismantle the following: • The clutch cover • The chain and bar. • The centrifugal clutch * • The cylinder cover • The starter * • The flywheel * • The carburettor * •...

  • Page 53: Dismantling Of Crankshaft Bearings

    Repair Instructions If the crankshaft bearing is assembled in the crankcase it must be revmoved 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.

  • Page 54: Assembly Of Crankshaft Bearings

    Repair Instructions 7.48.3 Assembly of crankshaft bearings WARNING! Beware of burn injuries as the crankcase halves are hot. Wear protective gloves. New bearings must be used. Proceed as follows: A. Heat up the crankcase half in question to 200°C. Fig 76 B.

  • Page 55: Assembly Of Sealing Rings

    Repair Instructions Assemble the following parts: A. Tank unit. B. Piston and cylinder. C. Muffler. D. Carburettor. E. Centrifugal clutch. F. Electrical System. G. Starter. H. Bar and chain. See the Operator’s Manual. 7.50 Assembly of sealing rings To replace the crankshaft’s sealing rings, first dismantle the following parts: On the flywheel side: •...

  • Page 56: Assembling

    Repair Instructions 7.51 Assembling Fit the following parts: • The piston and cylinder * • The fuel unit * • The handle system * • The muffler * • The hand guard * • The bottom of the carburettor * •...

  • Page 57: Repairing Damaged Threads

    Repair Instructions 7.53 Repairing damaged threads If threads on the chainsaw are worn, the reparation kit, 503 27 33-01, is available. First drill with: 6.1 mm drill for the magnesium crankcase Then screw in the thread plug using a suitable Fig 84 screw and wrench.

  • Page 58: Troubleshooting

    Troubleshooting 8 Troubleshooting The different faults which may occur on the chain saw are divided into four groups. Within each group possible operating faults are listed to the left while the probable fault alternatives are listed to the right. The most likely fault is listed first, etc.

  • Page 59: Troubleshooting Methods

    Troubleshooting High speed Acceleration and retardation Will not run Blocked air filter Does not Blocked air filter accelerate at full throttle Tank venting clogged Tank venting clogged Blocked fuel filter Blocked fuel filter Blocked fuel line Blocked fuel line Loose or faulty fuel pipe Loose or faulty fuel pipe Blocked impulse channel Impulse channel leaking...
  • Page 60 • 115 26 56-26 2016W43...

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