Husqvarna TrioBrake 550XPG Workshop Manual
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Husqvarna TrioBrake 550XPG Workshop Manual

Husqvarna TrioBrake 550XPG Workshop Manual

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Workshop Manual
545, 545 TrioBrake
550XP, 550XP TrioBrake
550XPG, 550XPG TrioBrake
English

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Summary of Contents for Husqvarna TrioBrake 550XPG

  • Page 1 Workshop Manual 545, 545 TrioBrake 550XP, 550XP TrioBrake 550XPG, 550XPG TrioBrake English...
  • Page 3 Service data ..................14 Safety equipment ..............18 Repair instructions ..............29 Carburettor ..................38 Troubleshooting .................66 Husqvarna AB has a policy of continuous product development and therefore reserves the right to modify the design and appearance of products without prior notice. English -...
  • Page 4 Index Index Bar bolt 65 Muffler 23 Replacing the bar bolt 65 Assembling the muffler 23 Dismantling the muffler 23 Carburettor 38 Assembly 42 Oil pump and screen 35 Cleaning and inspection 42 Assembling the oil pump and screen 36 Design 38 Cleaning and inspection 35 Dismantling 40...
  • Page 5 Index Assembly 47 Cleaning and inspection 47 Dismantling 47 English -...
  • Page 6 Introduction and safety instructions 2 Introduction and safety regulations Contents General ..................................7 Safety .....................................7 Target group ................................7 Modifications ................................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 Introduction 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 hazardous properties: accordance with local regulations.
  • Page 9 Introduction 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 injury Choke Lever when the instructions are not followed. Use protective gloves. Refuelling Use protective goggles.
  • Page 10 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 545: 50,1 / 3.06 43 / 1.69 34,5 / 1.36 2.5 / 3,4 / 9 600 545 TB: 50,1 / 3.06 43 / 1.69 34,5 / 1.36 2.5 / 3,4 / 9 600...
  • Page 11 Technical data Engage speed Spark plug Type of oil pump 545: 4 200 NGK CMR6H Adjustable 545 TB: 4 200 NGK CMR6H Adjustable 550XP: 4 200 NGK CMR6H Adjustable 550XP TB: 4 200 NGK CMR6H Adjustable 550XPG: 4 200 NGK CMR6H Adjustable 550XPG TB: 4 200...
  • Page 12 Service tools 4 Service tools 4 mm 4 mm 5 mm - English...
  • Page 13 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 14 Service data - Allen screws 5 Service data - Allen 18-20Nm 16mm 1,5-2Nm 4mm 12-14Nm 13mm 8-10Nm 4mm 1-2Nm 16-20Nm 5mm 5-6Nm 4mm 14-16Nm 5mm 4-5Nm 4mm 1-2Nm 15Nm 13mm 25Nm The numbers by the components to be assembled with screws state the tightening torque in Nm.
  • Page 15 Service data - Allen screws 9-11Nm 4mm 1-2Nm 7-9Nm 4mm 9-11Nm 4mm 3-4Nm 4mm 22-25Nm 13mm 6-8Nm 4mm 6-8Nm 4mm 4-5Nm 4mm 3-4Nm 4mm 7-9Nm 4mm 3,5-4,5Nm 4mm 3,5-4,5Nm 4mm 3,5-4,5Nm 4mm 3-4Nm 4mm English -...
  • Page 16 Service data - Torx screws 5 Service data - Torx 1,5-2Nm 18-20Nm 16mm 8-10Nm 12-14 Nm 13mm 1-2Nm 16-20Nm 5-6Nm 14-16Nm 4-5Nm 1-2Nm 15Nm 13mm 25Nm The numbers by the components to be assembled with screws state the tightening 1- Nm torque in Nm.
  • Page 17 Service data - Torx screws - Nm 1-2Nm 7-9Nm - Nm - Nm - Nm - Nm 22-25Nm 13mm - Nm - Nm - Nm - Nm - Nm 7-9Nm - Nm - Nm - Nm English -...

  • Page 18: Table Of Contents

    Safety equipment 6 Safety equipment Contents Dismantling the chain brake ..........................19 Assembling the chain brake ..........................20 Dismantling the right-hand brake trigger .......................21 Assembling the right-hand brake trigger ......................23 Dismantling the muffler ............................23 Assembling the muffler ............................23 Replacing the chain catcher ..........................24 Dismantling the start/stop control ........................24 Assembling the start/stop control ........................25 6.10 Resistance test - stop function ..........................25...

  • Page 19: Dismantling The Chain Brake

    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. Loosen the bar nuts and remove the clutch cover, Fig 1 bar and chain, see fig. 1. Alt.

  • Page 20: Assembling The Chain Brake

    Safety equipment 6.2 Assembling the chain brake Screw the knee joint and the brake band together (see figure 5) using a tightening torque of 1-1.5 Nm. Place the knee joint with the fitted chain brake band in the opening in the clutch cover. The space for the spring in the cover must be lubricated with grease.

  • Page 21: Dismantling The Right-Hand Brake Trigger

    Safety equipment NOTE! After repairing, the chain brake must be in- spected in line with the instruction below. 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 shown in the table above.
  • Page 22 Safety equipment Loosen the movement limiter E. Loosen the screw F and remove the cover. See figure 3. Fig 3 Loosen the screws H to release the brake cable. Pull back the rubber casing and loosen the screw G. See figure 4 Fig 4 Detach the right-hand brake trigger from its mount on the rear handle.

  • Page 23: Assembling The Right-Hand Brake Trigger

    Safety equipment 6.4 Assembling the right-hand brake trigger (545 TrioBrake, 550 XP TrioBrake, 550 XPG TrioBrake) Reattach the right-hand brake trigger in its mount on the rear handle and tighten screw G. Reposition the brake cable in its track and tighten screws H See figure 5 and 4.

  • Page 24: Replacing The Chain Catcher

    Safety equipment 6.6 Assembling the muffler If the saw is fitted with a spark arrestor mesh, put it in place first. When fitting the mesh, make sure that the mesh is inserted in the right position. If necessary, use the combination spanner to insert the mesh.

  • Page 25: Assembling The Start/Stop Control

    Safety equipment 6.9 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.

  • Page 26: 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 27: Assembling The Throttle Control Lock, Throttle Control And Spring

    Safety equipment 6.12 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.
  • Page 28 Repair Instructions 7 Repair instructions Contents Dismantling the starter ............................29 Replacing a broken or worn starter cord ......................30 Tensioning the return spring ..........................30 Replacing a broken return spring ........................31 Starter assembly .................................31 Dismantling the ignition module and flywheel .....................32 Assembling the ignition module and flywheel ....................33 Dismantling the centrifugal clutch ........................34 Assemby of centrifugal clutch ..........................35 7.10 Dismantling the oil pump and screen .......................35...

  • Page 29: 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. See figure 1a Fig 1a Pull the cord out about 30 cm and lift it into the notch on the outside of the starter pulley.

  • Page 30: 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 31: Replacing A Broken Return Spring

    Repair Instructions 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. Remove the clip in the centre of the pulley. Remove the spacer and the pulley. See figure 3a. Remove the broken cassette and replace it with a new one.

  • Page 32: Dismantling The Ignition Module And Flywheel

    Repair Instructions 7.6 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. Fig 7 Knock out a few of the pins in the tool if it does not match up with the flywheel.

  • Page 33: Assembling The Ignition Module And Flywheel

    Repair Instructions 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 figure 11. Fit the cabling to the stop button. Position the cable channel as outlined in figure 11. NOTE! Take care that the cable channel is posi- tioned correctly under the ignition module so that the cables are not crushed.

  • Page 34: Dismantling The Centrifugal Clutch

    Repair Instructions 7.8 Dismantling the centrifugal clutch 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 Loosen the spark plug hat and remove the spark plug, and insert the plastic piston stop (575 29 36-01).

  • Page 35: Assemby Of Centrifugal Clutch

    Repair Instructions 7.9 Assembly of centrifugal clutch Insert the clutch springs on the side of the shoes without text. See figure 17. Screw in the clutch (anti-clockwise) until it stops. Then tighten the clutch using tool 502 54 16-02 and a suitable socket wrench or combination spanner.

  • Page 36: Assembling The Oil Pump And Screen

    Repair Instructions 7.11 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, us- ing a tightening torque of 25 Nm.
  • Page 37 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”. Fig 24 Hook off the cabling H from the holder on the intake system.

  • Page 38: Assembling The Intake System

    Dismantle the intake system. Pull up and then out- ward. See figure 26. 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. Fig 25b Fig 26 7.13 Assembling the intake system...

  • Page 39: Carburettor

    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 figures accompanying this description do not correspond with the carburettor on the chain saw.
  • Page 40 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 F.
  • Page 41 Repair Instructions Dismantling the carburettor Dismantle the cylinder cover and the air filter. Loosen the screws E. Unhook the rubber attach- ment 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 for loosening the hoses.
  • Page 42 Repair Instructions Use a small flat screwdriver to snap open the con- nector 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 Alternative 1;...
  • Page 43 Repair Instructions Alternative 2; AT-12 carburettor Dismantle the metering cover G and carefully remove the gasket H, diaphragm I, spiral J and gasket K.See figure 39. Unscrew screw N and remove needle valve M with lever arm O, shaft L and spring P. See figure 39. To access the pump diaphragm and the inlet screen, first remove the air throttle housing from the pump cover by unscrewing the two screws Z.
  • Page 44 Cleaning and inspection Assembly Clean all units in clean petrol. Observe cleanliness when assembling the car- burettor. The slightest contamination can result in Use compressed air to dry the petrol on the com- downtime. ponents. Direct the air through all channels in the carburettor housing and ensure that they are not 1.
  • Page 45 Assemble needle valve M with lever arm O, shaft L and spring P, and tighten screw N. (Fit the expansion washer). See figure 41. Fig 41 6. Check, using a ruler or the like, that the lever O is 0.66 mm under the plane of the gasket sur- face for AT-7 carburettors, or 0.55 mm over the plane of the gasket surface for AT-12 carburet- tors.
  • Page 46 Repair Instructions Alternativ 1, AT-7 carburettor 7. Fit gasket I, the control membrane H and the metering cover G. See figure 43. 8. Carry out a pressure test. Fig 43 Alternativ 2, AT-12 carburettor 7. Fit the gasket K, spiral J, diaphragm I, gasket H. and the metering cover G .
  • Page 47 Repair Instructions 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. Option 1 See the figure and carry out the check as follows: Connect pressure tester to the carburettor fuel inlet.
  • Page 48 Repair Instructions Fitting on the saw Press the connector together as outlined in figure 46 and push it into place in the holder. Fig 46 Make sure the cabling is fitted to its mounting on Fig 47 the intake flange. Press the fuel hose in place in the collar on the intake bellows.
  • Page 49 Repair Instructions Fig 49 Position the guide taps on the air filter holder in the rubber grommets, F. See figure 50. Fig 50 Hook on the throttle cable E. See figure 48. Fasten the return hose B and secure it in its mount- ings on the air filter holder.

  • Page 50: Tank Unit

    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. Can cause skin irritation. Is highly inflammable. Dismantling 1. Drain the fuel from the tank. 2.

  • Page 51: Vibration Damping System

    Repair Instructions Assembly 1. Thread the throttle cables in the connection K as outlined in figure 57. NOTE! The figure is shown from underneath. 2. Run the fuel hose C through hole I and hoses B in hole J. See figure 57. Pull the hoses so that the collars are on each side of the bottom on the carburettor compartment.

  • Page 52: Replacing The Fuel Filter

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

  • Page 53: Heated Handles And Carburettor Heating

    Repair Instructions 7.21 Handle heater and carburettor heater (550XPG, 550XPG TrioBrake) Certain chain saw models can be fitted with a han- dle heater and a carburettor heater and comprise the following: • Generator • Power switch • Heating element in the rear handle •...
  • Page 54 Repair Instructions Carefully remove the power switch using a flat screwdriver or similar tool. See Figure 4 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. Carry out a resistance test according to step 2.
  • Page 55 Repair Instructions 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 Troubleshooting the heating element, front...
  • Page 56 Repair Instructions Troubleshooting the carburettor’s heating ele- ment 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 57 Repair Instructions 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. ” Fig 13 Loosen the screws to the generator without remov- ing it.
  • Page 58 Repair Instructions 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.
  • Page 59 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 60: Dismantling The Piston And Cylinder

    Repair Instructions 7.22 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 61 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 62: 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 63: Pressure Testing The Cylinder

    Repair Instructions 7.24 Pressure testing the cylinder Loosen • The cylinder cover • The carburettor Attach the cover plate 574 71 14-01 and plug 578 02 13-01. See figure 66a. Fig 66a Loosen the screws on the muffler and press the cover plate 578 04 18-01 between the muffler and cylinder.

  • Page 64: Dismantling The Crankshaft And Crankcase

    Repair Instructions 7.25 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 65 Repair Instructions 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 If the crankshaft bearings are still attached to the crankshaft when dismantling, pull them off using...

  • Page 66: Assembly Of Crankshaft Bearings

    Repair Instructions 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. B. Use protective gloves. When fitting the bearing in Fig 76 the crunkcase half the bearing must be fitted to the stop in the crankcase.

  • Page 67: 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. 7.27 Assembly of sealing rings To replace the crankshaft’s sealing rings, first dis- mantle the following parts: On the flywheel side: •...

  • Page 68: Assembling The Complete Crankshaft

    Repair Instructions 7.26 Assembling a complete crankshaft Fit the complete crankshaft in the crankcase. Fit the following parts: • The piston and cylinder * • The fuel unit * • The handle system * • The muffler * • The hand guard * •...

  • Page 69: Replacing The Bar Bolt

    Repair Instructions 7.27 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. Remove 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 70 Troubleshooting 8 Troubleshooting Contents Troubleshooting ................................71 Troubleshooting methods .............................72 - English...
  • Page 71 Troubleshooting 8.1 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. See separate instruction for Autotune troubleshooting. Starting Idling (low speed) (continued) Difficult to start...
  • Page 72 Troubleshooting High speed Acceleration and retardation Does not Blocked air filter Will not run Blocked air filter accelerate Tank venting clogged at full throttle 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 74 • 115 49 42-26 2018W32...

This manual is also suitable for:

Triobrake 550xpTriobrake 545Triobrake 545 tbTriobrake 550xp tbTriobrake 550xpg tb

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