Husqvarna 555 XP Workshop Manual
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Husqvarna 555 XP Workshop Manual

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

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Summary of Contents for Husqvarna 555 XP

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

  • Page 3: Table Of Contents

    Safety equipment ..........16 Repair instructions ..........24 Carburettor ............34 Troubleshooting ........... 56 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 Index Bar bolt 54 Muffler 19 Assembling the muffler 19 Replacing the bar bolt 53 Dismantling the muffler 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 Design 34 Dismantling the oil pump and screen 31...
  • Page 5 Index Vibration damping system 43 Assembly 43 Cleaning and inspection 43 Dismantling 43 English -...

  • Page 6: Introduction And Safety Instructions

    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: Numbering

    Usage is made apparent in each section. Some sections include an introductory Descrip- tion of the actual unit in order to increase the basic understanding. Always use Husqvarna’s original: • Spare parts 2.7 Numbering • Service tools Position references to components inside the fig- •...

  • Page 8: Special Instructions

    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: Symbols On The Saw

    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. Refuelling Stop button Chain oil fill.

  • Page 10: 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 / 9600 560XP/XPG: 59,8 / 3.65 46 / 1.81 36 / 1.42 3.5 / 4.8 / 9600 562XP/XPG:...
  • 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 560XP/XPG:...

  • Page 12: Service Tools

    Service tools 4 Service tools 4 mm 4 mm 5 mm - English...
  • Page 13 Service tools Pos 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

    Service 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 Service 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: Safety Equipment

    Safety equipment 6 Safety equipment Contents Dismantling the chain brake ...................17 Assembling the chain brake ....................18 Dismantling the muffler ....................19 Assembling the muffler ....................19 Replacing the chain catcher ...................20 Dismantling the start/stop control ...................20 Assembling the start/stop control ..................21 Resistance test - stop function ..................21 Dismantling the throttle control lock, throttle control and spring ........22 6.10 Assembling the throttle control lock, throttle control and spring ........23...

  • Page 17: 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 18: 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 19: Dismantling The Muffler

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

  • Page 21: Assembling The Start/Stop Control

    Safety equipment 6.7 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 22: Dismantling 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. 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 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 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 24: Repair Instructions

    Repair Instructions 7 Repair instructions Contents Dismantling 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 Dismantling the ignition module and flywheel ..............28 Assembling the ignition module and flywheel ..............29 Dismantling the centrifugal clutch ...................30 Assemby of centrifugal clutch ..................31 7.10...

  • Page 25: 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 26: Cleaning And Inspection

    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 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. 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 28: Cleaning And Inspection

    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 29: 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 10. NOTE! Take care that the cable channel is posi- tioned correctly under the ignition module so that the cables are not crushed.

  • Page 30: Cleaning And Inspection

    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 31: Cleaning And Inspection

    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 575 25 14-01 Fig 17 and a suitable socket wrench or combination span- ner.

  • Page 32: 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 33 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 from the holder on the intake system (J).

  • Page 34: Carburettor

    Repair Instructions 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 35 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 36 Repair Instructions Dismantling the carburettor Dismantle the cylinder cover and the air filter. Loosen the screws, F. Unhook the rubber attach- ment G on both sides. See Figure 35. Loosen the suction hose A, the return hose B, and the tank bleeding hose C. See figure 34. Fig 34 Remove the air filter holder.
  • Page 37 Repair Instructions Dismantle the pump cover H and carefully remove the control diaphragm J and gasket K. Unscrew screw P and remove needle valve M with lever arm Q, shaft L and spring R. Use a needle or similar device and carefully pull up the fuel screen (W).
  • Page 38 Repair Instructions Assembly Cleaning and inspection Observe 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. Direct the air through all channels in the 1.
  • Page 39 Repair Instructions 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. Fig 40 5. Check using a ruler or the like that the lever is level with the assembly plane on the cover.
  • Page 40 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 41 Repair Instructions Make sure the cabling is fitted to its mounting on the intake flange. Press the fuel hose (D) in place in the collar on the intake bellows. Hook on the throttle cable (E) in its mounting on the intake bellows. See figure 46. Make sure the lug on the carburettor hooks in place on its mounting on the intake system.

  • Page 42: Dismantling

    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 43: Assembly

    Repair Instructions Assembly 1. Thread the throttle cables in the connection M as outlined in figure 55. NOTE! The figure is shown from underneath. 2. Run the fuel hose D through hole K and hoses B and C in hole L. See figure 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 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 45: Dismantling The Piston And Cylinder

    Repair Instructions 7.21 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 46 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 47: Faults And Causes

    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 48: Pressure Testing The Cylinder

    Repair Instructions 7.23 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 49: Dismantling The Crankshaft And Crankcase

    Repair Instructions 7.24 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 50 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 51 Repair Instructions Assembly WARNING! Beware of burn injuries as the crankcase halves are hot. Wear protective gloves. Proceed as follows if a bearing must be fitted: A. Heat up the crankcase half in question to 200°C. B. Use protective gloves. Fit the bearing in the Fig 76 flywheel side of the crankcase half.
  • Page 52 Repair Instructions Assemble the following parts: A. Tank unit. See page 43. B. Piston and cylinder. See page 47. C. Muffler. See page 19. D. Carburettor. See page 40. E. Centrifugal clutch. See page 31. F. Electrical System. See page 29. G.

  • Page 53: Assembling The Complete Crankshaft

    Repair Instructions 7.25 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 54: Replacing The Bar Bolt

    Repair Instructions 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. 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 55 English -...

  • Page 56: Troubleshooting

    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 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 58: Troubleshooting Methods

    Troubleshooting High speed Acceleration and retardation Does not Blocked air filter Will not run Blocked air filter at full throttle Tank venting clogged accelerate 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 59 • 115 26 56-26 2011W31...

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