Husqvarna 545 Workshop Manual
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Husqvarna 545 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 545

  • Page 1 Workshop Manual 545, 545 TrioBrake 550XP, 550XP TrioBrake 550XPG, 550XPG TrioBrake English...
  • Page 3 Contents Workshop Manual Husqvarna 545, 545 TrioBrake, 550XP 550XP TrioBrake, 550XPG and 550XPG TrioBrake Contents Index ..............4 Introduction and safety instructions ....6 Technical data ............10 Service tools ............12 Service data ............14 Safety equipment ..........16 Repair instructions ..........
  • Page 4 Inde Index Muffler 21 Bar bolt 63 Assembling the muffler 21 Replacing the bar bolt 63 ismantling the muffler 21 Carburettor 36 Assembly 40 Oil pump and screen 33 Cleaning and inspection 40 Assembling the oil pump and screen 34 esign 36 Cleaning and inspection 33 ismantling the oil pump and screen 33...
  • Page 5 Inde Assembly 45 Cleaning and inspection 45 ismantling 45 English -...
  • Page 6 Introduction and safety instructions 2 Introduction and safety regulations Contents eneral ...........................7 Safety ..........................7 Target group ........................7 odifications........................7 Tools ..........................7 Structure .........................7 umbering ........................7 eneral instructions ......................8 Special instructions ......................8 2.10 Symbols on the saw .......................9 2.11 Symbols in the Workshop anual ..................9 - English...
  • Page 7 Some sections include an introductory Descrip- Usage is made apparent in each section. 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- ures are designated A, , etc.
  • 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 ha ardous 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 in ury Choke Lever when the instructions are not followed. Use protective gloves. Refuelling Use protective goggles.
  • Page 10 . output speed cm3 cubic inch inch mm inch kW hp rpm 50,1 3.06 43 1.69 34,5 1.36 2.5 3,4 9 600 545 T 50,1 3.06 43 1.69 34,5 1.36 2.5 3,4 9 600 550 P 50,1 3.06 43 1.69 34,5 1.36 2.8 3,8 9 600...
  • Page 11 Technical data Engage speed Spark plug Type of oil pump 4 200 C R6 Ad ustable 545 T 4 200 C R6 Ad ustable 550 P 4 200 C R6 Ad ustable 550 P T 4 200 C R6 Ad ustable...
  • Page 12 Service tools 4 Service tools 4 mm 4 mm 5 mm - English...
  • Page 13 Service tools escription Used for rder o. Piston stop Locking the crankshaft 575 29 36-01 ook for fuel filter Suspending the fuel filter 502 50 83-01 Allen key, 4 mm 5 bolts 502 50 87-01 Allen key, 4 mm 5 bolts 502 50 18-01 Allen key, 5 mm 6 bolts...
  • Page 14 Service data 5 Service data 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 1-2Nm The numbers by the components to be assembled with screws state the tightening torque in m.
  • Page 15 Service data 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: Table Of Contents

    Safety equipment 6 Safety equipment Contents ismantling the chain brake ...................17 Assembling the chain brake ....................18 ismantling the right-hand brake trigger ................19 Assembling the right-hand brake trigger .................21 ismantling the muffler ....................21 Assembling the muffler ....................21 Replacing the chain catcher ...................22 ismantling the start stop control ...................22 Assembling the start stop control ..................23 6.10...

  • Page 17: Ismantling 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 oint and the brake band together (see figure 5) using a tightening torque of 1-1.5 m. Place the knee oint 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: Ismantling The Right-Hand Brake Trigger

    Fig 11 must trigger. 6.3 Dismantling the right-hand brake trigger (545 TrioBrake, 550 XP TrioBrake, 550 XPG TrioBrake) Release the brake by moving the front hand guard towards the front handle. Loosen the bar nuts and remove the clutch cover, bar and chain, see fig. 1.
  • Page 20 Safety equipment Loosen the movement limiter E. Loosen the screw F and remove the cover. See figure 3. Fig 3 Loosen the screws to release the brake cable. Pull back the rubber casing and loosen the screw . See figure 4 Fig 4 etach the right-hand brake trigger from its mount on the rear handle.

  • Page 21: 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 . Reposition the brake cable in its track and tighten screws See figure 5 and 4.

  • Page 22: 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 23: Assembling The Start Stop Control

    Safety equipment 6.9 Assembling the start/stop control Fit the new stop control (A) and tighten screw ( ) in place at a torque of 1 m. Slide in the stop con- trol in the rubber sleeve C and hook the sleeve on the guide taps.

  • Page 24: Ismantling 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 ( ) as shown in the figure using a screwdriver or similar tool.

  • Page 25: 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 oined surfaces with a light oil. ook on the throttle cable ( ). Slide in the throttle control and make sure the spring is fitted as outlined in figure 24.
  • Page 26 Repair Instructions 7 Repair instructions Contents ismantling the starter ....................27 Replacing a broken or worn starter cord ................28 Tensioning the return spring ...................28 Replacing a broken return spring ...................27 Starter assembly......................29 ismantling the ignition module and flywheel ..............30 Assembling the ignition module and flywheel ..............31 ismantling the centrifugal clutch ...................32 Assemby of centrifugal clutch ..................33 7.10...

  • Page 27: 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 28: 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 29: 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. Re- move the spacer and the pulley. See figure 3a. Remove the broken cassette and replace it with a new one.

  • Page 30: Ismantling 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 1. Fig 1 nock out a few of the pins in the tool if it does not match up with the flywheel.

  • Page 31: 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 1. Fit the cabling to the stop button. Position the cable channel as outlined in figure 1. TE Take care that the cable channel is posi- tioned correctly under the ignition module so that the cables are not crushed.

  • Page 32: Ismantling 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 1. Fig 1 Loosen the spark plug hat and remove the spark plug, and insert the plastic piston stop (575 29 36-01).

  • Page 33: Assemby Of Centrifugal Clutch

    Repair Instructions 7.9 Assembly of centrifugal clutch Insert the clutch springs on the side of the shoes without te t. See figure 1. Screw in the clutch (anti-clockwise) until it stops. Then tighten the clutch using tool 575 25 14-01 Fig 1 and a suitable socket wrench or combination span- ner.

  • Page 34: 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 m.

  • Page 35: Assembling The Intake System

    Repair Instructions ismantle the air filter, the filter holder, the cable from the intake flange holder and the carburettor and the throttle cable as outlined in ismantling the carburettor . TE The lug on the carburettor sits on the bracket on the partition wall. Fig 24 ook off the cabling from the holder on the intake system ( ).

  • Page 36: 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 37 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 is completely shut. This increases the vacuum in the carburettor and fuel is easier to suck from all the diffuser ets , E, and F.
  • Page 38 Repair Instructions Dismantling the carburettor ismantle the cylinder cover and the air filter. Loosen the screws, F. Unhook the rubber attach- ment on both sides. See Figure 35. Loosen the suction hose A, the return hose , and the tank bleeding hose C. See figure 34. Fig 34 Remove the air filter holder.
  • Page 39 Repair Instructions ismantle the pump cover and carefully remove the control diaphragm and gasket . Unscrew screw P and remove needle valve with lever arm , shaft L and spring R. Use a needle or similar device and carefully pull up the fuel screen (W).
  • Page 40 Repair Instructions Assembly Cleaning and inspection bserve 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 41 Repair Instructions 4. Assemble needle valve with lever arm shaft L and spring R, and tighten screw P. (Fit the e pansion 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 42 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. ption 1 See the figure and carry out the check as follows Connect pressure tester to the carburettor fuel inlet.
  • Page 43 Repair Instructions ake sure the cabling is fitted to its mounting on the intake flange. Press the fuel hose ( ) in place in the collar on the intake bellows. ook on the throttle cable (E) in its mounting on the intake bellows.

  • Page 44: 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 rain the fuel from the tank. 2.

  • Page 45: Ibration Damping System

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

  • Page 46: 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 47: Eated 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 • enerator • Power switch • eating element in the rear handle •...
  • Page 48 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 o idation. See Figure 5. Clean and assemble the power switch.
  • Page 49 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 hm. Replace the heating element if you get another reading. 0.5 - 1.2 Fig 7 Troubleshooting the heating element, front...
  • Page 50 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 51 Repair Instructions Replacing the generator ismantle the following parts • Clutch cover • ar and chain • Cylinder cover • Starter • Flywheel See the chapter ismantling the ignition module and flywheel. Fig 13 Loosen the screws to the generator without remov- ing it.
  • Page 52 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 53 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 54: Ismantling The Piston And Cylinder

    Repair Instructions 7.22 Dismantling the piston and cylinder ismantle • The cylinder cover • The carburettor (see ismantling 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 55 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. inor scratches can be polished off using fine emery paper.

  • Page 56: 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 57: 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 58: Ismantling The Crankshaft And Crankcase

    Repair Instructions 7.25 Dismantling the crankshaft and crankcase ismantle the following • The clutch cover • The chain and bar. • The centrifugal clutch • The cylinder cover • The starter • The flywheel • The carburettor • The bottom of the carburettor •...
  • Page 59 Repair Instructions If required, remove the crankshaft bearing from the crankcase. Proceed as follows A. Remove the oil refill cap. . eat up the crankcase half in question to 200 C. C. Use protective gloves. Press the bearing out of the crankcase half.
  • Page 60 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. eat up the crankcase half in question to 200 C. . Use protective gloves. Fit the bearing in the Fig 76 flywheel side of the crankcase half.
  • Page 61 Repair Instructions Assemble the following parts A. Tank unit. . Piston and cylinder. uffler. . Carburettor. E. Centrifugal clutch. F. Electrical System. . Starter. . ar and chain. Sealing rings To replace the crankshaft s sealing rings, first dis- mantle the following parts n the flywheel side •...

  • Page 62: 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 • The bottom of the carburettor •...

  • Page 63: Replacing The Bar Bolt

    Repair Instructions 7.27 Replacing the bar bolt Replacing a bar bolt with intact crankcase Empty the oil tank. nock 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 64 Troubleshooting 8 Troubleshooting Contents Troubleshooting ......................65 Troubleshooting methods ....................66 - English...
  • Page 65 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) ifficult to start...
  • Page 66 Troubleshooting High speed Acceleration and retardation Will not run locked air filter oes not locked air filter accelerate Tank venting clogged at full throttle Tank venting clogged locked fuel filter locked fuel filter locked fuel line locked fuel line Loose or faulty fuel pipe Loose or faulty fuel pipe locked impulse channel Impulse channel leaking...
  • Page 68 • 115 49 42-26 2015W04...

This manual is also suitable for:

545 triobrake550xp550xp triobrake550xpg550xpg triobrake

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