Husqvarna 966451906 Chainsaw User Manual
Contents
1. lt gt CT D CIR p De C113 Pos Description Used for Order No 1 Piston stop Locking the crankshaft 575 29 36 01 2 Hook for fuel filter Suspending the fuel filter 502 50 83 01 3 Allen key 4 mm For M5 bolts 502 50 87 01 4 Allen key 4 mm For M5 bolts 502 50 18 01 4 Allen key 5 mm For M6 bolts 502 50 64 01 5 Air gap tool Setting ignition module 502 51 34 02 6 Clutch tool Centrifugal clutch 575 25 14 01 7 Assembly fixture Securing the chain saw 502 51 02 01 8 Pressure gauge Pressure testing 531 03 06 23 9 Test spark plug Checking the ignition module 501 97 64 01 10 Assembly pliers Fitting the spark plug guard 502 50 06 01 11 Dismantling device Dismantling the crankcase 575 28 69 01 12a Assembly tool Assembling the sealring 575 34 70 01 12b Guide sleeve Assembling the sealring 575 34 69 01 13a Cover plate outlet Closure of outlet 574 71 14 01 13b Cover plate inlet Closure of inlet 575 29 81 01 13c Cover plug inlet Closure of inlet 574 70 12 01 13d Pressure tester Pressure testing the cylinder 503 84 40 03 14 Mandrel Dismantling the flywheel 502 51 94 01 15 Assembly tool Assembling the crankshaft 502 50 30 23 16 Puller Dismantling the crankshaft 531 00 48 67 17 Engine Diagnostic Tool Diagnosis and troubleshooting 576 69 23 01 English 13 Service data Min 15Nm 13mm Key A Lubricate using two stroke oil E Lubricate using chain oil2. 3 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 4 Hook off the cabling from the holder on the intake system J Knock out the POP out window using a screwdriver See figure 25 Lower the tank slightly and slide the fuel hose down into the hole Loosen the lower screws of the intake system using the POP out hole and the fuel hose hole Loosen the other screws Fig 25a 5 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 7 13 Assembling the intake system 1 Assemble the intake system 2 Fit the lower screws of the intake system using the POP out hole and the fuel hose hole Fit the other screws Fit the fuel hose and the throttle cable to their attachments See figure 24 Fit the rubber grommet to the throttle cable Push the tank back in position Hook on the cabling to the holder on the intake system 3 NOTE Press the lug on the carburettor in place on its bracket on the partition wall See figure 24 Z Fit the carburettor the filter holder and the air filter
3. 3 Use the 502 50 30 23 tool Use the back end of the sleeve and slot the crankshaft in place into the clutch side of the crankcase half See Figure 76 Tighten until the crankshaft collar comes into con tact with the bearing 4 Insert the guide pin in the crankcase half on the clutch side apply grease and fit the gasket C See Figure 77 5 Use the 502 50 30 23 tool Turn the sleeve and slot the crankcase half in place on the flywheel side Tighten until the gasket is pinned in place between the crankcase halves See Figure 78 6 Fit the screws Tighten them alternately Finally tighten then to 8 Nm See figure 79 7 Fit the carburettor bottom with the four screws Tighten the screws using 5 Nm of torque See figure 79 NOTE Make sure that any excess gasket does not finish up in the crankcase Fig 76 a 4 Q English 51 Repair Instructions 8 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 Starter See page 25 H Bar and chain See the Operator s Manual Sealing rings 4 To replace the crankshaft s sealing rings first dis mantle the following parts On the flywheel side Starter See page 25 Flywheel See page 28 On the clutch side Bar and
4. 4 Husqvarna Workshop Manual 555 560XP XPG tb 562XP XPG English Contents Workshop Manual Husqvarna 555 560XP 560XPG 562XP and 562XPG Contents Index icaro ee 4 Introduction and safety instructions 6 Technical data 10 Service TOONS nsii aiina 12 Service data 14 Safety equipment 16 Repair instructions 24 Carburettor 34 Troubleshooting cessere 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 3 Index Index B Bar bolt 54 Replacing the bar bolt 53 C Carburettor 34 Assembly 38 Cleaning and inspection 38 Design 34 Dismantling 36 Function 35 Pressure testing the carburettor 40 Centrifugal clutch 30 Assembly of centrifugal clutch 31 Cleaning and inspection 30 Dismantling the centrifugal clutch 30 Chain brake 17 Assembling the chain brake 18 Cleaning and inspection 17 Dismantling the chain brake 17 Chain catcher 20 Replacing the chain catcher 20 Crankshaft and crankcase 49 Assembling a complete crankshaft 54 Dismantling the crankcase and crankshaft 49 F Fuel system 44 Replacing the fuel filter 44 Replacing the f
5. Exercise care to ensure the spring does not fly out and cause person al injury Wear protective goggles 1 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 2 Remove the broken cassette and replace it with a new one 3 Tighten the screw at the centre of the starter pulley at a tightening torque of 2 3 Nm Load the return spring see Loading the return spring See also the Dismantling the starter chapter 7 5 Starter assembly 1 Position the starter against the crankcase and tighten the screws at a tightening torque of 3 4 Nm English 27 Repair Instructions 7 6 Dismantling the ignition module and flywheel 1 Remove the cylinder cover Remove the starter Snap off the ignition cable from the guide rail and remove the guide rail See figure 7 2 Knock out a few of the pins in the tool if it does not match up with the flywheel Use the tool to hold the flywheel in place while the flywheel nut is loosened using a suitable socket wrench See figure 8 4 Thread the mandrel on the crank pin Screw in until 1 2 threads are left to the flywheel Knock on the mandrel with a suitable metal hammer while at the same time pulling the flywheel outward until the flywheel comes off the shaft Remove mandrel and flywheel See figure 9 Unscrew the air nozzle to replace the ignition mod ule Loosen the
6. 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 The throttle valve is partly open The throttle valve J is closed See figure 30 In idling mode the throttle valves and J are closed and the choke valve H is open Air is sucked in through an aperture in the throttle valve and a small amount of fuel is supplied through the diffuser jet D See figure 31 In part throttle mode the throttle valve is partly open and the choke valve H is fully open Fuel is supplied through the diffuser jets D and E The throttle valve J starts to open See figure 32 In the full throttle mode both valves are open and fuel is supplied through all four diffuser jets D E F and G The throttle valve J is fully open See figure 32 English 35 Repair Instructions Dismantling the carburettor 1 Dismantle the cylinder cover and the air filter 2 Loosen the screws F Unhook the rubber attach ment G on both sides See Figure 35 3 Loosen the suction hose A the return hose B and the tank bleeding hose C See figure 34 4 Remove the air filter holder Let the air filter holder remain in place in the cabling for the stop button Loosen the
7. Repair Instructions 7 Repair instructions Contents 7 1 Bismantling the starler oce xii Ex t ee nee 25 7 2 Replacing a broken or worn starter cord 26 1 3 ensioning the return Spring 5a oett ail 26 7 4 Replacing a broken return spring enne 27 TH Starter assembly een b pe te aeree deci ie te a ie ani aa 27 7 6 Dismantling the ignition module and flywheel sees 28 7 7 Assembling the ignition module and flywheel nn 29 7 8 Dismantling the centrifugal clutch ss 30 7 9 Assemby of centrifugal clutch iccse 31 7 10 Dismantling the oil pump and screen e 31 7 11 Assembling the oil pump and screen nne 32 7 12 Dismantling the intake system sisi 32 7 13 Assembling the intake system ins 32 FAA SCANOURCTION mmmmmmmmmmmmmmmrmrmmiimimrmmmmmmmmmmmmmmmmmm rr vr m c m mrmrmrm mrm rm mrmrurHum rairuirir 34 Fen MS aiaininrnrirns 42 7 16 Mentng the fuel talk a en nnd 42 7 17 Vibration damping system iii 43 7 18 Replacing the fuel filter is 44 7 19 Replacing the fuel hose return hose sss eene 44 7 20 Replacing the fuel pump enne nennen nennen nnne 44 7 21 Dismantling the piston and cylinder sse 45 7 22 Assembling the piston and cylinder ne 47 1 23 Pressure testing the Cylinder otia etre 48 7 24 Dismantling the crankshaft and crankcase sse 49 7 25 Assembling t
8. The carburettor 2 Attach the cover plate 574 71 14 01 and plug 574 70 12 01 See figure 66 3 Loosen the screws on the muffler and press the cover plate 575 29 05 01 between the muffler and cylinder Tighten the screws for the muffler See figure 66 Use the plastic piston stop 575 29 36 01 4 Screw the pressure test connection 503 84 40 02 in place Connect tool 531 03 06 23 to the nipple 5 Pump the pressure up to 80 kPa 0 8 bar Wait 30 seconds The pressure should not be less than 60 kPa 0 6 bar Remove the cover plates from the silencer and carburettor tighten the bolts to the specified torgue Remove the pressure test nipplle and refit the spark plug WARNING Once the cylinder has been pressure tested make sure the inlet manifold is fitted correctly Otherwise the chainsaw can be damaged 48 English Fig 66a Fig 66b Fig 67 Repair Instructions 7 24 Dismantling the crankshaft and crankcase 1 Dismantle 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 The hand guard The muffler The handle system The fuel unit The piston and cylinder The ignition module Cabling The oil pump See specific instruction NOTE Take care to prevent any dirt and foreign particles from entering the bearings 2 If
9. Will not run Blocked air filter at full throttle Tank venting clogged Blocked fuel filter Blocked fuel line Loose or faulty fuel pipe Impulse channel leaking Blocked impulse channel The cover on the carburettor pump side is loose Faulty pump diaphragm Leaking inlet hose rubber Loose carburettor mounting Control system set too low Damaged control system Control system incorrectly assembled Leaking diaphragm cover plate Control system sticking Blocked muffler Low power Tank venting clogged Blocked fuel filter Impulse channel leaking Blocked impulse channel The cover on the carburettor pump side is loose Faulty pump diaphragm Blocked air filter Control system sticking Leaking control system air or fuel Control system incorrectly assembled Loose diaphragm Hole in diaphragm Leaking diaphragm cover plate Will not four Tank venting clogged stroke Blocked fuel filter Blocked fuel line Loose or faulty fuel pipe Impulse channel leaking Blocked impulse channel The cover on the carburettor pump side is loose Faulty pump diaphragm Leaking inlet hose rubber Loose carburettor mounting Control system set too low Leaking control system air or fuel Control system incorrectly assembled Loose diaphragm Hole in diaphragm Leaking diaphragm cover plate 58 English Acceleration and retardation Blocked air filter Tank venting clogged Blocked fuel filter Blocked fuel line Loose or faulty fuel pipe Bl
10. by using the saw s hand guard as a tool Mesh with the brake and tighten anti clock wise until the brake is activated see fig 2 3 Loosen the screws and insert a screwdriver to maintain pressure on the spring and then carefully remove the cover over the brake spring see fig 3 WARNING Exercise care to ensure the spring does not fly out and cause personal injury Wear protective goggles Hold one hand on top of the brake spring and press in a small screwdriver into the spring Care fully bend upwards until the spring is released and it slides onto the screwdriver see fig 4 Cleaning and inspection Clean and check carefully all components Parts must be replaced if cracked or show signs of other defects Always use original spare parts Measure the thickness of the chain brake band It must not be less than 0 6 mm in any place See figure 5 Lubricate the knee joint with grease Fig 1 Fig 3 Fig 4 Fig 5 min 0 6 mm English 17 Safety equipment 6 2 Assembling the chain brake 1 Screw the knee joint and the brake band together see figure 5 using a tightening torgue 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 See figure 6 2 Compress the spring with a wide screwdriver and press it down with
11. chain See the Operator s Manual Chain guide plate See page 17 Centrifugal clutch See page 30 Oil pump See page 31 2 Use a screwdriver to remove the sealing ring and pull it out 3 Slide the dowel 575 34 69 01 figure 80 on the crankcase pin Knock the new sealing ring in place using the 575 34 70 01 tool See Figure 81 4 Fit the parts as outlined in point 1 above 52 English Fig 80 Fig 81 Repair Instructions 7 25 Assembling a complete crankshaft 1 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 The carburettor The flywheel The starter The cylinder cover The centrifugal clutch The chain and bar The clutch cover See specific instruction English 53 Repair Instructions 7 26 Replacing the bar bolt Replacing a bar bolt with intact crankcase 1 Empty the oil tank 2 Knock in the old bar bolts from the outside so that they end up in the oil tank 3 Remove the bolts from the oil tank 4 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 See figure 83 o 5 L Pull out the bar bolt so that it protrudes from its opening See figure 83 Fig 83 6 Pull out the
12. control and spring 23 Cleaning and inspection 22 Dismantling the throttle control lock throttle control and spring 22 Troubleshooting 57 Troubleshooting methods 58 Index V Vibration damping system 43 Assembly 43 Cleaning and inspection 43 Dismantling 43 English 5 Introduction and safety instructions 2 Introduction and safety regulations Contents 2 1 General M 2 2 Safety ccleaner 2 3 Target group iii ia ai 24 MOGINCAUONS ranieri portano oi cmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmrmmmmmmmmmmmmmmmrmmmmmmmmmmmmmmmmmmiirr 2 6 SUI CHUNG mmmmmmmmmmmmmmmmmmmmmmmmmmmmrmrmrmrmmmrmrmmmmmmmmmmmmmrmrmmmmmm mmmmmmmiHiHHr T XEM spem 2 8 Generalinstr ctions mmmmmmmmmmmmmrmmrmrmrrmmrmmmmmrmmmmm mrm mmmmmrmmmmmmmmmmmmrmrmmmmmmmmmmmciH 2 9 Special instriCtlOLIS rca 2 10 Symbols on the Saw iii 2 11 Symbols in the Workshop Manual ss 6 English Introduction and safety instructions 2 Introduction and safety instructions 2 1 General This Workshop Manual describes in detail how to be troubleshoot repair and test the chain saw A description of different safety steps that must be taken during repair work is also given 2 2 Safety Note The section dealing with safety must be read and understood by all those carrying out repair work or service on the chain saw Warning symbols can be found in this Workshop Manual and on the chain saw Se
13. e Lubricate using grease 12 14Nm 13mm The numbers by the components to be assembled with screws state the tightening torque in Nm 5 Service data 18 20Nm 16mm 1 5 2Nm 4mm 14 English Service data SEN 3 4Nm 4mm i KA F L 8 10Nm 4mm NA 3 5 4 5Nm 4mm English 15 Safety equipment 6 Safety equipment Contents 6 1 Dismantling the chain brake ss 17 6 2 Assembling the chain brake e 18 6 3 Dismantling the Muffler iii 19 6 4 Assembling the muffler sise 19 6 5 Replacing the ch in catcher i i aaa 20 6 6 Dismantling the start stop control i 20 6 7 Assembling the start stop control 21 6 8 Resistance test stop function nn 21 6 9 Dismantling the throttle control lock throttle control and spring seess 22 6 10 Assembling the throttle control lock throttle control and spring esssssse 23 16 English Safety equipment 6 Safety equipment 6 1 Dismantling the chain brake 7 1 Remove the cylinder cover Release the brake by moving the front hand guard backward Loosen the bar nuts and remove the clutch cover bar and chain see fig 1 2 Unscrew the kickback guard and remove it NOTE Make sure that the spring and rocker do not fly out Carefully tighten the clutch housing in a vice Re lease the brake
14. on the oil pump from the crank case and remove it together with the oil pressure hose See figure 20 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 Lubricate all moving parts with chain oil Fig 17 English 31 Repair Instructions 7 41 Assembling the oil pump and screen 1 Lower the oil filter in place and replace the oil pump as outlined in figure 19 and tighten the screws 2 Fit the pump drive wheel the needle bearing the drive sprocket the clutch drum and the clutch us ing a tightening torgue of 25 Nm 3 Adjust the oil pump See Figure 21 4 Fit the clutch See the Assembling the centrifugal clutch chapter 5 Fit the chain bar and clutch cover WARNING Insufficient chain lubrication can result in chain breakage which can cause serious personal injury 7 12 Dismantling the intake system The intake system consists of The inlet manifold A The partition wall B The intake flange C See Figure 22 1 Dismantle the cylinder cover 2 Loosen screws D and the movement limiter E as outlined in figure 23 Loosen the ignition cable 32 English 1000000009 f ARRRARRARA Fig 21 Fig 23 Repair Instructions
15. out the throttle control pin C with the help of a punch See figure 21 4 Loosen the throttle cable D and lift out the throttle control and the spring See figure 22 5 Cleaning and inspection Carefully clean and check all parts See figure 13 Parts must be replaced if cracked or show signs of other defects Always use original spare parts Check that the spring is intact and retains all its tension 22 English Fig 19 Fig 20 Fig 22 Fig 23 Safety equipment 6 10 Assembling the throttle control lock throttle control and spring 1 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 edg ing before the pin is pressed in place 2 Fit the throttle control s pin C using a punch See figure 25 3 Fit the throttle control lock B by sliding it on the shaft in the handle See figure 26 Make sure the spring is positioned inside the throttle control lock when you press it down so that the barbs are hooked in place 4 Fit the handle insert using a screw when the throttle control spring throttle cable and throttle control lock with pin are fitted correctly Fig 24 Fig 25 English 23
16. required remove the circlip on the flywheel side 3 Remove the 5 screws from the pulley wheel side See Figure 69 4 Fit tool 575 28 69 01 as outlined in figure 70 Remove the crankcase half on the clutch side 5 Fit tool575 28 69 01 as outlined in figure 71 Remove the flywheel side s crankcase half 6 Carefully pull the crankcase halves apart Two guide pins keep the crankcase halves together Lift out the connecting rod and dispose of the gasket WARNING Beware of burn injuries as the crankcase halves are hot Wear protective gloves A g 17 Sk Fig 71 English 49 Repair Instructions 7 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 8 If the crankshaft bearings are still attached to the crankshaft when dismantling pull them off using the 531 00 48 67 pulling device See figure 73 Also inspect the bearing grip in the crankcase half Cleaning and inspection NOTE If the bearings are fitted to the crankcase take care to prevent any dirt and foreign particles from entering Clean all parts and scrape off all gasket remains from the contact surfaces on the crankcase halves Check the following 1 That the big end bearing does
17. screws on the ignition module See figure 10 Dismantle the air filter air filler holder and carburet tor See the Dismantling the carburettor chapter Dismantle the tank unit as outlined in the Disman tling the tank unit chapter Dismantle the intake system see the Dismantling the intake system chapter Loosen the earth cable See figure 11 Pull the cables through the openings in the crankcase Cleaning and inspection Clean all parts especially the tapers on the flywheel and shafts Check the flywheel for cracks or any other signs of damage 28 English Fig 7 Fig 8 Fig 9 Fig 10 Repair Instructions 7 7 Assembling the ignition module and flywheel 1 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 2 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 3 Place the ignition module in position See figure 13 Do not tighten the screws 4 Fit the flywheel onto the crankshaft pin Turn the flywheel until the key fits into the key slot on the shaft See figure 12 Tighten the screw for the flywheel 5 Insert the plastic air gap tool at a thickness of 0 3 0 1 mm between the lugs on the ignition module and fly
18. 3 0 012 Zama 560XP XPG 0 5 0 02 SEM 0 3 0 012 Zama 562XP XPG 0 5 0 02 SEM 0 3 0 012 Zama Usable cutting length Chain speed at Chain pitch Drive link cm inch max output speed mm inch mm inch m s rpm 555 33 61 13 24 21 3 9600 8 25 0 325 9 53 0 375 1 3 0 050 1 5 0 058 560XP XPG 33 61 13 24 21 3 9600 8 25 0 325 9 53 0 375 1 3 0 050 1 5 0 058 562XP XPG 38 71 15 28 21 3 9600 9 53 0 375 1 3 0 050 1 5 0 058 10 English Technical data Engage speed Spark plug rpm 555 3800 NGK CMR6H 560XP XPG 3800 NGK CMR6H 562XP XPG 3800 NGK CMR6H Volume fuel tank Capacity oil pump at Litre US pint 9 000 rpm ml min 555 0 65 1 37 6 15 560XP XPG 0 65 1 37 6 15 562XP XPG 0 65 1 37 8 18 Weight without bar and chain kg bs 555 5 6 12 3 560XP XPG 5 6 12 3 562XP XPG 5 7 12 6 J N Automatic oil pump Yes Yes Yes Volume oil tank Litre US pint 0 33 0 70 0 33 0 70 0 35 0 74 Gu Weight with bar and chain kg bs Weight depending on selected cutting equipment English 11 Service tools 4 mm 12 English 4 mm 5 mm 4 Service tools Airgap tool 502 5134 02 Service tools 14 16 277777 oi
19. N Ze as outlined in Assembling the carburettor Sy OU Fig 26 KE English 33 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 They show only the principle of design and func tion Design The carburettor is based on three sub systems Metering unit A Mixing unit B Pump unit C The needles and the fuel s control functions are located in the metering unit A Here the correct quantity of fuel is adjusted for the actual speed and power output See figure 27 The mixing unit B houses the choke the throttle valve and the diffuser jets Here air is mixed with the fuel to give a fuel air mixture that can be ignited by the ignition spark See figure 28 In the pump unit C fuel is pumped from the fuel tank to the carburettor s metering unit One side of the pump diaphragm is connected to the crankcase and pulses in time with the pressure changes in the crankcase The other side of the diaphragm pumps the fuel See figure 29 34 English Fig 27 Fig 28 Fig 29 Repair Instructions
20. bar bolt with its nut Insert a spacer between the nut and the crankcase See figure 83 7 Fill with chain oil 7 27 Repairing damaged threads If threads on the chainsaw are worn the repa ration 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 screw and wrench i isi for plasti This type of screw plug is ideal for plastic Fig 84 and magnesium but cannot be used to repair threads in aluminium There is another type of thread plug and metric screw available for this purpose See figure 84 Check the manufac turer s manual for thread information 54 English English 55 Troubleshooting 8 Troubleshooting Contents 8 1 Troublesh dting u nee een 82 Troubleshooting methods iaia a nal nad 56 English 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 Air filter blocked Worn needle needle tip Choke does not work Leaking diaphragm cover plate Worn choke axle Worn lever arm in the control Worn choke valve sys
21. crews F See figure 51 6 Hook on the throttle cable E in the intake bellow See figure 50 7 Fit the tank unit The two short screws are fitted to the bottom of the handle bar 8 Assemble the carburettor as outlined in Assem bling the carburettor Assemble the air filter and cylinder cover 7 17 Vibration damping system Dismantling 1 Dismantle the following parts Bar and chain See the Operator s Manual Cylinder cover See the Operator s Manual Tank unit and handle See Dismantling the tank unit 2 Dismantle the spring on the handle bar using a 4 mm Allen key see figure 57 3 Dismantle the springs on the tank unit using a 4mm Allen key tool 502 50 18 01 See figure 57 Cleaning and inspection Clean and inspect all parts Assembly 1 Fit the springs on the handle bar using a 4 mm Allen key tool 502 50 18 01 2 Assemble the following parts Tank unit and handle See Assembling the tank unit Cylinder cover See the Operator s Manual Bar and chain See the Operator s Manual Xn I q Fig 55 English 43 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 1 When replacing the fuel filter the old fuel filter must be taken out of the ta
22. e Symbols on the saw and Symbols in the Workshop Manual A new warning symbol decal must be applied as soon as possible if a warning symbol on the chain saw has been damaged or is missing so that the greatest level of safety can be maintained when using the chain saw 2 3 Target group This Workshop Manual is written for personnel who are assumed to have general knowledge of repair ing and servicing chain saws The Workshop Manual must be read and under stood by personnel who will carry out repair work and service on the chain saw The Manual is also suitable for use when training new employees 2 4 Modifications Any modifications to the chain saw will be gradually introduced into ongoing production As these modi fications affect service and or spare parts specific service information will be sent out on each occa sion This means that in time this Workshop Manu al will become out of date In order to prevent this the Manual should be read together with all service information concerning the chain saw in question 2 5 Tools Special tools are required for some stages All service tools are listed in the Workshop Manual Usage is made apparent in each section Always use Husqvarna s original Spare parts Service tools Accessories 2 6 Structure This Workshop Manual can be used in two different Ways Repair of a specific system on the chain saw Dismantling and assembly of the entire chain
23. e return spring by allowing the starter pulley to rotate slowly backwards WARNING If the spring tension is activated on the starter pulley the spring can fly out and cause personal injury Wear protective glasses Fig 3b 2 Loosen the screw in the centre of the pulley and remove the pulley See figure 3a 3 When the starter pulley is removed insert a new starter cord and attach it to the starter pulley Thread the other end of the starter cord through the hole in the starter housing and starter handle and tie a double knot on the cord Wind approx 3 turns of the starter cord on the starter pulley Turn the starter pulley until it latches into the correct po sition Tighten the screw at the centre of the starter pulley at a tightening torque of 2 3 Nm Cleaning and inspection Clean and check carefully all components Worn or damaged parts must be replaced Lubricate the return spring with a light oil 7 3 Tensioning the return spring 1 Pull the starter cord up into the notch in the starter pulley and turn the pulley about 3 turns clockwise Check that the pulley can be turned at least a fur ther 1 2 turn when the starter cord is pulled all the way out See figure 4 Fig 4 2 Stretch the line with the handle Remove your thumb and let the cord spin back See figure 5 Fig 5 26 English Repair Instructions 7 4 Replacing a broken return spring WARNING
24. fuel hose D Unhook the throttle cable E See figure 34 5 NOTE Press down the lug to release the carburet tor Lift out the carburettor See figure 36 NOTE The lug on the carburettor is securely attached to the partition wall 6 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 36 English Fig 34 Fig 35 F Fig 36 Repair Instructions 7 Dismantle the pump cover H and carefully remove the control diaphragm J and gasket K 8 Unscrew screw P and remove needle valve M with lever arm Q shaft L and spring R 9 Use a needle or similar device and carefully pull up the fuel screen W See figure 39 10 If necessary dismantle throttle valve T and choke valve U and air valve S and remove the shafts with lever arms and springs see figure 39 11 If necessary dismantle the AutoTune AB unit See figure 39 English 37 Repair Instructions Cleaning and inspection Clean all units in clean petrol Use compressed air to dry the petrol on the com ponents Direct the air through all channels in the carburettor housing and ensure that they are not blocked Check the following 1 That the gasket pump and control diaphragms are undamaged as wel
25. g 4 Remove the circlips for the gudgeon pin and press out the gudgeon pin The lift off the piston See figure 61 5 Remove the gudgeon pin bearing the needle bear ing using a pliers See figure 61 Replace with a new bearing Cleaning and inspection of the cylinder Clean all components scrape off all gasket re mains and soot from the following areas The piston crown The top of the cylinder bore inside The cylinder exhaust port The base of the cylinder and or crankcase Fig 60 Fig 61 English 45 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 That the piston ring is not burnt into its groove Measure the wear on the piston ring This must not exceed 1 mm See figure 62 Use the pis ton to push the piston ring downward That the gudgeon pin bearing is intact That the intake bellows is intact Pressure test the decompression valve Carry out pressure testing on the decompression valve as follows See also figure 68 A Fit the pressure gauge tool 531 03 06 23 to the decompression valve Pump up the pressure to 80 kPa 0 8 bar Wait 30 seconds The pressure must not fall below 60 kPa 0 6 ba
26. g a ruler or the like that the lever is level with the assembly plane on the cover If necessary the lever arm can be bent see figure 41 7 Fit gasket K the control membrane J and the pump cover H See figure 42 8 Carry out a pressure test English 39 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 1 Connect pressure tester to the carburettor fuel inlet 2 Submerge the carburettor into a container with water See figure 43 3 Pump up the pressure to 20 kPa 4 No leakage is permitted If a leakage occurs refer to the table below Option 2 1 Plug the connections to the fuel inlet 2 Create a vacuum to the purge nipple on the car burettor No leakage is permitted In the case of leakage leakage spray can be used even it if is dif ficult Try and identify where the spray is absorbed It can be used to show leakages in main jets idling needles measuring cover gaskets and measuring diaphragms and autotune gaskets Diffuser jets Needle valve Leak in the impulse pipe Pump membrane Ventilation hole on the Control membrane metering unit Fitting on the saw 1 Press the connector toget
27. he complete crankshaft sss 54 7 26 Heplac ng the bBarbolt se ren iii 53 7 27 Repairing damaged threads sis 54 24 English Repair Instructions 7 Repair instructions 7 1 Dismantling the starter 1 Loosen the four screws which hold the starter against the crankcase and remove the starter 2 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 See figures 1 and 2 Fig 1 WARNING If the spring tension is activated 9 _ on the starter pulley the spring can fly out and cause personal injury Wear protective glasses Fig 2 3 Loosen the screw in the centre of the pulley and remove the pulley See figure 3 Loosen the screws on the cassette and remove the cassette and spring Cleaning and inspection Clean the parts and check The starter cord That the starter pawls on the flywheel are intact i e that they spring back to the centre and move easily To lubricate the return spring using light oil Fig 3a English 25 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 1 Pull the cord out about 30 cm and lift it into the notch on the outside of the starter pulley Release the tension on th
28. he surface the chain brake must trigger 6 3 Dismantling the muffler WARNING 0 Do not touch the muffler until it L has cooled Risk of burns 1 Remove the cylinder cover muffler gasket and cooling fin 2 The saw is fitted with spark arrestor mesh which is removed If necessary use the combination span ner to push down the plate edge and remove the spark arrestor mesh See figure 12 Cleaning and inspection Clean and check all components carefully Parts must be replaced if cracked or show signs of other defects Always use original spare parts The spark arrestor mesh is best cleaned with a wire brush The mesh must be replaced if damaged The saw will overheat if the mesh is clogged result ing in damage to the cylinder and piston Never use a saw with a clogged or defective muffler 6 4 Assembling the muffler 1 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 2 Fit the cooling fin gasket muffler tightening torque of 12 14 Nm Cylinder cover 3 Warm up the saw for at least one minute and retighten the screws on the muffler to 12 to 14 Nm Fig 11 Fig 12 English 19 Safety equipment 6 5 Replacing the chain catcher A worn chain catcher must always be replaced with a new o
29. her as outlined in figure 44 and push it into place in the holder 40 English Fig 43 Fig 44 Fig 45 Repair Instructions 2 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 Make sure that the following components are correctly fitted ba ip u Position the air filter holder against the carburettor mi CA Make sure the carburettor cover s intake channel Q Fig 46 is aligned correctly with the slot for the air filter holder The spring must be fitted under the choke pin on the carburettor See figure 47 The rubber collar on the stop button must be on the inside of the bottom of the carburettor com partment See figure 47 NOTE Make sure that the fuel and return hoses are not crushed 3 Position the guide taps on the air filter holder in the Fig 47 rubber grommets G See figure 48 4 Fig 48 Hook on the throttle cable E See figure 46 Fasten the return hose B and secure it in its mount ings on the air filter holder Attach the pressure hose A with the short hose on the short
30. ith the clutch springs as opening them too much can result in material damage 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 Check the thickness of the clutch shoes by meas uring them with slide callipers across the whole clutch hub If the thickness is below 60 mm the clutch must be replaced See figure 16 30 English amp Fig 14 ZA i e Wi di i Fig 16 Repair Instructions 7 9 Assembly of centrifugal clutch 1 Insert the clutch springs on the side of the shoes without text See figure 17 2 Screw in the clutch anti clockwise until it stops Then tighten the clutch using tool 575 25 14 01 and a suitable socket wrench or combination span ner Tightening torque of at least 25 Nm 3 Remove the piston stop and fit the spark plug using a tightening torque of 20 Nm and the spark plug hat Then fit The cylinder cover The bar The chain The clutch cover 7 10 Dismantling the oil pump and screen 1 Empty and clean the oil tank Dismantle the centrifugal clutch as outlined in Dismantling the centrifugal clutch 2 Loosen the clutch drum the drive sprocket the needle bearing and the pump drive wheel See figure 18 3 Unscrew the chain guide plate See figure 19 4 Loosen the screws
31. l as the gasket between the carburettor body and the autotuner 2 That there is no play on the throttle and choke valve shafts 3 That the needle valve M and its lever arm Q are not worn See figure 38 4 That the fuel screen W is intact and clean See figure 39 5 That the inlet manifold V is intact See figure 39 6 Use the service tool Engine Diagnostic Tool 576 69 23 01 to inspect the AutoTune unit See separate instruction Assembly Observe cleanliness when assembling the car burettor The slightest contamination can result in downtime 1 If throttle and choke valves with shafts lever arms and springs are removed these must be assembled The spring is tensioned 1 2 turns Lubricate the shaft bearings using a light oil 2 Fit the fuel screen W using the handle of a small screwdriver See figure 39 e Fit the gasket X in the carburettor as well as the holder Y Screw in place screw Z as outlined in figure 39 4 See figure 39 on how to assemble the AutoTune AB unit with gasket Note When replacing the AutoTune unit or car burettor with an AutoTune unit the unit must first be programmed before it can be used Refer to the local support page for more information Fig 39 38 English 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 5 Check usin
32. n the shrink tube covering both cables and shrink tubing that encloses the cable ends Clean the contact areas and check resistance in the following way Test the resistance by connecting a multimeter to the cable ends NOTE The power switch must be in the on position to get the correct reading See figure 17 The stop switch is in the on position when the button is held down see figure 17 and in the off position when the button is in neutral Resistance can be 0 5 Ohm at most with the power switch in the on position When assembling see figure 18 pull the cable ends apart and slide on a thicker shrink tube over both cables Then slide on the thinner shrink tubes over each cable Connect the cable ends together Slide the thinner shrink tubes over the cable ends and heat the shrink tube first on both cables sepa rately Slide the thicker shrink tube over the thinner shrink tubes and then heat the thicker shrink tube Fig 15 Fig 16 BEE CHE BS s Fig 18 English 21 Safety equipment 6 9 Dismantling the throttle control lock throttle control and spring 1 Loosen the screw on the rear handle Remove the handle insert A See figure 19 2 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 See figure 20 3 Press
33. ne Always use original spare parts 1 Release the brake by moving the front hand guard backward Loosen the bar nuts and remove the clutch cover chain and bar 2 Remove the chain catcher and replace it with a new one Make sure that the vibration element is fitted cor rectly on the crankcase when a new chain catcher is screwed in place See figure 13 6 6 Dismantling the start stop control 1 Remove the cylinder cover and air filter Dismantle the air filter holder See the Dismantling the carbu rettor chapter 2 Loosen screw B and dismantle the stop control A See figure 14 Unhook the rubber collar around the control from the guide plugs Cleaning and inspection Clean and check carefully all components Parts must be replaced if cracked or show signs of other defects Always use original spare parts 20 English Safety equipment 6 7 Assembling the start stop control 1 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 2 Attach the cables as outlined in figure 16 3 Attach the air filter holder See the Assembling the carburettor chapter 4 Fit air filter and cylinder cover 6 8 Resistance test stop function Dismantle the ignition module as outlined in 7 7 Dismantling the ignition module and flywheel Cut ope
34. ng does not fly out and cause personal injury Wear protective glasses If the spring tension is activated on the starter pulley when it is to be taken up the spring can fly out and cause personal injury Check that the brake is applied when removing the pressure spring on the chain brake Otherwise the pressure spring can fly out and cause personal injury After repairing check the chain brake see Assem bling chain brake Function check Keep in mind the fire risk The chain saw may emit sparks which cause ignition Check the chain catcher and replace it if it is dam aged 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 Choke Lever This symbol warns of personal injury when the instructions are not followed Refuelling 3 mw S Stop button Chain oil fill X Chain brake Decompression valve 5 Adjusting the oil pump il 0 Fuel pump EX English 9 Technical data 3 Technical data Y 1 AH lo Displacement Cylinder diameter Stroke length Max output speed cm3 cubic inch mm 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 59 8 3 65 46 1 81 36 1 42 3 5 4 8 9600 0 m Electrode gap Ignition system Air gap Carburettor type mm inch mm inch 555 0 5 0 02 SEM 0
35. nk unit using special tool 502 50 83 01 2 Pull out fuel hose B from the tank unit and pull away the filter A See figure 58 3 Fit the new fuel filter A and press the fuel hose back into place 7 19 Replacing the fuel hose return hose The fuel hose is moulded and can only be removed from outside of the fuel tank Use suitable pliers with a smooth cutting face and loosen the hose B from the fuel tank See figure 58 Replace the return hose when required Tighten the fuel hose on the filter side with your fingers 7 20 Replacing the fuel pump Purge Dismantle 1 Dismantle the cylinder cover and the air filter 2 Loosen suction hose C and return hose from the fuel pump See figure 59 3 Snap off the fuel pump from the filter holder Assembling 1 Snap the fuel pump in place in the filter holder See figure 59 2 Fit the return and suction hose on the fuel pump 3 Assemble the air filter and cylinder cover 44 English Repair Instructions 7 21 Dismantling the piston and cylinder 1 Dismantle The cylinder cover The carburettor see Dismantling the carburettor The muffler The vibration element The spark plug cap The intake system 2 Unscrew the cylinder s four screws and carefully lift away the cylinder and the gasket NOTE Take care to prevent any dirt and foreign particles from entering the crankcase 3 Cover over the crankcase openin
36. not have any radial play Axial play is permitted See figures 74 and 75 2 That the big end bearing does not have any score marks or is discoloured on the sides 3 That the bearing surface for the gudgeon pin bearing does not have any score marks or is discoloured 4 That the crankshaft bearing has no play or knocks 5 That the sealing surfaces of the sealing rings fitted against the crankshaft are not worn and that the rubber is not hard 6 That the crankcase is not cracked 50 English Fig 72 Fig 73 Fig 74 Fig 75 Repair Instructions Assembly WARNING Beware of burn injuries as the crankcase halves are hot Wear protective gloves 1 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 flywheel side of the crankcase half When fitting the bearing in the clutch side of the crankcase half the bearing must be fitted aligned with the inside of the crankcase C Allow the crankcase half to cool down before continuing with the work NOTE Take care to prevent any dirt and foreign particles from entering D Fit the oil refill cap 2 See page 52 figure 80 for how to fit new sealing rings NOTE Make sure the connecting rod is not crushed against the crankcase when the crankcase and crankshaft are fitted together
37. ocked impulse channel The cover on the carburettor pump side is loose Faulty pump diaphragm Leaking inlet hose rubber Loose carburettor mounting Control system set too low Control system incorrectly assembled Control system sticking Faulty diffuser jet Blocked muffler Does not accelerate The engine Faulty pump diaphragm stops when Control system set too high releasing the Control system sticking throttle Faulty diffuser jet Blocked air filter Faulty pump diaphragm Faulty diffuser jet 8 2 Troubleshooting methods In addition to faults given in the above schematic troubleshooting can be carried out on a specific component or specific chain saw system The different procedures are described in respective sections and are as follows Function check of chain brake Resistance testing the stop plate Pressure testing the carburettor Pressure testing the decompression valve Pressure testing the cylinder H Husqvarna www husqvarna com 115 26 56 26
38. plastic plug on the fuel pump Attach the tank bleeding hose C See figure 49 5 Hook it on the left side and then the right side of the carburettor in the rubber mounting Then screw the carburettor in place See figure 48 6 Fit the air filter Fig 49 English 41 Repair Instructions 7 15 Tank unit WARNING The fuel used in the chain saw has e the following hazardous properties 1 The fluid and its vapour are poisonous 2 Cancause skin irritation 3 Is highly inflammable Dismantling 1 Drain the fuel from the tank 2 Remove the cylinder cover the clutch cover the chain and the bar See the Operator s Manual Dismantle the carburettor as outlined in Dis mantling the carburettor Loosen the hoses A to D See figure 50 Loosen the screws F See figure 51 Loosen the movement limiter H See figure 53 Pull out the hoses A to D in the bottom of the car burettor compartment Unhook the throttle cable E from the intake bellows before pulling out from the bottom of the carburettor compartment DAR Co NOTE Exercise care so that the fuel hose and throttle cable are not damaged 7 16 Venting the fuel tank The two way valve has the following properties Controlled opening pressure in both directions which prevents a positive pressure or a vacu um developing in the fuel tank and impairing engine performance This also prevents fuel leakage Opening press
39. r Unscrew the cover plates for the carburettor and muffler Tighten the screws to the stated torque Remove the pressure test connection 503 84 40 02 and fit the spark plug DOW 46 English Fig 62 Fig 68 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 Piston ring breakage 1 Piston ring worn out 2 Oversized piston ring groove 7 22 Assembling the piston and cylinder 1 Oil the gudgeon pin bearing with two stroke oil and insert it into the crank rod See figure 64 2 Replace the piston with the arrow facing the ex haust port and slide in the gudgeon pin and fit the circlips NOTE Use nev circlips See figure 64 3 Oil the piston and piston ring with two stroke oil 4 Put a new cylinder base gasket in place Compress the piston ring and carefully push the piston into the cylinder opening 5 Attach the cylinder The screws must be tightened crosswise with a tightening torgue of 8 10 Nm NOTE lt is very important that the intake system is sealed Otherwise the engine may seize up d Fig 63 Fig 64 IM Fig 65 English 47 Repair Instructions 7 23 Pressure testing the cylinder 1 Loosen The cylinder cover
40. saw Repair of a specific system When a particular system on the chain saw is to be repaired proceed as follows 1 Look up the page for the system in question 2 Carry out the following steps Dismantling Cleaning and inspection Assembly Dismantling and assembling the chain saw Proceed as follows when the chain saw is to be dismantled and assembled 1 Open the Repair instructions chapter which deals with the Starter and carry out the in structions outlined under the Dismantling heading 2 Work forward in the Manual and carry out Dis mantling in the order set out in the sections 3 Go back to the Starter and carry out the in structions under Cleaning and Inspection 4 Work forward in the Manual and carry out Cleaning and Inspection in the order set out in the sections 5 Order or collect all requisite spare parts from the stores 6 Look up the Repair instructions chapter which deals with the Crankcase and carry out the instructions outlined in Assembling 7 Work back in the Manual and carry out Assem bling in the order set out in the sections Some sections include an introductory Descrip tion of the actual unit in order to increase the basic understanding 2 7 Numbering Position references to components inside the fig ures are designated A B etc The figures are numbered 1 2 etc The position references and figure numbers restart English 7 Introduction and safety ins
41. tem Blocked fuel filter Faulty diffuser jet Blocked fuel line Piston ring is stuck Blocked impulse channel Uneven idling Blocked fuel filter Blocked fuel line Leaking inlet hose rubber The carburettor Loose or faulty fuel pipe Loose carburettor mounting leaks fuel Hole in diaphragm Worn throttle valve axle Worn needle needle tip Loose throttle valve screw Control system sticking Worn throttle valve Control system set too high Leaking control system Leaking control system air or fuel air or fuel The control system s centre The cover on the carburettor knob is worn pump side is loose Hole in diaphragm Leaking diaphragm Floods when the Worn needle needle tip cover plate engine is not Control system set too high Leaking crankcase running Control system sticking Idling low speed Blocked fuel line Leaking control system Does not idle Leaking inlet hose rubber air or fuel Loose carburettor mounting Leaking diaphragm cover plate Loose or faulty fuel pipe Faulty diffuser jet Blocked fuel filter Leaking crankcase Blocked fuel line Tank ventilator blocked The throttle valve shaft is inert Throttle stay is binding Defective throttle return spring Too much fuel at Worn needle needle tip Bent valve axle stop idle speed Leaking diaphragm Faulty diffuser jet cover plate Too rich idling Worn needle needle tip Worn lever arm in the control system Leaking diaphragm cover plate English 57 Troubleshooting High speed
42. tructions 2 8 General Instructions The workshop where the chain saw is to be re paired must be equipped with safety equipment in accordance with local regulations No one may repair the chain saw unless they have read and understood the content of this Workshop Manual This workshop manual contains the following warn ing boxes in relevant places WARNING The warning box warns of the risk of personal injury if the instruc tions are not followed NOTE This box warns of material damage if the instructions are not followed 8 English 2 9 Special Instructions The fuel used in the chain saw has the following hazardous properties The fluid and its vapour are poisonous Can cause eye and skin irritation Can cause breathing problems Is highly inflammable When using compressed air do not direct the jet towards your body Air can penetrate into the blood stream which can endanger life Wear protective earplugs or earmuffs when test running After test running do not touch the muffler until it has cooled down Risk of burns Use protective gloves when working with the muffler Do not start the chain saw unless the bar chain and clutch cover chain brake are fitted otherwise the clutch may loosen and cause personal injury Insufficient chain lubrication can result in chain breakage which can cause serious or even life threatening injury Exercise care to ensure the starter spri
43. uel hose 44 Ignition module and flywheel 28 Assembling the ignition module and flywheel 29 Cleaning and inspection 28 Dismantling the ignition module and flywheel 28 Intake system 32 Assembling the intake system 33 Cleaning and inspection 33 Dismantling the intake system 32 Introduction and safety instructions 7 General 7 General Instructions 8 Modifications 7 Numbering 7 Safety 7 Special Instructions 8 Structure 7 Target group 7 Tools 7 4 English Muffler 19 Assembling the muffler 19 Dismantling the muffler 19 O Oil pump and screen 31 Assembling the oil pump and screen 32 Cleaning and inspection 31 Dismantling the oil pump and screen 31 P Piston and cylinder 45 Assembling the piston and cylinder 47 Dismantling the piston and cylinder 45 Faults and causes 47 Pressure testing the cylinder 48 S Service data 14 Service tools 12 Starter 25 26 Cleaning and inspection 25 Cleaning and inspection 26 Dismantling the starter 25 Replacing a broken or worn starter cord 26 Replacing a broken return spring 27 Starter assembly 27 Stop control 20 Dismantling the stop control 20 21 Stop function 21 Resistance test stop function 21 Symbols Symbols in the Workshop Manual 9 Symbols on the saw 9 T Tank unit 42 Assembly 43 Dismantling 42 Tank valve 42 Technical Data 10 Threads 54 Repairing damaged threads 54 Throttle control lock throttle lock and spring 22 Assembling the throttle lockout throttle
44. ure outward 100 450 mbar Opening pressure inward vacuum max 70 mbar 2 locations Test Opening pressure outwards 1 Open the tank lock and leave it open during the entire test Drain the fuel from the tank 2 Loosen the positive pressure hose as outlined in figure 54 Connect the pump ref no 531 03 06 23 to the tank valve J 3 Switch the pump to vacuum mode 4 After pumping the indicator should be between 10 45 kPa Opening pressure inwards 1 Open the tank lock and leave it open during the entire test Drain the fuel from the tank 2 Loosen the positive pressure hose as outlined in figure 54 Connect the pump ref no 531 03 06 23 to the tank valve J 3 Switch the pump to pressure mode 4 After pumping the indicator should stop at max 7 kPa 42 English Fig 50 Fig 51 1000000000 f ARRARARARA Fig 52 Fig 53 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 3 Tighten the chain catcher in place 4 Press the movement limiter H into position See figure 53 Tighten the s
45. wheel Turn the flywheel so that the magnets are positioned opposite the ignition mod ule Tighten the screws at a tightening torque of 4 5 6 Nm Remove the plastic air gap tool Fit the intake system as outlined in 7 14 Assembling the intake system the tank unit as outlined in 7 16 tank unit and the air filter as outlined in Assem bling the carburettor 6 Press the ignition lead into the holder on the parti tion wall 7 Then fit The air nozzle The guide rail and press the cable in place the spark plug hat by unscrewing the piston stop The starter at a tightening torque of 2 5 3 5 Nm The cylinder cover Fig 11 Fig 12 Fig 13 Air gap tool English 29 Repair Instructions 7 8 Dismantling the centrifugal clutch 1 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 2 Loosen the spark plug hat and remove the spark plug and insert the plastic piston stop 575 29 36 01 See figure 15 3 Loosen the clutch using tool 575 25 14 01nd a suit able socket wrench or combination spanner Turn the clutch clockwise to loosen it See figure 15 4 Secure the clutch in a vice as shown in figure 16 Carefully remove the clutch springs Remove the clutch shoe springs from the side that does not have text NOTE Be careful w
46. your thumb See figure 7 WARNING Exercise care to ensure the spring does not fly out and cause personal injury Wear protective goggles 3 Fit the cover over the brake spring using 1 1 5 Nm tightening torgue See figure 8 4 Tighten the brake by using the saw s hand guard as a tool Mesh with the brake and tighten clock wise until the brake is in the off position See figure 9 5 NOTE Make sure the bushings in the kickback guard s attachments are kept in place from the inside See figure 9 Screw the kickback guard in place and put the rocket in position Position the spring B in the plastic housing C see figure 10 and press the spring against the rocker and then press the plastic housing into its groove Tighten the chain guide plate in place Fit the bar chain clutch shoe cylinder cover 18 English Fig 6 Fig 7 Fig 8 Fig 9 Fig 10 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 Let go of the front handle and let the chain saw drop toward the surface underneath e When the bar hits t
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