Husqvarna 455 Rancher Chainsaw parts manual

Workshop manual English 455 Rancher 460

2 – English Workshop manual Husqvarna 455 Rancher and 460 Contents Introduction ........................................................... 3 Safety regulations ................................................ 4 General instructions ........................................... 4 Special instructions ............................................ 4 Special tools ......................................................... 5 Technical data ....................................................... 7 Carburettor ............................................................ 9 Carburettor ........................................................ 9 Carburettor - pressure testing .......................... 14 Carburettor - adjustment .................................. 15 Troubleshooting ................................................. 17 Repair instructions ............................................. 19 Chain brake ...................................................... 19 Silencer ............................................................ 21 Chain catcher ................................................... 21 Stop switch ....................................................... 22 Stop switch – resistance measurement............ 22 Choke control ................................................... 23 Throttle trigger .................................................. 24 Starter assembly .............................................. 25 Starter cord....................................................... 25 Recoil spring..................................................... 26 Ignition module – testing .................................. 27 Ignition module and ﬂywheel ............................ 27 Centrifugal clutch.............................................. 29 Oil pump ........................................................... 30 Air intake system ............................................. 32 Fuel ﬁlter........................................................... 33 Fuel hose.......................................................... 33 Fuel tank........................................................... 34 Piston and cylinder ........................................... 34 Decompression valve – pressure testing ......... 35 Cylinder – pressure testing............................... 37 Crankshaft complete ........................................ 37 Crankshaft bearings ......................................... 38 Thread insert .................................................... 39 Guide bar bolts ................................................. 39

English – 3 Arrangement of the manual This workshop manual can be used in two different ways. • To repair a specific sub-assembly on a chainsaw. • To dismantle and reassemble a complete chainsaw. Repairing a specific sub-assembly If a specific sub-assembly on the chainsaw needs to be repaired: 1. Look up the page referring to the relevant sub- assembly. 2. Follow the instructions under the headings: • Removal/Dismantling • Cleaning and inspection • Refitting/Reassembly Dismantling and reassembling the entire chainsaw If the entire chainsaw is to be dismantled, follow the instructions under the heading “Removal/Dis- mantling”. Work through the manual and follow the instructions given in each section under the heading “Removal/Dismantling”. Then follow all the “Cleaning and inspection” instructions in each section. Working from the back of the manual, follow all the instructions under the headings “Refitting/Reas- sembly” in reverse order. Each of the sections covering removal/dismantling and refitting/reassembly include the relevant lubrication instructions and bolt torques for each stage of repair. Construction and function This chapter gives a simple description of the chainsaw carburettor and its various parts. Introduction Troubleshooting These pages describe the most common faults that affect a chainsaw. They are divided into four different groups with the most likely faults described first. Repair instructions The section that describes how to repair the chainsaw consists of detailed, step-by-step instructions. It explains in detail the special tools, lubricants and bolt torques that are needed when working on each component. This workshop manual covers the following chainsaw models: 455 Rancher 460

4 – English General instructions This workshop manual gives detailed instructions on how to troubleshoot, repair and test a chainsaw. This section also describes the various safety precautions that should be taken when carrying out repairs. The workshop manual has been written for person- nel who are assumed to have general experience of repairing and servicing chainsaws. Workshops where chainsaws are repaired must be equipped with safety equipment that meets local regulations. No-one should carry out repairs on a chainsaw until they have read and understood the contents of this workshop manual. Chainsaws are type-approved to meet the relevant safety legislation, but this only applies when the saw is fitted with the cutting equipment speci- fied in the user’s manual. The fitting of any other equipment, or of accessories or parts that are not approved by Jonsered, could mean that the saw no longer meets these safety requirements and the person who carried out the work may be held responsible for its non-conformance. In this workshop manual the following boxes indi- cate where caution should be taken. Special instructions The fuel that is used in a chainsaw poses the following hazards: • The fuel and its fumes are toxic. • May cause irritation to skin or eyes. • May cause breathing difficulties. • Highly flammable. When using compressed air the air jet should never be pointed at the body. Air can be forced into the bloodstream and cause fatal injury. Wear ear protection when testing saws. After testing a saw do not touch the silencer until it has cooled down. The silencer gets very hot and you may burn yourself. Wear protective gloves when working on the silencer. The guide bar, chain and clutch cover (chain brake) must be fitted before the saw is started. If not, the clutch may come loose and cause injury. Poor chain lubrication can result in failure of the chain, which could cause serious or fatal injury. Take care to ensure that the spring inside the starter assembly does not fly out and cause injury. Wear eye protection. If the spring is under compression when the pulley is removed it could fly out and cause injury. Before removing the tensioning spring from the chain brake, ensure that the brake is in the on position, otherwise the spring may fly out and cause injury. After completing the repair the chain brake must be tested, see “Chain brake – reassembly \ Operating test”. Always consider the fire risk. A chainsaw can produce sparks that could start a fire. Inspect the chain catcher and replace it if it is damaged. WARNING! The warning text warns of the risk of personal injury if the instructions are not followed. NOTE! The warning text warns of the risk of ma- terial damage if the instructions are not followed. Safety regulations Safety regulations

English – 5 10 Special tools 4 5 8 1 2 3 6 7 9 Special tools

6 – English Item Description Used for Order no. 1 Clutch tool Centrifugal clutch 502 54 16-01 2 Piston stop Locking the crankshaft 504 91 06-05 3 Fuel filter hook Withdrawing the fuel filter 502 50 83-01 4 Allen key For M5 bolts 502 50 18-01 5 Pressure tester Pressure testing cylinder 503 84 40-02 6 Feeler gauge Adjusting ignition module 502 51 34-02 7 Assembly fixture Assembling chain saw 502 51 02-01 8 Pressure gauge Pressurisation during testing 531 03 06-23 9 Test spark plug Checking the ignition module 502 71 13-01 10 Rev counter Adjusting carburettor 502 71 14-01 11 Assembly pliers Fitting spark plug guard 502 50 06-01 12a Cover plate, exhaust Sealing the exhaust port 502 54 11-02 12b Cover plates, inlet Sealing the intake manifold 502 52 48-02 13 Assembly tool Assembling spring, chain brake 502 50 67-01 14 Puller Pulling bearing of crankshaft 504 90 90-01 15a Sleeve Fitting crankshaft 502 50 30-18 15b Shaft extension Flywheel side 502 50 30-18 15c Shaft extension Cluch side 502 50 30-18 16 Punch Dismantling the flywheel 502 51 94-01 11 12a 13 14 12b 15a 15c 15b 16 Special tools

English – 7 Displacement Cylinder bore Stroke Max power/speed cm 3 /cubic inches Ø mm/Ø inches mm/inches kW/hp/rpm 455: 55,5 / 3,38 47 / 1,85 32 / 1,28 2,6 / 3,5 / 9 000 460: 60,3 / 3,68 49 / 1,93 32 / 1,28 2,7 / 3,7 / 9 000 Spark plug gap Ignition system Air gap Carburettor type mm/inches mm/inches 455: 0,5 / 0,02 SEM CD 0,3 / 0,012 Walbro WTA 29 460: 0,5 / 0,02 SEM CD 0,3 / 0,012 Walbro WTA 29 Effective cutting length Chain speed at Chain pitch Drive link cm/inches max power – revs mm/inches mm/inches m/s – rpm 455: 31-50 / 13-20 20,0 / 9 000 9,52 / 3/8 1,3 / 0,050 - 1,5 / 0,058 460: 31-50 / 13-20 20,0 / 9 000 8,25 / 0,325 1,3 / 0,050 - 1,5 / 0,058 Technical data Technical data

8 – English Idling speed Engagement speed Spark plug rpm rpm 455: 2 700 3 800 NGK BPMR 7A Champion RCJ 7Y 460: 2 700 3 800 NGK BPMR 7A, Champion RCJ 7Y Fuel tank capacity Oil pump capacity at Oil tank capacity Automatic oil pump Litres/US pints 8,500 rpm, Litres/US pints ml/min 455: 0,44 / 0,93 9 0,32 / 0,68 Yes 460: 0,44 / 0,93 9 0,32 / 0,68 Yes Weight without Weight with bar and chain bar and chain kg / lbs kg / lbs 455: 5,8 / 12,8 6,2 / 13,6 460: 5,8 / 12,8 6,2 / 13,6 rpm GAS OIL Technical data

English – 9 Carburettor WARNING! The fuel used in the chainsaw has the following hazardous properties: 1. The ﬂuid and its fumes are poisonous. 2. Can cause skin irritation. 3. Is highly inﬂammable. Carburettor Description The drawings accompanying this description do not correspond with the carburettor on the chainsaw. They only show the principle for the design and function. Design The carburettor is based on three sub-systems: • The metering unit, A. • The mixing venturi, B. • The pump unit, C. The jets 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. A B C The mixing venturi (B) houses the choke, throttle valve and diffuser jets. Here air is mixed with the fuel to give a fuel/air mixture that can be ignited by the ignition spark. In the pump unit (C), fuel is pumped from the fuel tank to the 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. Carburettor

10 – English Function The carburettor operates differently in the following modes: • Cold start mode • Idling mode • Part throttle mode • Full throttle mode In the cold start mode (see figure below) the choke valve (H) is fully closed. This increases the vacuum in the carburettor so that fuel is sucked more easily from all the diffuser jets (D, E and F). The throttle valve (I) is partly open. Extra air inlet (J) is closed. I H G D F E J In the idling mode (see figure below) the throttle valve (I and J) is 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). In the part throttle mode (see figure below) the throttle valve (I) is partially open and the choke valve (H) is open. Fuel is supplied through the diffuser jets (D and E). In full throttle mode (se figure below) all valves are open and fuel is supplied through all diffuser jets (D, E, F and G). Extra air inlet (J) is also fully opened. I D H E I H D G D F E H I J Carburettor

Husqvarna 455 Rancher Chainsaw parts manual

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