545 Mark II, 545G Mark II, 550 XP® Mark II, 550 XP® G Mark II EN Operator's manual 2-39
Contents Introduction..................................................................... 2 Transportation and storage...........................................33 Safety..............................................................................4 Technical data.............................................................. 33 Assembly........................................................................ 9 Accessories.................................................................. 34 Operation..
11. Fuel level window 12. Fuel tank 13. Air purge bulb 14. Starter rope handle 15. Starter housing 16. Chain oil tank 17. Muffler 18. Chain brake and front hand guard 19. Front handle 20. Switch for heated handles (545G Mark II, 550 XPG Mark II) 21. Right hand guard 22. Clutch cover 23. Clutch drum 24. Oil pump adjustment screw 25. Chain tensioning screw 26. Chain catcher 27. Spiked bumper 28. Saw chain 29. Guide bar 30. Bar tip sprocket 31. Brake band 32. Guide bar cover 33. Operator's manual 34.
EPA III The Emissions Compliance Period referred to on the Emission Compliance label indicates the number of operating hours for which the engine has been shown to meet Federal emissions requirement. Maintenance, replacement or repair of the emission control devices and system may be performed by any nonroad engine repair establishment or individual.
Safety instructions for operation ladder, in a tree or where you do not have a firm ground to stand on. WARNING: Read the warning instructions that follow before you use the product. • • • • • • Before using the chainsaw you must understand the effects of kickback and how to avoid them. Refer to Kickback information on page 12 for instructions. Never use a product that is faulty. Never use a product with visible damage to the spark plug cap and ignition cable.
• • • • • pointing backwards. Fit a transportation guard to the guide bar before transporting the product or carrying it for any distance. When you put the product on the ground, lock the saw chain using the chain brake and ensure you have a constant view of the product. Switch the engine off before leaving your product for any length of time. Sometimes chips get stuck in the clutch cover causing the saw chain to jam. Always stop the engine before cleaning.
Chain brake and front hand guard Your product has a chain brake that stops the saw chain if you get a kickback. The chain brake decreases the risk of accidents, but only you can prevent them. maintenance on the saw chain and guide bar, decrease the risk of accidents. The chain brake engages (A) manually by your left hand or automatically by the inertia release mechanism. Push the front hand guard (B) forward to engage the chain brake manually.
• • • • Muffler WARNING: The muffler gets very hot during/ after operation and at idle speed. There is a risk of fire, especially when you operate the product near flammable materials and/or fumes. • • • observe caution when handling fuel and make sure there is adequate ventilation. Take care when handling fuel and chain oil. Be aware of the risks of fire, explosion and those associated with inhalation. Do not smoke and do not place any hot objects in the vicinity of fuel.
professional repairs and servicing available for your product. • Make sure that the saw chain has the correct tension. If the saw chain is not tight against the guide bar, the saw chain can derail. An incorrect saw chain tension increases wear on the guide bar, saw chain and chain drive sprocket. Refer to To adjust the tension of the saw chain on page 28. • Do maintenance on the cutting equipment regularly and keep it correctly lubricated.
5. Make sure that the edges of the cutters point forward on the top edge of the guide bar. 6. Align the hole in the guide bar with the chain adjuster pin and install the clutch cover. 7. Tighten the bar nuts finger tight. 8. Tighten the saw chain. Refer to To adjust the tension of the saw chain on page 28 for instructions. 9. Tighten the bar nuts. Note: Some models have only one bar nut. Operation Introduction 10. Do a check of the saw chain tension.
To mix fuel Gasoline Use good quality unleaded gasoline with a maximum of 10% ethanol contents. • CAUTION: Do not use gasoline with an octane grade less than 90 RON/87 AKI. Use of a lower octane grade can cause engine knocking, which causes engine damages. • We recommend that you use gasoline of a higher octane grade for work with continuously high rpm. Limbing is an example of such work. 1. Fill half the quantity of gasoline in a clean container for fuel. 2. Add the full quantity of oil.
WARNING: The saw chain can break if the lubrication of the cutting equipment is not sufficient. Risk of serious injury or death to the operator. WARNING: This product has a function that lets the fuel run out before the chain oil. Use the correct chain oil for this function to operate correctly. Speak to your servicing dealer when you select your chain oil. Note: This product has an automatic chain lubrication system. You can also adjust the oil flow. Refer to To adjust the chain oil flow on page 31.
• brake is too sensitive, it can engage during rough operation. Will the chain brake always protect me from injury during a kickback? No. The chain brake must operate correctly to give protection. The chain brake must also be engaged during a kickback to stop the saw chain. If you are near the guide bar, it is possible that the chain brake does not have time to stop the saw chain before it hits you. WARNING: Only you and the correct working technique can prevent kickbacks.
5. Pull the starter rope handle quickly and with force. To stop the product 1. Push the start/stop switch down to stop the engine. Pull stroke and push stroke CAUTION: Do not pull the starter rope to full extension and do not let go of the starter rope handle. This can cause damage to the product. You can cut through wood with the product in 2 different positions. • To cut on the pull stroke is when you cut with the bottom of the guide bar. The saw chain pulls through the tree when you cut.
To cut a trunk on the ground 1. Cut through the trunk on the pull stroke. Keep full throttle but be prepared for sudden accidents. To use the cutting technique WARNING: Use full throttle when you cut and decrease to idle speed after each cut. CAUTION: Engine damage can occur if the engine runs for too long at full throttle without load. WARNING: Make sure that the saw chain does not touch the ground when you complete the kerf. 2. Cut approximately ⅔ through the trunk and then stop.
1. Remove the limbs on the right side of the trunk. a) Keep the guide bar on the right side of the trunk and keep the body of the product against the trunk. b) Select the applicable cutting technique for the tension in the branch. 1. Cut on the pull stroke approximately ⅓ through the trunk. 2. Cut through the remaining part of the trunk on the push stroke to complete the cut. 1. 2. WARNING: Stop the engine if the saw chain gets caught in the trunk. Use a lever to open up the kerf and remove the product.
a) Select the applicable cutting technique for the tension in the branch. 2. Make sure that no person is in the risk zone before or during felling. To calculate the felling direction WARNING: If you are not sure about how to cut the branch, speak to a professional chainsaw operator before you continue. Refer to To cut trees and branches that are in tension on page 20 for instructions on how to cut branches that are in tension.
complete. It is important that you hear sounds and warning signals. The felling hinge To clear the trunk and prepare your path of retreat The most important procedure during tree felling is to make the correct felling hinge. With a correct felling hinge, you control the felling direction and make sure that the felling procedure is safe. Cut off all branches from your shoulder height and down. The thickness of the felling hinge must be equal and a minimum of 10% of the tree diameter. 1.
To use the safe corner method The felling cut must be made slightly above the directional cut. WARNING: Be careful when you cut with the guide bar tip. Start to cut with the lower section of the guide bar tip as you make a bore cut into the trunk. b) Cut on the pull stroke through the remaining trunk. c) Cut straight into the trunk from the other side of the tree to complete the felling hinge. d) Cut on the push stroke, until ⅓ of the trunk is left, to complete the safe corner. 3.
5. Make one or more cuts of sufficient depth necessary to decrease the tension. Cut at or near the point of maximum tension. Make the tree or branch break at the point of maximum tension. The safest procedure is to use one of the following winches: • Tractor-mounted WARNING: Do not cut straight through a tree or branch that is in tension. WARNING: Be very careful when you cut a tree that is in tension. There is a risk that the tree moves quickly before or after you cut it.
2. For temperatures below -5°C/23°F and/or in conditions with snow, a special cover is available. Assemble the cover on the starter housing. The cover decreases the flow of cool air and keeps large quantities of snow away from the carburetor space. Risk of too high engine temperature and damage to the engine. Heated handles (545G Mark II, 550XPG Mark II) The product has heated front and rear handles. The electrical heating coils are powered by a generator.
Daily maintenance Weekly maintenance Monthly maintenance Do a check of the chain catcher. Refer to To do a check of the chain catcher on page 24. Clean or replace the spark arrestor mesh on the muffler. Do a check of the fuel filter and the fuel hose. Replace if necessary. Turn the guide bar, do a check of the lubrication hole and clean the groove in the guide bar. Refer to To do a check of the guide bar on page 30. Clean the carburetor area. Do a check of all cables and connections.
Maintenance and checks of the safety devices on the product To do a check of the brake band 1. Use a brush to remove wood dust, resin and dirt from the chain brake and clutch drum. Dirt and wear can decrease the function of the brake. To do a check of the chain brake 1. Start the product. Refer to To start the product on page 13 for instructions. WARNING: Make sure that the saw chain does not touch the ground or other objects. 2. Hold the product tightly. 3.
4. Start the product and apply full throttle. To do a check of the muffler 5. Release the throttle trigger and make sure that the saw chain stops and stays stationary. 1. Make sure that the muffler is not defective. WARNING: If the saw chain rotates when the throttle trigger is in the idle position, speak to your servicing dealer. To do a check of the chain catcher WARNING: Do not use a product that has a defective muffler or a muffler that is in bad condition. 2.
AutoTune™ Your product has the AutoTune™ function that adjusts the carburetor automatically, which gives the best possible adjustment. AutoTune™ lets the engine adapt to weather conditions, altitude, gasoline and the type of two-stroke oil. CAUTION: If AutoTune™ does not work correctly, speak to your servicing dealer. The product adjusts correctly after some fuelings. To replace a broken or worn starter rope 6. Remove the used starter rope from the handle and the pulley. 7.
3. Tighten the screws that hold the starter. 1. If the product is not easy to start or to operate or if the product operates incorrectly at idle speed, examine the spark plug for unwanted materials. To decrease the risk of unwanted material on the spark plug electrodes, do these steps: a) make sure that the fuel mixture is correct. b) make sure that the air filter is clean. 2. Clean the spark plug if it is dirty. 3. Make sure that the electrode gap is 0,5 mm/0.020 in.
• Chain pitch, in. The distance between the drive links of the saw chain must align with the distance of the teeth on the bar tip sprocket and drive sprocket. PITCH = D 2 D • Number of drive links. The number of drive links is decided by the type of guide bar. General information about how to sharpen the cutters Do not use a blunt saw chain. If the saw chain is blunt, you must apply more pressure to push the guide bar through the wood.
will help you to keep maximum cutting performance and the kickback risk at a minimum. WARNING: The force of the kickback increases a lot if you do not follow the sharpening instructions. page 35 for instructions about how to receive the correct depth gauge setting for your saw chain. A C B Note: Refer to Filing equipment and filing angles on page 35 for information about sharpening of the saw chain. To sharpen the cutters 1. Use a round file and a file gauge to sharpen the cutting teeth.
1. Loosen the bar nuts that hold the clutch cover/chain brake. Use a wrench. 2. If the saw chain lubrication is correct, you see a clear line of oil on the surface after 1 minute. Note: Some models have only one bar nut. 2. Tighten the bar nuts by hand as tightly as you can. 3. Lift the front of the guide bar and turn the chain tensioning screw. Use a wrench. 4. Tighten the saw chain until it is tight against the guide bar but still can move easily. 3.
4. Lubricate the needle bearing with a grease gun. Use engine oil or a bearing grease of high quality. To do a check of the guide bar 1. Make sure that the oil channel is not blocked. Clean if it is necessary. 2. Examine if there are burrs on the edges of the guide bar. Remove the burrs using a file. 3. Clean the groove in the guide bar. To examine the cutting equipment 1. Make sure that there are no cracks in rivets and links and that no rivets are loose. Replace if it is necessary. 2.
7. Turn the guide bar daily to extend its life cycle. Air cleaning system AirInjection™ is a centrifugal air cleaning system that removes dust and dirt before the particles is caught by the air filter. AirInjection™ extends the life of the air filter and the engine. To do maintenance on the fuel tank and the chain oil tank • • Drain and clean the fuel tank and the chain oil tank regularly. Replace the fuel filter yearly or more frequently if necessary.
Troubleshooting The engine does not start Product part to examine Possible cause Action Starter pawls The starter pawls are blocked. Adjust or replace the starter pawls. Clean around the pawls. Speak to an approved service workshop. Fuel tank Ignition, no spark Incorrect fuel type. Drain the fuel tank and fill with correct fuel. The fuel tank is filled with chain oil. If you have tried to start the product, speak to your servicing dealer.
Transportation and storage Transportation and storage • • To prepare your product for long-term storage • • • • For storage and transportation of the product and fuel, make sure that there are no leaks or fumes. Sparks or open flames, for example from electrical devices or boilers, can start a fire. Always use approved containers for storage and transportation of fuel. Empty the fuel and chain oil tanks before transportation or before long-term storage.
Husqvarna 545 Mark II Husqvarna 545G Mark II Husqvarna 550 XP Mark II Husqvarna 550 XPG Mark II Type of drive sprocket/number of teeth Rim/7 Rim/7 Rim/7 Rim/7 Saw chain speed at 133% of maximum engine power speed, ft/s / m/s. 83.3/25.4 83.3/25.4 85.6/26.1 85.6/26.1 Saw chain/guide bar Accessories Recommended cutting equipment A specific chainsaw model has to be evaluated with the cutting equipment to be recommended and fulfill the requirements in ANSI B175.
Approved cutting equipment - 545 Mark II and 545G Mark II Guide bar Saw chain Length, in/cm Pitch, in Gauge, in/mm Max. nose radius Type Length, drive links (no.) Low kickback 13/33 0.325 0.058/1,5 11T Husqvarna H25 56 Yes 15/38 16/41 12T 64 66 18/46 72 20/50 80 Approved cutting equipment - 550 XP Mark II and 550 XPG Mark II Guide bar Saw chain Length, in/cm Pitch, in Gauge, in/mm Max. nose radius Type 13/33 0.325 0.
SP33G H25 H21 36 586 93 84-04 4.8 mm / 3/16 in 505 69 81-09 505 69 81-09 80° 0.025 in / 0.65 mm 30° 80° 60° 544 - 004 - 07.02.
Warranty FEDERAL EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The EPA (The US Environmental Protection Agency), Environment Canada and Husqvarna Forest & Garden are pleased to explain the emissions control system warranty on your 2009 and later small nonroad engine. In U.S. and Canada, new small nonroad engines must be designed, built and equipped to meet the federal stringent anti-smog standards.
maintenance or repairs on emission-related parts, will be provided without charge to the owner if the part is under warranty. EMISSION CONTROL WARRANTY PARTS LIST 1. Carburetor and internal parts. 2. Intake pipe, airfilter holder and carburetor bolts. 3. Airfilter and fuelfilter covered up to maintenance schedule. 4. Spark Plug, covered up to maintenance schedule. 5. Ignition Module.
should be performed by competent chain saw service personnel. (For example, if improper tools are used to remove the flywheel or if an improper tool is used to hold the flywheel in order to remove the clutch, structural damage to the flywheel could occur and subsequently cause the flywheel to burst.) When transporting your chain saw, use the appropriate guide bar guard. Note: This Annex is intended primarily for the consumer or occasional user. 544 - 004 - 07.02.
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