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Husqvarna 123HD60, Workshop Manual

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Husqvarna 123HD60 Workshop Manual Download Page 35

6

33

6

Cylinder and piston

Cylinder and piston

Contents

Dismantling  __________________________________ 34

Cleaning, inspection  ___________________________ 35

Analysis and actions  __________________________  36

Service tips  _________________________________  40

Wear tolerances  _____________________________  41

Assembly   __________________________________  41

Summary of Contents for 123HD60

Page 1: ...Workshop manual 123HD60 123HD65X English ...

Page 2: ......

Page 3: ...___________ 13 4 Centrifugal clutch _______________________ 25 5 Cutting deck ___________________________ 29 6 Cylinder and piston ______________________ 33 7 Crankshaft and crankcase ________________ 43 8 Tools _________________________________ 49 9 Technical Data _________________________ 53 Workshop Manual Hedge trimmer Model 123 HD60 123 HD65X Husqvarna AB Sweden 2010 Contents ...

Page 4: ...t approved by Husqvarna can result in the failure to meet these safety demands and that the person carrying out assembly bears responsibility for this Fire risk Handle fuel with respect as it is extremely inflammable Never refuel while the engine is running Do not smoke and ensure there are no open flames or sparks in the vicinity Never start the engine if the machine is leaking fuel or if there h...

Page 5: ...1 3 1 Starter Starter Contents Dismantling ___________________________________ 4 Assembly_____________________________________ 5 Replacing the drive _____________________________ 6 ...

Page 6: ...ter cord about 30 cm Slow the starter pulley with your thumb Lift the starter cord up out of the cut out on the starter pulley Let the starter pulley rotate backwards until the spring tension ceases WARNING Wear protective glasses The return spring lies tensioned in the starter housing and can fly out and cause personal injury with careless handling Remove the screw A and lift off the drive disc B...

Page 7: ...de so that the steel wire A slides off the spring The pressure equalisation spring is sup plied as a spare part fitted to the starter pulley Lubricate the return spring and position the starter pulley Lubricate the return spring and the star ter pulley s stub axle with cold resistant grease or thin oil Move the starter cord through the guide in the starter housing A Guide the free end of the retur...

Page 8: ... Replace the drive dogs if they are worn or defective Prize off the circlip using a small screw driver Assemble in the reverse order as set out for dismantling Fit the starter in place on the fan housing cover and check that it works Do not forget the plate washer under the starter Turn the washer so that the protruding collar faces down towards the flywheel Tighten the return spring Check the spr...

Page 9: ...2 7 2 Electrical system Electrical system Contents Checking the ignition spark ______________________ 8 Dismantling __________________________________ 11 Assembly __________________________________ 12 ...

Page 10: ...ck the electrode gap It should be 0 6 mm Adjust the gap as needed to the correct value with the side electrode If the electrodes are worn more than 50 the spark plug should be changed If the electrodes are worn more than 50 the spark plug should be changed Too large a spark gap entails a great deal of stress on the ignition module and risk for short circuiting Check if a spark occurs when attempti...

Page 11: ... 502 50 06 01 to make a hole in the ignition cable When a part of the ignition lead has been cut off it helps to use pliers no 502 50 06 01 to make a new hole in the ignition lead to fit the contact coil NOTE It is important that the tip of the ignition coil hits the centre of the ignition cable to prevent sparking Attach the ignition coil to the ignition cable Attach the ignition coil to the igni...

Page 12: ...ure that the cables are correctly drawn See chapter 3 Throttle TIP Use an Ohmmeter in order to easily check if cable breakage has occurred due to pinching for example Still no spark Check the air gap Still no spark Check the air gap between the fly wheel magnet and the ignition module The gap should be 0 3 mm Use air gap gauge 502 51 34 02 Adjust the air gap Adjust the air gap to the right measure...

Page 13: ...er A and the cylinder cover B Separate the short circuit cables C Remove the screws D and remove the ignition module E NOTE Do not lose the insulation sleeves that are placed between the ignition module and the cylinder Fit the piston stop 522 43 18 01 and dismantle the drive disc cup Fit the piston stop 522 43 18 01 in the spark plug hole Remove both screws F and remove the drive disc cup NOTE Pl...

Page 14: ...ition module Adjust the air gap to 0 3 mm Adjust the air gap There should be 0 3 mm between the permanent magnets in the flywheel and the ignition module Tighten the screws that hold the ignition module in place and check the air gap once again Assemble other parts in the reverse order as set out for dismantling Assembly Check that the key and the key slot in the crankshaft are undamaged Assemble ...

Page 15: ...________________ 15 Fuel filter ____________________________________ 15 Carburettor __________________________________ 16 Assembly ___________________________________ 20 Carburettor settings ___________________________ 20 Throttle handle _______________________________ 21 Trouble Shooting Guide ________________________ 23 ...

Page 16: ...ir filter Fold the cover over the air filter to one side Press in the lock lid with your thumb and fold up the cover WARNING Do not clean not the filter with petrol Hazardous NOTE Make sure that the air filter is free of cleaning agent before it is impregnated with air filter oil TIP Use Husqvarna s cleaning agent Active Cleaning no 505 69 85 70 Impregnate the filter with air filter oil Impregnate...

Page 17: ... sure the seal D is not damaged Fuel filter The fuel hose in the tank contains a fuel filter It is accessible through the fill hole Pull out the filter using tool 502 50 83 01 If the filter is not too dirty its surface can be cleaned with a brush Otherwise it must be replaced Check the fuel hose for cracks and leaks Make sure that the filter s connection neck is inserted as far as possible into th...

Page 18: ... around the carburettor 3 Disconnect the throttle cable A from the carburettor s lever arm B 4 Dismantle the fuel hoses from the carburettor and note how they are con nected so that the fuel pump works as intended 5 Remove the carburettor screws 6 Lift off the air filter holder C 7 Remove the attachment for the throttle cable s adjustment screw D 8 Remove the carburettor Dismantling the carburetto...

Page 19: ...ng and check that the channels are open Check that the non return valve s seals D are undamaged by carefully squeezing the short sides together Replace the valve if necessary With the help of the fuel pump s bellows press fuel through the carburettor and fill all ducts with fuel With the help of the fuel pump s bellows press fuel through the carburettor and fill all ducts with fuel Any vapour bubb...

Page 20: ...aphragm and partly by the cut outs for the needle valve Also check wear to the tip of the needle valve and the groove for the lever arm Replace damaged parts with new parts Replace the needle valve s seat Press out the needle valve s seat for replacement Use a suitable punch Ø 4 5 mm NOTE Replace the seat needle valve and lever arm at the same time The needle valve s seat should be pressed in leve...

Page 21: ... the carburettor Clean and inspect all parts Worn or damaged parts are replaced with new ones Pay attention to the following when the carburettor is assembled in the reverse order to dismantling The screen A has to be cleaned and undamaged Check that the carburettor is sealed Connect the pressure tester no 531 03 06 23 to the fuel inlet B on the carburettor Pump up the pressure to 50 kPa Lower the...

Page 22: ...t and protective plate in place Connect the fuel hoses Put the carburettor gasket on the protec tive plate A Place the air filter holder and the screws on the carburettor and tighten them Connect the throttle cable B Connect the fuel hoses to the carburettor Place the gasket A on the protective plate and fasten it with a little grease Place th air filter holder and the carburet tor screws on the c...

Page 23: ... incl the adjustment screw 2 Separate the short circuit cables 3 Remove the lockwasher A that holds the throttle handle against the engine frame by prizing it open using a screwdriver that it inserted into the oval opening 4 Pull off the throttle handle from the engine frame Remove the 4 screws and carefully sepa rate both handle halves 5 Remove the 4 screws holding the handle halves together 6 Ca...

Page 24: ...t in the opposite direction the lock G that prevents handle rotation Assemble the throttle handle in the re verse order as set out for dismantling Note the following Make sure that the short circuit cable is properly pressed into the handle half so that it is jammed in place Lubricate the O ring with a little grease so that the handle is easy to twist ...

Page 25: ...alve s lever Lever arm damaged Lever arm too high Lever arm too low Lever arm does not work correctly Needle valve s spring The spring is deformed The spring is not fitted correctly Control diaphragm Diaphragm is damaged Faulty seal Needle valve Valve jams Valve worn Foreign object in the valve guide Diffi cult to start Flooding fuel leakage Diffi cult to prime when starting Engine does not idle I...

Page 26: ...3 24 Fuel system ...

Page 27: ...25 4 Centrifugal clutch Centrifugal clutch Contents Centrifugal clutch dismantling __________________ 26 Centrifugal clutch assembling __________________ 27 Clutch drum ________________________________ 27 ...

Page 28: ...d so that the engine can idle without the cutting equipment s drive shaft rotating Centrifugal clutch Dismantling Disconnect the throttle cable and sepa rate the connections on the short circuit cables Remove the screws holding the engine to the vibrational dampers Lift out the engine Centrifugal clutch Dismantling Unhook the throttle cable from the carbu rettor and separate the connections to the...

Page 29: ...t out for dismantling The key grip on the clutch must face in toward the crankcase Clutch drum Remove the cutting knives and the con tents of the gear housing Clutch drum To dismantle the clutch drum the cutting knives and gear housing contents must be removed first see also the Cutting deck chapter Remove the 4 screws A holding together the cutting knives the bar and the knife protector remove th...

Page 30: ... a suit able mandrel Check the inside diameter of the clutch drum If it exceeds 55 0 mm it should be replaced Check the clutch drum for wear The diameter must not exceed 55 0 mm If this is the case replace the clutch drum Assemble the different components in the reverse order as set out for dismantling Heat the gear housing before the ball bearings are fitted Assemble the different components in t...

Page 31: ...5 29 5 Cutting deck Cutting deck Contents Cutting deck disassembly _____________________ 30 Cutting deck assembly _______________________ 32 ...

Page 32: ...and separate the connections to the short circuit cable Remove the 4 screws holding the engine to the vibrational dampers Lift out the engine and the fitted cutting deck Remove the cutting deck from the engine Remove the three screws A and lift out the cutting deck from the engine Remove the knife protector cutting knives and the cover over the gear housing Remove the 4 screws A holding together t...

Page 33: ...ng deck Remove the crank rod C the sealing felt D and the cutting knives E Lift up the lower crank rod completely with sprocket and eccentric cam F This gives access to the screws G for dismantling the chain bar ...

Page 34: ...or information on the small gear wheel Assembly Clean and inspect all components for wear and damage Assemble in the reverse order as set out for dismantling NOTE Make sure that the 4 screws holding the cutting knives together are not tightened too much so that the knives or not locked and can move freely Fill the gear housing with grease no 531 00 92 05 Lubricate the friction surfaces of the cut ...

Page 35: ...__________________________ 34 Cleaning inspection ___________________________ 35 Analysis and actions __________________________ 36 Service tips _________________________________ 40 Wear tolerances _____________________________ 41 Assembly __________________________________ 41 ...

Page 36: ...e and sepa rate the connections on the short circuit cables Remove the screws holding the engine to the vibrational dampers Lift out the engine Dismantling Do the following to facilitate the process Unhook the throttle cable from the carbu rettor and separate the connections to the short circuit cable Remove the 4 screws holding the engine to the vibrational dampers Lift out the engine and the fit...

Page 37: ...combustion chamber 3 Scrape carbon deposits from the cylinder s exhaust port 4 Wash all the components 5 Inspect the different components for damage and wear Check the piston and cylinder for seizure damage and wear Also see the Analysis and actions section Check the piston ring for wear and possible breakage Also see the Analysis and actions section Check the gudgeon pin If it has blued it must b...

Page 38: ...e in engine body Leaking crankshaft seals Leaking cylinder and crankcase gas kets Poor maintenance Dirty cooling fins on the cylinder Blocked air intake on the starter Blocked spark arrestor mesh in the muffler For the best results we recommend Husqvarna two stroke oil or ready mixed fuel that is specially developed for air cooled two stroke engines Mixing ratio 1 50 2 If Husqvarna two stroke oil ...

Page 39: ...de pin for the piston ring has become loose Piston ring breakage A too lean carburettor setting results in a too high speed and a high piston temperatu re If the piston temperature rises above the normal working temperature the piston ring can seize in its groove consequently it will not sit deep enough in its groove The edges of the piston ring can then hit the top edge of the exhaust port and be...

Page 40: ...o hammer against the guide pin when the piston ring moves in its groove The intensive hammering can drive out the pin through the top of the piston causing serious damage also to the cylinder Damage caused by gudgeon pin circlips A too high engine speed can cause the gudgeon pin circlips to vibrate The circlips are drawn out of their grooves due to the vibrations which in turn reduces the circlips...

Page 41: ...orrectly fitted Air filter damaged or missing Inlet side Particles of dust and dirt from carbon like deposits on the top of the piston and in the piston ring groove The piston ring sits firmly in the groove Piston material has been worn away The lower part of the piston skirt is thinner on the inlet side than on the exhaust side The piston scored and worn from the piston ring down on the inlet sid...

Page 42: ...and clean the groove well before refitting Carbon deposits in the groove impair the important heat transfer between the piston and cylinder NOTE Be careful with the lower edge of the piston ring groove If this is damaged or if carbon deposits remain the compression pressure can leak through Check the wear on the piston ring by placing it in the lower part of the cylinder bore Position a suitable p...

Page 43: ...Assemble the cylinder with the help of as sembly set 502 50 70 01 Check that the pulse channel in the cylin der is open Place a new cylinder base gasket on the cylinder or the crankcase Lubricate the piston and the crank bearing with a few drops of engine oil Assemble the cylinder with the help of the piston ring compressor in the assembly set 502 50 70 01 NOTE Do not turn the cylinder as the pist...

Page 44: ...n leakage which in turn can cause uneven idling and starting difficulties Check that the impulse channel A is open all the way through the gaskets and the heat protective plate to the cylinder Assemble the remaining parts in the re verse order as set out for dismantling See respective sections in the manual ...

Page 45: ... 7 Crankshaft and crankcase Crankshaft and crankcase Contents Dismantling ________________________________ 44 Inspecting the crankshaft______________________ 45 Assembly _________________________________ 46 ...

Page 46: ...y sealed so as not to affect this pump function There cannot be any leakage from the crankshaft between the crankcase halves or between the crankcase and the cylinder Always replace the sealing rings and gaskets when servicing the crankcase Dismantling Dismantle all components so that only the crankcase and crankshaft remain Remove the 4 screws holding the clutch housing against the crankcase Dism...

Page 47: ...ock the crankcase half against a woo den block so that the ball bearing falls out Knock the crankcase half against a woo den block so that the ball bearing falls out Inspecting the crankshaft Inspect the large end of the connecting rod Inspecting the crankshaft The crankshaft cannot be reconditioned but must be replaced if it is worn or dama ged Inspect the large end of the connecting rod If seizu...

Page 48: ... Mount the bearings in the crankcase halves Assembly Mount the bearings in the crankcase halves Heat the crankcase halves to approx 110 C using a hot air gun Put the ball bearings in position Use a suitable punch and hammer if needed Make sure the bearing rests against the circlip and shoulder in the bearing seating Fit the sealing rings in the crankcase halves Fit the sealing rings in the crankca...

Page 49: ... crankcase screws a little at a time Check that the crankshaft can rotate easily Assemble the piston Attach the flywheel Position the cylinder base gasket Assemble the piston on the connecting rod Check that the piston is turned so the ar row points towards the exhaust port Make sure that the gudgeon pin circlips are seated correctly in the slots Place the flywheel key in position in the crankshaf...

Page 50: ...7 48 Crankshaft and crankcase ...

Page 51: ...______________________ 50 Fuel system ______________________________ 50 Centrifugal clutch__________________________ 51 Cutting deck _____________________________ 51 Cylinder and piston ________________________ 51 Crankshaft and crankcase___________________ 51 Workshop equipment_______________________ 51 ...

Page 52: ...1 502 50 18 01 0 3 502 51 34 02 502 50 19 01 522 43 18 01 502 50 19 01 505 69 85 70 531 00 60 76 531 03 06 23 502 50 83 01 502 50 19 01 502 02 61 02 502 71 14 01 501 60 02 03 522 43 18 01 List of tools Electrical system Starter Fuel system Fuel system Electrical system ...

Page 53: ...01 544 13 05 01 544 13 08 01 544 13 09 01 544 13 10 01 544 34 87 01 531 03 06 23 502 71 14 01 502 50 23 01 505 38 13 08 576 95 40 01 576 95 41 01 List of tools Centrifugal clutch Cutting deck Cylinder and piston Crankshaft and crankcase Workshop equipment 502 50 18 01 522 43 18 01 505 38 13 08 ...

Page 54: ...52 8 List of tools ...

Page 55: ...____________________________ 54 Ignition system____________________________ 54 Carburettor ______________________________ 54 Clutch __________________________________ 54 Cutting equipment _________________________ 54 Dimensions ______________________________ 54 ...

Page 56: ... BPMR 6Y NGK BPMR 6Y Electrode distance mm 0 7 0 7 Electronic speed limitation No No Carburettor Manufacturer Walbro WYL Walbro WYL Idle speed rpm 3000 3000 Max speed rpm 12000 12000 Clutch 2 shoe clutch Diameter mm 51 5 51 5 Engage speed rpm 4200 4200 Cutting equipment Cutters Double sided Double sided Blade length mm 550 600 Cutting frequency cuts min 3765 3765 Dimensions Fuel tank volume litre ...

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Page 58: ...2010W40 115 39 91 26 ...

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