Husqvarna 522HDR75S Instruction manual

Workshop manual
522HD60S, 522HDR60S,
522HDR75S English
1017 - 002 - 25.11.2020

Contents
1 Introduction
1.1 Document description............................................ 3
1.2 Target group...........................................................3
1.3 Revisions................................................................3
1.4 Safety..................................................................... 3
1.5 Servicing tools........................................................3
2 Safety
2.1 Safety definitions....................................................4
2.2 General safety instructions.....................................4
2.3 Symbols on the product......................................... 4
3 Prepare and do servicing on the product
3.1 Maintenance schedule........................................... 5
4 Servicing data
4.1 Servicing data........................................................ 6
5 Servicing tools
5.1 Servicing tools......................................................12
6 Function overview
6.1 Type plate and product serial number..................14
7 Repair instructions
7.1 Product overview for repair instructions............... 15
7.2 To clean and examine the product parts..............15
7.3 Starter.................................................................. 16
7.4 Muffler.................................................................. 19
7.5 Air filter................................................................. 19
7.6 Flywheel............................................................... 20
7.7 Ignition system..................................................... 22
7.8 Carburetor............................................................ 28
7.9 Handle and throttle trigger....................................32
7.10 Clutch, clutch drum and gearbox....................... 35
7.11 Cutting equipment.............................................. 38
7.12 Cylinder and piston............................................ 38
7.13 Crankshaft and crankcase................................. 44
7.14 Fuel tank............................................................ 50
8 Troubleshooting
8.1 Troubleshooting................................................... 52
9 Technical data
9.1 Technical data......................................................56
21017 - 002 - 25.11.2020

1 Introduction
1.1 Document description
This manual gives a full description of how to do
maintenance and repair on the product. It also gives
safety instructions that the personnel must obey.
1.2 Target group
This manual is for personnel with a general knowledge
of how to do repair and do servicing. All personnel that
do repair or do servicing on the product must read and
understand the manual.
1.3 Revisions
Changes to the product can cause changes to the
maintenance work and spare parts. Separate
information is sent out for each change.
Read the manual together with all received information
about changes to maintenance and spare parts for the
product.
1.4 Safety
WARNING: All personnel that repair or do
servicing on the product must read and
understand the safety instructions in this
workshop manual.
1.5 Servicing tools
The manual gives information about necessary servicing
tools. Always use original tools from Husqvarna.
1017 - 002 - 25.11.2020 Introduction - 3

2 Safety
2.1 Safety definitions
Warnings, cautions and notes are used to point out
specially important parts of the manual.
WARNING: Used if there is a risk of injury or
death for the operator or bystanders if the
instructions in the manual are not obeyed.
CAUTION: Used if there is a risk of damage to
the product, other materials or the adjacent area
if the instructions in the manual are not obeyed.
Note: Used to give more information that is necessary in
a given situation.
2.2 General safety instructions
WARNING: Read the warning instructions that
follow before you use the product.
The service center that repairs the product must have
safety devices that obey local regulations. Warnings and
cautions are used to point out specially important parts
of the workshop manual.
2.3 Symbols on the product
Stop.
Be careful and use the product correctly.
This product can cause serious injury or
death to the operator or others.
Read the operator's manual carefully and
make sure that you understand the
instructions before use.
Use approved hearing protection and
approved eye protection.
Use approved protective gloves.
Use heavy-duty slip-resistant boots.
Idle adjustment screw.
High speed needle.
Low speed needle.
Noise emissions to the environment
according to European Directive
2000/14/EC and New South Wales
legislation “Protection of the Environment
Operations (Noise Control) Regulation
2017”. Noise emission data can be found
on the machine label and in the Technical
data chapter.
The product agrees with the applicable
EC directives.
yyyywwxxxx The rating plate shows serial number.
yyyy is the production year and ww is
the production week.
Note: Other symbols/decals on the product refer to
certification requirements for some markets.
4 - Safety 1017 - 002 - 25.11.2020

3 Prepare and do servicing on the product
3.1 Maintenance schedule
Maintenance Before
operation After 40 h After 100 h
Clean the external surface. After each operation.
Clean the muffler, exhaust pipe and engine from leaves, dirt and unwanted lubri-
cant. After each operation.
Make sure that the cutting attachment does not move at idle speed. X
Do a check of the stop switch. X
Examine the cutting attachment and the cutting attachment guard for damages
and cracks. Replace if it is damaged. X
Examine the hand guard for damages and cracks. Replace if it is damaged. X
Do a check of the throttle trigger lockout and the throttle trigger. X
Examine the engine, the fuel tank and the fuel lines for leaks. X
Tighten nuts and screws. X
Examine the fuel filter for contamination and the fuel hose for cracks and other
defects. Replace if necessary. X
Examine the starter and the starter rope for damages. X
Clean the air filter. Replace if it is necessary. X
Examine the vibration damping units for damages and cracks. X
Examine the spark plug, refer to To examine the spark plug on page 22 . X
Clean the cooling system. X
Clean the external surface of the carburetor and the area around it. X
Clean or replace the spark arrester mesh. X
Clean the inner surface of the fuel tank. X
Examine the spark plug. X
Make sure that the gear housing is filled with grease. X
1017 - 002 - 25.11.2020 Prepare and do servicing on the
product - 5

4 Servicing data
4.1 Servicing data
▲ Lubricate with 2-stroke oil.
● Lubricate with grease.
T27
5 - 8 Nm
T27
3 - 4.5 Nm
T27
3 - 4 Nm
T27
2 - 3 Nm
T27
2 - 3 Nm
T27
4 - 5 Nm
T27
5 - 7 Nm
T27
4 - 5 Nm
T27
3 - 4.5 Nm
T27
2 - 3 Nm
6 - Servicing data 1017 - 002 - 25.11.2020

T27
6 - 8 Nm
T27
6 - 9 Nm
10 - 15 Nm
8 mm
6 - 9 Nm
T27
4 - 6 Nm
T27
3 - 5 Nm
1017 - 002 - 25.11.2020 Servicing data - 7

T27
1.5 - 2.5 Nm
T27
4.5 - 5.5 Nm
T27
6 - 8 Nm
T27
6 - 8 Nm
16 mm
10 - 12 Nm
T27
4 - 6 Nm
T27
8 - 10 Nm
T27
3 - 4 Nm 13 mm
14 - 16 Nm
T27
2.5 - 3 Nm
10 - 12 Nm T27
3 - 4 Nm
T27
3 - 4 Nm
8 - Servicing data 1017 - 002 - 25.11.2020

522HD60
T27
6 - 9 Nm
T27
3 - 5 Nm
8 mm
6 - 9 Nm
8 mm
6 - 9 Nm 8 mm
6 - 9 Nm
8 mm
6 - 9 Nm
T27
3 - 5 Nm
1017 - 002 - 25.11.2020 Servicing data - 9

522HDR60
T27
6 - 9 Nm
T27
3 - 5 Nm
8 mm
6 - 9 Nm
8 mm
6 - 9 Nm 8 mm
6 - 9 Nm
8 mm
6 - 9 Nm
T27
3 - 5 Nm
10 - Servicing data 1017 - 002 - 25.11.2020