Husqvarna W80P Instruction manual

English - 1
English
W 50P, W 80P
Workshop manual

2 - English
Workshop Manual
W 50P / W 80P
Contents
1. Introduction........................................................ 3
2. Safety................................................................. 4
3. Prepare and do servicing on the product........... 6
4. Servicing tools ................................................. 11
5. Function overview............................................ 12
6. Repair instructions........................................... 13
7. Troubleshooting................................................ 26
8. Technical data .................................................. 27

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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 instructions
WARNING: All personnel that
repair or do servicing on the lawn
mower must read and understand
the safety instructions.
Warning symbols can be found in this workshop manual
and on the lawn mower. Refer to “Symbols on the prod-
uct”. If a warning symbol decal on the product is dam-
aged or missing, replace the warning symbol decal.
Introduction
1 Introduction

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Safety
2 Safety
2.1 Safety definitions
Warnings, cautions and notes are used to point out spe-
cially 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 dam-
age 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 lawn mower must
have safety devices that obey local regulations. Warn-
ings and cautions are used to point out specially impor-
tant parts of the workshop manual.
2.3 Specific safety instructions
When you use compressed air, do not point the air jet
in the direction of your body. Air can go into the blood
circulation and kill you. Use eye protection when you do
work on springs that have tension.
WARNING: Do not use accessories that
are not approved by the manufacturer. Do
not do changes that are not approved by
the manufacturer. This can cause injury or
death to the operator or other persons.
WARNING: Always use original spare
parts and accessories.
WARNING: Use approved hearing pro-
tection. Noise from the product can result
in permanent hearing loss.
2.4 Symbols on the product
Warning: Careless or incorrect use can
result in injury or death to the operator
or others
Please read the operator’s manual care-
fully and make sure that you understand
the instructions before use.
The ignition lead should always be re-
moved from the spark plug before repair,
cleaning or maintenance work.
Use a helmet with hearing protector
Operation of this equipment may create
sparks.
WARNING marking concerning Risk
of Respiratory Injury. Operate engine
OUTSIDE and far away
Keep hands away from the rolling part.
Be care of hot surface
WARNING marking concerning Risk of
Fire while handling fuel. Do not smoke
while handling fuel.
Fast
Slow

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Safety

6 - English
3 Prepare and do servicing on the product
Prepare and do servicing on the product
3.1 Assembly
3.2 Function test
3.2.1 Before a start
Your safety is your responsibility. A little time spent in
preparation will significantly reduce your risk of injury.
Read and understand this manual. Know what the con-
trols do and how to operate them .
Familiarize yourself with the pump and its operation
before you begin pumping. Know what to do in case of
emergencies.
Be sure of what you are pumping. This pump is de-
signed to pump only fresh water that is not intended for
human consumption.
For your safety, and to maximize the service life of your
equipment, it is very important to take a few moments
before you operate the pump to check its condition. Be
sure to take care of any problem you find, or have your
servicing dealer correct it, before you operate the pump.
Examine the pump generally
• To prevent a possible fire, keep the pump at least
3 feet (1 meter) away from building walls and other
equipment during operation. Do not place flammable
objects close to the engine.
• Before beginning your pre-operation checks, be
sure the pump is on a level surface and the ignition
switch is in the OFF position.
• Before each use, look around and underneath the
engine for signs of oil or gasoline leaks.
• Remove any excessive dirt or debris, especially
around the engine muffler and recoil starter.
• Look for signs of damage.
• Check that all nuts, bolts, screws, hose connectors
and clamps are tightened.
Examine the hoses
• Check the general condition of the hoses. Be sure
the hoses are in serviceable condition before con-
necting them to the pump. Remember that the suc-
tion hose must be reinforced construction to prevent
hose collapse.
• Check that the sealing washer in the suction hose
connector is in good condition.
• Check that the hose connectors and clamps are
securely installed.
• Check that the strainer is in good condition and is
installed on the suction hose.
Examine the engine
• Before each use, look around and underneath the
engine for signs of oil or gasoline leaks.
• Check the engine oil level. Running the engine with
a low oil level can cause engine damage.
• Check the air filter. A dirty air filter will restrict air
flow to the carburetor, reducing engine and pump
performance.
• Check the fuel level. Starting with a full tank will help
to eliminate or reduce operating interruptions for
refueling.
3.2.2 To start the product
To prime the pump
Before starting the engine, remove the filler cap (A) from
the pump chamber. Fill the pump chamber to the under-
surface of the discharge port (B) with water. Reinstall
the filler cap and tighten it securely.
Note: Operating the pump dry will destroy the pump
seal. If the pump has been operated dry, stop the
engine immediately, and allow the pump to cool before
priming.
A
Figure 1
B
Figure 2
If the discharge hose (D) must run across a roadway,
the hose should cross the roadway perpendicular to traf-
fic flow. Also, heavy boards (C) should be placed next
to the hose so the motor vehicle weight does not shut
off the discharge as vehicles cross over the hose. See
figure 3.

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Prepare and do servicing on the product
C
D
Figure 3
Driving over a discharge hose while the pump is run-
ning, or even possibly when the pump is stopped, may
cause pump case failure.
To start the engine
1. Fill the product with fuel and engine oil.
2. Prime the pump.
3. Move the fuel valve lever (E) to the ON position. See
figure 4.
ON
OFF
E
Figure 4
4. To start a cold engine, move the choke lever (F) to
the CLOSED position. To restart a warm engine,
leave the choke lever in the OPEN position. See
figure 5.
CLOSED
OPEN
F
Figure 5
5. Move the throttle lever (G) away from the SLOW
position about 1/3 of the way toward the FAST posi-
tion. See figure 6.
G
SLOW
FAST
Figure 6
6. Turn the ignition switch (H) to the ON position. See
figure 7.
ON
OFF
H
Figure 7
7. Pull the recoil starter grip (I) lightly until you feel
resistance, and then pull briskly. Do not allow the
recoil starter grip to snap back against the engine.
Return it gently to prevent damage to the starter.

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Figure 8
8. lf the choke lever was moved to the CLOSED posi-
tion to start the engine, gradually move it to the
OPEN position as the engine warms up.
CLOSED
OPEN
F
Figure 9
3.2.3 To set the engine speed
After starting the engine, move the throttle lever (G)
to the FAST position for self-priming, and check pump
output. Pump output is controlled by adjusting engine
speed. Moving the throttle lever in the FAST direction
will increase pump output, and moving the throttle lever
in the SLOW direction will decrease pump output.
G
SLOW
FAST
Figure 10
3.2.4 To stop the product
To stop the engine in an emergency, simply turn the
ignition switch (H) to the OFF position. Under normal
conditions, use the following procedure.
1. Move the throttle lever (G) to the SLOW position.
G
SLOW
FAST
Figure 11
2. Turn the ignition switch (H) to the OFF position.
ON
OFF
H
Figure 12
Prepare and do servicing on the product

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3. Turn the fuel valve lever (E) to the OFF position.
ON
OFF
E
Figure 13
After use, remove the pump drain plug and drain the
pump chamber. Remove the filler cap, and flush the
pump chamber with clean, fresh water. Allow the water
to drain from the pump chamber, and then reinstall the
filler cap and drain plug.
3.2.5 To add fuel to the product
WARNING: Gasoline is highly flammable
and explosive. You can be burned or seri-
ously injured when handling fuel.
• Stop the engine and keep heat,
sparks, and flame away.
• Handle fuel only outdoors.
• Wipe up spills immediately.
With the engine stopped and on a level surface, remove
the fuel tank cap and check the fuel level. Refill the tank
if the fuel level is low.
I
J
K
Figure 14
Add the fuel in a well-ventilated area before starting the
engine. If the engine has been running, allow it to cool.
Refuel carefully to avoid spilling fuel. Do not fill the fuel
tank completely. Fill tank to approximately 1 inch
(25 mm) below (K) the top of the fuel tank (I) to allow
for fuel expansion. If may be necessary to lower the fuel
level depending on operating conditions. After refueling,
tighten the fuel tank cap securely.
Never refuel the engine inside a building where gasoline
fumes may reach flames or sparks. Keep gasoline away
from appliance pilot lights, barbecues, electric appli-
ances, power tools, etc.
Spilled fuel is not only a fire hazard, it causes environ-
mental damage. Wipe up spills immediately.
Note: Fuel can damage paint and plastic. Be careful
not to spill fuel when filling your fuel tank. Damage
caused by spilled fuel is not covered under warranty.
Fuel recommendations
This engine is certified to operate on unleaded gasoline
with a pump octane rating of 90 or higher.
Never use stale or contaminated gasoline or an oil gaso-
line mixture. Avoid getting dirt or water in the fuel tank.
3.2.6 To examine the oil level
Examine the level of the engine oil when the engine is
stopped and in a level position.
1. Remove the oil filler cap dipstick (M) and wipe it
clean.
2. lnsert and remove the dipstick without screwing it
into the filler neck. Check the oil level shown on the
dipstick.
3. lf the oil level is low, fill to the edge of the oil filler
hole with the recommended oil.
4. Screw in the oil filler cap dipstick (M) securely.
MN
O
Figure 15
O. Upper limit
N. Lower limit
Note: Running the engine with a low oil level can
cause engine damage.
Prepare and do servicing on the product

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3.3 Service schedule
X
Each use First month or 20
hours
Every 3 months
or 50 hours
Every 6 months
or 100 hours
Every year or 300
hours
Examine engine oil
level X
Change engine oil X X
Examine air cleaner X
Clean air cleaner X1
Examine spark plug X
Replace spark plug X
Clean spark arrester
optional part X
Clean sediment cup X
Examine idle speed X2
Examine valve clear-
ance X2
Clean combustion
chamber3
Clean the fuel tank and
the fuel filter X2
Examine the fuel tube4
Examine the impeller X2
Examine the impeller
clearance X2
Examine the pump inlet
valve X2
1. Service more frequently when used in dusty areas.
2. These items should be serviced by your local dealer unless you have the proper tools and are mechanically profi-
cient.
3. Clean the combustion chamber every 500 hours. Only clean the combustion chamber if you have the proper tools
and are mechanically proficient.
4. Examine the fuel tube every 2 years. Replace the fuel tube, if it is necessary.
Prepare and do servicing on the product

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4 Servicing tools
Servicing tools
The tools listed here are service tools intended for use on the product in question. In addition to these tools, a standard
set of hand tools is required.
Item Description
1Open wrench 8 mm
1Open wrench 10 mm
1Open wrench 12 mm
1Open wrench 13 mm
1Open wrench 21 mm
2Screw driver flat
3Wrench
4 Pliers
5Feeler gauge
1 2 3 4
5

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5.1 Type plate/Product serial number
Figure 1
5 Function overview
Function overview

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Repair instructions
6 Repair instructions
6.1 Introduction
WARNING: Make sure the engine
is off before you begin any repairs.
This will eliminate several potential
hazards:
- Carbon monoxide poisoning from
Engine exhaust.
- Burns from hot parts.
- Injury from moving parts.
6.2 Product overview for repair instruction
1. Air filter
2. Muffler
3. Water pump
4. Pump drain cap
5. Suction port
6. Fuel tank
7. Fuel filler cap
8. Oil drain plug
9. Frame
10. Starter
11. Recoil starter grip
12. Choke lever
13. Primer water filler cap
14. Discharge port
1
2
6
10
8
5
7
4
3
11
12
14
13
9

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Repair instructions
6.3 Air filter
6.3.1 To disassemble the Air filter
1. Unscrew the star nut (A) and remove the air filter
cover (B).
2. Unscrew the wing nut (C) and remove the air filter
(D). If the air filter is dirty, clean the air filter. Replace
the air filter if it is damaged.
A
B
C
D
Figure 1
Note: Operating the engine without an air filter, or with
a damaged air filter, will allow dirt to enter the engine,
causing rapid engine wear.
6.3.2 To clean and examine the Air filter
A dirty air filter will restrict air flow to the carburetor,
reducing engine performance.
1. Clean the air filter in warm soapy water, rinse, and
allow to dry thoroughly. Or clean in nonflammable
solvent and allow to dry.
2. Dip the air filter in clean engine oil, and then
squeeze out all excess oil. The engine will smoke
when started if too much oil is left in the foam.
3. Wipe dirt from the air cleaner base and cover, using
a moist rag. Be careful to prevent dirt from entering
the air duct that leads to the carburetor.
6.3.3 To assemble the Air filter
1. Place the air filter on the air filter stand.
2. Tighten the wing nut.
3. Place the air filter cover over the air filter.
4. Tighten the star nut.

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Repair instructions
6.4 Muffler
6.4.1 To disassemble the Muffler
Locate the muffler.
Figure 1
1. Remove the M6 screws (A) and (B).
2. Remove the heat protector (C).
A
C
B
Figure 2
3. Remove the M6 screw (D) and the nuts (E).
4. Remove the muffler (F).
F
E
D
Figure 3

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Repair instructions
6.5 Fuel tank
6.5.1 To disassemble the Fuel tank
Locate the fuel tank.
Figure 1
1. Move the fuel valve (A) to the OFF position.
ON
OFF
A
Figure 2
2. Place a suitable container under the carburetor.
Turn the fuel valve lever (A) to the ON position.
Loosen the drain screw (B) and drain the fuel
B
Figure 3
3. Disconnect the fuel house from the carburetor.
4. Remove the nuts (C) and the screw (D).
5. Remove the fuel tank (E).
D
C
E
Figure 4
6. Remove and clean the fuel filter (F).
F
Figure 5
6.5.2 To clean and examine the Fuel tank
Clean the fuel tank with nonflammable solvent and al-
low the fuel tank to dry thoroughly. Clean the filter with
nonflammable solvent. Inspect the fuel filter to be sure it
is undamaged.

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6.6 Starter
6.6.1 To disassemble the Starter
Locate the starter.
Figure 1
1. Remove the M6 bolts (A) and the washers (B).
2. Remove the complete starter (C)
C
B
A
D
E
Figure 2
3. Disconnect the electric wires that are linked to the
stop switch.
Figure 3
Repair instructions
4. Remove the bolts (D) and remove the starter cover
(E) from the product.
C
B
A
D
E
Figure 4
6.6.2 To clean and examine the Starter
Clean the stater (C), Figure 2. Examine that the starter
handle can be pulled out fully and that the spring pulls
the starter handle back to its original position.
6.6.3 To assemble the Starter
Assemble in the opposite sequence.

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6.7 Engine oil
6.7.1 To drain the engine oil]
Drain the used oil while the engine is warm. Warm oil
drains quickly and completely.
1. Place a suitable container (A) below the engine to
catch the used oil, and then remove the oil filler cap
dipstick (B), O-ring (C) drain plug (D) and sealing
washer (E). See Figure 1.
A
C
B
ED
Figure 1
2. Tilt the product to make sure the oil goes out of the
drain plug hole.
3. Allow the used oil to drain completely into an ap-
proved container, then reinstall the drain plug with a
new sealing washer, and tighten it securely.
Note: Improper disposal of engine oil can be harmful
to the environment. Dispose of used motor oil prop-
erly. Put it in a sealed container, and take it a recy-
cling center Do not throw it in the trash, pour it on the
ground, or pour it down a drain.
6.7.2 Engine oil recommendation
Use 4-stroke automotive detergent oil.
-20 0 20 32 40
403020100-10-20-30
F
C
60 80 10050
SAE 30
10W-30
Figure 2
SAE 10W-30 is recommended for general use. Other
viscosities shown in the chart may be used when the
average temperature in your area is within the recom-
mended range.
Repair instructions
6.7.3 To fill the product with engine oil
1. With the engine in a level position, fill to the edge of
the oil filler hole with the recommended oil.
Engine oil capacities:
W 50P: 0.60 L
W 80P: 0.60 L
2. Screw in the oil filler cap dipstick securely

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6.8 Water pump
6.8.1 To disassemble the Water pump
If the product comes with a suction hose and/or a dis-
charge hose connected, remove these first (see Figure
3).
Figure 1
F
E
G
H
I
D
K
J
ML
A
B
C
Figure 2
See Figure 2.
1. Remove the M8 bolts (A) and the washers (B) and
remove the pump house (C).
2. Remove the large O-ring (D).
3. Remove the Impeller cover (E) and the seal (F).
4. Lock the flywheel so that the flywheel can not turn.
5. Remove the bolt (G) and the washer (H) and re-
move the Impeller (I).
6. Remove the key (J).
7. Remove the seal (N).
8. Remove the bolts (K) and the washers (L).
Repair instructions
9. Remove the cover (M).
6.8.2 To clean and examine the Water pump
Clean pump housing, impeller and other parts from dirt
and deposits. Examine that the parts are not damaged.
Replace any damaged parts.
6.8.3 To assemble the Water pump
A
B
C
E
D
F
C
F
G
H
I
J
Figure 3
Suction hose installation (see Figure 3)
Use a commercially available hose (G). Use the hose
connector/hose clamps (C, D, E) provided with the pump
if necessary. The suction hose (G) must be reinforced
with a no collapsible wall or braided wire construction
and cannot contain any perforations.
Do not use a hose smaller than the pump s suction port
size. Minimum hose size W 40P 1.5 inch 40 mm
The suction hose (G) should be no longer than neces-
sary. Pump performance is best when the pump is near
the water level and the hoses are short.
Use a hose clamp (C) to securely fasten the hose con-
nector to the suction hose (G) in order to prevent air
leakage and loss of suction. Verify that the hose connec-
tor sealing washer (F) is in good condition.
Install the strainer (A) provided with the pump with
equivalent hole sizes on the other end of the suction
hose, and secure it with a hose clamp. The strainer will
help to prevent the pump from becoming clogged or
damaged by debris.
Never operate the pump without the strainer (A) in-
stalled.

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Repair instructions
6.9 Sediment cup
6.9.1 To disassemble the Sediment cup
1. Move the fuel valve (A) to the OFF position.
ON
OFF
A
Figure 1
2. Unscrew the sediment cup (B) using a wrench and
remove the O-ring (C).
A
B
Figure 2
6.9.2 To clean and examine the Sediment
cup
1. Wash the cup and O-ring in non-flammable solvent
and dry thoroughly.
2. Place the O-ring in the fuel valve then screw the
sediment cup into place and tighten securely.
3. Move the fuel valve to the ON position and check for
leaks. Replace the O-ring if there is any leakage.
Securely tighten the hose connector on the pump suc-
tion port.
Discharge hose installation (see Figure 3)
Use a commercially available hose (J). Use the hose
connector and the hose clamp provided with the pump.
It is best to use a short, large-diameter hose, because
that will reduce fluid friction and improve pump output.
A long or small-diameter hose will increase fluid friction
and reduce pump output.
Tighten the hose clamp securely (C) to prevent the dis-
charge hose from disconnecting under pressure.