Husqvarna 570 XP/G Workshop Manual
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Husqvarna 570 XP/G Workshop Manual

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570, 576 XP/G
570 AT, 576 XP/G AT
English

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Summary of Contents for Husqvarna 570 XP/G

  • Page 1 Workshop manual 570, 576 XP/G 570 AT, 576 XP/G AT English...

  • Page 2: Table Of Contents

    CONTENTS Introduction........... 3 Safety.regulations........4 Symbols............5 Technical.data..........6 Service.tools..........8 Service.data..........10 Safety.equipment........12 Starter............18 Electrical.system........20 Centrifugal.clutch........26 Lubrication.system........28 Carburettor..........30 Tank.unit............41 Anti-vibration.system.

  • Page 3: Introduction

    Workshop Manual. Usage is evident from respective sections. Position references to components inside the figures are designated A, and B, etc. Always.use.Husqvarna.original.parts: The figures are number 1, 2 etc. The position references figure numbers restart in each •...

  • Page 4: Safety.regulations

    SAFETY.REGULATIONS General.instructions Special.instructions The workshop where chainsaw repairs are to be done The fuel used in the chainsaw has the following hazardous must be equipped with safety equipment as set out in properties: local regulations. 1. The fluid and its fumes are poisonous. 2.

  • Page 5: Symbols

    SYMBOLS Symbols.on.the.chainsaw Symbols.in.this.Workshop.Manual The following symbols are moulded into the chainsaw casing. This symbol indicates a risk of personal Choke injury if instructions are not followed. Use protective gloves. Switch for hand grip heater Use protective goggles. Fuel filler Stop button Screw to adjust chain lubrication Saw chain oil filler Chain brake...

  • Page 6: Technical.data

    TECHNICAL.DATA Displacement Bore Stroke Max. power/rpm / cubic inch Ømm/Øinch mm/inch kW/hp / rpm 67,9/4.1 49/1,9 36/1,4 3,6/4,9 / 9 600 576 XP/G 73,5/4.5 51/2,0 36/1,4 4,2/5,7 / 9 600 Spark plug gap Ignition system Air gap Carburettor type mm/inch mm/inch 0,5/0,02 SEM/CD/COT...
  • Page 7 TECHNICAL.DATA Idling speed Engage speed Max. speed Spark plug 2 700 3 600 13 300 NGK BPMR7A Champion RCJ 7Y 576 XP/G 2 700 3 600 13 300 NGK BPMR7A Champion RCJ 7Y Fuel tank volume Oil pump capacity Oil tank volume Automatic oil pump Litres/US pint /min...

  • Page 8: Service.tools

    SERVICE.TOOLS 8 – English...
  • Page 9 SERVICE.TOOLS 4 mm 2 mm Item Description Used for Order No. Piston stop Locking the crankshaft 504 91 06-05 Cover plate, exhaust Sealing the exhaust port 502 54 11-02 The tools listed here are service Cover plates, inlet kit Sealing the intake system 502 52 48-01 tools intended for use on the chainsaw in question.

  • Page 10: Service.data

    SERVICE.DATA 8.5Nm 1.5Nm 20Nm 19mm 1.5Nm 3.5Nm 13Nm 13mm 15Nm 5.5Nm 20Nm 11Nm 4.5Nm 15Nm 13mm 20Nm Key.to.diagrams The figures next to parts screwed on indicate the tightening torque Nm. = Lubricate with two-stroke oil. = Lubricate with chain oil. = Lubricate with grease.
  • Page 11 SERVICE.DATA 4.5Nm 14Nm 11Nm 23Nm 13mm 2.5Nm English – 11...

  • Page 12: Safety.equipment

    SAFETY.EQUIPMENT Chain.brake Dismantling 1. Dismantle the following parts first: • Chain and bar. See the Operator's Manual. 2. Push the hand guard forward so that the chain brake is on. See fig. 1. 3. Remove the chain guide-plate (A). See fig. 1. Fig.
  • Page 13 SAFETY.EQUIPMENT Assembly Assemble the chain brake as follows: 1. Fit the toggle joint and brake band. 2. Grease the moving parts of the toggle joint (D) and fit the unit on the chain saw. See fig. 6. WARNING!. Ensure.that.the.spring.does.not.fly.out. Fig. 6 and.cause.personal.injury..
  • Page 14 SAFETY.EQUIPMENT Function.check WARNING!. After. repair,. the. chain. brake. must. be. checked. according. to. the. following. instructions. For this test, the engine must not.be running. Check that the chain brake cuts in as follows: 1. Hold the chain saw over a stable surface as shown in fig.
  • Page 15 SAFETY.EQUIPMENT Muffler WARNING!. Do. not. touch. the. muffler. until. it. has. cooled..Risk.of.burn.injuries. Dismantling 1. Remove the two lower M5 bolts and the muffler’s two M6 bolts. See fig. 12. 2. Remove the gasket and cooling plate. See fig. 12. 3. If the saw is fitted with a spark-arrester, remove it. See fig.
  • Page 16 SAFETY.EQUIPMENT Throttle.lock Lower the rear of the tank by removing the screws A, B and C. See fig. 15. Fig. 15 Remove the screw A on hand grip insert. See fig. 16. Fig. 16 Remove the handle insert (A). Remove the guide pin for the throttle (B) and throttle lock (C) using a punch.
  • Page 17 SAFETY.EQUIPMENT Remove the throttle cable and lever. See fig. 19 Inspection Clean all components and check the following: 1. That the throttle cable and lever are undamaged and run easily. 2. That the lock activation mechanism is not worn. See fig. 19. Fig.

  • Page 18: Starter

    STARTER Starter Dismantling WARNING!. If.the.spring.is.tensioned.on.the.starter. pulley.it.can.fly.up.and.cause.personal. injury. Wear.protective.glasses. 1. Remove the four bolts holding the starter to the crankcase and remove the starter. See fig. 1. Fig. 1 2. Pull out the handle 20-30 cm and take out the cord from the slot in the starter pulley.
  • Page 19 STARTER Assembly WARNING!. If.the.spring.is.tensioned.on.the.starter. pulley.it.can.fly.up.and.cause.personal. injury. Wear.protective.glasses. 1. If a new spring is to fitted, place the new spring with cassette so that the end loop comes over the peg. Fit the spring cassette’s 2 screws. Fig. 4 3. If a new cord is to be fitted, push the free end in the hole in the starter pulley.

  • Page 20: Electrical.system

    ELECTRICAL.SYSTEM Ignition.system Dismantling 1. Remove the cylinder cover and starter unit. See page 18. 2. Release the lead (A) (which connects to the stop button) from the ignition module (B). See fig. 1. 3. Remove the ignition cable (C) from the spark plug and release both cables from the cable guide, and lift off the cable guide.
  • Page 21 ELECTRICAL.SYSTEM 7. Insert the feeler gauge ”Air Gap Tool” (0.3 mm) Assembly between the ignition module and the flywheel Assemble the ignition system as follows: magnet. The clearance only applies to the two lower pegs on the ignition module. See fig. 8. 1.
  • Page 22 ELECTRICAL.SYSTEM Hand.grips.and.carburettor.heater,. 576.XPG Some chainsaws are fitted with hand grip heaters and carburettor heaters, and consist of the following parts: • Generator. • Switch. • Heating element in rear hand grip. • Front hand grip with heating element. • Carburettor heating element. •...
  • Page 23 ELECTRICAL.SYSTEM 576.XPG.AutoTune The electrical system for models with AutoTune differ from models without AutoTune. The yellow short-circuit wire (A) from the ignition module is connected to the stop switch. The red wire (A) from the generator is connected to the carburettor (AutoTune). See figure 9b. Fig.
  • Page 24 ELECTRICAL.SYSTEM Replacing.the.generator 1. The following components must be removed before the generator can be replaced: A. Starter. See page 18. B. Flywheel. See page 20. 2. Remove the bolt for the rear damper element (D) and upper AV spring (B). Remove the bolt on the front AV element (D).
  • Page 25 ELECTRICAL.SYSTEM Dismantle the cables (A) and (B) on the heater switch. Loosen connection (C). See fig. 12. Fig. 12 Loosen the cable fastening on the tank. See fig. 13. Fig. 13 Dismantle the screws (A) on the generator. fig. 14. Replacing.the.switch 1.
  • Page 26 ELECTRICAL.SYSTEM Replacing.the.front.hand.grip 1. Dismantle the earth cable. See fig. 16. Fig. 16 2. Remove the five bolts (A, B and C) which hold the front hand grip. See fig. 17. 3. Fit the new front hand grip by screwing in the five bolts (A, B and C).

  • Page 27: Centrifugal.clutch

    CENTRIFUGAL.CLUTCH Centrifugal.clutch Dismantling When dismantling the centrifugal clutch the chain brake must be in the off position. 1. Remove the cylinder cover, chain and bar. See Operator's Manual. 2. Remove the chain guide plate by unscrewing the bolt (A). See fig. 1. Fig.
  • Page 28 CENTRIFUGAL.CLUTCH Cleaning and inspection Clean all components and check the following: 1. The lining thickness on the clutch shoes must not be min.3.5.mm less than 3.5 mm at the most worn point. See fig. 5. 2. There should be no play between the clutch shoes and the clutch hub.

  • Page 29: Lubrication.system

    LUBRICATION.SYSTEM Lubrication.system WARNING!. Insufficient.lubrication.of.the.chain.can. result.in.the.chain.breaking,.which.can. cause.serious.or.even.life-threatening. injury. The lubrication system consists of the following parts: • Oil pump. • Suction pipe with filter. • Oil pipe with seals. Fig. 1 All the above parts are described in sequence under the headings that follow.
  • Page 30 LUBRICATION.SYSTEM Cleaning.and.inspection Clean all parts, including the pump and oil pipe mounts in the crankcase, and check the following: 1. The taper on the adjuster screw (F) should not have any wear marks. See fig. 4. 2. The eccentric face on the pump piston (I) should not have any wear marks.

  • Page 31: Carburettor

    CARBURETTOR 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. 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: Fig.
  • Page 32 CARBURETTOR 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 (fig. 4) 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).
  • Page 33 CARBURETTOR Dismantling 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. 1. Remove the cylinder cover and air filter. 2. Remove the carburettor control (D) by pulling. Disconnect switch wires (E and F). See fig. 8. 3. Unhook the throttle cable (A). See fig. 8. 4.
  • Page 34 CARBURETTOR Carburettor 8. Remove the cover (A) over the metering unit and carefully remove the metering diaphragm (B) and gasket. See fig. 10. 9. Remove the screw (E) and take out the needle valve (D) with lever (C), spindle and spring. See fig. 10. Fig.
  • Page 35 CARBURETTOR 5. The tips of the high and low speed screws are not Cleaning.and.inspection damaged. WARNING!. 6. The intake manifold is undamaged. See page 44. Fuel.has.the.following.hazardous.properties: The carburettor has an extra air shutter connected in 1..The.fluid.and.its.fumes.are.poisonous. parallel with the ordinary throttle valve. The valve housing 2..Can.cause.skin.irritation.
  • Page 36 CARBURETTOR Assembly Where no figure is referred to, see fig. 12 on the previous page. Maintain a high level of cleanliness when assembling the carburettor. The slightest contamination can result in running problems. 1. If the throttle and choke valves, together with levers and springs were removed, they should be refitted.
  • Page 37 CARBURETTOR 7. Fit the control diaphragm (B) with gasket and cover (A) on the metering unit. See fig. 17. Fit the axle (L) on the air shutter and connect the throttle actuator rod (N) in parallel with the ordinary throttle valve. The valve housing (P) is secured in the carburettor using two screws.
  • Page 38 CARBURETTOR Refitting to the chainsaw See fig. 20 and 21. 1. Mount the filterholder with carburettor and choke system. Connect the rear rubber mounts (H). Check that the choke is fitted in the right position in the partition. See page 47, fig. 15. 2.
  • Page 39 CARBURETTOR Basic.adjustment.for.EPA.II.saws.with.speed.limited. ignition.systems.and.capped.carburettors The models 576XP/G and 570 are equipped with speed limited ignition systems and capped carburettors. A slightly different adjustment procedure is necessary when replacing the carburettor or needles on these models. Tachometer Due to the integrated speed limitation in the ignition system most tachometers will not indicate a speed above the value that the speed limitation is set to.
  • Page 40 CARBURETTOR 5. Let the engine run at ”B” rpm ~ 1 minute, until warm. 6. Close the H-needle further ”C” turn on a scale to get correct setting. Model C = 1/4 576XP/G C = 3/4 Tachometer Due to the integrated speed limitation in the ignition system most tachometers will not indicate a speed above the value that the speed limitation is set to.
  • Page 41 CARBURETTOR Adjustment.of.the.air.screw.. (570.AT,.576.XP/G.AT) 1. Warm up the motor. Assess any hesitation in ac- celeration. Adjustment is not necessary if motor acceleration is good. Continue with step 2 if there is any hesitation in acceleration. 2. Turn off the motor and remove the cylinder cover. 3.

  • Page 42: Tank.unit

    TANK.UNIT Tank.unit 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. Dismantling 1. Drain off the fuel from the tank. 2. Remove the cylinder cover, chain and bar. See the Operator's Manual. 3. Unhook the throttle cable (A) from the carburettor. See fig.
  • Page 43 TANK.UNIT Cleaning.and.inspection Clean all parts and check that the fuel pipe is intact. Assembly 1. If the chainsaw is fitted with hand grip heating, fit the heating element if it has been removed. See page and 24. NOTE!. Take.care.not.to.damage.the.fuel.pipe.and. throttle.cable. 2.

  • Page 44: Anti-Vibration.system

    ANTI-VIBRATION.SYSTEM Anti-vibration.system 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. Dismantling 1. Dismantle the following parts: • Chain and bar. See the Operator's Manual. • Cylinder cover. See the Operator's Manual. • Tank unit and front handle. 2. Remove the spring on the cylinder with a 4 mm Allen key.

  • Page 45: Piston.and.cylinder

    PISTON..and..CYLINDER Piston.and.Cylinder Dismantling 1. Dismantle the following parts: • Cylinder cover. • Spark plug. • Carburettor. See page 32. • Muffler. See page 15. Fig. 1 2. Unscrew the anti-vibration spring (C) from the cylinder. See fig. 1. 3. Unscrew the cylinder’s four bolts (A). See fig. 1. 4.
  • Page 46 PISTON..and..CYLINDER Check the following: 1. That the cylinder’s surface coating is not worn. Especially in the upper part of the cylinder. 2. That the cylinder is free of score marks. See fig. 5. 3. That the piston is free of score marks. Minor scratches can be polished off with fine emery paper.
  • Page 47 PISTON..and..CYLINDER Faults.and.causes Score marks in the piston, fig. 8 (A) 1. Incorrect carburettor setting. Too high maxspeed. 2. Too low octane fuel. 3. Too little, or incorrect oil in the fuel. Carbon build-up, fig. 8 (B) 1. Incorrect carburettor setting. Too low maxspeed. Fig.
  • Page 48 PISTON..and..CYLINDER 8. Guide up the cylinder base gasket with the four bolts (A) and tighten them alternately. Tighten them finally to 10 Nm. See fig. 12. 9. Fit the anti-vibration spring (C) on the cylinder. See fig. 12. Tighten the bolt to 10 Nm. 10.Pressure test as shown in page 36.
  • Page 49 PISTON..and..CYLINDER 11. Fit the filterholder with choke on carburettor. Use long screws (L) on the upper part and short screws (M) on lower part. See fig. 14. 12. Fit carburettor with filter holder on manifold. • Fit choke shaft (P) in notch. •...
  • Page 50 PISTON..and..CYLINDER Pressure.testing The following parts must be removed to pressure test the crankcase and cylinder: • Air filter and carburettor. See page 32. Carry out pressure testing as follows: 1. Fit both cover plate 502 52 48-01 with bolt on the intake manifold.

  • Page 51: Crankcase.and.crankshaft

    CRANKCASE.and.CRANKSHAFT This section deals with the following: • Crankcase and crankshaft (describes how the whole assembly is dismantled and reassembled) • Seals (describes only replacement of seals) • Bar bolts (describes only replacement of bar bolts) Crankcase.and.crankshaft Dismantling 1. Before the crankcase can be separated the following parts must be dismantled: A Chain and bar.
  • Page 52 CRANKCASE.and.CRANKSHAFT 8. If the crankshaft bearing should remain on the crankshaft remove it with puller 504 90 90-01. See fig. 6. 9. If necessary, remove the following parts: A Spike bumper. B. Rubber stop (A). See fig. 5. Fig. 5 Cleaning.and.inspection NOTE!.
  • Page 53 CRANKCASE.and.CRANKSHAFT Assembly Fit the crankcase and crankshaft as follows: WARNING!. The.crankcase.halves.are.hot.and.can. cause. burn. injuries.. Wear. protective. gloves. 1. If bearings are to be fitted, do as follows: A. Heat the relevant crankcase half to 200°C. B. Use protective gloves and fit the bearing in the Fig.
  • Page 54 CRANKCASE.and.CRANKSHAFT 5. Use tool 502 50 30-20. Turn around the sleeve (B) and pull on the flywheel side’s crankcase half. Pull until the gasket is clamped between the crankcase halves. See fig. 12. 6. Fit the six bolts. Tighten them alternately. Tighten them finally to 8 Nm.
  • Page 55 CRANKCASE.and.CRANKSHAFT Seals 1. To replace the seals on the crank shaft, remove the following parts first: On the flywheel side: • Starter. • Flywheel. • Generator, where appropriate. On the clutch side: • Chain and bar. See Operator's Manual. • Chain guide plate. •...

  • Page 56: Troubleshooting

    TROUBLESHOOTING Troubleshooting The different faults which may occur on the chain saw are divided into four groups. Within each group possible operating faults are listed to the left while the probable fault alternatives are listed to the right. The most likely fault is listed first, etc. Starting Idling.(low.speed).(cont.) Starting...
  • Page 57 TROUBLESHOOTING High.speed Acceleration.and.retardation Does not Blocked air filter Does not run Blocked air filter accelerate Tank venting clogged at full throttle Tank venting clogged The fuel filter is clogged The fuel filter is clogged The fuel line is clogged The fuel line is clogged Loose or defective fuel hose Loose or defective fuel hose Blocked impulse channel...
  • Page 58 115.59.20-26 2015-08-31.

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