Husqvarna 592 XP Workshop Manual
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Husqvarna 592 XP Workshop Manual

Husqvarna 592 XP Workshop Manual

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Workshop manual
592 XP, 592 XPG
English
1490 - 004 - 02.11.2021

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Summary of Contents for Husqvarna 592 XP

  • Page 1 Workshop manual 592 XP, 592 XPG English 1490 - 004 - 02.11.2021...

  • Page 2: Table Of Contents

    2.4 Symbols on the product......... 4 7.12 Lubrication system..........30 2.5 Cutting equipment safety........5 7.13 Air filter............... 31 7.14 Husqvarna connectivity device......31 3 Prepare and do servicing on the product 7.15 Carburetor............32 3.1 Maintenance schedule........... 6 7.16 Start/stop switch..........38 7.17 Fuel tank............

  • Page 3: Introduction

    1.5 Servicing tools The manual gives information about necessary servicing tools. Always use original tools from Husqvarna. 1490 - 004 - 02.11.2021 Introduction - 3...

  • Page 4: Safety

    2 Safety 2.1 Safety definitions • Wear protective gloves when you replace the crankshaft bearings. The crankcase halves are hot, Warnings, cautions and notes are used to point out risk of burn injuries. specially important parts of the manual. • Make sure that the chain brake is engaged when you remove the pressure spring on the chain brake.

  • Page 5: Cutting Equipment Safety

    Chain oil. If your product has this symbol it has heated handles. yyyywwxxxx The rating plate shows se- rial number xxxx. 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.

  • Page 6: Prepare And Do Servicing On The Product

    3 Prepare and do servicing on the product 3.1 Maintenance schedule Maintenance Before After 100 After 40 h operation Clean the external surfaces. After each operation. Clean the muffler, exhaust pipe and engine from dirt and unwanted lubricant. After each operation. Make sure that the saw chain does not move at idle speed.

  • Page 7: Servicing Data

    4 Servicing data 4.1 Servicing data ■ Lubricate with two-stroke oil. ● Lubricate with grease. ▲ Lubricate with chain oil. 1–2 Nm 3–4 Nm (XPG) 1– 2 Nm 18–20 Nm 16 mm 9 Nm 5–6 Nm 16–18 Nm 3–4 Nm 1–2 Nm 40 Nm 3–4 Nm...
  • Page 8 1.5–2.5 Nm 11–13 Nm 13 mm (XPG) 6–7 Nm 2–3 Nm 3.5–4.5 Nm 1.5–2.5 Nm 1 Nm 11–13 Nm 13 mm 4–5 Nm (XP) 6–8 Nm 3–4 Nm 8–10 Nm 5–6 Nm 1.5–2.5 Nm *3 Nm + 90° 3–4 Nm 3–4 Nm 3–4 Nm 3–4 Nm...

  • Page 9: Servicing Tools

    5 Servicing tools 5.1 Servicing tools 0. 3 1490 - 004 - 02.11.2021 Servicing tools - 9...
  • Page 10 Item Description Article num- Piston stop To lock the crankshaft. 575 29 36-01 Cover plate for exhaust To seal the exhaust port. 529 36 00-01 Cover plate for inlet To seal the intake system. 529 59 27-01 Assembly fixture To hold the product when you disassemble and assemble the 502 51 02-01 product.
  • Page 11 Item Description Article num- Crankshaft assembly tool To assemble the crankshaft. 502 50 30-17 Mounting kit for bearings To install the bearings on the crankshaft. 593 72 69-01 Clutch tool To remove the clutch. 597 37 07-01 Seal ring guide To install the seal ring.

  • Page 12: Function Overview

    For best results and performance use Husqvarna two- stroke oil. If Husqvarna two-stroke oil is not available, use a two- stroke oil of good quality for aircooled engines. Speak to your servicing dealer to select the correct oil. 6.2.2.3 To mix gasoline and two-stroke oil...

  • Page 13: Repair Instructions

    7 Repair instructions 7.1 Product overview for repair instructions 592XPG 1490 - 004 - 02.11.2021 Repair instructions - 13...

  • Page 14: To Clean And Examine The Product Parts

    1. Cylinder cover 16. Muffler 2. Starter unit 17. Heated handle control 3. Front handle 18. Connector for CST 4. Chain brake and front hand guard 19. Ignition system 5. Air filter 20. Flywheel 6. Start/stop switch 21. Crankcase 7. Rear handle 22.

  • Page 15: To Connect The Common Service Tool (Cst)

    WARNING: Make sure that the chain brake Note: I can be necessary to install firmware to a new spring does not eject and cause injury. Use spare part. Make sure that you know the Husqvarna protective goggles. identification number (HID) of the new spare parts before you connect the product to common service tool 1.
  • Page 16 4. Remove the 3 screws and the chain brake cover. 8. Remove the handguard (C) and the brake band assembly (D). 5. Remove the knee joint unit (A). 9. Remove the brake band assembly from the handguard. 10. Assemble in the opposite sequence. Note: It is easier to install the chain brake spring if To remove you remove the front handle.

  • Page 17: Chain Catcher

    7.6 Muffler WARNING: The engine must be off. 7.6.1 To remove and install the muffler 2. Release the front handle. The guide bar tip falls onto WARNING: Do not touch a hot muffler. Risk of the stump. burn injuries. 1. Remove the screw and the muffler cover. Guide bar length, L Height, H 15 inch...

  • Page 18: Handles

    7.7 Handles 3. Remove the gasket (A) and the heat shield (B). 7.7.1 To remove and install the front handle 1. Remove the 3 screws. 4. Remove the screw and pull out the spark arrester screen. 2. Remove the 2 screws. 5.
  • Page 19 7.7.2 To remove and install the front heated handle 3. Remove the screw to the vibration damping unit. 1. Remove the 3 screws and the front heated handle cover on products with a heated front handle. 4. Remove the 2 screws. 2.
  • Page 20 4. Remove the 4 screws and the heat shield. 7. Remove the 3 screws and the front heated handle cover. 5. Remove the snap lock and the 4 screws. 8. Disconnect the wires to the rear heated handle. 6. Remove the carburetor bottom plate and pull out the 3 hoses.
  • Page 21 7.7.4 To disassemble and assemble the rear 3. Remove the pins (A). handle 1. Remove the screw and the handle cover. 4. Remove the throttle wire (B) from the lever for the throttle wire (C). 2. Use a flat screwdriver to push out and remove the throttle trigger lockout.

  • Page 22: Starter

    7.7.6 To replace the throttle wire 4. Pull out the rope approximately 30 cm /12 in and put it into the notch in the pulley. 1. Disassemble the rear handle. Refer to disassemble and assemble the rear handle on page 21 .
  • Page 23 6. Remove the screw (C) and washer (D). Lift the 7.8.3 To assemble the starter starter pulley (E). WARNING: Use protective glasses. The spring in the starter pulley can eject and cause injury. 1. Put the spring cassette (A) in the starter housing (B). 2.

  • Page 24: Ignition System

    6. Put the starter pulley (E) on the spring cassette (B) 4. Hold the spark plug against the cylinder and pull the and attach the washer (F) and the screw (G). starter rope handle. If the ignition operates correctly, you will see a spark between the electrodes on the 7.
  • Page 25 CAUTION: Use resistor spark plugs to prevent problems during operation and permanent damage to the ignition system. Only use spark plugs recommended by Husqvarna, refer to the operator's manual. • Examine the spark plug if the engine is low on power, is not easy to start or does not operate correctly at idle speed.

  • Page 26: Flywheel

    9. Remove the cable holder, the cables and the ignition 6. Put a clearance gauge between the ignition module module. and the flywheel. Tighten the screw to the correct Servicing data on page 7 . torque. Refer to 10. Remove the cables from the cable holder if it is necessary.
  • Page 27 4. Remove the spark plug and put a piston stop in the 7. Use the flywheel puller kit to remove and install the Servicing tools on page 9 . Put the spark plug hole. flywheel. Refer to tool (F) supplied with the flywheel puller kit in the center of the flywheel and attach the screws (G) in the holes for the start pawls.
  • Page 28 7.10.2 To install the flywheel 6. Make sure that you install the springs in the correct position, as shown in the illustration. 1. Clean the crankshaft. 2. Put the flywheel on the crankshaft. Turn the flywheel until the key goes into the key slot on the shaft. 3.

  • Page 29: Centrifugal Clutch

    7.11 Centrifugal clutch Servicing 6. Remove the centrifugal clutch. Refer to tools on page 9 . 7.11.1 To remove and install the centrifugal clutch 1. Disengage the chain brake. 2. Remove the clutch cover. 3. Remove the guide bar and saw chain. 4.

  • Page 30: Lubrication System

    3. Clean and examine all parts. Replace damaged 6. Remove the 2 screws and the oil pump housing. parts. Always use the original spare parts. 7. Pull out the suction hose from the crankcase. 7.12 Lubrication system 7.12.1 To remove and install the lubrication system WARNING: The saw chain can break if the lubrication is not sufficient.

  • Page 31: Air Filter

    1. Examine the air filter. 2. Clean the air filter if it is dirty. Shake the air filter and ® 3. Attach the wires to the holder for the Husqvarna use compressed air to remove dirt particles. Connectivity Device. 3. Replace the air filter if it is damaged.

  • Page 32: Carburetor

    ® 4. Put the holder for the Husqvarna Connectivity inlet and outlet valve in the diaphragm moves the fuel Device on the air filter holder and install the 2 through a filter screen to the inlet needle. screws. The metering unit (B) adjusts the quantity of fuel to the 5.
  • Page 33 In cold start mode the choke valve (H) is completely In the full throttle mode both valves are open and fuel is shut. This increases the vacuum in the carburettor and supplied through all four diffuser jets (D, E, F and G). fuel is easier to suck from all the diffuser jets (D), (E), The air throttle valve (J) is fully open.
  • Page 34 6. Remove the 4 screws on the air filter holder. 11. Disconnect the throttle wire. 12. Disconnect the thermostat wires in the front handle. 7. Remove the air filter holder from the 2 vibration damping units. 8. Push the snap locks (A) to remove the air purge bulb.
  • Page 35 13. Disconnect and remove the heating element. 15. Remove the carburetor. 14. Disconnect the fuel hose. 16. Install in the opposite sequence. 7.15.4 To examine the inlet pipe 1. Remove the 4 screws and remove the inlet pipe from the cylinder. 2.
  • Page 36 7.15.5 To disassemble the carburetor 7. Remove the screw (J) and the throttle plate (K). To remove and 1. Remove the carburetor. Refer to install the carburetor on page 33 . 2. Remove the four screws (A). 8. Remove the screw (L) and the collar (M). 9.
  • Page 37 7.15.7 To adjust the metering lever 7.15.9 Troubleshooting leakage The distance between the metering lever and the gasket Fault Cause surface of the carburetor housing must be 0.55 mm. Leakage in the diffuser jets The needle Adjust the distance if it is more or less than 0.55 mm. valve •...

  • Page 38: Start/Stop Switch

    3. Disconnect the 3 wires. 9. Assemble the thermostat and heating element in the opposite sequence to how it was disassembled. 7.16 Start/stop switch 7.16.1 To remove and install the start/stop switch 1. Remove the cylinder cover. 2. Remove the air filter. 3.

  • Page 39: Fuel Tank

    3. Connect a multimeter to the blue cable and the 7. Remove the screw and the chain catcher. cylinder to measure the resistance. The resistance must not be higher than 0.5 Ω. To remove and 8. Remove the front handle. Refer to install the front heated handle on page 19 .
  • Page 40 11. Remove the tank unit. 5. Install the fuel tank cap. 7.17.3 Magnetic tube in the fuel hose ™ Products with AutoTune have a magnetic tube in the fuel hose. This prevents magnetic particles in the fuel to ™ cause damage to the AutoTune system.

  • Page 41: Vibration Damping System

    7.17.5 To replace the air purge bulb 5. Do a test of the positive pressure in the fuel tank. a) Use the pressure tester in pressure mode 1. Disassemble the cylinder cover and the air filter. increase the pressure in the fuel tank. 2.

  • Page 42: Generator

    4. Assemble in the opposite sequence. 5. Disconnect the generator wire. 7.19 Generator 7.19.1 To remove and install the generator To remove and 1. Remove the tank unit. Refer to install the fuel tank on page 39 . To disassemble 2.

  • Page 43: Cylinder And Piston

    7.19.2 Product overview of the generator cables 6. Remove the 4 screws. 7. Remove the cylinder and the cylinder base gasket. 7.20 Cylinder and piston 7.20.1 To remove the cylinder and piston CAUTION: Make sure that the piston does 1. Remove the cylinder cover. not move.
  • Page 44 9. Use pointed pliers to remove the G snap ring (A) 7.20.2 To clean the cylinder and piston from the pin. Keep your thumb on the snap ring to 1. Clean the piston crown. make sure that it does not eject. 2.
  • Page 45 4. Put the piston ring in the cylinder and measure the 7.20.5 To examine the piston rings ring gap with a feeler gauge. The space must not be 1. Examine the piston rings for damage. more than 1 mm. 2. Replace damaged piston rings. 7.20.6 Piston damages Score marks on the piston Incorrect carburetor setting.
  • Page 46 7.20.7 To install the cylinder and piston 7. Put a new cylinder base gasket on the crankcase. 1. Attach the carburetor heat shield to the inlet pipe. Tighten the screws to the correct torque. Refer to Servicing data on page 7 . 2.

  • Page 47: Crankshaft And Crankcase

    10. Attach the cylinder (G) to the crankcase. Install the 4 6. Loosen the screws on the muffler and attach the Servicing tools on page 9 for screws (B). Tighten the screws in the correct outlet cover. Refer to sequence as the illustration shows. Refer to the correct cover.
  • Page 48 To replace the 6. Remove the chain catcher. Refer to 7.21.2 To disassemble the crankcase chain catcher on page 17 . 1. Remove the 3 screws (A) and the carburetor bottom plate (B). To remove 7. Remove the centrifugal clutch. Refer to and install the centrifugal clutch on page 29 .
  • Page 49 5. Attach the crankcase disassemble tool on the a) Remove the centrifugal clutch. Refer to remove and install the centrifugal clutch on page flywheel side of the crankshaft and remove the Servicing 29 . crankshaft from the crankcase. Refer to tools on page 9 .
  • Page 50 7. Use the press tool to push the new seal ring to the 3. Make sure that the bearing surfaces in the small end Servicing tools on page 9 correct position. Refer to of the connecting rod are not worn or have discoloration.
  • Page 51 a) On the clutch side. b) On the flywheel side. 2. Put the bearing on top of the guide shaft with the sealing up. 3. Attach the bearing with the sleeve, the screw and the nut. Note: The vise, the screw and the nut are not necessary when you use a press.
  • Page 52 Servicing 4. Use the rear side of the sleeve and pull the 6. Use the crankshaft assembly tool, refer to tools on page 9 . Turn the sleeve and push the crankshaft into the crankcase half on the clutch side. Pull until the crankshaft shoulder touches the main crankcase half of the flywheel side.

  • Page 53: Guide Bar Bolts

    8. Install the 2 screws (D). Tighten them in turn to the 7.22.2 To install the guide bar bolts Servicing data on page 7 . correct torque. Refer to 1. Attach a steel wire to the thread of a guide bar bolt. 9.

  • Page 54: To Repair A Damaged Thread

    7.23 To repair a damaged thread A damaged thread can be repaired with a thread insert. Note: For aluminum threads, use helicoil and metric screws. Refer to the manufacturer’s manual for more information. 1. Use the applicable drill bit to make a new hole that removes the damaged threads.

  • Page 55: Troubleshooting

    8 Troubleshooting 8.1 Troubleshooting 8.3 To troubleshoot the heating element in the rear handle You can do the troubleshooting procedure with most components attached to the product. Tools necessary 1. Disconnect the cable connection at (B1) and (D1). for the troubleshooting procedure is: 2.

  • Page 56: Troubleshooting Diagram

    8.6 Troubleshooting diagram Starter rope Perform “Cleaning and inspec- Defect Change part or entire tion” of starter housing does not retract starter if needed. starter housing (see separate instr.) Sticking starter Change part or entire Defect starter housing housing starter if needed. Check air gap between Start rope stuck Change part if needed.

  • Page 57: Engine Running Issue

    Does the Crankcase gaskets engine Crankcase start ? Issue still remains? Perform a visual inspection of interface between Contact your Husqvarna carburettor and intake rubber for leakage. Local Sales Company for advice. 1490 - 004 - 02.11.2021 Troubleshooting - 57...

  • Page 58: Engine Running Issue

    Check cables and connectors for wear. Product OK Check torque on ignition coil screws. Check the ground wire. Issue still remains? Contact your Husqvarna Local Sales Company for advice Leakage Check function of decompression valve (if equipped). Check mounting/interface intake rubber and carburettor.

  • Page 59: Ignition System Diagnostic Flow Chart

    8.9 Ignition System Diagnostic Flow Chart Perform visual inspection of unit. Inspect spark plug wire, boot connections. Repair/replace any problem items Install new, properly gapped, manufacturer specified spark plug. Stop switch must be in run position. Perform Spark Test (See separate instructions). End Test Is a strong Does engine...

  • Page 60: Technical Data

    9 Technical data 9.1 Technical data Husqvarna 592 XP Husqvarna 592 XPG Engine Cylinder displacement, cm 92.7 92.7 Idle speed, rpm 2800 2800 Maximum engine power acc. to ISO 8893, kW/hp 5.6/7.6 @ 9600 5.6/7.6 @ 9600 @ rpm Ignition system...
  • Page 61 1490 - 004 - 02.11.2021 Technical data - 61...
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592 xpg

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