Husqvarna K970 SmartGuard Workshop Manual
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Husqvarna K970 SmartGuard Workshop Manual

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Workshop manual
K970 SmartGuard
English
1451 - 001 - 02.04.2020
Table of Contents
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Summary of Contents for Husqvarna K970 SmartGuard

  • Page 1 Workshop manual K970 SmartGuard English 1451 - 001 - 02.04.2020...

  • Page 2: Table Of Contents

    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 Servicing data 3.1 Symbols in the diagrams........5 3.2 Tightening torques ..........

  • Page 3: Introduction

    1.5 Servicing tools The manual gives information about necessary servicing tools. Always use original tools from Husqvarna. 1451 - 001 - 02.04.2020 Introduction - 3...

  • Page 4: Safety

    2 Safety 2.1 Safety definitions Read the manual carefully and make sure you understand the instructions before Warnings, cautions and notes are used to point out using the product. specially important parts of the manual. WARNING: Used if there is a risk of injury or Always put on personal protective death for the operator or bystanders if the equipment:...

  • Page 5: Servicing Data

    3 Servicing data 3.1 Symbols in the diagrams Tightening torque, Nm 1451 - 001 - 02.04.2020 Servicing data - 5...

  • Page 6: Tightening Torques

    3.2 Tightening torques 3,0-4,0 3,0-4,0 17,0-23,0 2,0-3,0 9,0-11,0 10,0-12,0 9,0-11,0 9,0 -11,0 9,0-11,0 3,0-5,0 7,0-9,0 6 - Servicing data 1451 - 001 - 02.04.2020...
  • Page 7 5,0-7,0 5,0-7,0 5,0-7,0 10,0-18,0 14,0-16,0 16,0-18,0 11,0-13,0 1451 - 001 - 02.04.2020 Servicing data - 7...
  • Page 8 1-1.5 1-1.5 38-42 8-10 14-16 0.5-0.8 14-16 4-10 8 - Servicing data 1451 - 001 - 02.04.2020...
  • Page 9 7,0-10,0 25,0-30,0 35,0-40,0 12,0-14,0 7,0-10,0 6,0-8,0 20,0-25,0 7,0-9,0 14,0 2,0-3,0 3,0-4,0 2,0-3,0 14,0 2,0-3,0 17,0 1451 - 001 - 02.04.2020 Servicing data - 9...

  • Page 10: Servicing Tools

    4 Servicing tools 4.1 Servicing tools overview Designation Used for Order No./Source tion Sealing plug To examine the crankcase for leaks. 503 55 22-01 Bearing press To assemble the primary bearing. 506 37 61-02 Press tool To disassemble and assemble the blade shaft bearings and axle. 575 96 20-01 Puller To disassemble the sealing rings of the crankcase in the crank- 504 91 40-01...

  • Page 11: Servicing Tools Overview

    4.2 Servicing tools overview Designation Used for Order No./Source tion Grip plate To divide the crankcase. 544 06 00-02 Bearing puller Remove the primary bearing from the crankshaft. 531 00 48-67 Bearing press To disassemble the primary bearing and assemble the crankshaft. 544 10 36-02 Combination wrench General.

  • Page 12: Servicing Tools Overview

    4.3 Servicing tools overview Designation Used for Order No./ Source tion Test spark plug To do servicing on the ignition unit. 502 71 13-01 Air clearance gauge To adjust the air clearance between the ignition module and the fly- 502 51 34-02 wheel.

  • Page 13: Product Overview For Repair And Servicing

    5 Product overview for repair and servicing 5.1 Product overview 1451 - 001 - 02.04.2020 Product overview for repair and servicing - 13...

  • Page 14: Basic Modules Of The Product

    1. SmartGuard 16. Belt adjustment screw 2. Adjustment handle for blade guard 17. Fuel tank cap 3. Water hose 18. Water connection with filter 4. Water valve 19. Sight glass for fuel 5. Air filter cover 20. Stop switch 6. Rear handle 21.
  • Page 15 5.2.1 To remove the starter 5.2.2 To remove the cutting head To disassemble the 1. Remove the 4 screws on the guard. 1. Loosen the hose clip. Refer to wet system on page 66 . Loosen the 3 nuts on the 2.
  • Page 16 3. Remove the front belt guard. 5. Remove the 2 screws on the rear belt guard. Remove the rear belt guard. 4. Remove the cutting head. 5.2.3 To remove the air filter CAUTION: Be careful when the air filter is removed.
  • Page 17 3. Loosen the center screw. Remove the air filter. 5.2.5 To remove the carburetor To remove the 1. Remove the cylinder cover. Refer to cylinder cover on page 17 . 2. Remove the choke handle. 3. Remove the fuel hoses CAUTION: Make sure that dust does not fall into the carburetor inlet.
  • Page 18 5. Remove screw for the inlet hose. 5.2.6 To remove the air duct To remove the starter 1. Remove the starter. Refer to on page 15 . 2. Remove the cable lug for the stop switch cable. 6. Loosen the carburetor. 3.
  • Page 19 5. Remove the air duct. 5.2.8 To remove and install the inlet manifold To remove the 1. Remove the carburetor. Refer to carburetor on page 17 . 2. Remove the screw that hold the muffler to the crankcase. 5.2.7 To remove the muffler To remove the 1.
  • Page 20 5. Remove the screws for the inlet manifold. 8. Remove the inlet manifold. 9. Install in opposite sequence. 6. Loosen the clamp. Note: Make sure that the clamp is put fully together. 7. Lift the cylinder approximately 1 cm. 20 - Product overview for repair 1451 - 001 - 02.04.2020 and servicing...
  • Page 21 5.2.9 To remove the inlet nozzle 8. Remove the 4 screws for the vibration damping units. 1. Remove the screw for the inlet nozzle. 2. Remove the the inlet nozzle. 3. Install in opposite sequence. 5.2.10 To remove the vibration damping units 1.

  • Page 22: Repair And Servicing

    6 Repair and servicing 6.1 Starter 3. Remove the starter rope from the starter pulley. 6.1.1 To remove the starter rope 1. To remove the spring force from the return spring, pull out the starter rope approximately 12 in/30 cm. Hold the starter pulley with your thumb and put the starter rope in the notch on the starter pulley.
  • Page 23 6.1.2 To attach the new starter rope 6.1.3 To apply tension to the return spring 1. Put one end of the new starter rope from the top 1. Put the starter rope in the notch. through the hole in the starter pulley. Then pull it out 2.
  • Page 24 6.1.4 To remove the starter pulley 6.1.5 To install the starter pulley 1. Decrease the tension in the return spring. Refer to Note: Make sure that the spacer sleeve does not fall off. To remove the starter rope on page 22 . 2.
  • Page 25 the flywheel rotates, the turning force pushes out the 6.1.9 To assemble the starter pawls center pawls. CAUTION: The spring must not get caught between the starter pawl and the flywheel. 1. Push the spring into position in the flywheel. 2.

  • Page 26: Ignition System

    6.1.10 To install the starter transformer. The secondary coil increases the voltage to 20 000V. This causes a spark. The starter pawls must come into the correct position against the starter pulley sleeve. 1. Pull out the rope approximately 0.5 m. 2.
  • Page 27 6.2.4 To examine the ignition spark .02 in. 1. Ground the spark plug to the cylinder. 0.5 mm 1. Replace the spark plug with the test spark plug. Servicing tools overview on page 12 . Refer to 2. Move the stop switch to the operation position. 3.
  • Page 28 6.2.6 To examine the ignition cable 6.2.7 To examine the short circuit cable and the stop switch 1. Pull up the rubber seal by the ignition unit and remove the ignition cable. To remove the starter 1. Remove the starter. Refer to on page 15 .
  • Page 29 6.2.8 To remove the stop switch 6.2.9 To install the stop switch 1. Remove the screw and the cable. 1. Push the switch into position (A). 2. Push the side until it locks (B). 2. Pull out the the switch approximately 10 mm (A). 3.

  • Page 30: Flywheel

    Tighten the screws with a torque of 10–12 6.3 Flywheel 6.3.1 To remove the flywheel Servicing Use a Husqvarna flywheel puller. Refer to tools overview on page 12 . 6. Hold the handle of the flywheel puller to lock the 1. Remove the starter, refer to To remove the starter flywheel.

  • Page 31: Air Filter

    7. Attach the screw press in the center. 6.3.3 To install the flywheel The crankshaft and the center of the flywheel must be free from grease. Tightening torque 18 – 22 lbf·ft / 25 – 30 Nm. Use a torque wrench to tighten the nut. 1.

  • Page 32: Fuel System

    CAUTION: Make sure that dust does not fall into the carburetor inlet. 2. Clean and examine the inlet duct. 2. Catch the fuel hose with a Husqvarna fuel filter hook (A). a) Make sure that there is no dust on the inner surface of the inlet duct.
  • Page 33 6.5.3 To examine the fuel system for leakages 6.5.4 To remove the fuel hose 1. Connect the adapter to a pressure test tool. Refer to 1. Remove the fuel hose from the carburetor. Refer to Servicing tools overview on page 12 . To remove the carburetor on page 17 .
  • Page 34 3. Attach the weight and the fuel filter. 6.5.8 To remove the filter for the fuel tank venting • Remove the check valve and then the filter for the fuel tank venting with a pair of pliers. 6.5.9 Function of the air purge bulb 6.5.6 Function of the tank venting The fuel tank has a check valve that lets air enter the tank, but prevents fuel from leakage.
  • Page 35 If the air purge bulb does not fill with fuel when you push 6.5.11 To remove the air purge bulb it, do this procedure. 1. Remove the return hose and carburetor hose from the air purge bulb. 1. Connect the pressure test tool to the hose from the air purge bulb.

  • Page 36: Carburetor

    6.6 Carburetor 6.6.1 Carburetor components 1. Lever for the start throttle 14. Needle valve 2. Connection to the air purge bulb 15. Pump diaphragm measurement chamber 3. Fuel line from the fuel tank 16. Fuel pump valves 4. Impulse channel, from the crankcase to the 17.
  • Page 37 connection as short as possible, this gives a more If the needle valve does not open at 36 psi/2.5 bar, the accurate test result. needle valve has locked. Blow through the hole for filter compensation (A) to open the needle valve. 6.6.3 Needle valve 6.6.3.1 Indications of a needle valve leak There are many symptoms of a needle valve with a leak.
  • Page 38 To examine and clean the the needle valve. Refer to 6.6.3.6 To examine and clean the needle valve needle valve on page 38 . 1. Remove the needle valve. 6.6.3.5 To examine external leakage and the function of the needle valve 2.
  • Page 39 6.6.4 Pump unit function measurement chamber diaphragm. The diaphragm controls and keeps a constant level of fuel in the fuel The pump diaphragm (A) receives power by changes of chamber through the mechanically connected needle pressure in the crankcase. The pressure changes are valve.
  • Page 40 6.6.8 To examine the fuel strainer 3. Clean the channels with compressed air. The rings in the illustration below show where to blow clean. 1. Examine the fuel strainer with a magnifying glass. 2. Remove loose dirt particles from the needle valve seating with air.

  • Page 41: Decompression Valve

    valve (A). The valve closes because of the combustion Note: Do not connect the tachometer directly to the pressure when the engine fires (B). ignition system. The tachometer senses the magnetic field from the ignition system. Note: Do not remove the air filter cover. WARNING: Adjust the idle speed outdoors.

  • Page 42: Cylinder And Piston

    5. Move the stop button to the stop position. The average for a new engine is approximately 7.5 bar/110 psi. Values less than 5.5 bar/80 psi show faults 6. Slowly pull the starter rope handle and make sure with or on the cylinder, piston or piston rings. that there are no leaks from the decompression valve.
  • Page 43 contains piston ring compressors, a piston stop, and a 4. Push out the wrist pin by hand. If it is tight, use a support plate for the piston. small hammer and light force. 1. Put the support plate below the piston. 2.
  • Page 44 hours must be examined carefully. It is important to 6.8.7 Piston wear tolerances identify the cause of the unusual wear. 6.8.7.1 Piston ring play If the piston ring play is more than 0.006 in./0.15 mm, the piston ring groove must be measured as set out below.

  • Page 45: Piston Wear

    6.9 Piston wear Examine the product to see if it has broken down because of an incorrect oil mixture, or no oil at all. If The cause of engine failure can be hard to find if the there is oil on a piston that is too hot it can carbonize. If previous operation and service of the product is not not, check if the connecting rod or the crankcase has a available.

  • Page 46: To Assemble The Piston

    6.10 To assemble the piston 3. Install a snap ring in the piston. Lubricate new or cleaned bearings and piston rings with 2-stroke oil before you assemble them. 4. Hold the piston in position, push in the wrist pin and 1.

  • Page 47: To Assemble The Cylinder

    6.11 To assemble the cylinder 5. Push down the cylinder on the piston and let the piston ring compressor move along the piston. 1. Clean and remove remaining bits of the first gasket Tighten the screws crosswise to a torque of 10–11 from the surfaces that connect with the gasket.
  • Page 48 6.12.1 To examine the crankcase for leaks 5. At the inlet port, attach the cylinder seal and connect the pressure tester. 1. Turn the crankshaft until the exhaust port is fully open. The piston must be at its bottom point. 2.
  • Page 49 6.12.2 To remove the crankcase seal 4. On the flywheel side, lubricate the axle. To replace the crankcase seal rings, use a Husqvarna Servicing tools puller and an assembly punch. Refer to overview on page 10 . 1. Push down the puller (A) and tighten the outer thread of the puller in the sealing ring with a wrench (B).
  • Page 50 4. Do the same with the other side of the crankcase. Divide the crankcase with a universal puller and a grip Servicing tools overview plate from Husqvarna. Refer to on page 10 and Servicing tools overview on page 11 . 1. Disassemble the basic modules from the crankcase.
  • Page 51 Servicing use 2 Husqvarna bearing press kits, refer to 3. Put the crankcase halves against a flat piece of tools overview on page 10 . wood or equivalent. Use a hot air gun around the bearing, maximum 100°C /212°F. 1. Put the puller plate behind the bearing.
  • Page 52 6.12.8 To assemble the crankcase Servicing tools Use a Husqvarna bearing press, refer to overview on page 10 . 1. Lock the crankcase half. The bottom of the cylinder plane must be down. This makes sure that the connecting rod does not push on the crankcase when you assemble the crankcase.

  • Page 53: Clutch

    This helps put the gasket into position. 6.13.1 To remove the clutch To remove the clutch, use a Husqvarna piston stop, Servicing tools overview on page 11 . refer to 1. Lock the crankshaft with the piston stop.
  • Page 54 3. Pull the clutch drum from the axle. Make a note of clutch. If it is necessary, replace with a full clutch the position of the washer against the bearing assembly. nearest the crankcase. 2. Measure the inner diameter of the clutch drum. 6.13.2 To examine the clutch for wear Repair the clutch if the cutting blade is engaged at engine speeds less than 3100 rpm.
  • Page 55 3. Remove the spring with a small screwdriver or a pin 6.13.7 Belt pulley bearings punch. The clutch drum and the belt pulley are connected units. The belt pulley has 2 permanently lubricated ball bearings that are adjacent to each other without spacers.
  • Page 56 3. Put the hex key in a vise. Put the head of the screw 6.13.9 To install the belt pulley bearings on the hex key. Put the socket and cover in position. 1. Put the support plate of the bearings in a vise. Put Install the washer and the nut.

  • Page 57: Cutting Head

    6.14 Cutting head 3. Remove the 4 screws and the bushings. Discard the screws. 6.14.1 To disassemble and assemble the SmartGuard 1. Remove the springs from the front arms. 4. Remove the SmartGuard. 2. Remove the plastic covers and the springs. Discard the 4 screws.
  • Page 58 5. Remove the 2 screws and remove the plates. 7. Remove the arms. Discard the screws. 6. Remove the 4 screws and the 2 wheels. Discard the 8. Remove the springs from the handle. screws. 58 - Repair and servicing 1451 - 001 - 02.04.2020...
  • Page 59 9. Remove the handle. CAUTION: Apply grease on the bushings. Refer to Servicing tools overview on page 12 . 10. Remove the spring. 11. Assemble the SmartGuard in opposite sequence. CAUTION: Discard and replace all self locking screws each time they are removed. 1451 - 001 - 02.04.2020 Repair and servicing - 59...
  • Page 60 6.14.2 To disassemble the blade guard and the 4. Lock the belt pulley with a mandrel or a screwdriver and loosen the center screw. bearing housing 1. Remove the cutting head from the product. Refer to To remove the cutting head on page 15 . 2.
  • Page 61 6. Remove the 3 screws and the retarder. brake shoes (D) are pressed against the brake drum (C) by the spring (A). These units are held in position by the guide plate (B). When the speed goes above work speed, the brake shoes are pushed out from the brake drum.
  • Page 62 6.14.6 To assemble the retarder unit 6.14.7 To assemble the retarder and belt pulley 1. Put the spring (A) in position in the guide plate (B). 1. Assemble the plate of the retarder unit and the belt Note where the spring ends must be. pulley with the 4 screws.
  • Page 63 • If you replace the bearings with a bearing press kit, housing. use the Husqvarna bearing press kit. Refer to Servicing tools overview on page 10 . 1. Turn the support for assemble with its shoulder up and put the bearing housing on top of it.
  • Page 64 CAUTION: Do not put force between the inner and outer rings of the blade shaft bearing. The bearings can become damaged. Use a hydraulic press or a Husqvarna bearing press kit Servicing to assemble the blade shaft bearings. Refer to tools overview on page 10 .

  • Page 65: Wet System

    6.15 Wet system 5. Use the assembly support to make the bearing housing level. 6.15.1 Function of the wet system Each side of the blade guard has a spray nozzle. The water hits a section of the cutting blade and the centrifugal force moves it out to the edge.
  • Page 66 6.15.2 To disassemble the wet system 6.15.3 To assemble the wet system 1. Remove the screws that hold the spray nozzles. 1. Put the spray nozzles on to the blade guard. 2. Remove the filter with a wood screw. 2. To put the filter in the connector, push it in on a flat surface.

  • Page 67: Throttle Trigger And Throttle Trigger Lockout

    6.16 Throttle trigger and throttle trigger lockout To remove the 1. Remove the carburetor. Refer to carburetor on page 17 . 6.16.1 To remove the throttle trigger and throttle 2. Push in the lower part of the throttle trigger lockout trigger lockout with a V-jaw adjustable pliers.
  • Page 68 5. Push out the spindle to the right side. Use a rod with 6.16.3 To install the throttle trigger and throttle a diameter of 0.08–1.0 in./2–2.5 mm and minimum 4 trigger lockout in./10 mm in length and remove the throttle trigger. The spindles for the throttle trigger and the throttle control wheel must be installed from the right side.
  • Page 69 4. Install the right handle side. 5. Install the throttle trigger lockout. 1451 - 001 - 02.04.2020 Repair and servicing - 69...

  • Page 70: Troubleshooting

    7 Troubleshooting 7.1 Engine does not start Remove the spark plug from the cylinder. Hold the cylinder, pull the starter rope and see if there are sparks between the spark plug electrodes. There are no sparks at the spark plug. Examine Cause Solution...

  • Page 71: Engine Stops During Operation - No Sparks

    7.2 Engine stops during operation - no sparks There are no sparks at the spark plug Problem Cause Solution Engine suddenly The switch is accidentally set to off. Set the switch to the left position. stops. The plug cap is not attached. Attach the plug cap fully.

  • Page 72: Weak Output Or Change Of Speed

    7.4 Weak output or change of speed There are no sparks at the spark plug Symptom/Category Cause Solution Compression is good Air has gone through the fuel pipe joint. Make sure it is tight. and there is no flame Air has gone into the fuel pipe because of a Replace.
  • Page 73 1451 - 001 - 02.04.2020 Troubleshooting - 73...
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