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Husqvarna 536LiP4 Workshop Manual

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Workshop Manual
536LiP4 / 536LiPT5
536LiPX
English

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Summary of Contents for Husqvarna 536LiP4

  • Page 1 Workshop Manual 536LiP4 / 536LiPT5 536LiPX English...
  • Page 3: Table Of Contents

    Basic dismantle/assembly ........20 Safety equipment ........... 24 Repair instructions ..........26 Husqvarna AB has a policy of continuous product development and therefore reserves the right to modify the design and appearance of products without prior notice. English – 3...
  • Page 4: Index

    Assembling the control unit 45 Assembling the main switch 41 Assembling the motor 29 Assembling the shaft and motor cabling 37 Assembling the shaft and motor cabling (536LiP4, 536LiPX) 34 Changing the EMC filter 39 Changing the handle 45 Dismantling shaft and motor cabling (536LiP4,...
  • Page 5 Index English – 5...
  • Page 6: Introduction And Safety Regulations

    Introduction and safety regulations 2 Introduction and safety regulations Table of contents 2.1 General ..........................7 2.2 Safety ............................ 7 2.3 Target group ........................... 7 2.4 Modifications .......................... 7 2.5 Tools ............................7 2.6 Structure ..........................7 2.7 Numbering ..........................7 2.8 General instructions .......................
  • Page 7 Workshop Manual. 2.7 Numbering Usage is made evident in each section. Position references to components in the figures Always use original Husqvarna: are designated A, B, etc. • Spare parts The figures are numbered 1, 2 etc.
  • Page 8 2.10 Limitations This Workshop Manual is intended mainly for the repair of pole saw 536LiP4 / LiPT5, LiPX. NOTE! This box warns of material damage if the instructions are not followed.
  • Page 9 Introduction and safety regulations 2.11 Symbols on the pole saw 2.12 Symbols in the Workshop Manual The pole saw keypad has the following symbols. This symbol warns of personal injury when the instructions are not followed. Starting/Stopping savE / Battery saver mode Warning lamp/Fault indicator English –...
  • Page 10: Technical Data

    6.8 / 3.4 10.1 / 4.7 536LiPT5 11.0 / 5.0 13.7 / 6.3 536LiPX 6.8 / 3.1 9.7 / 4.4 Chain speed, savE rpm Chain speed, normal m/sec operating rpm m/sec 536LiP4 1/4" 536LiPT5 1/4" 536LiPX 3/8 10 – English...
  • Page 11: Service Tool Lipx / Lip4 / Lipt5

    INSTRUCTION Common Service Tool The Common Service Tool (CST) is a service tool for Husqvarna products comprising Diagnostic Tool Kit (583 89 71-01) and software for the installation of a PC. If you have the previous "Engine Diagnostic Tool - AutoTune™" (576 69 23-01), it can be supplemented with the "Adapter Cable for Battery Products"...
  • Page 12: Service Data

    Service data 5 Service data 6 ~ 8 Nm 4 mm 3 ~ 4 Nm 10 mm Symbol used where The numbers by bolted components represent the tightening torque in Nm. grease is to be used. Tightening torque during inspection: 52 ft/lb (2.5 Nm) 12 –...
  • Page 13 Service data Service data LiPX LiP4 LiPT5 English – 13...
  • Page 14 Service data Service data LiPX, LiP4 LiPT5 14 – English...
  • Page 15 Service data Service data English – 15...
  • Page 16: Diagnosis And Troubleshooting

    Diagnosis and troubleshooting 6 Diagnosis and troubleshooting Table of contents 6.1 Remove the battery ......................17 6.2 Connect the diagnostic tool ....................17 6.3 No signal to diagnostic tool ....................17 6.4 Troubleshooting the main switch ................... 18 6.5 Troubleshooting the BLDC control unit ................. 19 6.6 Overhaul ..........................
  • Page 17: Remove The Battery

    Diagnosis and troubleshooting 6 Diagnosis and troubleshooting 6.1 Remove the battery Press in the catches and remove the battery. See figure 1. WARNING! The battery must always be removed for service/repair work and may only be replaced once the pole saw has been fully assembled again! WARNING! Do not short circuit the battery!
  • Page 18: Troubleshooting The Main Switch

    Diagnosis and troubleshooting 6.4 Troubleshooting the main switch The switch used in professional battery products from Husqvarna has two functions, to supply current to the control unit and the electric motor, and act as a position sensor for the variable speed control.
  • Page 19: Troubleshooting The Bldc Control Unit

    Diagnosis and troubleshooting 6.5 Troubleshooting the BLDC control unit Check that the blade terminals and associated wires are not bent or damaged. (A) 4.8x0.8mm M phase (Gray wire) (B) 4.8x0.8mm M phase (Black wire) (C) 4.8x0.8mm M phase (Red wire) See figure 7b.
  • Page 20: Basic Dismantle/Assembly

    Basic dismantle/assembly 7 Basic dismantle/assembly Table of contents 7.1 Battery ..........................21 7.2 Trigger guard......................... 21 7.3 Battery housing skidplate ..................... 21 7.4 Control handle ........................22 7.5 Battery housing ........................22 7.6 Chain and bar ........................22 20 – English...
  • Page 21 Basic dismantle/assembly 7 Basic dismantle/assembly The steps described below are the basic steps that must be carried out before any other service or repair work or final assembly is possible. 7.1 Battery Press in the catches and remove the battery. Replace the battery once assembly has been completed.
  • Page 22 Basic dismantle/assembly 7.4 Control handle Place something under the other handle half so that it does not come loose from the shaft. Loosen the screws (6x) and lift off the handle. Assemble in the reverse order. Tightening torque 2 ~ 3 Nm. 7.5 Battery housing Loosen the screws (4x) and lift off half the battery housing.
  • Page 23 Basic dismantle/assembly English – 23...
  • Page 24: Safety Equipment

    Safety equipment 8 Safety equipment Table of contents 8.1 Dismantling the throttle trigger lock and throttle trigger ............25 8.2 Assembling the throttle trigger lock and throttle trigger ............25 24 – English...
  • Page 25 Safety equipment 8 Safety equipment 8.1 Dismantling the throttle trigger lock and throttle trigger Dismantle the control handle as described in "7 Basic dismantle/assembly" on page 20 Lift off the throttle trigger lock and the throttle trig- ger from their attachments in the handle. Cleaning and inspection • Clean and check all parts thoroughly. Parts must be replaced if cracked or showing signs of other...
  • Page 26: Repair Instructions

    9.6 Dismantling the oil pump and/or chain tensioner, branch hook ..........32 9.7 Assemble the oil pump and/or chain tensioner, branch hook ..........32 9.8 Dismantling shaft and motor cabling (536LiP4, 536LiPX) ............ 33 9.9 Assembling the shaft and motor cabling (536LiP4, 536LiPX)..........34 9.10 Dismantling shaft and motor cabling (536LiPT5) ..............
  • Page 27: General Repair Instructions

    Repair instructions 9 Repair instructions 9.1 General repair instructions WARNING! NOTE! The battery must always be removed Note how wires, components, etc., are posi- for service/repair work and may only tioned before dismantling. be replaced once the pole saw has aavoid pinching when the pole saw is reas- been fully assembled again! sembled.
  • Page 28 Repair instructions Dismantle the screws holding the saw head on the shaft, 2 screws. Carefully split the shaft and saw head. Extract the cables one by one from the saw head. Dismantle the screws, 4 pcs, holding the motor. Press out the motor. Press out the pump gear that drives the oil pump.
  • Page 29: Assembling The Motor

    Repair instructions Change the gasket between the motor and motor housing. Cleaning and inspection Clean and check the motor. The motor must always be replaced with a new one if cracked or showing signs of other defects. Always use original spare parts.
  • Page 30 Repair instructions Couple the cables together. Assemble the cable holder on the motor (1). Press the shaft (2) into the saw head to facilitate assembly of the cabling. Screw finger tight (3). Couple the cabling together. Tigten the screws holding the saw head. Fit the cable protector, 2 screws.
  • Page 31: Dismantling The Oil Tank

    Repair instructions Fit spur wheel, washer and circlip. Use circlip pliers to install the circlip. Assemble the guide bar and chain. Assemble the motor cover. 9.4 Dismantling the oil tank Dismantle the motor as described in "9.2 Dismantling the motor" on page 27 Dismantle the oil tank screws, 2 screws. Work the oil hose out from the tank.
  • Page 32: Dismantling The Oil Pump And/Or Chain Tensioner, Branch Hook

    Repair instructions 9.6 Dismantling the oil pump and/or chain tensioner, branch hook Dismantle the motor as described in "9.2 Dismantling the motor" on page 27 Dismantle the oil tank as described in "9.4 Dismantling the oil tank" on page 31 Remove the oil pump and the oil hose out of its groove.
  • Page 33: Dismantling Shaft And Motor Cabling (536Lip4, 536Lipx)

    Repair instructions 9.8 Dismantling shaft and motor cabling (536LiP4, 536LiPX) Dismantle the trigger guard, handle, battery hous- ing as described in "9.1 General repair instruc- tions" on page 27 Dismantle the clamp holding the shaft. Separate the connector to the control unit.
  • Page 34: Assembling The Shaft And Motor Cabling (536Lip4, 536Lipx)

    Repair instructions 9.9 Assembling the shaft and motor cabling (536LiP4, 536LiPX) Thread the cabling into the shaft, starting from the saw head side. Press the cabling into the connector. Make sure the wings on both sides of the connector are pro- truding slightly so they hook onto the sides of the connector.
  • Page 35: Dismantling Shaft And Motor Cabling (536Lipt5)

    Repair instructions 9.10 Dismantling shaft and motor cabling (536LiPT5) Dismantle the trigger guard, handle, battery hous- ing as described in "9.1 General repair instruc- tions" on page 27 Dismantle the clamp holding the shaft. Separate the connector to the control unit. The shaft will now come loose from the battery housing.
  • Page 36 Repair instructions Start at the saw head end to split the shaft. Dismantle the screw inside the inner shaft. Unscrew the stop screw holding the cabling in place so it does not dislodge. Pull out the cabling slightly and rotate it 180° Remove the sleeve inside the inner shaft on the saw head and thread the cabling through the sleeve.
  • Page 37: Assembling Shaft And Motor Cabling (536Lipt5)

    Repair instructions 9.11 Assembling shaft and motor cabling (536LiPT5) Start with the cabling on the saw head side. Thread the cabling through the inner shaft. Thread the cabling into the sleeve holding the cabling in place in the inner shaft. Fasten the sleeve in the shaft making sure it is positioned correctly in the shaft.
  • Page 38 Repair instructions Insert the anti-vibration element, making sure the screw hole on the anti-vibration element corresponds with the hole in the shaft. The anti- vibration element has a guide ensuring it is positioned correctly in the shaft. Assemble the lower part of the shaft and screw on the anti-vibration element and lower part of the shaft.
  • Page 39: Changing The Emc Filter

    Repair instructions 9.12 Changing the EMC filter Always replace a damaged EMC filter with a new one. Dismantle the battery housing as described in "7 Basic dismantle/assembly" on page 20 Unplug the connector from the control unit. Loosen the cables from the connector at the battery housing end with a small flat screwdriver.
  • Page 40: Dismantling The Main Switch

    Repair instructions 9.13 Dismantling the main switch Dismantle the control handle as described in "7 Basic dismantle/assembly" on page 20. Dismantle the throttle trigger lock and throttle trigger as described in "8.1 Dismantling the throttle trigger lock and throttle trigger" on page 25. Fig 10b Lift out the main switch and disconnect cable (A).
  • Page 41: Assembling The Main Switch

    Repair Instructions 9.14 Assembling the main switch Connect the contact (C) to the main switch. NB! Make sure to apply grease to the contact sur- faces and also the connector. See figure 13b. Connect cable (A) and place the main switch in the battery housing.
  • Page 42: Dismantling The Control Cabling

    Repair Instructions 9.15 Dismantling the control cabling NOTE! Note how wires, components, etc., are posi- tioned before dismantling. Make sure to position them correctly to avoid pinching when the pole saw is reassembled. Dismantle the control handle as described in "7 Basic dismantle/assembly"...
  • Page 43: Assembling The Control Cabling

    Repair Instructions 9.16 Assembling the control cabling Place the bottom section of the cabling and the fan in the battery housing and connect the connector to the control unit. Assemble the fan, making sure it is positioned in the correct direction. Assemble the keypad.
  • Page 44: Dismantling The Control Unit

    Repair Instructions 9.17 Dismantling the control unit Dismantle the battery housing as described in "7 Basic dismantle/assembly" on page 20 Disconnect the connector to the motor. Loosen the screws (G) to the control unit and the screws (H) to the battery contact and lift out the entire unit and the fan.
  • Page 45: Assembling The Control Unit

    Repair Instructions 9.18 Assembling the control unit Connect the connector from the motor to the con- trol unit. Connect connector (D) to the control unit for the keypad, fan and main switch. Make sure the connector is plugged firmly into the control unit. See figure 18b.
  • Page 46 Troubleshooting - 536 LiPX / LiP4 / LiPT5 10 Troubleshooting - 536 LiPX / LiP4 / LiPT5 Symptom Possible causes Recommended action The product cannot be activated. No Faulty battery 1. Check the battery by pressing the LEDs come on after pressing the on/ status button.
  • Page 47 Troubleshooting - 536 LiPX / LiP4 / LiPT5 Warning triangle flashes continually Temperature too high 1. Wait for the product to cool down on keypad (min. 5 minutes) Temperature of control unit or bat- 2. Make sure neither the product nor tery too low the battery is colder than -10 °C Water in breaker signal contact...
  • Page 48 Troubleshooting - battery and charger 11 Troubleshooting - battery and charger Symptom Possible causes Recommended action No LEDs come on on the battery Faulty battery Change the battery. after pressing the status button. A warning triangle lights up solid red Faulty battery Change the battery.
  • Page 49 Troubleshooting - annexe 12 Troubleshooting - annexe 1. Power connectors Make sure connectors are free from dirt and that metal surfaces are not damaged. Pay certain attention to the connection tabs. Power connectors have the same basic design on prod- uct, battery and charger.
  • Page 50 Troubleshooting - annexe 3. Trigger switch signal connector with grease Apply grease between the specified pins, grease should be applied between pins 1, 2 and 3, 4 in- side as well as outside. 4. Communication cables Make sure the three small communication cables are not loose or damaged.
  • Page 51 Troubleshooting - annexe 5. Motor and power connectors Make sure the three motor connectors and the two power connectors are properly connected to respective plastic housing. 6. 26-pin wiring cable Make sure the 26-pin wiring cable is properly as- sembled, dry and not damaged. English –...
  • Page 52 • 115 83 57-26 2016W14...

This manual is also suitable for:

536lipt5536lipx