Husqvarna 536LiL Workshop Manual
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Husqvarna 536LiL Workshop Manual

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Workshop Manual
536LiL / 536LiR / 136LiC
536LiLX / 536LiRX / 336LiC
English

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Summary of Contents for Husqvarna 536LiL

  • Page 1 Workshop Manual 536LiL / 536LiR / 136LiC 536LiLX / 536LiRX / 336LiC English...
  • Page 3 Basic dismantle/assembly ........28 Safety equipment ............32 Repair Instructions ........... 39 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. – 3 English...
  • Page 4 Index Index Basic dismantle/assembly 28 Safety equipment 32 Battery 29 Assembling the throttle trigger lock and throttle Battery housing 31 trigger 37 Operating handle LiL / LiLX 29 Assembling the trimmer guard LiC 36 Operating handle LiR / LiRX 29 Changing a trimmer cord cutter 33 Wear guard LiR / LiRX 30 Dismantling the throttle trigger lock and throttle...
  • Page 5 Index – 5 English...
  • Page 6 Introduction and safety regulations 2 Introduction and safety regulations Table of contents General ..........................7 Safety ..........................7 Target group ........................7 Changes ..........................7 Tools ..........................7 Structure ..........................7 Numbering ........................7 General instructions ......................8 Special instructions ......................8 2.10 Symbols on the trimmer ....................9 2.11 Symbols in the Workshop Manual .................9 6 –...
  • Page 7 Workshop Manual. The position references and figure numbers restart Usage is made evident in each section. in each new section. Always use original Husqvarna: • Spare parts • Service tools • Accessories – 7...
  • Page 8 Introduction and safety regulations 2.8 General instructions 2.9 Special instructions The workshop where the trimmer is to be repaired Remove the battery from the trimmer before dis- must be equipped with safety devices in accor- mantling and troubleshooting. dance with local regulations. The battery must not be connected while the trim- No one may repair the trimmer unless they have mer is being dismantled.
  • Page 9 Introduction and safety regulations 2.10 Symbols on the trimmer 2.11 Symbols in the Workshop Manual The trimmer 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 Optional direction of rotation –...
  • Page 10 Ibs/kg 136LiC 6.6 / 3.0 9.2 / 4.2 336LiC 6.6 / 3.0 9.2 / 4.2 6.6 / 3.0 9.2 / 4.2 536LiL 536LiR 8.4 / 3.8 11.0 / 5.0 6.6 / 3.0 9.2 / 4.2 536LiLX 536LiRX 8.4 / 3.8 11.0 / 5.0...
  • Page 11 INSTRUCTION Common Service Tool The Common Service Too (CST) is a service tool for Husqvarna products comprising Diagnostic Took 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 5 Service data LiL/LiR/LiC LiL / LiR 3 ~ 4 Nm 10 mm 6 ~ 8 Nm 4 mm 6 ~ 8 Nm 4 mm Right threaded nut 8 ~ 12 Nm 19 mm LiL / LiR / LiC (x2) 3 ~ 4 Nm 4 mm (x4) 2 ~ 3 Nm...
  • Page 13 Service data Service data LiLX / LiRX LiLX / LiRX LiLX 3 ~ 4 Nm 10 mm 6 ~ 8 Nm 4 mm 4 mm 6 ~ 8 Nm 35 ~ 50 Nm Left threaded LiLX / LiRX (x2) 3 ~ 4 Nm 4 mm (x4) 2 ~ 3 Nm 4 mm...
  • Page 14 Service data Service data LiL S/N -2015080000 (x2) 1 Nm (x2) 1 Nm (x6) 1,7 ~ 2 Nm 4 mm 14 – English...
  • Page 15 Service data Service data LiL/LiLX S/N 2015080001- (x2) 1 Nm (x2) 1 Nm (x6) 1,7 ~ 2 Nm 4 mm – 15 English...
  • Page 16 Service data Service data LiR S/N -2015100000 (x2) 1 Nm (x2) 1 Nm 16 – English...
  • Page 17 Service data Service data LiR/LiRX S/N 201510001- (x2) 1 Nm (x2) 1 Nm – 17 English...
  • Page 18 Service data Service data LiR / LiRX 3 ~ 4 Nm 4 mm (x3) 2 ~ 3 Nm 4 mm (x4) 1 Nm 3 ~ 4 Nm 4 mm (x6) 3 ~ 4 Nm 4 mm (x4) 2 ~ 3 Nm 4 mm 18 –...
  • Page 19 Service data Service data LiC (x4) 2,5 ~ 3 Nm 4 mm (x4) 3 ~ 4 Nm 4 mm 5 ~ 6 Nm 4 mm 10 mm (x4) 2,5 ~ 3 Nm 4 mm 8 ~ 12 Nm 19 mm –...
  • Page 20 Service data Service data LiC (x2) 1 Nm (x2) 1 Nm 20 – English...
  • Page 21 – 21 English...

  • Page 22: Table Of Contents

    Diagnosis and troubleshooting 6 Diagnosis and troubleshooting Table of contents Remove the battery ......................19 Connect the diagnostic tool .....................19 No signal to diagnostic tool ....................19 Troubleshooting diagram - LiC ..................20 Troubleshooting the main switch ..................21 Troubleshooting the keypad .....................21 Troubleshooting the control unit PMDC - LiC ..............21 Troubleshooting the control unit BLDC - LiL/LiLX / LiR/LiRX ..........22 Overhaul ..........................22 22 –...

  • Page 23: Diagnosis And Troubleshooting

    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 trimmer has been completely assembled again! WARNING! Do not short circuit the battery!

  • Page 24: Troubleshooting Diagram - Lic

    Diagnosis and troubleshooting 6.4 Troubleshooting diagram - LiC The diagnostic tool cannot be used to troubleshoot trimmers 136 LiC/336 LiC. Therefore, troubleshoot the electrical system as shown in the diagram below and in Chapter 6.5-6.8. Product will not start Check the battery Let the machine cool Can the product be Is the keypad showing...

  • Page 25: Troubleshooting The Main Switch

    6.5 Troubleshooting the main switch The switch used in professional battery products from Husqvarna has two functions, to supply cur- rent to the control unit and the electric motor, and act as a position sensor for the variable speed control.

  • Page 26: Troubleshooting The Control Unit Pmdc - Lic

    Diagnosis and troubleshooting 6.7 Troubleshooting the control unit PMDC - LiC Check that the blade terminals and associated wires are not bent or damaged. (A) 6.3x0.8mm M- (Black wire) (B) 6.3x0.8mm M+ (Red wire) (C) 6.3x0.8mm PCB + (Yellow wire) (D) 6.3x0.8mm PCB 0V (Black wire) (E) 4.8x0.8mm Shutdown (blue wire) See figure 6...

  • Page 27: Overhaul

    Diagnosis and troubleshooting 6.8 Troubleshooting the control unit BLDC - LiL/LiLX S/N 201508001- / LiR / LiRX S/N 2015100001- 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 28 Basic dismantle/assembly 7 Basic dismantle/assembly Table of contents Battery ..........................25 Operating handle LiL/LiLX ....................25 Operating handle LiR/LiRX ....................25 Wear guard LiR/LiRX .......................26 Wear guard under battery housing ..................27 Battery housing ........................27 28 – English...

  • Page 29: Battery

    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. Fasten the shaft in a vice so you have both hands free and to facilitate carrying out the steps described below. 7.1 Battery Press in the catches and remove the battery. See figure 1.

  • Page 30: Wear Guard Lir/Lirx

    Basic dismantle/assembly 7.4 Wear guard LiR / LiRX Loosen the screws (A 6x) and (B 4x) and lift off the right half of the wear guard. See figure 4 NB! Secure the left half of the wear guard to the shaft with a cable tie or similar to hold the cables in place and avoid damage.

  • Page 31: Wear Guard Under Battery Housing

    Basic dismantle/assembly 7.5 Wear guard under battery housing Loosen the screws (6x) and lift off the wear guard. Assemble in the reverse order. Tightening torque 1Nm. See figure 6 Fig 6 7.6 Battery housing Loosen the screws (4x) and lift off the battery housing half.
  • Page 32 Safety equipment 8 Safety equipment Table of contents Changing a trimmer cord cutter ..................29 Dismantling the trimmer guard LiL/LiLX / LiR/LiRX ............29 Assembling the trimmer guard LiL/LiLX / LiR/LiRX ............30 Dismantling the trimmer guard LiC ..................31 Assembling the trimmer guard LiC ..................32 Dismantling the throttle lock and throttle control ..............33 Assembling the throttle trigger lock and throttle trigger ...........33 32 –...

  • Page 33: Changing A Trimmer Cord Cutter

    Safety equipment 8 Safety equipment 8.1 Changing a trimmer cord cutter Always replace a worn trimmer cord cutter with a new one. Loosen the screws (2x) and replace the trimmer cord cutter on each side. Tightening torque 3 ~ 4 Nm. See figure 1.

  • Page 34: Assembling The Trimmer Guard Lil/Lilx / Lir/Lirx

    Safety equipment 8.3 Assembling the trimmer guard - LiL / LiLX / LiR / LiRX Screw in screw (C) holding the trimmer guard fitting. Tightening torque 6 ~ 8 Nm. See fig. 5. Hook on the trimmer guard to the attachment (B) and secure it with the screw (A).
  • Page 35 Safety equipment 8.4 Dismantling the trimmer guard - LiC Loosen the screws (A 4x) and lift off the motor cover (B). See figure 7 Slide the trimmer guard (C) up the shaft. Separate the contact (E). Loosen the screw (D) and lift off the motor housing/trimmer head. Slide off the trimmer guard (C) from the shaft.
  • Page 36 8.5 Assembling the trimmer guard - LiC Slide the trimmer guard (C) up the shaft. Slide the motor housing/trimmer head onto the shaft and fasten it with the screw (D). Tightening torque 5 ~ 6 Nm. Connect the contact (E). See figure 10 Place the trimmer guard on the motor housing.

  • Page 37: Assembling The Throttle Trigger Lock And Throttle Trigger

    Safety equipment 8.6 Dismantling the throttle trigger lock and throttle trigger Dismantle the operating handle. Refer to "Basic dismantle/assembly". Lift off the throttle trigger lock and the throttle trigger from their attachments in the handle. LiL/LiLX/LiC - See figure 13. Fig 13 LiR/LiRX - See figure 14.
  • Page 38 Repair Instructions 9 Repair Instructions Table of contents General repair instructions ....................35 Dismantling the motor ......................35 Assembling the motor ......................36 Changing the EMC filter ....................36 Dismantling the main switch ...................37 Assembling the main switch ....................37 Dismantling the control unit ....................38 Assembling the control unit .....................39 Replacing the fan ......................39 9.10...

  • Page 39: Repair Instructions

    Dismantle the wear guard under the battery housing. Refer to "Basic dismantle/assembly". Dismantle the battery housing. Refer to "Basic dismantle/assembly". For products with S/N: -2015080000 (536LiL), -2015100000 (536LiR). Disconnect the wires (A, gray), (B, black) and Fig 2a (C, red) from the motor and extract them from the EMC filter (D).

  • Page 40: Assembling The Motor

    Repair Instructions Loosen the screw and lift off the motor while pulling the cables out of the shaft. See figure 3 Fig 3 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.
  • Page 41 Repair Instructions For products with S/N: -2015080000 (536LiL), -2015100000 (536LiR). Thread the wires through the resistance (D) and connect them to the control unit with (A, gray) at the top, followed by (B, black) in the middle and (C, red) at the bottom. NB! Thread the wires from the inside through the EMC filter twice.

  • Page 42: Changing The Emc Filter

    (C, red) at the bottom. NB! Thread the wires from the inside through the EMC-filter twice. See figure 7 9.5 Dismantling the main switch For products with S/N: -2015080000 (536LiL), -2015100000 (536LiR). Dismantle the operating handle. Refer to "Basic dismantle/assembly". Dismantle the throttle trigger lock and throttle trigger.

  • Page 43: Dismantling The Main Switch

    Repair Instructions Dismantling the main switch For products with S/N: 2015080001- (536LiL, 536LiLX), 20151000001- (536LiR, 536LiRX). Dismantle the operating handle. Refer to "Basic dismantle/assembly". Dismantle the throttle trigger lock and throttle trigger. Refer to "Dismantling the throttle trigger lock and throttle trigger"- Fig 10b Lift out the main switch and disconnect the yellow wire (A).

  • Page 44: Assembling The Main Switch

    Repair Instructions Assembling the main switch For products with S/N: 2015080001- (536LiL, 536LiLX), 20151000001- (536LiR, 536LiRX). Connect the contact (C) to the main switch. NB! Make sure to apply grease to the contact surfaces and also the connector. See figure 13b.

  • Page 45: Dismantling The Control Unit

    Repair Instructions 9.7 Dismantling the control unit For products with S/N: -2015080000 (536LiL), -2015100000 (536LiR). Dismantle the operating handle (LiL). Dismantle the handle arm (LiR). Refer to "Basic dismantle/assembly". Dismantle the wear guard under the battery housing. Refer to "Basic dismantle/assembly". Dismantle the battery housing.
  • Page 46 Repair Instructions 9.7 Dismantling the control unit For products with S/N: 2015080001- (536LiL, 536LiLX), 20151000001- (536LiR, 536LiRX). Dismantle the operating handle (LiL). Dismantle the handle arm (LiR). Refer to "Basic dismantle/assembly". Dismantle the wear guard under the battery housing. Refer to "Basic dismantle/assembly". Dismantle the battery housing.
  • Page 47 588 21 53-01 for 536LiR Make sure the support bar, see illustration, is cut off for products with 536LiL S/N -2015080000 and 536LiR with S/N -2015100000. Cut off the support bar as far down in the housing as possible and take out the piece of plastic. See Figure 19c.

  • Page 48: Assembling The Control Unit

    Repair Instructions Assembling the control unit For products with S/N: 2015080001- (536LiL, 536LiLX), 20151000001- (536LiR, 536LiRX). Connect the cables from the motor to the control unit with (A, gray) at the top, followed by (B, black) in the middle and (C, red) at the bottom. Connect connector (D) to the control unit for the keypad, fan and main switch.

  • Page 49: Replacing The Fan

    Repair Instructions 9.9 Replacing the fan For products with S/N: -2015080000 (536LiL), -2015100000 (536LiR). Always replace a damaged fan with a new one. Disconnect the fan and lift it out of the battery housing. Connect the fan and place it in the battery housing with the rotating part turned out from the battery housing and the text on the hub in/down.

  • Page 50: Replacing The Keypad

    Repair Instructions 9.10 Replacing the keypad NOTE! The circuits in the keypad are very sensitive and therefore always replace a dismantled keypad with a new one! The keypad need only be replaced if the diag- nosis or troubleshooting indicates there is a fault or when replacing the control handle.
  • Page 51 Repair Instructions 9.11 Dismantling the control cable - LiR For products with S/N: -2015080000 (536LiL), -2015100000 (536LiR). NOTE! Note how wires, components, etc., are positioned before dismantling. Make sure to position them correctly to avoid pinching when the trimmer is reassembled. Fig 25 Dismantle the operating handle.

  • Page 52: Dismantling The Control Cable Lir/Lirx

    Repair Instructions 9.11 Dismantling the control cable LiR/LiRX For products with S/N: 20151000001- (536LiR, 536LiRX). NOTE! Note how wires, components, etc., are positioned before dismantling. Make sure to position them correctly to avoid pinching when the trimmer is reassembled. Fig 25b Dismantle the operating handle. Refer to "Basic dismantle/assembly". Dismantle the wear guard.
  • Page 53 Repair Instructions 9.12 Assembling the control cable LiR For products with S/N: -2015100000 (536LiR). Place the lower part of the cable in the battery housing and connect the yellow wire (E) and contact (F). See figure 29 Connect the red wire in the control cables to the battery contact by pressing in the contact strip until it snaps on.

  • Page 54: Assembling The Control Cable Lir/Lirx

    Repair Instructions 9.12 Assembling the control cable LiR/LiRX For products with S/N: 20151000001- (536LiR, 536LiRX). Place the bottom section of the cabling in the battery housing and connect the connector to the control unit. See figure 29b. Assemble the battery housing. Refer to "Basic dismantle/assembly". Fig 29b Assemble the wear guard under the battery housing.

  • Page 55: Replacing The Handle Lil/Lilx/Lic

    Repair Instructions 9.13 Replacing the handle LiL/LiLX/LiC Loosen the knob (LiL) alternatively the wing nut (LiC) by hand and remove the parts from the shaft. Assemble the new parts between the spacer and the shaft. See figure 33 LiL/LiLX 9.14 Replacing the shaft LiLX Dismantle the handle and the control handle (LiL/LiLX/LiC).

  • Page 56: Motor/Drive Wheel 136Lic/336Lic

    Repair Instructions 9.15 Motor/drive wheel 136LiC/336LiC When changing/dismantling the motor and drive wheel always use original spare parts. Remove the motor housing and replace it with a new ready-assembled spare parts kit. Assemble according to basic assembly of trimmer guard. Fig 35 9.16 Repairing damaged threads If the plastic threads in the battery housing are...
  • Page 57 T25B Li-ion 6,0 m 10 cm 4" 3,05 m "Clic" 15 cm 6" – 57 English...
  • Page 58 Troubleshooting 10 Troubleshooting - 536 LiL, 536 LiR 10. 1For products with S/N: -2015080000 (536LiL), -2015100000 (536LiR). Symptom Possible causes Recommended action The product cannot be activated. Faulty battery 1. Check the battery by pressing the No LEDs come on after pressing the status button.
  • Page 59 Troubleshooting Warning triangle flashes continually Temperature too high 1. Wait for the product to cool down on keypad (max. 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 3.
  • Page 60 10 Troubleshooting - 536 LiL/LiLX, 536 LiR/LiRX 10.2 For products with S/N: 2015080001- (536LiL/LiLX), 2015100001- (536LiR/LiRX). 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 61 Warning triangle flashes continually Temperature too high 1. Wait for the product to cool down on keypad (max. 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 3.
  • Page 62 Troubleshooting 11 Troubleshooting - battery and charger Symptom Possible causes Recommended action No LEDs come on on the battery after Faulty battery Change the battery. pressing the status button. A warning triangle lights up solid red on Faulty battery Change the battery. the battery when the status button is pressed.
  • Page 63 Troubleshooting - annex 12 Troubleshooting - annexe 12.1 For products with S/N: -2015080000 (536LiL), -2015100000 (536LiR). 1. Current contacts Make sure the contacts are clean and that none of the metal surfaces are damaged. Take extra care in checking the connection tabs. The current contacts have the same basic design for product, battery and charger.
  • Page 64 Troubleshooting - annexe 4. Motor contact Make sure the motor contact is secure and assembled correctly, and that the connecting pins are not damaged. Figure 4 5. Communication cables Make sure the three small communication cables are secure and not damaged. Figure 5 64 –...
  • Page 65 Troubleshooting - annexe 12 Troubleshooting - annexe 12.2 For products with S/N: 2015080001- (536LiL/LiLX) 2015100001- (536LiR/LiRX). 1. Current contacts Make sure the contacts are clean and that none of the metal surfaces are damaged. Take extra care in checking the connection tabs. The current contacts have the same basic design for product, battery and charger.
  • Page 66 Troubleshooting - annexe 3. Breaker signal contact Apply grease between the contacts specified below. Grease is to be applied between contacts 1, 2 and 3, 4, and also on the inside. 3. Trigger switch signal connector with grease Apply grease between the specified pins, grease should be applied between pins 1, 2 and 3, 4 inside as well as outside.
  • Page 67 Troubleshooting - annex 5. Motor and current contacts Make sure the three small motor communication cables and the two current contacts are fixed to respective covers. 5. Motor and power connectors Make sure the three motor connectors and the two power connectors are properly connected to respective plastic housing.
  • Page 68 • 115 59 13-26 2015W44...

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