Husqvarna 536 Li XP Workshop Manual
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Husqvarna 536 Li XP Workshop Manual

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Workshop Manual
536 Li XP, 436 Li
English

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Summary of Contents for Husqvarna 536 Li XP

  • Page 1 Workshop Manual 536 Li XP, 436 Li English...

  • Page 3: Table Of Contents

    Diagnosis and troubleshooting ......14 Basic dismantle/assembly ........16 Safety equipment ..........18 Repair instructions ..........23 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 –...

  • Page 4: Index

    Cleaning and inspection 23 Assembling the chain tensioner 42 Dismantling the motor 23 Cleaning and inspection 42 Dismantling the chain tensioner 42 Chain tensioner 536 Li XP Assembling the chain tensioner 41 Oil pump Assembling the oil pump 40 Cleaning and inspection 41...
  • Page 5 Index Technical data 10 Threads Repairing damaged threads 44 Throttle lockout, throttle and spring Assembling the throttle lockout, throttle control and spring 21 Cleaning and inspection 20 Dismantling the throttle lockout, throttle and spring 20 Trigger switch Assembling the trigger switch 27 Cleaning and inspection 26 Dismantling the trigger switch 26 English –...

  • Page 6: Introduction And Safety Regulations

    Introduction and safety instructions 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 saw ......................
  • Page 7 A, B, etc. Usage is made apparent in each section. The figures are numbered 1, 2 etc. The position references and figure numbers restart Always use original Husqvarna: in each new section. • Spare parts • Service tools •...
  • Page 8 Introduction and safety regulations 2.8 General instructions 2.9 Special instructions The workshop where the chain saw is to be re- Remove the battery from the chain saw before paired must be equipped with safety devices in dismantling and troubleshooting. accordance with local regulations. The battery must not be connected while the chain No one may repair the chain saw unless they have saw is being dismantled.
  • Page 9 Introduction and safety regulations 2.10 Symbols on the saw 2.11 Symbols in the Workshop Manual The symbols below are embedded on the chain saw. This symbol warns of personal injury Filling with chain oil when the instructions are not followed. Use protective gloves.

  • Page 10: Technical Data

    23 - 33 / 9 - 13 436 Li 2.5 / 5.5 23 - 33 / 9 - 13 2.4 / 5.3 536 Li XP Chain speed at Chain speed at Chain pitch Drive link normal operation saveE...

  • Page 11: Service Tools

    INSTRUCTION Common Service Tool Common Service Tool (CST) is a service tool for Husqvarna products consisting of Diagnostic Tool Kit (583 89 71-01), and software for installation on a PC (not included). Anyone who already owns the "Engine Diagnostic Tool - AutoTune ™" (576 69 23-01) can supplement with the adapter cable for Battery Products (579 62 13-01) to upgrade to the Diagnostic Tool Kit.

  • Page 12: Service Data

    Service data 5 Service data 536 LiXP 436 Li 1 ~ 2 Nm 1 ~ 2 Nm 1 ~ 2 Nm (x2) 1 ~ 2 Nm (x4) 1 ~ 2 Nm 1 ~ 2 Nm S/N –20151600245 S/N 20151600245 – (x2) 1 Nm (x2) 1 Nm (x2) 1 Nm...
  • Page 13 Service data 4 mm 2 ~ 3 Nm (x3) 1 Nm (x2) 2,5 ~ 3 Nm 4 mm (x8) 1,7 ~ 2 Nm 4 mm 2,5 ~ 3 Nm 4 mm (x2) 1 Nm English –...

  • Page 14: Diagnosis And Troubleshooting

    Diagnosis and troubleshooting 6 Diagnosis and troubleshooting Table of contents Remove the battery ....................... 15 Connect the diagnostic tool ................... 15 No signal to diagnostic tool .................... 15 14 – English...
  • Page 15 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 chain saw has been completely assembled again! WARNING! Fig 1...

  • Page 16: Basic Dismantle/Assembly

    Basic dismantle/assembly 7 Basic dismantle/assembly Table of contents Battery ..........................17 Drive wheel cover and bar ....................17 Front hand guard ......................17 Separate the saw ......................17 16 – English...
  • Page 17 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. See figure 1.

  • Page 18: Safety Equipment

    Safety equipment 8 Safety equipment Table of contents Dismantling the hand guard ..................<?> Assembling the hand guard ..................<OV> Dismantling the throttle lockout, throttle and spring ............21 Assembling the throttle lockout, throttle control and spring ..........22 Replacing the chain catcher ................... 22 Replacing the spike bumper ...................

  • Page 19: Dismantling The Hand Guard

    Safety equipment 8 Safety equipment 8.1 Dismantling the hand guard Secure the saw with assembly fixture 502 51 02-01. Dismantle the drive wheel cover, saw chain and bar. Refer to "Basic dismantle/assembly". Fig 1 Release the brake by moving the hand guard back- wards.

  • Page 20: Assembling The Hand Guard

    Safety equipment 8.2 Assembling the hand guard WARNING! Exercise care to ensure the spring does not fly out and causes person- al injury. Wear protective goggles! Make sure the brake pin is in the correct position. See Figure 5a. Fig 5a Place and tension the spring as shown in Figure Fig 5b Secure the saw with assembly fixture...

  • Page 21: Dismantling The Throttle Lockout, Throttle And Spring

    Safety equipment Fasten screws A and B. Tightening torque 1-2 Nm, Carry out a function check of the chain brake to ensure the hand guard has been correctly fitted. Fig 6 8.3 Dismantling the throttle lockout, throttle and spring Dismantle the drive wheel cover, saw chain and bar.

  • Page 22: Assembling The Throttle Lockout, Throttle Control And Spring

    Safety equipment 8.4 Assembling the throttle lockout, throttle control and spring Hook the recoil spring and trigger switch piston back onto their respective attachments in the throttle control. Assemble the throttle control and throttle lockout to their respective attachments in the handle as well as the trigger switch in its groove.

  • Page 23: Repair Instructions

    9.20 Dismantling the oil pump ....................40 9.21 Assembling the oil pump ....................41 9.22 Dismantling the chain tensioner - 536 Li XP ..............42 9.23 Assembling the chain tensioner - 536 Li XP ..............42 9.24 Dismantling the chain tensioner - 436 Li ................ 43 9.25 Assembling the chain tensioner 436 Li ................

  • Page 24: Repair Instructions

    Repair Instructions 9 Repair instructions 9.1 General repair instructions WARNING! The battery must always be removed for service/repair work and may only be replaced once the chain saw has been completely assembled again! NOTE! Note how wires, components, etc., are posi- tioned before dismantling.

  • Page 25: Assembling The Motor

    Repair Instructions 9.3 Assembling the motor Place the motor on its attachments. Plug in the connectors. The chain brake sensor cable (C) from the control unit should lie in the crankcase half groove above the motor. The motor control cable (D) from the motor should be located on top of the motor so that it does not vibrate loose and get stuck in the clutch/drive shaft.

  • Page 26: Dismantling The Impeller

    Repair Instructions 9.4 Dismantling the impeller Dismantle the drive wheel cover, saw chain and bar. Separate the crankcase. Refer to "Basic dismantle/assembly". NOTE! The impeller can be dismantled with the motor assembled or dismantled. Fig 8 Take the impeller off the motor. See figure 8.

  • Page 27: Dismantling The Trigger Switch S/N - 20151600245

    Repair Instructions 9.6 Dismantling the trigger switch S/N – 20151600245 Dismantle the drive wheel cover, saw chain and bar. Separate the crankcase. Refer to "Basic dismantle/assembly". Fig 11 Remove the main sensor and cable. Separate contact (B). See figure 11. Take loose the contact (C) using a small screw- driver to carefully free the catches (D) on each end of the contact and trigger switch from each other.

  • Page 28: Assembling The Trigger Switch S/N - 20151600245

    Repair Instructions 9.7 Assembling the trigger switch S/N – 20151600245 Connect the red wire from the control cable to the battery contact. Carefully press the cable so the pin snaps onto the connector. NOTE! Do not bend the pin. Fig 16 See figure 16.

  • Page 29: Assembling The Trigger Switch S/N 20151600245

    Repair Instructions 9.8 Dismantling the trigger switch S/N 20151600245 – Dismantle the drive wheel cover, saw chain and bar. Separate the crankcase. Refer to "Basic dismantle/assembly". Remove the trigger switch from the crankcase See figure 11. Fig 11 Using a small screwdriver, carefully free the catches (D) on each end of the contact and trigger switch.
  • Page 30 Repair Instructions 9.9 Assembling the trigger switch S/N 20151600245 – To prevent corrosion on the trigger switch connec- tor, place two dots of grease (588 17 64-01) on the pins before assembly. See figure 16. Connect the wires to the trigger switch. See figure 17.

  • Page 31: Dismantling The Control Unit S/N - 20151600245

    Repair Instructions 9.10 Dismantling the control unit S/N – 20151600245 NOTE! Note how wires, components, etc., are posi- tioned before dismantling. Make sure to position them correctly to avoid pinching when the chain saw is reas- sembled. Dismantle the drive wheel cover, saw chain and bar.

  • Page 32: Assembling The Control Unit S/N - 20151600245

    Repair Instructions 9.11 Assembling the control unit S/N – 20151600245 Position the control unit and battery contact in the crankcase. Take care to return all the cables to their correct positions to avoid pinching. Fasten screws (2x) to the control unit (D) and screws (2x) to the battery contact (E).

  • Page 33: Assembling The Control Unit S/N 20151600245

    Repair Instructions 9.12 Dismantling the control unit S/N 20151600245 – NOTE! Note how wires, components, etc., are posi- tioned before dismantling. Make sure to position them correctly to avoid pinching when the chain saw is reas- sembled. Dismantle the drive wheel cover, saw chain and bar.
  • Page 34 Repair Instructions 9.13 Assembling the control unit S/N 20151600245 – Attach the wiring to the control unit in the or- der shown i figure 1. Make sure the sealing and bracket is properly attached. Fig 1 Attach the control unit and the battery terminal to the crankcase.

  • Page 35: Replacing The Keypad S/N - 20151600245

    Repair Instructions 9.14 Replacing the keypad S/N – 20151600245 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 diagnosis indicates there is a fault. Fig 1 Dismantle the drive wheel cover, saw chain and bar.

  • Page 36: Replacing The Keypad And Wiring S/N 20151600245

    Repair Instructions 9.15 Replacing the keypad and wiring S/N 20151600245 – Dismantle the drive wheel cover, saw chain and bar. Separate the crankcase. Refer to "Basic dismantle/assembly". Remove the motor. See "Dismantling the motor". Disconnect the wiring from the control unit. Note: disconnect the wire bracket in the order shown in figure 1.

  • Page 37: Dismantling The Chain Brake

    Repair Instructions 9.16 Dismantling the chain brake WARNING! Exercise care to ensure the springs do not fly out and causes personal injury. Wear protective goggles! Dismantle the drive wheel cover, saw chain and bar. Separate the crankcase. Refer to "Basic dismantle/assembly". Fig 33 Dismantle the motor.

  • Page 38: Assembling The Chain Brake

    Repair Instructions 9.17 Assembling the chain brake WARNING! Exercise care to ensure the springs do not fly out and causes personal injury. Wear protective goggles! Lubricate as instructed in "Service Data". Place the spring and shaft (B) with the heel in its groove on the crankcase followed by the catch (C).

  • Page 39: Dismantling The Chain Brake Sensor

    Repair Instructions 9.18 Dismantling the chain brake sensor Dismantle the drive wheel cover, saw chain and bar. Separate the crankcase. Refer to "Basic dismantle/assembly". Unplug the connector (A). See figure 40. Fig 40 Dismantle the chain brake. See "Dismantling the chain brake". Remove the chain brake sensor.

  • Page 40: Dismantling The Oil Pump

    Repair Instructions 9.20 Dismantling the oil pump Empty the chain oil tank. Dismantle the drive wheel cover, saw chain and bar. Separate the crankcase. Refer to "Basic dismantle/assembly". Remove the chain guide plate. Dismantle the motor. See "Dismantling the motor". Fig 45 Loosen screws (2x) and lift straight out the cover, lubricating shaft and cylinder.

  • Page 41: Assembling The Oil Pump

    Repair Instructions 9.21 Assembling the oil pump Lubricate as instructed in "Service Data". Insert the rubber hose through the hole. Carefully extract it with your fingers or a round-nose pliers without teeth. Place it in the groove on the outside. See figure 49.

  • Page 42: Dismantling The Chain Tensioner - 536 Lixp

    Always use original spare parts. See figure 53. 9.23 Assembling the chain tensioner - Fig 53 536 Li XP Place the chain tensioner with adjustment screw in the drive wheel cover and screw it on. Tightening torque 1 ~ 2 Nm.

  • Page 43: Assembling The Chain Tensioner 436 Li

    Repair Instructions 9.24 Dismantling the chain tensioner - 436 Li Dismantle the drive wheel cover, saw chain and bar. Refer to "Basic dismantle/assembly". Loosen the screw to the wear guard and the screw to the cap and remove the chain tensioner compo- nents See figure 55.

  • Page 44: Replacing The Bar Bolt

    Repair Instructions 9.27 Replacing the bar bolt Replacing a bar bolt with intact crankcase Dismantle the drive wheel cover, saw chain and bar. Refer to "Basic dismantle/assembly". Empty the chain oil tank. Fig 59 Knock in the old bar bolt from the outside so that it ends up in the chain oil tank.

  • Page 45: Replacing The Chain Oil Cap

    Repair Instructions 9.28 Replacing the chain oil cap If the chain oil cap is damaged, it can be opened using the combination spanner. Place the tool in the groove in the cap and turn anti-clockwise. Always replace a damaged cap with a new one. Always use original spare parts.
  • Page 46 Troubleshooting 10 Troubleshooting - 536 Li XP, 436 Li – S/N 20151600245 Symptom Possible causes Recommended actions Product cannot be activated. No Broken battery 1. Check battery by pressing the LED´s light up when pressing the status button. Minimum 1 green on/off button.
  • Page 47 Troubleshooting Warning triangle on keypad blinks Hand guard in active position 1. Pull back hand guard continuous Over temperature 2. Wait until product cools off (Max. 5 min) Too low temperature on control unit 3. Make sure product or battery are or battery not colder than -10°C Incorrect values from motor tempe-...
  • Page 48 Troubleshooting Troubleshooting - 436 Li, 536 Li XP S/N 20151600245 – Symptom Possible causes Recommended actions Product cannot be activated. No Broken battery 1. Check battery by pressing the LED´s light up when pressing the status button. Minimum 1 green on/off button.
  • Page 49 Troubleshooting Warning triangle on keypad blinks Hand guard in active position 1. Pull back hand guard continuous Over temperature 2. Wait until product cools off (Max. 5 min) Too low temperature on control unit 3. Make sure product or battery are or battery not colder than -10°C Water in trigger switch signal con-...
  • Page 50 Troubleshooting 11 Troubleshooting - battery & chargers Symptom Possible causes Recommended actions No LED´s light up on battery when Broken battery Replace battery pressing the status button Solid red warning triangle on battery Broken battery Replace battery when pressing the status button Flashing red warning triangle on bat- Over temperature 1.
  • Page 52 Troubleshooting Appendix 12 Troubleshooting Appendix S/N – 20151600245 1. Power connectors Make sure connectors are free from dirt and that metal surfaces are not damaged. Pay certain at- tention to the connection tabs. Power connectors have the same basic design on product, battery and charger.
  • Page 53 Troubleshooting Appendix 4. Motor connector Make sure the motor connector are assembled with a tight fi t (Pic 4), and that the connecting pins are not damaged. Pic 4 Pic 5 5. Communication cables Make sure the three small communication cables are not loose or damaged.
  • Page 54 Troubleshooting Appendix 13 Troubleshooting Appendix S/N 20151600245 – 1. Power connectors Make sure connectors are free from dirt and that metal surfaces are not damaged. Pay certain at- tention to the connection tabs. Power connectors have the same basic design on product, battery and charger.
  • Page 55 Troubleshooting Appendix Pic 5 5. Communication cables Make sure the three small communication cables are not loose or damaged. (Pic 6,7) Pic 6 Pic 7 6. Motor connector Make sure the motor connector are assembled with a tight fi t (Pic 8), and that the connecting pins (Pic 9) are not damaged.
  • Page 56 Troubleshooting Appendix Pic 9 7. 26-pin wiring cable chain saw Make sure the 26-pin wiring cable is properly as- sembled, dry and not damaged. (Pic 10) Pic 10 56 – English...
  • Page 58 • 115 53 99-26 2015W36...

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