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Husqvarna 536LiP4 Workshop Manual
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Husqvarna 536LiP4 Workshop Manual

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Workshop Manual
536LiP4/530iP4,
536LiPT5/530iPT5,
536LiPX/530iPX
English

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Summary of Contents for Husqvarna 536LiP4

  • Page 1 Workshop Manual 536LiP4/530iP4, 536LiPT5/530iPT5, 536LiPX/530iPX English...

  • Page 2: Table Of Contents

    7 Safety equipment ............17 Dismantling the throttle trigger lock and throt- tle trigger ..............17 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. 2 – English...

  • Page 3: Introduction And Safety Regulations

    Workshop Manual. 1.7 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 4: General Instructions

    1.12 Symbols in the Workshop Manual Use ear protection during testing. This symbol warns of personal injury 1.10 Limitations when the instructions are not followed. This Workshop Manual is intended mainly for the repair of pole saw 536LiP4/iP4, LiPT5/iPT5, LiPX/ iPX. 4 – English...

  • Page 5: Technical Data

    11.0 / 5.0 13.7 / 6.3 536LiPX/530iPX 6.8 / 3.1 9.7 / 4.4 Chain speed, normal Chain speed, savE operating rpm m/sec rpm m/sec 536LiP4/530iP4 1/4" 536LiP4 1/4" 14.6 536LiPT5/530iPT5 1/4" 536LiPT5/530iPT5 1/4" 14.6 536LiPX/530iPX 3/8 536LiPX/530iPX 3/8 14.6 5 – English...

  • Page 6: Service Tool

    3.1 Diagnostic Tool Kit 3.2 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 7: Service Data

    Service data 4 Service data 6 ~ 8 Nm 4 mm 3 ~ 4 Nm 10 mm The numbers by bolted components represent the tightening torque in Nm. * Tightening torque during inspection: 52 ft/lb (2.5 Nm) Symbol used where grease is to be used.
  • Page 8 Service data Service data LiPX LiP4 LiPT5 8 – English...
  • Page 9 Service data Service data LiPX: S/N -20180200001, LiP4: S/N -20174600001, LiPT5: S/N -20174600122 LiPX, LiP4 LiPT5 9 – English...
  • Page 10 Service data Service data LiPX/iPX: S/N 20180200001-, LiP4/iP4: S/N 20174600001-, LiPT5/iPT5: S/N 20174600122- LiPX/iPX, LiP4/iP4 LiPT5/iPT5 10 – English...
  • Page 11 Service data Service data 11 – English...

  • Page 12: Diagnosis And Troubleshooting

    Diagnosis and troubleshooting 5 Diagnosis and troubleshooting 5.1 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 put back once the pole saw has been fully assembled again! WARNING! Do not short circuit the battery!

  • Page 13: Troubleshooting The Main Switch

    -20174600001 (LiP4), -20174600122 (LiPT5). See figure 3. 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 14: Overhaul

    Diagnosis and troubleshooting 5.5 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 5.

  • Page 15: Basic Dismantle/Assembly

    Basic dismantle/assembly 6 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. 6.1 Battery Press in the catches and remove the battery. See figure 1.

  • Page 16: Control Handle

    Basic dismantle/assembly 6.4 Control handle Place something under the other handle half so that it does not come loose from the shaft. See figure 4. Loosen the screws (6x) and lift off the handle. See figure 5. Assemble in the reverse order. Tightening torque 2 ~ 3 Nm.

  • Page 17: Safety Equipment

    Safety equipment 7 Safety equipment 7.1  Dismantling the throttle trigger lock and throttle trigger Dismantle the control handle as described in "6 Basic dismantle/assembly". Lift off the throttle trigger lock and the throttle trig- ger from their attachments in the handle. See figure 1.

  • Page 18: Repair Instructions

    Repair instructions 8 Repair instructions 8.1 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. Make sure to po- be put back once the pole saw has sition them correctly to avoid pinching when been fully assembled again! the pole saw is reassembled.
  • Page 19 Repair instructions Dismantle the screws holding the saw head on the shaft, 2 screws. Carefully split the shaft and saw head. See figure 5. Fig 5 Extract the cables one by one from the saw head. See figure 6. Fig 6 Dismantle the screws, 4 pcs, holding the motor.

  • Page 20: Assembling The Motor

    Repair instructions Change the gasket between the motor and motor housing. See figure 8. 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 21 Repair instructions Couple the cables together. See figure 11. Fig 11 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). See figure 12. Fig 12 Couple the cabling together.

  • Page 22: Dismantling The Oil Tank

    Repair instructions Fit spur wheel, washer and circlip. Use circlip pliers to install the circlip. See figure 15. Assemble the guide bar and chain. Assemble the motor cover. Fig 15 8.4 Dismantling the oil tank Dismantle the motor as described in "8.2 Dismantling the motor".

  • Page 23: Dismantling The Oil Pump And/Or Chain Tensioner, Branch Hook

    Repair instructions 8.6  Dismantling the oil pump and/or chain tensioner, branch hook Dismantle the motor as described in "8.2 Dismantling the motor". Dismantle the oil tank as described in "8.4 Dismantling the oil tank". Remove the oil pump and the oil hose out of its groove.

  • Page 24: Dismantling Shaft And Motor Cabling (536Lip4/530Ip4, 536Lipx/530Ipx)

    Repair instructions 8.8 Dismantling shaft and motor cabling (536LiP4/530iP4, 536LiPX/530iPX) NB! Use the CST to check the functions before dismantling. Dismantle the trigger guard, handle, battery hous- ing as described in "8.1 General repair instruc- tions". Dismantle the clamp holding the shaft.

  • Page 25: Assembling The Shaft And Motor Cabling (536Lip4/530Ip4, 536Lipx/530Ipx)

    Repair instructions 8.9 Assembling the shaft and motor cabling (536LiP4/530iP4, 536LiPX/530iPX) 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-...

  • Page 26: Dismantling Shaft And Motor Cabling (536Lipt5/530Ipt5)

    Repair instructions 8.10 Dismantling shaft and motor cabling (536LiPT5/530iPT5) NB! Use the CST to check the functions before dismantling. Dismantle the trigger guard, handle, battery hous- ing as described in "8.1 General repair instruc- tions". Dismantle the clamp holding the shaft. Separate the connector to the control unit.
  • Page 27 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° See figure 32.

  • Page 28: Assembling Shaft And Motor Cabling (536Lipt5/530Ipt5)

    Repair instructions 8.11 Assembling shaft and motor cabling (536LiPT5/530iPT5) 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. Fig 38 See figure 38.
  • Page 29 Repair instructions Fit the sleeve in the lower shaft. Thread the cabling through the lower shaft. Turn the cabling through 180° so it is fixed in the sleeve and screw it on loosely with a screw. See figure 42. Fig 42 Assemble the lower clamp on the outer shaft.

  • Page 30: Changing The Emc Filter

    Repair instructions 8.12 Changing the EMC filter NB! Use the CST to check the functions before dismantling. Always replace a damaged EMC filter with a new one. Dismantle the battery housing as described in "6 Basic dismantle/assembly". Unplug the connector from the control unit. Fig 46B Loosen the cables from the connector at the battery housing end with a small flat screwdriver.

  • Page 31: Dismantling The Main Switch

    Repair instructions 8.13 Dismantling the main switch NB! Use the CST to check the functions before dismantling. For products with S/N: -20180200001 (LiPX), -20174600001 (LiP4), -20174600122 (LiPT5). Dismantle the control handle as described in "6 Basic dismantle/assembly". Fig 50 Dismantle the throttle trigger lock and throttle trigger as described in "7.1 Dismantling the throttle trigger lock and throttle trigger".

  • Page 32: Cleaning And Inspection Of The Main Switch

    Repair instructions For products with S/N: 20180200001- (LiPX/iPX), 20174600001- (LiP4/iP4), 20174600122- (LiPT5/ iPT5). Dismantle the control handle as described in "6 Basic dismantle/assembly". Dismantle the throttle trigger lock and throttle trigger as described in "7.1 Dismantling the throttle trigger lock and throttle trigger". Fig 52 Lift out the main switch and disconnect cable (A).

  • Page 33: Assembling The Main Switch

    Repair Instructions 8.15 Assembling the main switch For products with S/N: -20180200001 (LiPX), -20174600001 (LiP4), -20174600122 (LiPT5). Connect the contact (C) to the main switch. NB! Make sure to apply grease to the contact surfaces and also the connector. See figure 56. Connect cable (A) and place the main switch in the Fig 56 battery housing.

  • Page 34: Dismantling The Control Cabling

    "7.1 Dismantling the throttle trigger lock and throttle trigger". Dismantle the shaft and motor cabling as de- scribed in "8.8 Dismantling shaft and motor cabling (536LiP4/530iP4, 536LiPX/530iPX)" and "8.10 Dismantling shaft and motor cabling (536LiPT5/530iPT5)". Fig 61...
  • Page 35 "7.1 Dismantling the throttle trigger lock and throttle trigger". Dismantle the shaft and motor cabling as de- scribed in "8.8 Dismantling shaft and motor cabling (536LiP4/530iP4, 536LiPX/530iPX)" and "8.10 Dismantling shaft and motor cabling (536LiPT5/530iPT5)". Lift out the main switch and disconnect the connector (A), Dismantle the keypad and its cabling.

  • Page 36: Cleaning And Inspection Of The Control Cabling

    Repair Instructions 8.17  Cleaning and inspection of the control cabling Clean and inspect all parts of the control cable. The cables must always be replaced with new ones if cracked or showing signs of other defects. Always use original spare parts. 36 –...

  • Page 37: Assembling The Control Cabling

    Repair Instructions 8.18 Assembling the control unit -all models We recommend dismantling the control unit before assembling the control cabling, see "8.19 Disman- tling the control unit". For products with S/N: -20180200001 (LiPX), -20174600001 (LiP4), -20174600122 (LiPT5). Connect the connector to the control unit. See figure 64.
  • Page 38 Repair Instructions For products with S/N: 20180200001- (LiPX/iPX), 20174600001- (LiP4/iP4), 20174600122- (LiPT5/ iPT5). Plug the connector into the main switch, place the parts in the operating handle. See figure 67. Fig 66 Lay the cabling in place in the control handle. Make sure that it is positioned outside (A) and inside (B).

  • Page 39: Dismantling The Control Unit

    Repair Instructions 8.19 Dismantling the control unit NB! Use the CST to check the functions before dismantling. Dismantle the battery housing as described in "6 Basic dismantle/assembly". 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 40: Assembling The Control Unit

    Repair Instructions 8.20 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. •...

  • Page 41: Changing The Handle

    Repair Instructions 8.21 Changing the handle Loosen the knob by hand and remove the parts from the shaft. Assemble the new parts between the spacer and the shaft. See figure 74. Fig 74 41 – English...

  • Page 42: Troubleshooting

    Troubleshooting - 536 LiPX / LiP4 / LiPT5 Before troubleshooting, connect the product to the CST, and make sure that the product is updated with the latest firmware. 9 Troubleshooting - 536 LiPX/iPX/LiP4/LiPT5/iPT5 Symptom Possible causes Recommended action The product cannot be activated. No Faulty battery 1.
  • Page 43 Troubleshooting - 536 LiPX / LiP4 / LiPT5 Uneven motor speed Poor connection in main switch 1. Make sure the main switch signal signal contact. connector is correctly assem- bled, dry, is not damaged and is corrosion-free. See figure 3 in the appendix Damaged or worn out main switch 2.

  • Page 44: Troubleshooting - Battery And Charger

    Troubleshooting - battery and charger Symptom Possible causes Recommended action No LEDs come on on the battery Faulty battery Replace the battery. after pressing the status button. A warning triangle lights up solid red Faulty battery Replace the battery. on the battery when the status button is pressed.

  • Page 45: Troubleshooting - Appendix

    Troubleshooting - Appendix 11 Troubleshooting - Appendix 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 46 Troubleshooting - Appendix 3. Main switch signal connector with grease For products with S/N: -20180200001 (LiPX), -20174600001 (LiP4), -20174600122 (LiPT5). Apply grease to the contact surfaces and also the connector. For products with S/N: 20180200001- (LiPX/iPX), 20174600001- (LiP4/iP4), 20174600122- (LiPT5/ iPT5).
  • Page 47 Troubleshooting - Appendix 4. Communication cables Make sure the three small communication cables are not loose or damaged. 5. Motor and power connectors Make sure the three motor connectors and the two power connectors are properly connected to respective plastic housing. 6.
  • Page 48 115 83 57-26 2018-10-10...

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