Husqvarna T435 Instruction manual

T435
Workshop manual
English

English – 3
Workshop Manual
HusqvarnaT435
List of contents
Index ......................................................................4
Introduction and safety regulations ...................6
Technical data .....................................................10
Service tools .......................................................12
Service data .........................................................14
Safety equipment ................................................16
Repair instructions..............................................26
Carburettor ..........................................................35
Trouble shooting .................................................53
List of contents
HusqvarnaABhas apolicy of continuousproduct developmentand therefore reservesthe right tomodify the
design and appearance of products without prior notice.

4 – English
Index
Index
C
Carburettor 35
Adjusting the carburettor 43
Assembly 39
Cleaning and checking 39
Design 35
Dismantling 37
Function 35
Pressure testing the carburettor 41
Centrifugal clutch 32
Assembling the centrifugal clutch 33
Cleaning and checking 32
Dismantling the centrifugal clutch 32
Chain brake 17
Assembling the chain brake 18
Cleaning and checking 18
Dismantling the chain brake 17
Chain catcher 20
Replacing the chain catcher 20
Crankcase and crankshaft 52
Assembling the complete crankshaft 52
Dismantling the crankcase and crankshaft 52
Replacing the crankshaft bearing 52
F
Fuel system 47
Airing the fuel tank 46
Replacing the fuel filter 47
Replacing the fuel hose 47
Replacing the fuel pump 47
Replacing the suction hose/return hose 47
I
Ignition module and flywheel 29
Assembling the ignition module
and flywheel 31
Cleaning and checking 30
Dismantling the ignition module
and flywheel 30
Testing the ignition module 29
Intake system 44
Assembling the intake system 45
Cleaning and checking 44
Dismantling the intake system 44
Introduction and safety regulations 7
General information 7
General instructions 8
Modifications 7
Numbering 7
Safety 7
Special instructions 8
Structure 7
Symbols in the Workshop Manual 9
Symbols on the saw 9
Target group 7
Tools 7
M
Muffler 20
Assembling the muffler 20
Cleaning and checking 20
Dismantling the muffler 20
O
Oil pump and screen 33
Assembling the oil pump and screen 34
Cleaning and checking 34
Dismantling the oil pump and screen 33
P
Piston and cyliner 48
Assembling the piston and cylinder 51
Cleaning and checking 50
Dismantling the piston and cylinder 48
Faults and causes 51
S
Service data 14
Service tools 12
Starter 27
Assembling the starter 29
Cleaning and checking 27
Dismantling the starter 27
Replacing a broken or worn starter cord 28
Replacing a broken return spring 29
Tensioning the return spring 28
Stop function 22
Resistance test - stop function 22
Stop switch 21
Assembling the start/stop switch 21
Cleaning and checking 21
Dismantling the start/stop switch 21

English – 5
Index
T
Tank unit 46
Dismantling 46
Technical data 10
Throttle lockout, throttle and spring 23
Assembling the throttle lockout, throttle and
spring 24
Cleaning and checking 23
Dismantling the throttle lockout, throttle and
spring 23
Trouble shooting 54
Trouble shooting techniques 55
V
Vibrating damping system 48
Assembly 48
Cleaning and checking 48
Dismantling 48

6 – English
Introduction and safety regulations
2 Introduction and safety regulations
List of contents
2.1 General information ........................................................................................................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 ........................................................................................................8
2.9 Special instructions .........................................................................................................8
2.10 Symbols on the saw .......................................................................................................9
2.11 Symbols in the Workshop Manual ..................................................................................9

English – 7
2 Introduction and safety regulations
Introduction and safety regulations
2.1 General information
This Workshop Manual provides a comprehensive
description of how to trouble shoot, repair and
test the chain saw.A description of different safety
measures that should be taken during repair work
is also given.
2.2 Safety
Note!The section dealing with safety must be
read and understood by everyone carrying out
repairs or service on the chain saw.
Warning symbols can be found in this Workshop
Manual and on the chain saw. Refer to ”Symbols on
thesaw”and”SymbolsintheWorkshopManual”.Ifany
warningsymbolonthechainsawhasbeendamaged
orismissing,anewonemustbefittedassoonaspos-
sible in order to achieve the highest degree of safety
when using the chain saw.
2.3Target group
This Workshop Manual is written for personnel who
are assumed to have general knowledge of repai-
ring and servicing chain saws.
TheWorkshopManualmustbereadandunderstood
by personnel who will carry out repair work and
serviceonthechainsaw.Themanualisalsosuitableto
use when training new employees.
2.4 Modifications
Modifications will be successively introduced on
the chain saw during production. When these
modifications affect service and/or spare parts, a
separate service message will be sent out on each
occasion. This means that in time this Workshop
Manual will become out of date. In order to prevent
this, the Manual should be read together with all
service messages concerning the chain saw in
question.
2.5Tools
Special tools are required for some stages. All
service tools are listed in the Workshop Manual.
Usage is evident from the respective section.
Always use Husqvarna’s original:
• Spare parts
• Service tools
• Accessories
2.6 Structure
This Workshop Manual can be used in two diffe-
rent ways:
• Repair of a specific system on the chain saw.
• Dismantlingandassemblyoftheentirechainsaw.
Repair of a specific system
When a specific system on the chain saw must be
repaired, do as follows:
1. Look up the page for the system in question.
2. Carry out the steps: Dismantling
Cleaning and checking
Assembly
Dismantling and assembly of the entire chain saw
When taking apart and putting back together the
whole chain saw, do as follows:
1. Look up the chapter ”Repair instructions”, which
deals with The starter and carry out the instruc-
tions listed under the heading Dismantling.
2. Work forward in the Manual and carry out Dis-
mantling in the order set out in the sections.
3. Go back to Starter and carry out the instruc-
tions under Cleaning and checking.
4. Work forward in the Manual and carry out
Cleaning and checking in the order set out in
the sections.
5. Orderortakeoutallrequisitesparepartsfromthe
stores.
6. Look up the chapter ”Repair instructions”,
which deals with The crankcase and carry out
the instructions under Assembly.
7. Work backwards in the Manual and carry out
Assembly in the order set out in the sections.
In order to increase the basic understanding, some
sections include a Description of the unit in question.
2.7 Numbering
Position references to components inside the figu-
res are designated A, B, etc.
The figures are numbered 1, 2 etc.
Thepositionreferencesandfigurenumbersrestartin
each new section.

8 – English
2.8 General instructions
The workshop where the chain saw is to be repai-
red must be equipped with safety equipment in
accordance with local regulations.
No one may repair the chain saw without having
read and understood the contents of this workshop
manual.
Thisworkshopmanualcontainsthefollowingboxesin
relevant places.
2.9 Special instructions
The fuel used for the chain saw has the following
hazardous properties:
• The liquid and its fumes are poisonous.
• Can cause eye and skin irritation.
• Can cause breathing difficulties.
• Is very flammable.
When using compressed air, do not direct the jet
towards the body. Air can penetrate into the blood
circulation system, which entails mortal danger.
Use hearing protection when test running.
After test running, do not touch the muffler before it
hascooleddown.Riskofburns.Useprotectivegloves
when working with mufflers.
Do not start the chain saw unless the bar, chain and
clutch cover (chain brake) are fitted, otherwise the
clutch may come loose and cause personal injury.
Insufficientchain lubricationcan resultin chainbrea-
kage,whichcancauseseriousorevenlife-threatening
injury.
Exercisecaretoensurethespringdoesnotflyoutand
cause personal injury. Use protective goggles. If the
spring tension is activated on the starter pulley when
it is to be taken up, the spring can fly out and cause
personal injury.
Check that the brake is applied when removing the
pressure spring on the chain brake. Otherwise the
pressurespringcanflyoutandcausepersonalinjury.
Afterrepairing,checkthechainbrake,see“Assembling
chain brake \ Function check”.
Keep in mind the fire risk. The chain saw may emit
sparks, which cause ignition.
Checkthechaincatcherandreplaceitifitisdamaged.
WARNING!
The warning box warns of the risk
of personal injury if the instruc-
tions are not followed.
NOTE!
This box warns of material damage if the
instructions are not followed.
Introduction and safety regulations

English – 9
Introduction and safety regulations
2.10 Symbols on the saw
The symbols below are embedded in the chain
saw.
Choke control
Refuelling
Stop button
Filling up saw chain oil
2.11 Symbols in theWorkshop Manual
This symbol warns of personal injury
when the instructions are not followed.

10 – English
Displacement Cylinder diameter Length of stroke Max. output/speed
cm3/cubic inch Ømm/Øinch mm/inches kW/hp/rpm
T435: 35.235 / 2.15 40 / 1.57 28 / 1.10 1.5 / 2.0 / 9,500
Electrode gap Ignition system Air gap Carburettor type
mm/inches mm/inches
T435: 0.5 / 0.02 Ikeda Denso 0.3 / 0.012 Walbro WT 804
Usable cutting length Chain speed at Chain pitch Drive links
cm/inch max. output - speed mm/inches mm/inches
m/s - rpm
T435: 30-36/12-14 19.1 / 9,500 3/8” /9.52 1.3 / 0.050
3Technical data
Technical data

English – 11
Idle speed Engage speed Spark plug
rpm rpm
T435: 2,900 3,800 NGK CMR 7H
Volume fuel tank Capacity oil pump at Volume oil tank Automatic oil pump
Litres/US.pint 9,500 rpm, Litres/US.pint
ml/min
T435: 0.26 / 0.55 3-9 0.17 / 0.36 No
Weight without bar and chain Weight with bar and chain
kg/lbs kg/lbs
T435: 3.4 / 7.50 12”: 3.9 / 8.60
14”: 4.1 / 9.04
rpm

GAS
OIL
Technical data

12 – English
4 Service tools
Service tools
11
46
9
1 3
7
8
10
5
2

English – 13
Service tools
Pos. Description Used for Order No.
1 Piston stop Locking the crankshaft 521 34 51-01
2 Hook for fuel filter Lifting out the fuel filter 502 50 83-01
3 Screwdriver Carburettor adjustment 516 84 79-01
4 Combination spanner For torx screws 516 97 42-01
5 Pressure tester Pressure testing the cylinder 503 84 40-03
6 Feeler gauge Setting, ignition module 521 03 13-01
7 Fitting cone Assembling the intake system 522 63 97-01
8 Assembly fixture Securing the chain saw 502 51 02-01
9 Pressure gauge Pressure testing 531 03 06-23
10 Test spark plug Checking the ignition module 501 97 64-01
11 Revolution counter Adjusting the carburettor 502 71 14-01
12 Assembly pliers Assembling the spark plug 502 50 06-01
protector
13 Template Maintenance of chain and bar 520 98 33-01
14 Puller Dismantling the flywheel 504 90 90-01
15 Mandrel Dismantling the flywheel 502 51 94-01
16 Adjustment screwdriver Adjusting the carburettor 530 03 55-60
12 13 14
15 16

14 – English
5 Service data
Service data
Key
The numbers by the components to be assembled
with screws state the tightening torque in Nm.
▲ = Lubricate with two-stroke oil.
■ = Lubricate with engine oil.
● = Lubricate with grease.
❑ = Glued using 2 component adhesive.
❍ = Sealed with silicone.
8,8 ~ 12,8 Nm M10
2,9 ~ 4,9 Nm M4
14,7 ~ 18,6 Nm M8
6,9 ~ 8,8 Nm M5

English – 15
Service data
5,9 ~ 7,8 Nm M5
2,5 ~ 3,9 Nm TP5
4,9 ~ 7,8 Nm M5
2,5 ~ 3,9 Nm TP5 2,5 ~ 3,9 Nm TP5
2,5 ~ 3,9 Nm
3,2 ~ 3,6 Nm M5

16 – English
6 Safety equipment
Safety equipment
List of contents
6.1 Dismantling the chain brake ...........................................................................................17
6.2 Assembling the chain brake ............................................................................................18
6.3 Dismantling the muffler ...................................................................................................20
6.4 Assembling the muffler ...................................................................................................20
6.5 Replacing the chain catcher ...........................................................................................20
6.6 Dismantling the start/stop switch.....................................................................................21
6.7 Assembling the start/stop control ....................................................................................21
6.8 Resistance test - stop function .......................................................................................22
6.9 Dismantling the throttle lockout, throttle and spring ........................................................23
6.10 Assembling the throttle lockout, throttle and spring ........................................................24

English – 17
3
Secure a bolt in the vice, attain a distance of at
least 18 mm and approx. 40 cm from the vice, then
thread the clutch cover through the hole where the
bar bolt runs. Lock with the bar nut.
WARNING!
Exercise care to ensure the spring
does not fly out and causes perso-
nal injury.Wear protective goggles.
6.1 Dismantling the chain brake
2
Release the brake by pushing the kickback guard
forwards.
4
Loosen the screws and hold the cover in place with
one hand. Insert a screwdriver as illustrated over
the spring to prevent it from flying off when you lift
the cover.
Safety equipment
6 Safety equipment
1
Release the brake by moving the kickback guard
backwards.
Loosenthebarnutandremovetheclutchcover,chain
and bar.
Fig 1
Fig 2
Fig 3
Fig 4
Fig 5
5
Carefully bend upwards until the spring is released
and slides over the screwdriver.

18 – English
6.2 Assembling the chain brake
1
Fit the weight L, spring M and the sleeve N, see
figures 8 and 9.
2
Fit the knee joint G and the fork H. Punch in the pin
F. Insert the pin J through the brake band K into
its slot. Place the fork H in the notch of the brake
band and place the brake band K in its track.
In the jointed end of G is a fixed pin, which must be
placed in the notch in the fork H, see figure 9.
3
Fit the sleeve B and the screw A. Put the washer D
in place and tighten the nut E, see figure 6. Add the
spring C, use pliers to tension the spring behind
the plastic plug, see figure 10.
Safety equipment
Fig 6
Fig 8
Fig 9
Fig 10
6
Loosen the nut E, washer D, spring C, sleeve B
and screw A.
To remove the knee joint G and H, use a punch to
press out the pin F. Pull out the pin J to loosen the
brake band K and knee joint H, see figure 7.
Cleaning and checking
• Clean and check carefully, all components.
Parts must be replaced if cracked or show
signs of other defects. Always use original
spare parts.
• Measure the thickness of the chain brake band.
Itmustnotbe less than0.6mm in any place,see
figure 9.
• Lubricate the knee joint with grease. Fig 7
7
If necessary dismantle the weight L and check the
spring M and sleeve N.
J
H
FG

English – 19
Safety equipment
Fig 11
4
Insert the screwdriver into the end of the spring
and press the spring together while pushing it
down with the finger.
5
Hold the spring in place with your finger and
remove the screwdriver. Insert the screwdriver
straight from above and press down until the spring
catches against the cut-out edge.
Fig 12
6
Bend the screwdriver away from the spring so that
the spring is pressed together and slips down to
the bottom.
Fig 13
7
Fit and tighten the cover. Clamp the brake by mo-
ving the handle backwards, see figure 14.
Fig 14
8
Fit the kickback guard, see figure 15.
Fig 15

20 – English
Safety equipment
WARNING!
Do not touch the muffler before it
has cooled down. Risk of burns.
6.3. Dismantling the muffler
1
Release the brake by moving the kickback guard
backwards.
Loosen the bar nut and remove the clutch cover,
chain and bar. Fig 16
Fig 17
6.5 Replacing the chain catcher
A worn chain catcher must always be replaced with
a new one.
1
Loosen the screw and replace the chain catcher
with a new one as shown in figure 21.
Fig 18
Fig 19
Fig 20
6.4 Assembling the muffler
1
Assemble the muffler as shown in figure 20, tighte-
ning torque 12-14 Nm. The square screws should
be slided in the slot on the cylinder. Assemble the
chain, bar and clutch cover.
3
Warm up the saw for at least 1 minute and retigh-
ten the muffler screws with 12-14 Nm.
2
Loosen screws 1 and 2, see figure 17.
3
Slide the muffler cover as shown in figure 18.
4
Loosenthescrewsandnuts. Removeandcheckthat
the muffler is complete, see figures 19 and 20.
Cleaning and checking
Clean and check all components carefully.
Parts must be replaced if cracked or showing signs
of other defects.
Never use the saw with a muffler that is in bad con-
dition. Always use original spare parts.
Fig 21