Husqvarna T536LiXP Instruction manual

Workshop manual
T536LiXP/T535i XP
English
539 - 003 - 05.12.2018

Contents
1 Introduction
1.1 Document description............................................ 3
1.2 Target group...........................................................3
1.3 Revisions................................................................3
1.4 Safety..................................................................... 3
1.5 Servicing tools........................................................3
2 Safety
2.1 Safety definitions....................................................4
2.2 General safety instructions.....................................4
2.3 Symbols on the product......................................... 4
2.4 Special safety instructions......................................4
3 Servicing data
3.1 Service data T536LiXP/T535i XP...........................5
4 Servicing tools
4.1 Diagnostic tool kit................................................... 7
5 Repair instructions
5.1 To clean and examine the product parts................8
5.2 To replace the guide bar bolt................................. 8
5.3 To replace the chip guard...................................... 8
5.4 To replace the chain oil cap................................... 8
5.5 To repair damaged threads....................................8
5.6 To replace the chain catcher..................................9
5.7 To replace the spiked bumper................................9
5.8 Drive wheel cover and guide bar............................9
5.9 Crankcase.............................................................. 9
5.10 Power trigger......................................................10
5.11 Front hand guard................................................10
5.12 Motor.................................................................. 11
5.13 Impeller.............................................................. 12
5.14 Main switch S/N -20180600615......................... 13
5.15 Main switch S/N 20180600615-......................... 14
5.16 Control unit S/N -2015100001............................15
5.17 Control unit S/N 2015100001- ...........................16
5.18 Replacing the keypad S/N -20180600615......... 17
5.19 Chain brake........................................................18
5.20 Chain brake sensor............................................ 20
5.21 Oil pump.............................................................20
5.22 Chain tensioner T536LiXP/T535i XP................. 21
5.23 Chain tensioner ................................................. 22
6 Troubleshooting
6.1 To connect the common service tool................... 23
6.2 To do troubleshooting of the common service
tool............................................................................. 23
6.3 Troubleshooting of the product............................ 23
6.4 Troubleshooting of the battery and battery
charger....................................................................... 25
6.5 Troubleshooting appendix....................................26
2539 - 003 - 05.12.2018

1 Introduction
1.1 Document description
This manual gives a full description of how to do
maintenance and repair on the product. It also gives
safety instructions that the personnel must obey.
1.2 Target group
This manual is for personnel with a general knowledge
of how to do repair and do servicing. All personnel that
do repair or do servicing on the product must read and
understand the manual.
1.3 Revisions
Changes to the product can cause changes to the
maintenance work and spare parts. Separate
information is sent out for each change.
Read the manual together with all received information
about changes to maintenance and spare parts for the
product.
1.4 Safety
WARNING: All personnel that repair or do
servicing on the product must read and
understand the safety instructions in this
workshop manual.
1.5 Servicing tools
The manual gives information about necessary servicing
tools. Always use original tools from Husqvarna.
539 - 003 - 05.12.2018 Introduction - 3

2 Safety
2.1 Safety definitions
Warnings, cautions and notes are used to point out
specially important parts of the manual.
WARNING: Used if there is a risk of injury or
death for the operator or bystanders if the
instructions in the manual are not obeyed.
CAUTION: Used if there is a risk of damage to
the product, other materials or the adjacent area
if the instructions in the manual are not obeyed.
Note: Used to give more information that is necessary in
a given situation.
2.2 General safety instructions
WARNING: Apply a new warning label if a
warning symbol on the product is damaged or
missing.
2.3 Symbols on the product
Fill with chain oil
Indication of chain direction
Chain brake
Start/Stop
savE / Battery save mode
Warning lamp/Fault indicator
Adjustable handle
2.4 Special safety instructions
2.4.1 To remove the battery
WARNING: Always remove the battery before
you do repairs or do servicing on the product.
WARNING: Do not put the battery back until the
product is assembled.
1. Press in the catches (1) and remove the battery (2).
2
1
1
4 - Safety 539 - 003 - 05.12.2018

3 Servicing data
3.1 Service data T536LiXP/T535i XP
The numbers show the tightening torque for the
components in Nm.
▲ Lubricate with chainsaw oil
● Lubricate with grease
2 ~ 3 Nm 4 mm
(x3) 1 Nm
(x2) 1 Nm
(x2) 1 ~ 2 Nm
1 ~ 2 Nm
(x4) 3,5 Nm 4 mm
(x2) 1 Nm
(x2) 1 Nm
1 Nm
539 - 003 - 05.12.2018 Servicing data - 5

2,5 ~ 3 Nm 4 mm
4 mm
(x9) 1,7 ~ 2 Nm 4 mm
(x2) 2,5 ~ 3 Nm
2,5 ~ 3,5 Nm T27
6 - Servicing data 539 - 003 - 05.12.2018

4 Servicing tools
4.1 Diagnostic tool kit
COMMON
SERVICE
TOOL
INSTRUCTION
12
4.1.1 Common service tool
The common service tool (CST) tool is used with a
computer (not included) for Husqvarna products.
The common service tool transmits data from the
product and battery to the computer, for example
product ID. There is also a diagnostic tool list and a list
of saved error codes. The common service tool is also
used to update the software in battery products.
Pos. Designation Used for Order No.
1 Diagnostic Tool Kit Troubleshooting 583 89 71-01
2 Adapter cable for battery products Troubleshooting 579 62 13-01
539 - 003 - 05.12.2018 Servicing tools - 7

5 Repair instructions
5.1 To clean and examine the product parts
• Clean and examine all parts fully. You find more
instructions in the chapter for each part if special
tools or procedures are necessary.
• Replace damaged or defective parts.
• Always use original spare parts.
5.2 To replace the guide bar bolt
Note: Make sure that the guide bar bolt and the washer
for the guide bar bolt are put correctly in the crankcase.
1. Disassemble the drive wheel cover, saw chain and
guide bar. See To remove the drive wheel cover and
guide bar on page 9 .
2. Empty the chain oil tank.
3. Hit the worn guide bar bolt to make it fall into the
chain oil tank.
4. Move the guide bar bolt (B) and its washer (A) from
the chain oil tank.
5. Put the guide bar bolt washer (A) on the guide bar
bolt (B).
A
B
6. Put them into the chain oil tank with pliers and
through the hole in the crankcase.
7. Pull out the guide bar bolt with a nut. Put a spacer
between the nut and the crankcase.
8. Assemble the crankcase. See To assemble the
crankcase on page 9
9. Fill with chain oil.
5.3 To replace the chip guard
Note: Always replace a worn chip guard with a new one.
1. Disassemble the drive wheel cover, saw chain and
bar.
2. Remove the screw and replace the chip guard.
5.4 To replace the chain oil cap
1. Empty the chain oil tank.
2. Put a combination wrench in the groove in the cap.
3. Turn the wrench counterclockwise.
4. Replace the damaged cap with a new cap.
5.5 To repair damaged threads
1. If the plastic threads in the chassis are damaged,
make a hole with a 4.5 mm drill bit.
2. Replace the original screw with the screw 503 21
74-16 - IHSCT MT5x16.
8 - Repair instructions 539 - 003 - 05.12.2018

5.6 To replace the chain catcher
Always replace a worn chain catcher with a new one.
1. Disassemble the drive wheel cover, the saw chain
and the guide bar. To remove the drive wheel cover
and guide bar on page 9 .
2. Remove the screw and replace the chain catcher.
5.7 To replace the spiked bumper
Always replace a worn spiked bumper with a new one.
1. Disassemble the drive wheel cover, the saw chain
and the guide bar. See To remove the drive wheel
cover and guide bar on page 9
2. Remove the screws and replace the spiked bumper.
5.8 Drive wheel cover and guide bar
5.8.1 To remove the drive wheel cover and
guide bar
1. Release the chain brake, move the hand guard
rearward.
2. Remove the drive wheel cover and guide bar nut.
3. Remove the cover, saw chain and guide bar.
5.8.2 To assemble the drive wheel cover and
guide bar
• Assemble the drive wheel cover and guide bar in the
opposite sequence of To remove the drive wheel
cover and guide bar on page 9 .
5.9 Crankcase
5.9.1 To disassemble the crankcase
CAUTION: Make sure that all parts are put
correctly in the crankcase to prevent damage to
the cables.
1. Remove the 8 screws.
2. Remove the crankcase half.
5.9.2 To assemble the crankcase
• Assemble the crankcase in the opposite sequence
of To disassemble the crankcase on page 9 .
539 - 003 - 05.12.2018 Repair instructions - 9

5.10 Power trigger
5.10.1 To disassemble the power trigger
1. Remove the drive wheel cover, the saw chain and
guide bar. See To remove the drive wheel cover and
guide bar on page 9 .
2. Disassemble the crankcase.
To disassemble the
crankcase on page 9
3. Remove the power trigger lockout and the power
trigger from their brackets in the handle.
4. Remove the main switch piston and the recoil spring
from its holding in the throttle.
5. Make sure that there is tension in the recoil spring.
5.10.2 To assemble the power trigger
1. Put the recoil spring and main switch piston onto the
throttle.
2. Assemble the throttle and the power trigger and
power trigger lockout to their brackets in the handle.
3. Make sure the holders are in the handle.
4. Put the recoil spring in the throttle lockout.
5.11 Front hand guard
5.11.1 To disassemble the front hand guard
WARNING: Use protective goggles. The spring
in the hand guard can eject and cause injury.
1. Make sure the product does not move during the
following procedure.
2. Disassemble the drive wheel cover, the saw chain
and the guide bar.
3. Move the hand guard rearward to release the brake.
This makes the assembly of the hand guard easier.
4. Remove the screws (A and B) for the front hand
guard.
B
A
5. Carefully turn the front hand guard horizontally.
Keep turning until the screw hole in the front hand
guard is released the holding (B) on the product.
B
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6. Turn the front handle guard down and away from the
product. Keep turning until the heel in the front
handle guard (C) is released from the heel in the
product (D).
B
DC
5.11.2 To assemble the front hand guard
WARNING: Use protective goggles. The spring
in the hand guard can eject and cause injury.
1. Put the brake pin in its position.
2. Put the spring in its position and tension it.
3. Make sure the product can not move during the
following procedure.
4. Align the hand guard holding and hold the hand
guard in position.
B
A
A
B
5. Pull the hand guard on to the holding on the left
side.
6. Put the spring into the slot on the hand guard.
7. Attach the screws (A and B).
B
A
8. Try the hand guard to make sure the hand guard is
attached correctly.
5.12 Motor
5.12.1 To disassemble the motor
CAUTION: Do not pull the wires.
1. Remove the drive wheel cover, the saw chain and
the guide bar. See To remove the drive wheel cover
and guide bar on page 9
2. Remove the crankcase. See To disassemble the
crankcase on page 9
539 - 003 - 05.12.2018 Repair instructions - 11

3. Remove the screws.
4. Press in holder (A) and disconnect the connector
(B).
D
C
D
A
B
5. Put a screwdriver (C) above the connector (D) and
carefully press down to release and disconnect the
connector.
6. Remove the motor.
5.12.2 To assemble the motor
CAUTION: Do not let the cables get caught
between other motor parts.
1. Put the motor on its brackets.
2. Connect the connectors.
3. Attach the chain brake sensor cable (C) to the
crankcase groove above the motor.
4. Make sure that the motor control cable (D) is on top
of the motor. If not, there is a risk that it comes loose
and gets caught in the clutch shaft.
C
D
5. Rotate the motor shaft until it aligns with the drive
shaft.
6. Attach the motor with the screws.
7. Assemble the product.
For motor with temperature sensor (–20140101) and
Gen. 1 control unit
Put the loose connector in the holder (D). No connection
is necessary.
For motor without temperature sensor (20140101–)
and Gen. 2 control unit
No connection is necessary.
5.13 Impeller
5.13.1 To disassemble the impeller
Note: The impeller can be removed with the motor
attached or removed.
1. Remove the drive wheel cover, the saw chain and
the guide bar. See To remove the drive wheel cover
and guide bar on page 9 .
2. Disassemble the crankcase. See
To disassemble
the crankcase on page 9 .
12 - Repair instructions 539 - 003 - 05.12.2018

3. Insert a screwdriver between the motor and the
impeller to remove the impeller from the motor.
5.13.2 To assemble the impeller
• Press the impeller onto the motor. The motor shaft
(A) must not be more than 1.85 mm or 0.073 above
the impeller.
A1,85 mm
5.14 Main switch S/N -20180600615
5.14.1 To remove the main switch
CAUTION: Do not pull the cables.
1. Remove the drive wheel cover, the saw chain and
the guide bar. See To remove the drive wheel cover
and guide bar on page 9 .
2. Disassemble the crankcase. See To disassemble
the crankcase on page 9
3. Remove the main switch and wire.
4. Disconnect the connector (B).
B
5. Carefully free the catches (D) on each end of the
connector with a small screwdriver.
C
D
D
6. Disconnect the connector (C).
7. Loosen the screws and remove the battery
connector from the crankcase.
8. Disconnect the connector cable from the battery
connector. Push the connector spring (X) with a
screwdriver to release the pin (Y).
X
Y
X
Y
9. Pull the cable out. Do not bend the pin.
5.14.2 To attach the main switch
1. Connect the red wire from the control cable to the
battery connector. Carefully press the cable until the
pin connects onto the connector.
CAUTION: Do not bend the pin.
539 - 003 - 05.12.2018 Repair instructions - 13

2. Attach the battery connector to the crankcase.
3. To prevent corrosion on the main switch connector,
put grease on the pins before you attach the main
switch.
4. Connect the connectors (B) and attach the
connector (C) to the main switch.
B
C
5. Put grease on the connector and the yellow wires.
6. Put the cables and the main switch in the crankcase.
Note: Make sure that you put the cables correctly to
prevent damage to the cables when the product is
assembled.
5.15 Main switch S/N 20180600615-
5.15.1 To disassemble the main switch
CAUTION: Do not pull the cables.
1. Remove the drive wheel cover, the saw chain and
the guide bar. See To remove the drive wheel cover
and guide bar on page 9
2. Disassemble the crankcase. See To disassemble
the crankcase on page 9
3. Remove the main switch from the crankcase.
4. Carefully free the catches (D) on each end of the
connector with a small screwdriver.
5. Disconnect the connector (C).
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5.15.2 To assemble the main switch
1. Connect the cable to the main switch.
2. Put the cables as shown in figure.
3. Put the main switch as shown in figure.
4. Assemble the product.
5.16 Control unit S/N -2015100001
5.16.1 To disassemble the control unit
Note: Look at how cables and other components are
assembled before you disassemble. Be careful when
you assemble and make sure that the cables do not get
caught between other parts.
1. Disassemble the drive wheel cover, saw chain and
guide bar. See To remove the drive wheel cover and
guide bar on page 9 .
2. Disassemble the crankcase. See To disassemble
the crankcase on page 9 .
3. Disassemble the motor. See To disassemble the
motor on page 11 .
4. Remove and disconnect the connector from the
keypad. See
To disassemble the keypad on page
18 .
5. Remove the main switch and disconnect the
connectors. See To remove the main switch on page
13 .
6. Disconnect the connector from the chain brake
sensor.
A
7. Remove the screw to the cable holder.
8. Remove the screws to the control unit and the
battery connector. Remove all control unit
components.
5.16.2 To assemble the control unit
1. Assemble the control unit and battery connection in
the crankcase.
2. Assemble the cables in their correct positions. Make
sure that no cables get caught between the
crankcase halves.
539 - 003 - 05.12.2018 Repair instructions - 15

3. Attach the screws to the control unit (D) and the
battery connection (E).
D
D
E
E
4. Connect the connector to the keypad and put the
connector together with the cables in the crankcase.
5. Put the motor connection with cable and the chain
brake sensor cables in the crankcase and assemble
the cable holder.
C
6. Connect the connector to the chain brake sensor
and attach it in its bracket.
7. Connect in the connectors to the main switch and
put the main switch into the crankcase.
8. Attach the connectors to the motor.
9. Make sure that the gray area in the illustration (A) is
free from cables. This is the battery ejector (B).
B
A
CAUTION: There is a risk that cables
around the battery ejector get caught
between other parts when the battery is
attached.
10. Assemble the product. See To assemble the drive
wheel cover and guide bar on page 9 and To
assemble the crankcase on page 9 .
5.17 Control unit S/N 2015100001-
5.17.1 To disassemble the control unit
Note: Look at how cables and other components are
assembled before you disassemble. Be careful when
you assemble and make sure that the cables do not get
caught between other parts.
1. Disassemble the drive wheel cover, saw chain and
guide bar. See To remove the drive wheel cover and
guide bar on page 9 .
2. Disassemble the crankcase. See To disassemble
the crankcase on page 9 .
3. Disassemble the motor. See To disassemble the
motor on page 11 .
4. Remove the screws to the main switch and battery
terminal.
16 - Repair instructions 539 - 003 - 05.12.2018

5. Disconnect the wire bracket from the control unit.
First holder (A) and then holder (B).
A
B
6. Remove the motor connector from the holder.
Remove the control unit and battery terminal.
5.17.2 To assemble the control unit
1. Attach the wires to the control unit. Make sure that
the sealing and bracket is correctly attached. First
attach (A) and then (B).
B
A
2. Attach the control unit and the battery terminal to the
crankcase.
3. Put the motor connector in the holder. Assemble the
cables as shown in the illustration.
4. Make sure that the gray area in the illustration (A) is
free from cables. This is the battery ejector (B).
B
A
Note: There is a risk that cables around the battery
ejector get caught between other parts when the
battery is attached.
5. Assemble the product. See To assemble the drive
wheel cover and guide bar on page 9 , To assemble
the crankcase on page 9 and To assemble the
motor on page 12 .
5.18 Replacing the keypad S/N
-20180600615
5.18.1 To replace the keypad
CAUTION: Do not bend the keypad when you
assemble.
1. Remove the drive wheel cover, saw chain and guide
bar. See To remove the drive wheel cover and guide
bar on page 9 .
2. Disassemble the crankcase. See To disassemble
the crankcase on page 9 .
3. Carefully remove the keypad.
539 - 003 - 05.12.2018 Repair instructions - 17

4. Disconnect the connection from the keypad.
5. Clean the surface where the keypad is attached.
6. Make sure the temperature is not lower than 15°C or
59°F. The surface where you attach the keypad
must not be more than ± 3°C or 5°F from the air
temperature. The temperature differs.
7. Remove the protective tape from the new keypad
and press the keypad onto the surface. Press the
keypad with 10 N/cm² for no less than 10 seconds.
>10 sec
10 N/cm2
8. Apply grease in the connector (A). Connect the
connector and apply grease on all sides (B).
A
B
9. Put the flat cable correctly in the crankcase.
5.18.2 To disassemble the keypad
1. Remove the drive wheel cover, saw chain and guide
bar. See To remove the drive wheel cover and guide
bar on page 9 .
2. Disassemble the crankcase. See
To disassemble
the crankcase on page 9 .
3. Disassemble the motor. See
To disassemble the
motor on page 11 .
4. Disconnect the wire bracket from the control unit.
First disconnect (A) and then (B).
B
A
5. Disconnect the hand guard connector (B).
B
C
D
6. Remove the keypad (C).
7. Disconnect the main switch connection (D). See To
remove the main switch on page 13 .
5.19 Chain brake
5.19.1 To disassemble the chain brake
WARNING: Use protective goggles. The inner
spring can eject out and cause injury.
1. Remove the drive wheel cover, saw chain and guide
bar. See To remove the drive wheel cover and guide
bar on page 9 .
2. Disassemble the crankcase. See To disassemble
the crankcase on page 9 .
3. Disassemble the motor. See To disassemble the
motor on page 11 .
18 - Repair instructions 539 - 003 - 05.12.2018

4. Disconnect the chain brake connector and put the
cable to the side.
5. Remove the screws and the chain brake cover.
6. Steer the large spring onto a screwdriver and
remove the spring.
A
7. Remove the spring and the shaft (B), and then the
clamp (C).
B
C
5.19.2 To assemble the chain brake
WARNING: Use protective goggles. Springs
can eject and cause injury.
1. Lubricate the parts.
2. Put the spring and shaft (B) in the crankcase with
the heel in its groove.
B
C
3. Put the clamp (C) in the crankcase.
4. Compress the large spring (A) and put it in its
groove.
A
5. Attach the chain brake cover.
6. Connect the sensor plug for the hand guard and put
the cable in its holder.
D
539 - 003 - 05.12.2018 Repair instructions - 19

5.20 Chain brake sensor
5.20.1 To disassemble the chain brake sensor
WARNING: Use protective goggles. Springs
can eject and cause injury.
1. Remove the drive wheel cover, saw chain and guide
bar. See To remove the drive wheel cover and guide
bar on page 9 .
2. Disassemble the crankcase. See
To disassemble
the crankcase on page 9 .
3. Disconnect the sensor plug on the chain brake.
A
4. Disassemble the chain brake. See To disassemble
the chain brake on page 18 .
5. Remove the chain brake sensor.
5.20.2 To assemble the chain brake sensor
WARNING: Use protective goggle. Springs can
eject and cause injury.
1. Attach the sensor in the crankcase.
2. Assemble the chain brake. See To assemble the
chain brake on page 19 .
3. Connect the sensor plug on chain brake.
A
5.21 Oil pump
5.21.1 To disassemble the oil pump
1. Empty the chain oil tank.
2. Remove the drive wheel cover, saw chain and guide
bar. See To remove the drive wheel cover and guide
bar on page 9 .
3. Disassemble the crankcase. See
To disassemble
the crankcase on page 9 .
4. Remove the chain guide plate.
5. Disassemble the motor. See
To disassemble the
motor on page 11 .
6. Remove the screws and the cover.
7. Remove the lubrication shaft and cylinder. Remove
them from the rubber hose.
20 - Repair instructions 539 - 003 - 05.12.2018