Husqvarna K 535i Instruction manual

Workshop manual
K 535i
English
744 - 002 -

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 Special safety instructions......................................4
2.4 Symbols on the product......................................... 4
3 Servicing data
3.1 Symbols in the diagrams........................................5
3.2 Tightening torques ................................................ 5
4 Servicing tools
4.1 Servicing tools overview.........................................7
5 Product overview for repair and servicing
5.1 Product overview....................................................8
6 Repair instructions
6.1 To clean and examine the product parts................9
6.2 To repair damaged threads....................................9
6.3 Wet system............................................................ 9
6.4 Handle half........................................................... 10
6.5 Power trigger........................................................10
6.6 Main switch.......................................................... 11
6.7 Control unit...........................................................12
6.8 Keypad................................................................. 13
6.9 Drive belt ............................................................. 14
6.10 Pulleys................................................................15
6.11 Motor.................................................................. 15
6.12 Cutter arm.......................................................... 16
6.13 Front ground support..........................................17
6.14 Impeller.............................................................. 17
6.15 To disassemble the impeller.............................. 17
6.16 To assemble the impeller................................... 17
6.17 Blade shaft bearings ......................................... 17
6.18 Motor shaft bearing............................................ 19
7 Troubleshooting
7.1 To connect the common service tool................... 20
7.2 To do troubleshooting of the common service
tool............................................................................. 20
7.3 Troubleshooting of the product............................ 20
7.4 Troubleshooting of the battery and battery
charger....................................................................... 22
7.5 Troubleshooting appendix ...................................23
7.6 Troubleshooting of the battery connector.............24
2744 - 002 -

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.
744 - 002 - 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: Read the warning instructions that
follow before you use the product.
The service center that repairs the product must have
safety devices that obey local regulations. Warnings and
cautions are used to point out specially important parts
of the workshop manual.
2.3 Special safety instructions
• Apply a new warning label if a warning symbol on
the product is damaged or missing.
• Do not use accessories or spare parts that are not
approved by the manufacturer. Do not do changes
that are not approved by the manufacturer. This can
cause injury or death to the operator or other
persons.
• Use protective gloves and eye protection. Approved
protective goggles must agree with the ANSI Z87.1
standard in the USA or EN 166 in EU countries.
• When you use compressed air, do not point the
airflow in the direction of your body. Air can go into
the blood circulation and kill you.
• Use approved hearing protection. Noise from the
product can result in permanent hearing loss.
• The product can cause sparks. Do not operate the
product near flammable materials.
2.3.1 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
2.4 Symbols on the product
Start/Stop
savE / Battery save mode
Warning lamp/Fault indicator
Read the manual carefully and make sure
you understand the instructions before
using the product.
Always put on personal protective
equipment:
WARNING! Kickbacks can be sudden,
fast and can cause injuries. Read and
understand the instructions in the manual
before using the product.
WARNING! Dust from cutting can cause
breathing problems. Use breathing
protection. Do not breathe exhaust fumes.
Always make sure there is good airflow.
WARNING! Sparks from the cutting blade
can cause a fire in materials such as,
gasoline, wood, fabric and dry grass.
WARNING! Do not use circular saw
blades.
Make sure the cutting disc is not
damaged.
4 - Safety 744 - 002 -

3 Servicing data
3.1 Symbols in the diagrams
Tightening torque, Nm
Torx
Bolt
3.2 Tightening torques
T10
0.8-1
T27
4-5
T10
0.8-1
744 - 002 - Servicing data - 5

T27
3.5-4
T27
6-7
T27
3-3.5
T27
2-3
T27
2-3
T27
5-6
13
26-30
13
26-30
T27
5-6
T27
2-2.5
T27
5-6
7-8
T27
4-4.5
T27
13
3-10
6 - Servicing data 744 - 002 -

4 Servicing tools
4.1 Servicing tools overview
13 2
4 65
7
10
8 9
Position Designation Used for Order No./
Source
1 Combination wrench General. 506 38 26-01
2 Bearing press To assemble the motor shaft bearing. 504 56 79-01
3 Wrench To disassemble and assemble the drive belt pulley. 596 51 18-01
4 Diagnostic Tool Kit Troubleshooting. 583 89 71-01
5 Adapter cable for battery Troubleshooting. 579 62 13-01
6 Belt assembly tool To install and remove the drive belt. 596 55 26-01
7 Bearing press To assemble blade shaft bearings. 596 83 49-01
8 Adapter for bearing press To assemble blade shaft bearings. 596 83 50-01
9 Key Torx T10 General. 502 71 27-02
10 Internal bearing extractor To remove bearings. SKF TMIC 7-28
744 - 002 - Servicing tools - 7

5 Product overview for repair and servicing
5.1 Product overview
23
22
21
1314
12
11
20
4
10
5 6
31 2
18 17 16
19
7
8
9
15
1. Power trigger lockout
2. Power trigger
3. Water valve
4. Water nozzle
5. Cutting blade (not included)
6. Cutter arm
7. SavE button
8. Warning indicator
9. Start and stop button
10. Handle half
11. Rear ground support with a rope eyelet
12. Battery slot
13. Fan housing
14. Front handle
15. Belt guard
16. Front ground support
17. Type plate
18. Water connection with filter
19. Button, battery status
20. Battery status
21. Warning indicator
22. Battery release button
23. Battery (not included)
8 - Product overview for repair and servicing 744 - 002 -

6 Repair instructions
6.1 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.
6.2 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.
6.3 Wet system
6.3.1 Wet system function
Each side of the blade guard has a spray nozzle. The
water hits a section of the cutting blade and the
centrifugal force moves it out to the edge.
6.3.2 To remove the wet system
1. Remove the handle.
2. Remove the screws that hold the spray nozzles.
3. Remove the hose from the notches on the housing.
744 - 002 - Repair instructions - 9

4. Remove the screw that holds the valve.
5. Remove the wet system.
6. Remove the filter with a wood screw.
6.3.3 To assemble the wet system
1. Push the filter fully into the connector. Push against
a flat surface.
2. Assemble in the opposite sequence of To remove
the wet system on page 9 .
6.4 Handle half
6.4.1 To disassemble the handle half
1. Disassemble the wet system. Refer to To remove
the wet system on page 9 .
2. Remove the handle half.
6.5 Power trigger
6.5.1 To disassemble the power trigger
1. Disassemble the wet system. Refer to
To remove
the wet system on page 9 .
2. Disassemble the handle half. Refer to To
disassemble the handle half on page 10 .
10 - Repair instructions 744 - 002 -

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.
5. Make sure that there is tension in the recoil spring.
6.5.2 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.
6.6 Main switch
6.6.1 To disassemble the main switch
CAUTION: Do not pull the cables.
1. Disassemble the wet system. Refer to To remove
the wet system on page 9 .
2. Disassemble the handle half. Refer to To
disassemble the handle half on page 10 .
3. Remove the main switch from the other handle half.
4. Release the catch with a small screwdriver and
remove the connector.
744 - 002 - Repair instructions - 11

6.6.2 To assemble the main switch
1. Attach the connector to the main switch.
2. Put the cables as shown in the figure.
3. Put the main switch as shown in the figure.
6.7 Control unit
6.7.1 To disassemble the control unit
Note: Look at how cables and other components are
assembled before you disassemble.
1. Disassemble the wet system. Refer to To remove
the wet system on page 9
2. Disassemble the handle half. Refer to To
disassemble the handle half on page 10
3. Remove the connector to the motor.
4. Remove the screws to the main switch and battery
terminal.
5. Disconnect the wire bracket from the control unit.
First disconnect holder (A) and then holder (B).
A
B
12 - Repair instructions 744 - 002 -

6. Remove the motor connector from the holder.
Remove the control unit and battery terminal.
6.7.2 To assemble the control unit
CAUTION: Be careful when you assemble and
make sure that the cables do not get caught
between other parts.
1. Attach the wires to the control unit. Make sure that
the sealing and bracket is correctly attached. First
attach (A) and then (B).
A
B
2. Attach the control unit and the battery terminal to the
handle half.
3. Put the motor connector in the holder. Assemble the
cables as shown in the illustration.
4. Make sure that there are no cables in the area (A).
This is the battery ejector (B).
A
B
5. To assemble the product, do steps 1-3 in the section
To disassemble the control unit on page 12 .
6.8 Keypad
6.8.1 To disassemble the keypad and wire harness
1. Disassemble the wet system. Refer to To remove
the wet system on page 9 .
2. Disassemble the handle half. Refer to To
disassemble the handle half on page 10 .
3. Disconnect the wire bracket from the control unit.
First disconnect (A) and then (B).
A
B
744 - 002 - Repair instructions - 13

4. Disconnect the main switch connection (B). Refer to
To disassemble the main switch on page 11 .
A
B
5. Remove the keypad (A) and the connector (B).
Remove the wire harness.
6.8.2 To assemble the keypad and wire assembly
1. Assemble the wire assembly as shown in the
illustration.
2. Assemble in opposite sequence of To disassemble
the keypad and wire harness on page 13 .
6.9 Drive belt
6.9.1 To remove the drive belt
Note: The belt assembly tool is supplied with the new
drive belt.
1. Remove the belt cover.
2. Put the belt tool on top of the front pulley and turn
the pulley clockwise. Use a wrench if it is necessary.
Remove the belt from the pulley.
6.9.2 To install the drive belt
Note: The belt assembly tool is supplied with the new
drive belt.
1. Put the belt around the rear pulley.
2. Put the belt assembly tool on top of the front pulley.
14 - Repair instructions 744 - 002 -

3. Turn the front pulley clockwise with the combination
wrench. At the same time, push the drive belt onto
the pulley.
4. Attach the belt cover.
6.10 Pulleys
6.10.1 To remove the motor pulley
1. Remove the belt cover and the drive belt. Refer to
To remove the drive belt on page 14 .
2. Lock the pulley with a combination wrench (A). Refer
to Servicing tools overview on page 7 .
A
B
3. Loosen the bolt with a 13 mm wrench (B).
6.10.2 To remove the blade shaft pulley
1. Remove the drive belt. Refer to To remove the drive
belt on page 14 .
2. Lock the blade shaft with the spindle lock button (A)
and loosen the pulley screw (B) with the combination
wrench.
A
B
6.11 Motor
6.11.1 To disassemble the motor
1. Remove the handle half. Refer to To disassemble
the handle half on page 10 .
2. Remove the drive belt. Refer to To remove the drive
belt on page 14 .
3. Remove the motor pulley. Refer to To remove the
motor pulley on page 15 .
4. Remove the connector.
744 - 002 - Repair instructions - 15

5. Loosen the screws to the motor.
6. Remove the motor.
6.12 Cutter arm
6.12.1 To remove the cutter arm
1. Remove the wet system. Refer to To remove the wet
system on page 9 .
2. Remove the drive belt. Refer to To remove the drive
belt on page 14 .
3. Remove the handle half.
4. Remove the connector to the motor.
5. Loosen the screws to the motor.
6. Remove the motor.
16 - Repair instructions 744 - 002 -

7. Remove the screws and remove the cutter arm.
6.13 Front ground support
6.13.1 To replace the front ground support
1. Replace only the wear protection (A) or the complete
ground support (B).
A
B
6.14 Impeller
6.15 To disassemble the impeller
Note: The impeller can be removed with the motor
attached or removed.
1. Disassemble the handle half. See To disassemble
the handle half on page 10 .
2. Put a screwdriver between the motor and the
impeller to remove the impeller from the motor.
6.16 To assemble the impeller
• Push the impeller onto the motor. The motor shaft
must not be more than 1.85 mm above the impeller.
6.17 Blade shaft bearings
6.17.1 To remove the blade shaft bearings
1. Remove the cutting arm. Refer to To remove the
cutter arm on page 16 .
2. Remove the motor. Refer to To disassemble the
motor on page 15 .
3. Put a pipe as support. Minimum inner diameter: 34
mm. Maximum outer diameter: 56 mm.
744 - 002 - Repair instructions - 17

4. Push the blade shaft with a mandrel and the first
bearing and the blade shaft is removed.
5. Push the second bearing with the mandrel to
remove it.
Note: It is also possible to remove the bearing with an
internal bearing extractor and slide hammer.
Refer to: Servicing tools overview on page 7
6.17.2 To assemble the blade shaft bearings
Use the bearing tools to install the bearings and the
blade shaft. Refer to Servicing tools overview on page 7 .
1. Push the bearing onto the blade shaft. Use the
smaller hole of the bearing press.
2. Put the adapter as a support before you put the
bearing and the blade shaft onto the cutting head.
Note: You must use the adapter. The blade side of
the cutting head is not at a right angle to the blade
shaft.
18 - Repair instructions 744 - 002 -

3. Use the larger hole of the bearing press.
4. Make sure that the bearings are in level before you
push them.
5. To put the second bearing to the blade shaft, use
the smaller hole of the bearing press.
6.18 Motor shaft bearing
6.18.1 To remove the motor shaft bearing
1. Remove the cutting arm. Refer to
To remove the
cutter arm on page 16 .
2. Remove the pulley. Refer to To remove the motor
pulley on page 15 .
3. Remove the motor. Refer to To disassemble the
motor on page 15 .
4. Remove the bearing with an internal bearing
extractor and slide hammer. Refer to Servicing tools
overview on page 7 .
6.18.2 To install the motor shaft bearing
• Use the bearing press and the bearing press
adapter to install the bearing. Refer to Servicing
tools overview on page 7 .
744 - 002 - Repair instructions - 19

7 Troubleshooting
7.1 To connect the common service tool
1. Connect the adapter cable for the common service
tool to the battery and the battery connector on the
product. Connect cable (A) to the common service
tool to do troubleshooting of the product. Connect
cable (B) to the common service tool to do
troubleshooting of the battery.
A B
Note: Refer to the manual for the common service
tool for instructions and obey the instructions.
2. Do troubleshooting as given in the common service
tool instructions.
7.2 To do troubleshooting of the common
service tool
If there is no signal to the common service tool when it is
connected to the product, do the procedure that follows.
1. Make sure that the connectors on the battery and on
the product are clean and not damaged. Replace the
battery or control unit on the product if there is
damage.
2. Make sure that the cable to the common service tool
is clean and not damaged. Replace the cable if there
is damage.
3. Restart the computer.
4. Install the software again.
7.3 Troubleshooting of the product
Symptom Possible causes Recommended step
The product does not start. No LEDs
come on when you push the on/off
button.
Defective battery. Push the on/off button to do a check
of the battery. A minimum of 1 green
LED must come on.
Defective plug between battery and
product.
Make sure that the power connectors
between the battery and the product
are not dirty or damaged.
Defective connection in keypad con-
nector.
Make sure that the keypad connector
is correctly assembled, dry, not dam-
aged and that there is no corrosion.
Broken keypad. Replace keypad.
Cables between control unit and key-
pad/main switch are damaged.
Repair/replace the cables if you can
see damages.
Short circuit in control unit. Replace control unit.
No reaction from the electrical motor
when you push the power trigger.
Defective connection in the signal
connector for the main switch.
Make sure that the main switch signal
connector is correctly assembled, dry,
not damaged and that there is no cor-
rosion.
Motor connector not correctly assem-
bled.
Make sure that the motor connector
are correctly assembled.
Internal damage to main switch. Replace main switch.
Short circuit in control unit. Replace control unit.
Electrical motor makes sudden move-
ment when you push the power trig-
ger, then stops.
Short circuit in control unit. Replace the control unit.
Product stops when you apply work
load.
Defective connection in keypad con-
nector.
Make sure that the power connectors
between battery and product are
clean and not damaged.
20 - Troubleshooting 744 - 002 -