Husqvarna 136 LiHD50 Instruction manual

Workshop manual
136LiHD50,
536LiHD60X/520iHD60,
536LiHD70X/520iHD70 English
456 - 002 - 03.10.2018

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 Servicing data 136 LiHD50.................................... 5
3.2 Servicing data 536LiHD60X/520iHD60,
536LiHD70X/520iHD70................................................7
4 Servicing tools
4.1 Diagnostic tool kit................................................... 9
5 Repair instructions 136 LiHD50
5.1 To clean and examine the product parts..............10
5.2 Wear guard.......................................................... 10
5.3 Chassis................................................................ 10
5.4 Gear housing and cutting unit.............................. 10
5.5 Hand guard.......................................................... 12
5.6 Front handle ........................................................ 12
5.7 Power trigger........................................................12
5.8 Motor and gear package...................................... 13
5.9 Keypad................................................................. 13
6 Repair instructions 536LiHD60X/
520iHD60, 536LiHD70X/520iHD70
6.1 To clean and examine the product parts..............15
6.2 Chassis................................................................ 15
6.3 Cutting unit........................................................... 15
6.4 Front handle ........................................................ 16
6.5 Power trigger........................................................18
6.6 Gears................................................................... 19
6.7 Gear, cutting unit and gear housing..................... 20
6.8 Control unit and battery plug................................ 21
6.9 Keypad................................................................. 22
6.10 Main switch and main cable .............................. 23
6.11 Rear handle........................................................25
7 Troubleshooting
7.1 Overhaul...............................................................29
7.2 To connect the common service tool................... 29
7.3 To do troubleshooting of the common service
tool............................................................................. 29
7.4 Troubleshooting of the product............................ 29
7.5 Troubleshooting of the battery and battery
charger....................................................................... 31
7.6 Troubleshooting of the connectors.......................32
8 Troubleshooting of the electrical system
8.1 Troubleshooting diagram for the electrical
system........................................................................33
8.2 To do troubleshooting of the main switch ............33
8.3 Troubleshooting of the keypad.............................34
8.4 Troubleshooting the control unit PMDC - 136
LiHD50....................................................................... 34
8.5 Troubleshooting of the control unit PMDC -
536LiHD60X/520iHD60, 536LiHD70X/520iHD70...... 34
8.6 Troubleshooting of the battery connector.............35
2456 - 002 - 03.10.2018

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.
456 - 002 - 03.10.2018 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
Start/stop
SavE battery save mode
Warning/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 456 - 002 - 03.10.2018

3 Servicing data
3.1 Servicing data 136 LiHD50
The numbers show the tightening torque for the
component in Nm.
▲ Lubricate with chainsaw oil
● Lubricate with grease
1 Nm
(x6) 2 ~ 3 Nm 4 mm
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(x2) 1 Nm
(x8) 2 ~ 3 Nm 4 mm
(x2) 2 ~ 3 Nm 4 mm
(x11) 2 ~ 3 Nm 4 mm
6 - Servicing data 456 - 002 - 03.10.2018

3.2 Servicing data 536LiHD60X/520iHD60, 536LiHD70X/520iHD70
LiHD60x US
(x6) 2 ~ 3 Nm 4 mm
(x2/x3(70X)) 2 ~ 3 Nm 4 mm
(x5/x7(60X US)) 2 ~ 3 Nm 4 mm
(x2) 2 ~ 3 Nm 4 mm
8 mm
456 - 002 - 03.10.2018 Servicing data - 7

(x4) 2 ~ 3 Nm 4 mm
(x10) 2 ~ 3 Nm 4 mm
(x8) 2 ~ 3 Nm 4 mm
(x4) 2 ~ 3 Nm 4 mm
(x2) 2 ~ 3 Nm 4 mm
(x5) 2 ~ 3 Nm 4 mm
(x2) 1 Nm
(x2) 1 Nm
8 - Servicing data 456 - 002 - 03.10.2018

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
456 - 002 - 03.10.2018 Servicing tools - 9

5 Repair instructions 136 LiHD50
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 Wear guard
• The wear guard is attached with 8 screws.
5.3 Chassis
5.3.1 To disassemble the chassis
1. Remove the battery, see To remove the battery on
page 4 .
2. Remove the handle protection with a screwdriver.
3. Remove the 11 screws and remove the right chassis
half.
AB
Note: One of the screws (A) is behind the decal (B).
5.3.2 To assemble the chassis
• Assemble the chassis in the opposite sequence of
To disassemble the chassis on page 10 .
5.3.2.1 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.
5.4 Gear housing and cutting unit
5.4.1 To disassemble the gear housing and
remove the cutting unit
1. Disassemble the wear guard. See To disassemble
the hand guard on page 12 .
2. Remove the 6 screws and remove the bottom plate
for the gear housing.
10 - Repair instructions 136 LiHD50 456 - 002 - 03.10.2018

3. Remove the 2 screws and remove the gears and the
cutting unit from the gear housing.
4. Remove the circlip (A) and remove the washer (B).
Carefully lift up the hook (C) and remove the cutting
unit.
A
C
B
5.4.2 To assemble the gear housing and the
cutting unit
Note: Always replace the gasket after you disassemble
the gear housing.
1. Put the cutting unit on the hook (C). Attach the
washer (B) and the circlip (A).
A
C
B
2. Put the gear and cutting unit in the gear housing and
attach the 2 screws.
3. Lubricate the moving parts on the gears and the
cutting unit with grease.
4. Put the bottom plate and a new gasket on the gear
housing. Attach the screws. Tighten the screws
crossways.
1
2
3
5
6
4
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5.5 Hand guard
5.5.1 To disassemble the hand guard
1. Disassemble the wear guard, the front handle and
the right chassis half.
2. Remove the hand guard from the chassis.
5.5.2 To assemble the hand guard
1. Make sure the hand guard fits into the related
grooves in the chassis.
2. Assemble the right chassis half and the front handle.
5.6 Front handle
5.6.1 To disassemble the front handle
1. Disassemble the wear guard.
2. Remove the 2 screws that hold the handle.
3. Remove the connector for the handle out of the
chassis and disconnect it. Remove the handle from
the product.
5.6.2 To assemble the front handle
Assemble in the opposite sequence of To disassemble
the front handle on page 12 .
5.7 Power trigger
5.7.1 To disassemble the power trigger
1. Disassemble the wear guard, the front handle and
the right chassis half.
2. Remove the power trigger (A), the catch (B) and the
spring (C).
A
B
C
12 - Repair instructions 136 LiHD50 456 - 002 - 03.10.2018

5.7.2 To assemble the power trigger
1. Put the power trigger (A), the catch (B) and the
spring (C) in their initial positions in the chassis.
Make sure that the start inhibitor is set correctly
against the main switch. Make sure that the spring is
in the groove (D) on the power trigger and in the
space (E).
A
B
C
D
E
2. Assemble the right chassis half and the front handle.
5.8 Motor and gear package
5.8.1 To disassemble the motor and gear
package
1. Disassemble the wear guard, the front handle and
the right chassis half.
2. Remove the gear housing and motor from the
chassis and disconnect the plug.
3. Disassemble the gear housing and remove the gear
package and cutting unit. See To disassemble the
gear housing and remove the cutting unit on page
10 .
5.8.2 To assemble the motor and gear package
1. Put the motor on the gear housing.
2. Put the gear package and cutting unit in the gear
housing and assemble the bottom plate on the gear
housing. See To disassemble the gear housing and
remove the cutting unit on page 10 .
3. Connect the plug and put the gear housing and
motor in the chassis. Make sure the cables from the
plug to the motor are put correctly in the chassis.
Make sure that the resistor is put in its correct
position in front of the motor.
4. Assemble the right chassis half and the front handle.
5.9 Keypad
5.9.1 To disassemble the keypad and control
unit
1. Disassemble the wear guard, the front handle and
the right chassis half.
2. Remove the power trigger, the lock and the spring
from the chassis. See To disassemble the power
trigger on page 12 .
3. Disconnect the plug to the motor. See To
disassemble the motor and gear package on page
13 .
4. Remove the 2 screws for the battery plug.
5. Remove the control unit, the cables with the main
switch and the keypad from the chassis.
6. Disconnect the keypad from the control unit.
5.9.2 To assemble the keypad and control unit
CAUTION: Be careful. The flat cable to the
keypad is easily damaged.
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WARNING: Do not press the button on the main
switch if it is not assembled in the handle.
1. Connect the keypad to the control unit.
2. Put the control unit, the cables with the main switch
and the keypad into the chassis. Attach the battery
plug with 2 screws.
3. Connect the plug to the motor. See To assemble the
motor and gear package on page 13 .
4. Put the power trigger (A), the catch (B) and the
spring (C) back in their initial positions in the
chassis. See To disassemble the front handle and
start inhibitor on page 17 .
5. Assemble the right chassis half and the front handle.
14 - Repair instructions 136 LiHD50 456 - 002 - 03.10.2018

6 Repair instructions 536LiHD60X/520iHD60, 536LiHD70X/
520iHD70
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 Chassis
6.2.1 To disassemble the chassis
• Remove the 8 screws.
• Lift off the right chassis half.
6.2.2 To assemble the chassis
• Assemble in the opposite sequence of To
disassemble the chassis on page 15 .
6.2.2.1 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 Cutting unit
6.3.1 To disassemble the cutting unit
1. Remove the circlip (A) and remove the washer (B).
Carefully lift up the hook (C) and remove the cutting
unit.
A
C
B
2. Remove all the screws on the cutting unit and
disconnect the parts as shown in the expanded view
illustration.
6.3.2 To replace the blade guard
Note: Always replace a damaged blade guard.
456 - 002 - 03.10.2018 Repair instructions 536LiHD60X/
520iHD60, 536LiHD70X/520iHD70 -
15

1. Loosen the nut (A) that holds the connection plate
(B).
A
B
CD
2. Loosen the nuts (C).
Note: For model 536LiHD60X/520iHD60 and
536LiHD70X/520iHD70 there are 5 nuts. For model
536LiHD60X (US) there are 7 nuts.
3. Remove the blade guard (D) and the connection
plate (B) and disconnect them.
6.3.3 To assemble the cutting unit
• Assemble in the opposite sequence of To
disassemble the cutting unit on page 15 . Tightening
torque: see Servicing data 536LiHD60X/520iHD60,
536LiHD70X/520iHD70 on page 7 .
6.3.4 To lubricate the gearbox
Instructions of lubricating when replacing the cutting
board.
To make sure product efficiency and lifetime the
recommended grease must be used. The recommended
grease is specified in the IPL and has the article number
503 98 96-03 (20g). The gearbox must not be fully filled
with grease.
• Apply approximately 2.5 g of grease.
1
3
4
5
2
6.4 Front handle
6.4.1 To remove the front handle
CAUTION: Make sure that the cables to the
handle are not damaged when you assemble
the cover.
16 - Repair instructions
536LiHD60X/520iHD60,
536LiHD70X/520iHD70
456 - 002 - 03.10.2018

1. Remove screw (A) and lift off the cover (B) above
the handle cables.
A
B
2. Remove the 3 screws that holds the handle.
3. Remove the handle and position it by the product.
Make sure that the cables are not damaged.
6.4.1.1 To disassemble the front handle and start
inhibitor
1. Remove the front handle and the right chassis half.
2. Disassemble the gear housing and motor. See
To
remove the gear housing and the motor from the
chassis on page 19 .
3. Disconnect the handle cables (A) from the control
unit and remove them through the hole (B) in the
chassis.
A
B
WARNING: The spring can eject and cause
injury. Put on protective goggles.
4. Remove the 10 screws and carefully remove the
handle half.
5. Remove the relay with cables (C) and the loop (D)
out of the handle.
CD
6. Lift the start inhibitor (E), the 3 plastic clips (F), the 3
springs (G) and the spring (H) out of the handle.
F
F
F
G
G
H
E
G
6.4.1.2 To assemble the start inhibitor and the front
handle
CAUTION: Make sure that the cables are set
correctly to prevent damage.
456 - 002 - 03.10.2018 Repair instructions 536LiHD60X/
520iHD60, 536LiHD70X/520iHD70 -
17

1. Put the start inhibitor (E), plastic clips (F) and
springs (G and H) in the handle.
F
F
F
G
G
H
E
G
2. Put the relay with cables (D) and the loop (C) in the
handle.
CD
3. Attach the handle halves with the 10 screws.
4. Make sure the safety catch moves to the rear in all
directions.
5. Put the cables through the hole (B) in the chassis
and connect the plugs (A) to the control unit.
A
B
CAUTION: Make sure that the safety catch
operates correctly when the plugs (A) are
connected.
6. Assemble the gear housing and motor in the
chassis. See To assemble the gear housing and
motor in the chassis on page 19 .
7. Assemble the right half of the chassis. See To
remove the front handle on page 16 .
8. Attach the front handle in opposite sequence of To
disassemble the front handle and start inhibitor on
page 17 .
6.5 Power trigger
6.5.1 To disassemble the power trigger and
handle stop
1. Disassemble the front handle and the right chassis
half. See To remove the front handle on page 16
and To disassemble the chassis on page 15 .
2. Disassemble the rear handle. See To disassemble
the rear handle on page 25 .
3. Remove the handle stop (A) and the spring (B).
Remove the power trigger (C).
C
B
A
18 - Repair instructions
536LiHD60X/520iHD60,
536LiHD70X/520iHD70
456 - 002 - 03.10.2018

6.5.2 To assemble the power trigger
1. Put the power trigger (C) into the handle.
C
B
A
2. Put the handle stop (A) and the spring (B) into the
handle.
3. Assemble the rear handle. See To assemble the
rear handle on page 26 .
4. Assemble the right chassis half and the front handle.
See To remove the front handle on page 16 and To
disassemble the chassis on page 15 .
6.6 Gears
6.6.1 To remove the gear housing and the
motor from the chassis
1. Disassemble the front handle and the right chassis
half. See To remove the front handle on page 16
and To disassemble the chassis on page 15 .
2. Disconnect the motor plug from the control unit.
3. Remove the 2 screws that hold the gear housing
and motor in the chassis.
4. Remove the gear housing and motor from the
chassis.
6.6.2 To assemble the gear housing and motor
in the chassis
1. Put the gear housing and the motor in the left half of
the chassis. Make sure that the motor cables are put
in position (A) at the air holes in the chassis. Make
sure that the cables are put in the groove (B) above
the control unit.
A
B
B
B
CAUTION: Make sure that the cables do not
get damaged when the gear housing and
the motor are put on top.
2. Connect the gear housing and the motor in the
chassis with 2 screws.
456 - 002 - 03.10.2018 Repair instructions 536LiHD60X/
520iHD60, 536LiHD70X/520iHD70 -
19

3. Connect the plug from the motor to the control unit.
Attach the plug with the gray cable in position (C).
C
CAUTION: Make sure that the cables hang
straight down from the plug.
4. Assemble the right half of the chassis and the front
handle. See To remove the front handle on page 16
and To disassemble the chassis on page 15 .
6.7 Gear, cutting unit and gear housing
6.7.1 To disassemble the gear, cutting unit and
motor out of the gear housing
1. Remove the 6 screws and remove the bottom plate
of the gear housing.
2
3
6
4
5
1
2. Remove the 2 screws and remove the gears and the
cutting unit from the gear housing.
Note: The front screw locks also the safety point
with the related nut.
6.7.2 To disassemble the gears
1. Remove the circlip (A), remove the washer (B),
carefully lift up the hook (C) and remove the cutting
unit.
A
C
B
2. Disconnect the parts as shown in the illustration.
6.7.3 To assemble gears, cutting unit and motor
in the gear housing
Note: Lubricate moving parts on gears and the cutting
unit with grease so they move easily.
Note: Always replace the gasket after you disassemble
the gear housing.
20 - Repair instructions
536LiHD60X/520iHD60,
536LiHD70X/520iHD70
456 - 002 - 03.10.2018