320iB Mark II/436LiB, 525iB/536LiB, 530iBX

Transcription

1 Workshop manual 320iB Mark II/436LiB, 525iB/536LiB, 530iBX From S/N English

2 Contents 1 Introduction 1.1 Document description Target group Revisions Safety Servicing tools Safety 2.1 Safety definitions General safety instructions Symbols on the product Special safety instructions Troubleshooting 6.1 Overhaul To connect the common service tool To do troubleshooting of the common service tool Troubleshooting of the product Troubleshooting of the battery and battery charger Troubleshooting of the battery connector Servicing data 3.1 Servicing data 320iB Mark II/436LiB Servicing data 525iB/536LiB Servicing data 320iB Mark II/436LiB and 525iB/536LiB Servicing data 530iBX Servicing tools 4.1 Diagnostic tools Repair instructions 5.1 To clean and examine the product parts To disassemble the nozzle To disassemble the chassis - 320iB Mark II/ 436LiB and 525iB/536LiB To disassemble the chassis - 530iBX Power trigger To disassemble the power trigger To assemble the power trigger ESD cables To disassemble ESD cables To assemble the ESD cables The motor and the blow pipe To disassemble the motor and the blow pipe To assemble the motor and the blow pipe Main cable To disassemble the main cable To assemble the main cable Control unit To disassemble the control unit To assemble the control unit Main switch To disassemble the main switch To assemble the main switch

3 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 Introduction 1.5 Servicing tools The manual gives information about necessary servicing tools. Always use original tools from Husqvarna Introduction - 3

4 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. WARNING: Do not put the battery back until the product is assembled. 1. Press in the catches (1) and remove the battery (2). 1 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 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 Cruise control Boost Warning indicator / Fault indicator 2.4 Special safety instructions To remove the battery WARNING: Always remove the battery before you do repairs or do servicing on the product. 4 - Safety

5 3.1 Servicing data 320iB Mark II/436LiB The numbers show the tightening torque for the component in Nm. 3 Servicing data (x2) (x2) 11 Nm (x3) 1,9 1.9 Nm Nm 4 mm Servicing data - 5

6 3.2 Servicing data 525iB/536LiB The numbers show the tightening torque for the component in Nm. (x2) 1 Nm (x2) 1 Nm (x3) 2.8 Nm (x3) 2,8 Nm (x3) 1,9 1.9 Nm Nm 44 mm 4 mm 6 - Servicing data

7 3.3 Servicing data 320iB Mark II/436LiB and 525iB/536LiB 436LiB/320iB Mark II 536LiB/525iB (x2) 0.7 Nm (x12) 1.9 Nm 4 mm 536LiB/525iB (x13) 1.9 Nm 4 mm Servicing data - 7

8 3.4 Servicing data 530iBX The numbers show the tightening torque for the component in Nm. (x3) 1.6 Nm 4 mm (x3) 2.8 Nm 4 mm (x3) 1.9 Nm 4 mm 8 - Servicing data

9 (x3) (x3) 1.9 1,9 Nm 4 mm (x9) 1,9 1.9 Nm 4 mm 4 mm (x3) 0,7 0.7 Nm Nm 4 mm 1.9 Nm 4 mm 1,9 Nm 4 mm Servicing data - 9

10 4 Servicing tools 4.1 Diagnostic tools CST INSTRUCTION Common service tool The common service tool (CST) tool is used with a computer (not included) for Husqvarna products. 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. The common service tool transmits data from the product and battery to the computer, for example Pos. Description Used with Order No. 1 Diagnostic Tool Kit Diagnosis and troubleshooting Adapter cable for battery products Supplement/upgrade for Engine Diagnostic Tool - AutoTune ( ) Servicing tools

11 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. 5.4 To disassemble the chassis - 530iBX 1. Remove the 9 screws and lift off the left chassis half and vent cover. Always use original spare parts. 5.2 To disassemble the nozzle Turn the nozzle to loosen it from the blow pipe. 2. Remove the service cable from the left chassis half. Use tweezers or a small pair of pliers. 5.3 To disassemble the chassis - 320iB Mark II/436LiB and 525iB/536LiB Remove the 12 screws. Lift off the left chassis half, the front cover (A) and the rear vent cover (B). A B 5.5 Power trigger 5.6 To disassemble the power trigger Lift the power trigger control out of the chassis Repair instructions - 11

12 5.7 To assemble the power trigger Press in the pin on the main switch to make it easier to put the power trigger control in its bracket. Make sure the rear edge on the power trigger control enters into the chassis. Make sure the ESD cable is is put onto the clamps on the chassis. 1. Put the ESD cable onto the handle. Make sure the cable is put in the clamps in the chassis. 5.8 ESD cables 5.9 To disassemble ESD cables 1. Loosen the connection (B) from the motor and the connection (C) from the ESD cable from the connection spring (A). B C A 2. Connect the connection (C) from the ESD cable and connection (B) from the motor to the connection spring (A). 2. remove the ESD catch from the handle and carefully loosen the cable from its bracket in the chassis. B C A 5.10 To assemble the ESD cables Note: Make sure the cables are put correctly to prevent them from being caught between the chassis halves Repair instructions

13 5.11 The motor and the blow pipe 4. Loosen the screws and lift the nose cone from the motor housing. Only for 530iBX 5.12 To disassemble the motor and the blow pipe 1. Loosen the connector (A) from the control unit. Make sure not to cause damage to the connector (B) or the cables. Loosen the connector/cable from the connection spring. A B C 5. Attach the shaft (F) to the motor. Use an M4 screw as a puller and push it onto the shaft (G) to remove the fan. For 320iB Mark II/436LiB replace the motor assy kit. 2. Lift the blow pipe and motor housing out of the chassis. 3. Loosen the screws and the brushes/cables (D). Lift off the blow pipe from the motor housing. Make sure the rubber seal (E) comes loose from the pipe. F D G E 6. Loosen connector (H) from the connection spring in the motor housing. H Repair instructions - 13

14 7. Loosen the screws attaching the motor in the motor housing. Note: Do not pull the wires. 1. Put the motor with cables and connection spring into the motor housing. It is very important that the motor is put in correctly. Make sure that the red (X) and blue (Y) cables are connected to the right of the connection spring (H). The white (Z) cable must be connected to the left. 8. Lift the motor out of the motor housing. Z H X Y 2. Attach the motor in the motor housing with the 3 screws To assemble the motor and the blow pipe Note: Make sure the cables are put correctly to prevent them from being caught between the chassis halves Repair instructions

15 3. Connect the connector (H) to the connection spring in the motor housing. 5. Attach the nose cone in the motor housing with the screws. Only for 530iBX. H 4. Attach the shaft (F) on the motor. Press on the fan (G) with a maximum force of 9 kn and a minimum force of 2 kn. Press the fan on the shaft until the fan is 0-1 mm above the edge of the motor housing. 6. Put the bushing/cables (E) into the groove in the blow pipe. Attach the blow pipe in the motor housing with the screws. Put the brushes/cables (D) in the clamp on the blow pipe. F D E G Min 0 mm Max 1 mm Min 2 kn Max 9 kn Min 0 mm Note: Do not press down the fan more Repair instructions - 15

16 7. Put the blow pipe and motor housing in the chassis. The heels of the engine housing must be put correctly to close the product. Note: Do not pull the wires. 1. Loosen the connection spring that is found in the cover above the electronics. See To disassemble ESD cables on page Disassemble the motor housing/blow pipe. See To disassemble the motor and the blow pipe on page Loosen the screw and lift off the cover. 8. Connect connector (A) to the control unit. Make sure not to cause damage to the connector (B) with cables. Connect connector (C) to the connector spring. A 4. Loosen the screws for the battery connection, 320iB Mark II/436LiB and 525iB/536LiB B C 5.14 Main cable 5.15 To disassemble the main cable Note: The flat cable to the keypad is easily damaged Repair instructions

17 5. Loosen the screws holding the battery cable, 530iBX 7. Remove the cover from the keypad. 6. Loosen all the cables from their clamps and lift the control unit, main switch and main cables out of the chassis. 8. Disassemble the control unit. See To disassemble the control unit on page Disassemble the main switch. See To disassemble the main switch on page To assemble the main cable Note: Make sure the cables are put correctly to prevent them from being caught between the chassis halves. 1. Assemble the main switch. See To assemble the main switch on page Assemble the control unit. See To assemble the control unit on page Attach the cover onto the keypad Repair instructions - 17

18 4. Pull the main cables through the display cover. 6. Attach the screws (A) for the battery connection. Attach the screws holding the battery cable. 5. Put all cables (in their attachments), control unit, main switch and main cables into the chassis Repair instructions

19 7. Assemble the cover above the electronics. the screwdriver too far to it cause damage the connector or the control unit. 1. Disassemble the main cables. See To disassemble the main cable on page Disconnect the connector between the main cables and the control unit. 8. Assemble the motor housing/blow pipe. See To assemble the motor and the blow pipe on page Assemble the connection spring. See To assemble the ESD cables on page Control unit 5.18 To disassemble the control unit Note: Do not pull the wires. Use the screwdriver only on the outer side of the connector. Make sure not to press 3. Lift the cover (A) and loosen the connector (B) from the control unit. Carefully use a screwdriver to help to loosen the connector if it is blocked. A B Repair instructions - 19

20 5.19 To assemble the control unit 1. Connect connector (B), make sure the seal closes tightly to the control unit and then attach on the cover (A). B A 5.20 Main switch 5.21 To disassemble the main switch Note: Do not pull the wires. 1. Disassemble the main cables. See To disassemble the main cable on page Loosen the connection (A) from pin B+ on the main switch. 2. Connect the connector to the control unit. A 3. Remove the connection (B) from the main switch. Use a small screwdriver to carefully free the heels (C) on the main switch. 3. Assemble the main cables in the chassis. See To assemble the main cable on page 17 A 5.22 To assemble the main switch Assemble the main switch in the opposite sequence Repair instructions

21 6 Troubleshooting 6.1 Overhaul Examine the components of the product. You find repair and servicing instructions for each component in the related chapters of this manual. 6.2 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. 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. 6.3 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. A B 3. Restart the computer. 4. Install the software again. 6.4 Troubleshooting of the product Symptom Possible causes Recommended step The product does not start. No LEDs come on when you press the on/off button. Electrical motor makes sudden movement when you push the power trigger, then stops. Product stops when you apply work load. Keypad lights flash. Defective battery. Defective plug between battery and product. Defective connection in keypad connector. Broken keypad. Cables between control unit and keypad/main switch are damaged. Short circuit in control unit. Short circuit in control unit. Defective connection in keypad connector. Defective connection in keypad connector. Short circuit in keypad. Press the on/off button to do a check of the battery. A minimum of 1 green LED must come on. Make sure that the power connectors between the battery and the product are not dirty or damaged. Make sure that the keypad connector is correctly assembled, dry, not damaged and that there is no corrosion. Replace keypad. Repair/replace the cables if you can see damages. Replace control unit. Replace the control unit. Make sure that the power connectors between battery and product are clean and not damaged. Make sure that the keypad connector is correctly assembled, dry, not damaged and that there is no corrosion. Replace keypad Troubleshooting - 21

22 Symptom Possible causes Recommended step Changing motor speed. A warning sign on keypad flashes continuously. A warning sign on the keypad flashes after start. The product then stops. A warning sign on the keypad flashes after start. The product hangs up with the green led on. Product works but there is no indication light on the keypad. Product starts immediately when battery is added, without pressing the keypad. A warning sign on keypad shows a red light. Product shows red light after installing a new control unit. Defective connection in main switch signal connector. Damaged or worn main switch. Temperature too high. Temperature of control unit or battery too low. Front handle safety switch is caught in engaged position. Power trigger is pushed during start. Water in main switch signal connector. Short circuit in keypad. Short circuit in main switch. The signal between battery and product is defective. Defective connection in keypad connector. Broken keypad. Short circuit in keypad. Permanent error codes prevent the product from running. Broken control unit. Spare part comes without software. Make sure that the keypad connector is correctly assembled, dry, not damaged and that there is no corrosion. Replace keypad. Wait for the product to become cool (max. 5 min.). Make sure that the product and the battery is not colder than -10 C. Disassemble front handle and remove dirt. Do not push the power trigger when you start the product. Disassemble and dry the stop signal connector and then assemble it. Replace the keypad. Replace the main switch. Make sure that the power connectors between the battery and the product are not dirty or damaged. Make sure that the small cables between connector and the control unit are not loose or damaged. Do a check of the keypad function in battery diagnostic tool. Make sure that the keypad connector is correctly assembled, dry, not damaged and that there is no corrosion. Replace the keypad. Replace the keypad. Erase error codes in diagnostic tool. Replace control unit. Use diagnostic tool to install software Troubleshooting

23 6.5 Troubleshooting of the battery and battery charger Symptom Possible causes Recommended step No LEDs flash on the battery when you press the start button. A warning sign shows a constant red light on the battery when the start button is pressed. A warning sign flashes red on the battery when the start button is pressed. The battery shows less than 100% after a full charge. (Usually 96-97%). Charger does not start and no LEDs come on when the battery is attached. A red warning sign flashes on the charger when the battery is attached. Solid red warning sign on charger when put into mains outlet. Solid red warning sign on charger during charging. Defective battery. Defective battery. Temperature is too high. Low voltage. Temperature too low. Defective battery. Some ratio of the charge may be used up by the electronics. Defective connection between charger and battery. Defective battery. Defective charger. Defective connection between charger and battery. Battery temperature too high. Ambient temperature too low. Battery temperature too low. Defective battery. Defective charger. Defective charger. Defective charger. Replace the battery. Replace the battery. Wait until the battery has become cool (or insert in charger to let it become cool faster). Charge the battery. Make sure that the battery temperature is higher than -10 C. Replace the battery. None. The charger restarts when the charge level is less than 95%. Make sure that the power plugs between the charger and the battery are clean and not damaged. Check battery start. Disconnect charger from the mains outlet for a minimum of 1 minute and then connect to the mains outlet again. Make sure that the fan starts and that the green LED comes on for approximately 3 seconds. If not, replace the charger. Make sure the power plugs between the charger and battery are not dirty or damaged. Let the battery become cool in the charger (1-5 min). Make sure that the ambient temperature is above 5 C. Make sure that the battery temperature is higher than 5 C. Make sure that the battery is in order by pressing the battery start button. A minimum of 1 green LED must come on. If not, replace the battery. Disconnect charger from the mains outlet for a minimum of 1 minute and then connect to the mains outlet again. Make sure that the fan starts and that the green LED comes on for approximately 3 seconds. If not, replace the charger. Replace the charger. Replace the charger Troubleshooting - 23

24 Symptom Possible causes Recommended step A green lamp on the charger comes on for approximately 5-10 seconds when the battery is attached. After that a red warning sign flashes on the charger. This sequence then occurs again. Defective Battery. Defective charger. Put the battery in a QC330 charger. If the same problem occurs, replace the battery. Put a battery in the charger. If the same problem occurs, replace the charger. 6.6 Troubleshooting of the battery connector 3. Pull out the wires and connectors to the positive and negative terminals To disassemble the battery connector CAUTION: The pin in the connector of the communication cable is loose and can fall out. 1. Remove the battery connector. 2. Push out the pins with a screwdriver. 4. Lift the plastic fastener and pull out the communication cable, if installed Troubleshooting

25 6.6.2 To assemble the battery connector CAUTION: The pin in the connector of the wire is loose and can fall out. 3. Put the battery connector with the black wire into the negative side of the plastic housing. Align the holes for the pins. 1. Push the communication cable connector into the plastic housing, if the battery connector has a communication cable. 4. Push the pins into the holes through the housing and the connectors. A CAUTION: Make sure the pin in the communication cable connector is in the correct position (A). The product cannot send information to the common service tool, if the pin is missing or in the incorrect position. CAUTION: Make sure that the holes in the connections align with the holes in the housing before you push in the pins. 2. Put the battery connector with the red wire into the positive side of the plastic housing. Align the holes for the pins Troubleshooting - 25

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