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Husqvarna 520iHE3, Workshop Manual

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Husqvarna 520iHE3 Workshop Manual Download Page 53

53 – English

Troubleshooting - Appendix

11 Troubleshooting - Appendix

1. Power connectors

Make sure connectors are free from dirt and that 

metal surfaces are not damaged.

Pay certain attention to the connection tabs. Power 

connectors have the same basic design on prod-

uct, battery and charger. Only colors may vary.

2. Keypad connector

Make sure cabling is not damaged.

For products with S/N: -20180400173 (LiHE3).

For products with S/N: 20180400173- (LiHE3).

Summary of Contents for 520iHE3

Page 1: ...Workshop Manual English 536LiHE3 520iHE3 ...

Page 2: ......

Page 3: ...ata 10 Service Tools 11 Service Data 12 Diagnosis and Troubleshooting 18 Basic Dismantle Assembly 22 Safety Equipment 26 Repair Instructions 28 Table of contents Husqvarna AB has a policy of continuous product development and therefore reserves the right to modify the design and appearance of products without prior notice ...

Page 4: ...ntling the gear package 29 Assembling the gear package 31 Dismantling and assembling the cutting unit 33 Gears 33 Dismantling the motor 34 Assembling the motor 34 Dismantling the cutting unit joint and cabling 35 Assembling cutting unit joint and cabling 37 Dismantling and assembling of shaft and motor cabling 40 Dismantling the main switch 40 Assembling the main switch 41 Assembling the main swit...

Page 5: ...ns Table 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 Limitations 8 2 11 Symbols on the product 9 2 10 Symbols in the Workshop Manual 9 ...

Page 6: ... time this Workshop Manu al will become out of date In order to prevent this the Manual should be read together with all service information concerning the product in question 2 5 Tools Special tools are required for some stages All service tools are listed in the Workshop Manual Usage is made evident in each section Always use original Husqvarna Spare parts Service tools Accessories 2 6 Structure...

Page 7: ...s are not followed NOTE This box warns of material damage if the instructions are not followed 2 9 Special instructions Remove the battery from the product before dis mantling and troubleshooting The battery must not be connected while the prod uct is dismantled Never unscrew the battery Replace a damaged battery When using compressed air do not direct the air jet toward your body Air can penetrat...

Page 8: ...Symbols on the product The product s keypad has the following symbols 2 12 Symbols in the Workshop Manual This symbol warns of personal injury when the instructions are not followed Starting Stopping savE Battery saver mode Warning lamp Fault indicator ...

Page 9: ...chnical Data Technical Data 536LiHE3 Cutting speed rpm in savE m sec 3200 Cutting speed rpm in normal operation m sec 4000 Weight without battery Ibs kg 9 15 4 15 Weight with battery 4 2 Ah Ibs kg 12 12 5 5 536LiHE3 ...

Page 10: ...it 583 89 71 01 and software for the installation of a PC If you have the previous Engine Diagnostic Tool AutoTune 576 69 23 01 it can be supplemented with the Adapter Cable for Battery Products 579 62 13 01 to upgrade to the Diagnostic Tool Kit CST transmits various data from the product and battery to the computer such as product ID There is also a troubleshooting guide in the form of a diagnost...

Page 11: ...ervice Data Service data Key The numbers by bolted components represent the tightening torque in Nm Tightening torque during inspection 52 ft lb 2 5 Nm Symbol used where grease is to be used 3 4 Nm 10 mm 6 8 Nm 4 mm ...

Page 12: ...English 12 Service data Service Data ...

Page 13: ...13 English Service data Service Data ...

Page 14: ...English 14 Service data Service data LiHE3 S N 20180400173 LiHE3 S N 20180400173 ...

Page 15: ...English 15 Service data Service Data ...

Page 16: ...Diagnosis and troubleshooting Table of contents 6 1 Remove the battery 19 6 2 Connect the diagnostic tool 19 6 3 No signal to diagnostic tool 19 6 4 Troubleshooting the main switch 20 6 5 Troubleshooting the BLDC control unit 20 6 6 Overhaul 20 ...

Page 17: ... shooting the pole hedge trimmer Connect cable B to the diagnostic tool for trouble shooting the battery NB Refer to the manual for the Diagnostic Tool Battery for detailed instructions and follow the instructions in the diagnostic tool 2 Diagnose troubleshoot according to the diagnostic tool instructions and make any necessary repairs as instructed in the relevant chapter in this manual 6 3 No si...

Page 18: ...than 6 mm and not to its end position when testing Measure between B and B when the switch is not depressed The result should be open circuit Measure between B and B when the switch is depressed The result should be closed circuit Measure between pin 2 and pin 5 when the switch is not depressed The result should be closed circuit Measure between pin 2 and pin 5 when the switch is depressed The res...

Page 19: ...t Check that the blade terminals and associated wires are not bent or damaged A 4 8x0 8mm M phase Green wire B 4 8x0 8mm M phase Black wire C 4 8x0 8mm M phase Red wire 6 6 Overhaul Inspect the component parts of the product Re place damaged parts as described in the relevant chapter ...

Page 20: ...20 English 7 Basic Dismantle Assembly Basic dismantle assembly Table of contents 7 1 Battery 23 7 2 Trigger guard 23 7 3 Wear guard under battery housing 23 7 4 Control handle 24 7 5 Battery housing 24 ...

Page 21: ...WARNING The battery must always be re moved for service repair work and may only be replaced once the pole hedge trimmer has been fully assembled again NOTE Note how wires components etc are posi tioned before dismantling Make sure to position them correctly to avoid pinching when the pole hedge trimmer is re assembled 7 2 Trigger guard Remove the screws and push the guard forward 7 3 Battery hous...

Page 22: ...andle half so that it does not come loose from the shaft Loosen the screws 6x and lift off the handle Assemble in the reverse order Tightening torque 2 3 Nm 7 5 Battery housing Loosen the screws 4x and lift off half the battery housing Assemble in the reverse order Tightening torque 2 3 Nm ...

Page 23: ...23 English 8 Safety Equipment Safety equipment Table of contents 8 1 Dismantling the throttle lock and throttle control 27 8 2 Assembling the throttle trigger lock and throttle trigger 27 ...

Page 24: ...d inspection Clean and check all parts thoroughly Parts must be replaced if cracked or showing signs of other defects Always use original spare parts Check that the spring blade is intact and retains all its tension 8 2 Assembling the throttle trigger lock and throttle trigger 1 Assemble the throttle and throttle lockout on their respective attachments on the handle Make sure that the spring blade...

Page 25: ...ng the motor 34 9 8 Dismantling the cutting unit joint and cabling 35 9 9 Assembling the cutting unit joint and cabling 37 9 10 Dismantling and assembling the shaft and motor cabling 40 9 11 Dismantling the main switch 40 9 12 Assembling the main switch 41 9 13 Assembling the main switch 41 9 14 Dismantling the control cabling 42 9 15 Assembling the control cabling 43 9 16 Dismantling the control ...

Page 26: ...f the wiring and the wiring colors are engraved in the air conductor 2 Dismantle the screw holding the air conductor and lift away the guide Lift out the lower engine cover NB See 9 20 To disassemble and assemble the air conductor on page 48 for a detailed description of disassembling the air conductor Refer to SB B1180039A 07 for important information about the Air Conductor NOTE Note that the sc...

Page 27: ...he cables are not damaged 6 Dismantle the nuts holding the cutting unit 7 Dismantle the screws holding the gearbox cover 6 pcs 8 Pull out the two screws holding the cutting unit in the gear 9 Remove the cutting unit and the gear package from the bevel gear Repair Instructions ...

Page 28: ...rts on gears and the cutting unit with grease so that they move easily Use grease according to IPL Assemble the cutting unit and gear package in the bevel gear 2 Assemble the two screws holding the cutting unit in the gear Lubricate the points marked in the figure with 2 5 g grease 3 Assemble the screws holding the gearbox cover 6 pcs Repair Instructions ...

Page 29: ...conductor NB See 9 20 To disassemble and assemble the air conductor on page 48 for a detailed description of assembling the air conductor Refer to SB B1180039A 07 for important information about the Air Conductor 9 Assemble the cables to the motor Press the cable shoes straight down on the pin NB See 9 21 To connect the motor cables on page 49 for a detailed description of connecting the motor NB ...

Page 30: ...be replaced if cracked or showing signs of other defects Always use original spare parts 3 Assemble in the reverse order Tightening torque See service data 9 5 Gears 1 Loosen the circlip A lift off the washer B care fully lift up the hook C and lift off the cutting unit 2 Separate the parts as shown in the exploded view drawing Tap out the locking pins using a punch Cleaning and inspection Clean a...

Page 31: ...l and the motor out of their mounting on the bevel gear body 9 7 Assembling the motor 1 Always use a new circlip The pinion gear and the motor are connected and must be replaced as one unit Assemble the motor by pulling the flywheel and the motor into their mounting on the bevel gear body 2 Use circlip pliers to fit a new circlip 3 Assemble the cutting unit and gear package ac cording to 9 4 Disma...

Page 32: ...ackage on page 26 2 Refers to side without cabling Pry off the lockwasher holding the cabling in place in the lower cover Loosen the cables 3 Dismantle the adjusting screw used to adjust the inertia of the angle joint Dismantle the lower cover 4 Loosen the joint for the transport mode sensor 1 Loosen the clamp 2 Loosen the bushing 3 Loosen the indexing ring 4 1 2 3 4 ...

Page 33: ... angular adjustment of the cutting unit 8 Work the cabling one wire at a time through the angle joint NB Exercise care so that the cabling is not damaged Remove the lower angle joint cover 9 Remove the locking pin retainer from the cabling The tape holds the locking pin retainer in place on the cabling 10 If the cabling is whole and intact assemble the locking pin onto the cabling The tape on the ...

Page 34: ...ss to the control board A B C Then carefully pull the cabling through the shaft 9 9 Assembling the cutting unit joint and cabling 1 Assemble the positioning handle Position the handle over the shaft 2 If the cabling is whole and intact assemble the locking pin onto the cabling The tape on the ca bling is the locking pin retainer positioning 3 Assemble the locking pin retainer from the cabling The ...

Page 35: ...cabling is not damaged Assemble the lower angle joint cover 5 Assemble the screw holding the locking pin for the angular adjustment of the cutting unit 6 Assemble the screws holding the upper angle joint cover 5 pcs 7 Refers to cabling side Take care not to damage the cabling Assemble the bushing 2 Assemble the clamp 1 2 1 ...

Page 36: ... Assemble the lower joint cover Assemble the adjusting screw used to adjust the inertia of the angle joint 10 Refers to side without cabling Assemble the cabling Assemble the lockwasher holding the cabling in place in the lower cover 11 Assemble the cutting unit and gear package according to 9 4 Dismantling and assembling the cutting unit on page 30 1 2 3 4 ...

Page 37: ...ge 28 Assemble in reverse order 9 11 Dismantling the main switch For products with S N 20180400173 LiHE3 1 Dismantle the control handle as described in 7 Basic dismantle assembly on page 20 2 Dismantle the throttle trigger lock and throttle trig ger as described in 8 1 Dismantling the throttle trigger lock and throttle trigger on page 24 3 Lift out the main switch and disconnect cable A 4 Take loo...

Page 38: ...gger on page 18 3 Lift out the main switch and disconnect cable A 4 To disconnect the cable A free the catch D with a small screwdriver and pull the contact C out NB Do not pull on the wires Hold the contact only when you pull it out 9 12 Cleaning and inspection of the main switch Clean and check the main switch The main switch must always be replaced with a new one if cracked or showing signs of ...

Page 39: ...2 Assembling the throttle trigger lock and throttle trigger on page 18 4 Assemble the control handle as described in 6 Ba sic dismantle assembly on page 16 For products with S N 20180400173 LiHE3 1 Connect cable A and make sure that the contact clicks into place Place the main switch in the product housing 2 Assemble the throttle trigger lock and throttle trig ger as described in 7 2 Assembling th...

Page 40: ...tle the shaft and motor cabling as de scribed in 8 8 Dismantling shaft and motor cabling LiHE3 on page 25 and 8 10 Dismantling shaft and motor cabling LiHE3 on page 27 4 Lift out the main switch and disconnect the connec tor B and the wire A Dismantle the keypad and its cabling NB 13 Dismantling the main switch on page 32 for a detailed description of discon necting the contact C 5 Dismantle the c...

Page 41: ...cabling LiHE3 on page 27 4 Lift out the main switch and disconnect the connector A Dismantle the keypad and its cabling NB See 8 13 Dismantling the main switch on page 32 for a detailed description of discon necting the contact C 5 Dismantle the connector on the control unit Use a flat sharp tool to carefully snap off the bracket holder Carefully insert a small flat screwdriver be tween the silico...

Page 42: ...e the bottom section of the cabling and the fan in the battery housing Assemble the fan making sure it is positioned in the correct direction 3 Assemble the keypad Make sure the surface is clean Connect the cable A to the position marked B on the main switch C Place the parts in the operating handle NB Make sure to apply grease to the contact surfaces and also the connector see service data 4 Lay ...

Page 43: ...g and the fan in the battery housing Assemble the fan making sure it is positioned in the correct direction 3 Lay the cabling in place in the control handle Make sure that it is positioned outside A and inside B Put the overmoulding behind C and the loose cables in front of C Push the cabling all the way down NB Make sure that no cables are in a position where they don t get pinched or damaged whe...

Page 44: ... motor Loosen the screws G to the control unit and the screws H to the battery contact and lift out the entire unit and the fan 3 Unplug connector D for the keypad main switch and the fan Cleaning and inspection Clean and inspect all parts of the control unit The control unit must always be replaced with a new one if cracked or showing signs of other defects Always use original spare parts G G H H...

Page 45: ...sket in place with your fingers and make sure it fits tightly all around Snap on the bracket holder NOTE Do not use the bracket holder to press the silicone gasket in place 2 Place all the control unit components in the battery housing Take care to return all the cables to their correct positions to avoid pinching Fasten screws 2x to the control unit G and screws 2x to the battery contact H Tighte...

Page 46: ...the connector of the communica tion cable is loose and can fall out 1 Remove the battery connector 2 Push out the pins with a screwdriver 3 Pull out the wires and connectors to the positive and negative terminals 4 Lift the plastic fastener and pull out the communica tion cable if installed ...

Page 47: ...position A The product cannot send information to the common service tool if the pin is missing or in the incorrect position 2 Put the battery connector with the red wire into the positive side of the plastic housing Align the holes for the pins 3 Put the battery connector with the black wire into the negative side of the plastic housing Align the holes for the pins 4 Push the pins into the holes ...

Page 48: ...he connector 2 Push the connector staight up 9 20 To disassemble and assemble the air conductor 9 20 1 To disassemble the air conductor Refer to SB B1180039A 07 for important information about the Air Conductor 1 Refer to 9 19 To disconnect the motor cables 2 Remove the screw and lift the air conductor 9 20 2 To assemble the air conductor 1 Put the black and yellow cables in a curve A next to the ...

Page 49: ...ack and yellow cables are between the motor and the cable holder 9 21 To connect the motor cables Caution The connectors and the terminals can be damaged if you use pliers to connect the cables 1 Put the cable on the terminal 2 Push the connector straight down ...

Page 50: ...main switch signal contact 1 Make sure the main switch signal connector is correctly assembled dry is not damaged and is corrosion free See illustration in annex Motor contacts not properly as sembled 2 Make sure the motor contact mo tor contacts are correctly fitted See figure 5 in the annex Interior damage to main switch 3 Replace the main switch Short circuit in control unit 4 Replace the contr...

Page 51: ... The product subsequently hangs while the green LED is on Bad communication signal between battery and product 1 Make sure the power connectors between the battery and the prod uct are not dirty or damaged See figure 1 in the appendix 2 Make sure the small cables be tween connector and the control unit are not loose or damaged See figure 6 in the appendix The product is in working order but the in...

Page 52: ...art replace the charger A red warning triangle flashes on the charger when the battery is inserted Poor connection between char ger and battery 1 Make sure the power connectors between the charger and the battery are not dirty or damaged See figure 1 in the appendix Battery temperature too high 2 Allow the battery to cool down in the charger 1 5 minutes Ambient temperature too low 3 Make sure the ...

Page 53: ... dirt and that metal surfaces are not damaged Pay certain attention to the connection tabs Power connectors have the same basic design on prod uct battery and charger Only colors may vary 2 Keypad connector Make sure cabling is not damaged For products with S N 20180400173 LiHE3 For products with S N 20180400173 LiHE3 ...

Page 54: ...with grease For products with S N 20180400173 LiHE3 Apply grease to the contact surfaces and also the connector For products with S N 20180400173 LiHE3 No grease necessary C 4 Communication cables Make sure the three small communication cables are not loose or damaged ...

Page 55: ...ic housing Troubleshooting Appendix 6 26 pin wiring cable Make sure the 26 pin wiring cable is properly as sembled dry and not damaged See 8 18 Assem bling the control cabling on page 38 7 Transport mode sensor Make sure the transport mode sensor is assem bled and connected properly Check the cables for damages See 9 2 Dismantling the gear package ...

Page 56: ... for product battery and charger It is only the colors that can differ 1 Power connectors Make sure connectors are free from dirt and that metal surfaces are not damaged Pay certain attention to the connection tabs Power connectors have the same basic design on prod uct battery and charger Only colors may vary 2 Keypad connector Make sure cabling is not damaged 2 New generation keypad connector Ma...

Page 57: ...ee small communication cables are not loose or damaged Troubleshooting annexe 3 Main switch signal connector with grease S N 20180400173 Apply grease between the specified pins grease should be applied between pins 1 2 and 3 4 in side as well as outside ...

Page 58: ... Make sure the three motor connectors and the two power connectors are properly connected to respective plastic housing 6 26 pin wiring cable Make sure the 26 pin wiring cable is properly as sembled dry and not damaged Troubleshooting annex ...

Page 59: ...2018W15 115 87 83 26 ...

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