Husqvarna 550iBTX Instruction manual

Workshop manual
550iBTX
English
761 - 002 - 18.11.2019

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 Battery use and safety........................................... 4
2.5 Special safety instructions......................................4
3 Servicing data
3.1 Servicing data........................................................ 5
4 Servicing tools
4.1 Servicing tools........................................................8
4.2 Diagnostic tools......................................................8
5 Repair instructions
5.1 To assemble the tube and handle on the
product....................................................................... 10
5.2 To adjust the harness...........................................11
5.3 To put the product in transportation mode........... 11
5.4 To clean and examine the product parts..............11
5.5 To disassemble the nozzle...................................11
5.6 To remove and install the harness....................... 11
5.7 To remove and install the support .......................12
5.8 To disassemble and assemble the motor
housing.......................................................................12
5.9 Electrical system.................................................. 13
6 Troubleshooting
6.1 Overhaul...............................................................19
6.2 Troubleshooting of the product............................ 19
6.3 Troubleshooting of the battery and battery
charger....................................................................... 20
7 Technical data
7.1 Technical data......................................................22
2761 - 002 - 18.11.2019

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.
761 - 002 - 18.11.2019 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
Boost button
Cruise control button
Warning indicator/Fault indicator
2.4 Battery use and safety
•Use appliances only with specifically designated
battery packs. Use of any other battery packs may
create a risk of injury and fire.
•When battery pack is not in use, keep it away from
other metal objects, like paper clips, coins, keys,
nails, screws or other small metal objects, that can
make a connection from one terminal to another.
Shorting the battery terminals together may cause
burns or a fire.
•Under abusive conditions, liquid may be ejected
from the battery; avoid contact. If contact
accidentally occurs, flush with water. If liquid
contacts eyes, additionally seek medical help. Liquid
ejected from the battery may cause irritations or
burns.
•Do not use a battery pack or appliance that is
damaged or modified. Damaged or modified
batteries may exhibit unpredictable behavior
resulting in fire, explosion or risk of injury.
•Do not expose a battery pack or appliance to fire or
excessive temperature. Exposure to fire or
temperature above 130°C (266°F) may cause
explosion.
•Follow all charging instructions and do not charge
the battery pack or appliance outside of the
temperature range specified in the instructions.
Charging improperly or at temperatures outside of
the specified range may damage the battery and
increase the risk of fire.
2.5 Special safety instructions
2.5.1 To remove and install the battery
WARNING: Always remove the battery before
you do repair work or do servicing on the
product.
WARNING: Assemble the product before you
attach the battery.
1. Disconnect the battery (B).
2. Remove the cable from the cable holder (C).
3. Pull out the clips (A).
A
A
B
C
4. Remove the battery.
5. Install in opposite sequence.
4 - Safety 761 - 002 - 18.11.2019

3 Servicing data
3.1 Servicing data
(x3) 1.9 Nm
(x1) 1.9 Nm
(x1) 4.6 Nm
T27
T27
T27
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(x4) 1.9 Nm
(x2) 1.9 Nm
(x2) 1.9 Nm
(x1) 1.9 Nm
(x6) 1.9 Nm
(x4) 1.9 Nm
(x7) 1.9 Nm
(x1) 1.9 Nm
T27
T27
T27
T27
T27
T27
T27
T27
6 - Servicing data 761 - 002 - 18.11.2019

(x5) 2.2 Nm
(x1) 1.9 Nm
(x2) 1.9 Nm
T27
T27
T27
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4 Servicing tools
4.1 Servicing tools
CST
INSTRUCTION
3
2
1
4
Pos. Description Used for Order No.
1 Diagnostic Tool Kit Diagnostic examination and
troubleshooting
583 89 71-01
2 Adapter cable for battery prod-
ucts
Diagnostic examination of bat-
tery products with Engine Diag-
nostic Tool - AutoTune™ (576
69 23-01)
581 19 23-01
3 T-handle Torx T27 Torx screws 502 71 27-03
4 Tool - fan assembley To install the fan 598 95 65-01
4.2 Diagnostic tools
4.2.1 Common service tool
The common service tool (CST) 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.
4.2.2 To connect the common service tool (CST)
Note: I can be necessary to install firmware to a new
spare part. Make sure that you know the Husqvarna
identification number (HID) of the new spare parts
before you connect the product to common service tool
8 - Servicing tools 761 - 002 - 18.11.2019

(CST). The identification number is found on the spare
part.
1. Remove the screw (A) to tilt the harness (B).
A
B
C
2. Use tweezers to remove the servicing cable (C).
3. Connect the product to the backpack battery.
4. Push the start button on the backpack battery.
5. Make sure that the adapter cable for the common
service tool (CST) is not connected to the product.
6. Push the start button on the product.
7. Connect the adapter cable for the common service
tool (CST with the product servicing cable.
8. Obey the instructions on the common service tool
(CST) and in the related chapter in this manual.
CAUTION: Do not disconnect the product
until the update is completed.
WARNING: The motor can start in servicing
mode.
4.2.3 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.
3. Restart the computer.
4. Install the software again.
761 - 002 - 18.11.2019 Servicing tools - 9

5 Repair instructions
5.1 To assemble the tube and handle on the
product
1. Put the clamp (B) on the flexible tube (C) and attach
the flexible tube to the blower outlet (A).
A
B
C
D
2. Make sure to put the clamp screw (D) as the
illustration shows. Tighten the screw.
3. Attach the transport strap (O) to the guide track of
the joint swivel (H).
H
O
4. Put the clamp (B) on the flexible tube (C) and attach
the joint swivel (H).
B
C
D
H
5. Make sure to put the clamp screw (D) as the
illustration shows. Tighten the screw.
6. Align the knobs (J) to each side of the joint swivel
(H).
7. Attach the control handle (I) to the guide track (K) of
the joint swivel (H). Make sure that the screw on the
control handle is on the bottom side of the control
pipe.
HJ
I
K
8. Tighten the screw on the control handle fully.
9. Connect the intermediate pipe (L) to the joint swivel
(H). Make sure that the knob (J) aligns with the
guide track of the intermediate pipe.
H
L
N
M
J
10. Turn the intermediate pipe fully to lock the control
pipe and the intermediate pipe.
11. Connect the blow pipe (M) to the intermediate pipe
(L). Make sure that the knob (N) on the intermediate
pipe points up and goes into the guide track of the
blow pipe.
12. Turn the blow pipe fully to lock the intermediate pipe
and the blow pipe.
13. Attach the sleeve around the flexible tube and the
cable as shown in the illustration. Close the zipper.
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5.2 To adjust the harness
A correctly adjusted harness and product makes
operation easier. Adjust the harness to give the best
operation position.
1. Put on the harness of the product.
C
B
A
2. Connect the hip strap with the clip (C). Tighten the
strap until the weight of the product is on your hips.
3. Tighten the side straps (B) until the product is tight
against your body.
4. Connect the chest strap to the clip (A).
5. Tighten the strap.
5.3 To put the product in transportation mode
1. Turn the blower tube counterclockwise until it points
up.
2. Connect the transport clip.
5.4 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.
5.5 To disassemble the nozzle
• Turn the nozzle to remove it from the blow pipe.
5.6 To remove and install the harness
1. Remove the 5 screws to remove the harness.
2. Remove the harness fasteners.
3. Install in opposite sequence.
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5.7 To remove and install the support
1. Remove the 5 screws on the harness.
2. Remove the 4 screws on the rear side of the
support.
3. Remove the 4 screws on the front side of the
support.
4. Remove the support halves.
5. Install in opposite sequence.
5.8 To disassemble and assemble the motor
housing
WARNING: Disconnect the battery to prevent
short circuit.
CAUTION: Do not pull the wires.
1. Remove the support. Refer to To remove and install
the support on page 12
.
2. Remove the 2 screws that hold the air intake.
3. Remove the 7 screws and remove the cover (A).
A
B
C
D
E
F
4. Remove the outer muffler (B).
5. Remove the air outlet (C).
6. Remove the air intake (D).
7. Move the motor assembly (E) in the direction of the
cables.
8. Remove the inner muffler (F).
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9. Assemble in opposite sequence. Make sure that the
air outlet is installed in the correct position.
5.9 Electrical system
5.9.1 Electrical diagram
1
Motor/Fan
Trigger
Battery Backpack 36V
123 4 56789
Blue
Red
White
Black
J4
J3
J2
J1
J5
Red
Black
J8
J7
2
123
1
2
3
6
5
4
2
3
4
5
6
1
2
3
4
5
6
123 1 23
PCB SERVICE
J15 P21
P1
Cruise Control 1
2
1
2
2
P3
J8
1
4
7
3
6
9
2
5
8
J7
123 4 56789
123 4 56789
Red
Black
White
Grey
Black
Red Black Black Red Black Blue
White
Blue
Grey
White Blue
Grey
Green Black
Orange Red
White
Blue
Yellow
Grey
Green
Pink
Black
Orange
Red
Black
Black
Yellow
Pink
P7
P8 ESD Handle
1
3
Blue
Blue
P9
P6
J10
1
4
7
3
6
9
2
5
8
J10
1
2
1
5.9.2 Main cable
5.9.2.1 To replace the main cable in the operation
handle
WARNING: Disconnect the battery to prevent
short circuit.
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CAUTION: Do not pull the wires.
1. Remove the lower screw and remove the operation
handle from the handlebar.
2. Remove the 3 screws and remove the handle half.
3. Lift the power trigger from the handle.
4. Lift the main cable (A), the ESD catch (B) and the
user interface (C) from the handle.
C
BA
D
E
5. Disconnect the user interface (D) and the connector
for the cruise control button (E). If it is necessary to
remove the cruise control button, refer to To remove
and install the cruise control button on page 15 .
Note: If the user interface is replaced, make a note
of the Husqvarna identification number (HID) of the
new user interface before installation. The
identification number is found on the new user
interface.
6. Remove the ESD cable from the hooks on the ESD
catch.
7. Install the main cable in opposite sequence. When
you install the power trigger, refer to To install the
power trigger on page 14 .
8. Connect the product to the common service tool
(CST) and update the firmware if the user interface
is replaced. Refer to To connect the common
service tool (CST) on page 8 .
5.9.2.2 To install the power trigger
1. Push and hold the spring in the direction of the
power trigger.
2. Make sure that the edge of the power trigger is in
the handle.
3. Assemble the operation handle.
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5.9.2.3 To remove and install the cruise control button
1. Disassemble the operation handle. Refer to To
replace the main cable in the operation handle on
page 13 .
2. Remove the screw and remove the cruise control
button.
3. Pull out the connector of the cruise control button.
4. Assemble in opposite sequence.
5.9.2.4 To replace the main cable in the motor housing
WARNING: Disconnect the battery to prevent
short circuit.
CAUTION: Do not pull the wires.
1. Remove the support. Refer to To remove and install
the support on page 12 .
2. Disassemble the motor housing. Refer to To
disassemble and assemble the motor housing on
page 12 .
3. Remove the 2 screws and lift the plate.
4. Remove the strain relief (A).
A
C
B
5. Disconnect the connector (B).
6. Remove the EMC filter (C) from the main cable.
7. Install the main cable in opposite sequence.
5.9.3 To replace the motor
1. Disassemble the motor housing. Refer to To
disassemble and assemble the motor housing on
page 12 .
2. Remove the motor cables.
3. Remove the motor.
4. Install in opposite sequence.
761 - 002 - 18.11.2019 Repair instructions - 15

5.9.4 To remove the fan from the motor
1. Disassemble the motor housing. Refer to
To
disassemble and assemble the motor housing on
page 12 .
2. Remove the motor. Refer to
To replace the motor on
page 15 .
3. Put the motor axle in an vise.
CAUTION: Do not cause damage to the
cables.
4. Clean the hole in the center of the fan and apply
mineral oil.
5. Attach a screw to the hole in the center of the fan.
Tighten the screw until the fan is loose.
>22 mm
Note: The thread on the screw must be minimum 22
mm long. Some fan models have M4 thread and
some models have M5 thread.
5.9.5 To install the fan on the motor
1. Clean the motor axle.
2. Make sure that the 3 screws are tightened correctly.
The torque must be 2 Nm.
3. Lubricate the motor axle with mineral oil.
4. Make sure that the hole in the center of the fan is
clean.
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5. Put the press tool in the hole in the center of the fan.
Refer to Servicing tools on page 8 .
6. Use a press to carefully push (4-8 kN) the fan onto
the motor axle. Make sure that the pressure on the
press tool, fan and motor axle applies straight.
CAUTION: Do not hit the press tool with a
hammer.
CAUTION: Do not cause damage to the
cables.
Note: It is possible to use a vise if you do not have a
press machine.
7. Carefully push the press tool until the press tool
touches the motor shaft. The press tool is then
approximately at the same level as the edge of the
motor housing.
8. Remove the press tool.
9. Make sure that the fan can rotate freely without
sound.
5.9.6 To replace the control unit
WARNING: Disconnect the battery to prevent
short circuit.
761 - 002 - 18.11.2019 Repair instructions - 17

CAUTION: Do not pull the wires.
1. Remove the main cable from the motor housing.
Refer to
To replace the main cable in the operation
handle on page 13 .
2. Remove the 3 motor cables (A) from the control unit.
B
C
A
3. Remove the 2 battery cables (B) from the control
unit.
4. Disconnect the connector (C) from the control unit.
5. Remove the control unit from the 4 hooks.
6. Make a note of the Husqvarna identification number
(HID) of the new control unit before you install it. The
identification number is found on the new control
unit.
7. Install in opposite sequence.
8. Connect the product to the common service tool
(CST) and update the firmware if the control unit is
replaced. Refer to To connect the common service
tool (CST) on page 8 .
5.9.7 Power connectors
Make sure that the connectors are clean and that the
metal surfaces are not damaged.
5.9.8 To replace the battery connector
1. Remove the cover.
2. Push out the pins with a screwdriver.
3. Push out the wires and connectors.
4. Assemble in opposite sequence.
CAUTION: Make sure that the holes in the
connectors align with the holes in the
housing before you push in the pins.
18 - Repair instructions 761 - 002 - 18.11.2019

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 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.
Broken user interface. Replace user interface.
Cables between control unit and user
interface switch are damaged.
Repair/replace the cables if you can
see damages.
Short circuit in control unit. Replace control unit.
The product does not start. Battery
LEDs come on when you press the
on/off button.
Power trigger is pushed during start. Do not push the power trigger when
you start the product. Release power
trigger and push it again.
The product starts immediately when
the battery is installed, without use of
the user interface.
Short circuit in user interface. Replace the user interface.
A warning sign on the user interface
shows a red light.
Broken control unit. Replace control unit.
Temperature too high. Wait for the product to become cool
(max. 5 min).
Temperature of control unit or battery
too low.
Make sure that the product and the
battery is not colder than -10° C.
Product shows red light after you in-
stall a new control unit or user inter-
face.
Spare part comes without software or
an update of the software is necessa-
ry.
Use diagnostic tool to install soft-
ware.
761 - 002 - 18.11.2019 Troubleshooting - 19

6.3 Troubleshooting of the battery and battery charger
Symptom Possible causes Recommended step
No LEDs flash on the battery when
you press the start button.
Defective battery. Replace the battery.
A warning sign shows a constant red
light on the battery when the start but-
ton is pressed.
Defective battery. Replace the battery.
A warning sign flashes red on the bat-
tery when the start button is pressed.
Temperature is too high. Wait until the battery has become
cool (or insert in charger to let it be-
come cool faster).
Low voltage. Charge the battery.
Temperature too low. Make sure that the battery tempera-
ture is higher than -10° C.
Defective battery. Replace the battery.
The battery shows less than 100% af-
ter a full charge. (Usually 96-97%).
Some ratio of the charge may be
used up by the electronics.
None. The charger restarts when the
charge level is less than 95%.
Charger does not start and no LEDs
come on when the battery is attach-
ed.
Defective connection between charg-
er and battery.
Make sure that the power plugs be-
tween the charger and the battery are
clean and not damaged.
Defective battery. Check battery start.
Defective charger. 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, re-
place the charger.
A red warning sign flashes on the
charger when the battery is attached.
Defective connection between charg-
er and battery.
Make sure the power plugs between
the charger and battery are not dirty
or damaged.
Battery temperature too high. Let the battery become cool in the
charger (1-5 min).
Ambient temperature too low. Make sure that the ambient tempera-
ture is above 5°C.
Battery temperature too low. Make sure that the battery tempera-
ture is higher than 5°C.
Defective battery. 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.
Defective charger. 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, re-
place the charger.
Solid red warning sign on charger
when put into mains outlet.
Defective charger. Replace the charger.
Solid red warning sign on charger
during charging.
Defective charger. Replace the charger.
20 - Troubleshooting 761 - 002 - 18.11.2019