Zenoah BHT250PD60 Instruction manual

Workshop manual
BHT250PD60
English
620 - 002 - 29.01.2019

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 Special safety instructions......................................4
3 Servicing data
3.1 Servicing data BHT250PD60 ................................ 5
4 Servicing tools
4.1 Diagnostic tools .....................................................7
5 Repair instructions
5.1 To clean and examine the product parts................8
5.2 Chassis.................................................................. 8
5.3 Cutting unit............................................................. 8
5.4 Front handle .......................................................... 9
5.5 Power trigger........................................................11
5.6 Gears................................................................... 11
5.7 Gear, cutting unit and gear housing..................... 12
5.8 Control unit and battery plug................................ 14
5.9 Keypad................................................................. 14
5.10 Main switch and main cable .............................. 16
5.11 Rear handle........................................................16
6 Troubleshooting
6.1 Overhaul...............................................................20
6.2 To connect the common service tool................... 20
6.3 To do troubleshooting of the common service
tool............................................................................. 20
6.4 Troubleshooting of the product............................ 20
6.5 Troubleshooting of the battery and battery
charger....................................................................... 22
6.6 Troubleshooting of the battery connector.............23
7 Technical data
7.1 Technical data......................................................25
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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/Zenoah.
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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 620 - 002 - 29.01.2019

3 Servicing data
3.1 Servicing data BHT250PD60
The numbers show the tightening torque for the
component in Nm.
▲ Lubricate with chainsaw oil
● Lubricate with grease
(x6) 2 ~ 3 Nm 4 mm
8 mm
(x7/) 2 ~ 3 Nm 4 mm
(x2) 2 ~ 3 Nm 4 mm
(x6) 3 ~ 4 Nm 8 mm
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(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
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4 Servicing tools
4.1 Diagnostic tools
CST
INSTRUCTION
4.1.1 Common service tool
The common service tool (CST) tool is used with a
computer (not included) for Husqvarna/Zenoah
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. Description Used with Order No.
1 Diagnostic Tool Kit Diagnosis and troubleshooting 583 89 71-01
2 Adapter cable for battery products Supplement/upgrade for Engine Diagnostic
Tool - AutoTune™ (576 69 23-01)
581 19 23-01
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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.
• Always use original spare parts.
5.2 Chassis
5.2.1 To disassemble the chassis
• Remove the 8 screws.
• Lift off the right chassis half.
5.2.2 To assemble the chassis
• Assemble in the opposite sequence of To
disassemble the chassis on page 8 .
5.2.2.1 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.
5.3 Cutting unit
5.3.1 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.
5.3.2 To assemble the cutting unit
• Assemble in the opposite sequence of To
disassemble the cutting unit on page 8 . Tightening
torque: see Servicing data BHT250PD60 on page 5 .
5.3.3 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
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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
5.4 Front handle
5.4.1 To remove the front handle
CAUTION: Make sure that the cables to the
handle are not damaged when you assemble
the cover.
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.
5.4.1.1 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 11 .
3. Disconnect the handle cables (A) from the control
unit and remove them through the hole (B) in the
chassis.
A
B
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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
5.4.1.2 To assemble the start inhibitor and the front
handle
CAUTION: Make sure that the cables are set
correctly to prevent damage.
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.
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