Zenoah BHT250PD60 Workshop Manual

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 2 620 - 002 - 29.01.2019

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. 620 - 002 - 29.01.2019 Introduction - 3

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

3.1 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 620 - 002 - 29.01.2019 Servicing data - 5

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 6 - Servicing data 620 - 002 - 29.01.2019

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 23-01 620 - 002 - 29.01.2019 Servicing tools - 7

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 8 - Repair instructions 620 - 002 - 29.01.2019

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 620 - 002 - 29.01.2019 Repair instructions - 9

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. C D 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. C D 3. Attach the handle halves with the 10 screws. 4. Make sure the safety catch moves to the rear in all directions. 10 - Repair instructions 620 - 002 - 29.01.2019

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 12. 7. Assemble the right half of the chassis. See To remove the front handle on page 9. 8. Attach the front handle in opposite sequence of To disassemble the front handle and start inhibitor on page 9. 5.5 Power trigger 5.5.1 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 9 and To disassemble the chassis on page 8. 2. Disassemble the rear handle. See To disassemble the rear handle on page 16. 3. Remove the handle stop (A) and the spring (B). Remove the power trigger (C). C B A 5.5.2 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 18. 4. Assemble the right chassis half and the front handle. See To remove the front handle on page 9 and To disassemble the chassis on page 8. 5.6 Gears 5.6.1 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 9 and To disassemble the chassis on page 8. 2. Disconnect the motor plug from the control unit. 620 - 002 - 29.01.2019 Repair instructions - 11

and motor in the chassis. 4. Remove the gear housing and motor from the chassis. 5.6.2 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. 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 9 and To disassemble the chassis on page 8. 5.7 Gear, cutting unit and gear housing 5.7.1 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. 12 - Repair instructions 620 - 002 - 29.01.2019

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. 5.7.3 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. 1. Put the motor on the gear housing. 2. Put the gear and cutting unit in the gear housing. Attach the cutting unit into the gear housing with 2 screws. Note that the front screw also locks the safety point with the related nut. Tightening torque 3~4 Nm. 3. Assemble the bottom plate with gasket on the gear housing and connect with 6 screws. Tighten the screws crossways and refer to the number on the bottom plate. Tightening torque 3 ~4 Nm. 2 3 6 4 5 1 620 - 002 - 29.01.2019 Repair instructions - 13

5.8.1 To disassemble the control unit and battery plug 1. Disconnect the plugs to the front handle from the control unit. See To assemble the start inhibitor and the front handle on page 10. 2. Remove the screws (A) on the control unit and the screws (B) on the battery plug. Remove the plug (C) and lift out the control unit, the battery plug and the cables from the chassis. A A B B C 3. Remove the plugs (D and E) to disconnect the control unit and the battery plug. D E 5.8.2 To assemble the control unit and battery plug Note: Make sure the cables are not damaged and are set correctly in the chassis. CAUTION: The cables must hang straight down from the plugs. Make sure that they are not bent too much. 1. Connect plugs (D and E) on the battery plug to the control unit. F G D E 2. Make sure that cables (F) and (G) are red. 3. Put the control unit, battery plug and cables into the chassis. 4. Connect the plug (C). Attach screws (A) on the control unit and screws (B) on the battery plug. Tightening torque 1 ~4 Nm. A A B B C 5. Connect the plugs for the front handle to the control unit. See To assemble the start inhibitor and the front handle on page 10. 5.9 Keypad 5.9.1 To disassemble the keypad CAUTION: The flat cable to the keypad is very easily damaged. 14 - Repair instructions 620 - 002 - 29.01.2019

handle, the keypad or when troubleshooting indicates a defect. 1. To disconnect the plug (A), press the catch (B) and carefully pull the plug. B A 2. Push the 4 catches, one at a time, from below with a screwdriver. C D 3. Carefully remove the keypad with holder from the bracket (D). 5.9.2 To assemble the keypad CAUTION: Do not bend the keypad. CAUTION: The flat cable to the keypad is very easily damaged. Do steps 1-3 only when you replace the keypad. 1. Clean the surface where the keypad is attached. 2. Make sure that the temperature is minimum 15°C. Make sure that the temperature of the surface where the keypad is attached does not change more than ±3°C from the ambient temperature. >15°C 3. Remove the protective tape from the new keypad and press it onto the holder. Press on the keypad with 10 N/cm². >10 sec 10 N/cm2 4. Push the keypad with holder into the bracket (A) until you hear a click. A 5. Put the flat cable into the grooves in the bracket. 620 - 002 - 29.01.2019 Repair instructions - 15

A 5.10 Main switch and main cable 5.10.1 To disassemble the main switch 1. Remove the control handle. 2. Remove the power trigger lock and power trigger. See To disassemble the power trigger and handle stop on page 11 3. Lift out the main switch and disconnect cable (A). A 4. To disconnect the cable, release the catch (D) with a small screwdriver and pull the connection (C) out. C D 5.10.2 To assemble the main switch 1. Connect cable (A) and make sure that the contact clicks into place. A 2. Assemble the throttle trigger lock and throttle trigger. 3. Assemble the control handle. 5.11 Rear handle 5.11.1 To disassemble the rear handle WARNING: Make sure the spring does not eject out and causes injury. Put on protective goggles. CAUTION: Do not to damage the cables or the plugs. CAUTION: The flat cable to the keypad is very easily damaged. 16 - Repair instructions 620 - 002 - 29.01.2019

disassemble it. 1. Carefully lift out the cables, plug (A) and clips (B). Disconnect the plug. B A 2. Remove the 4 screws and remove the handle from the chassis. 3. Pull out the handle stop (C) and turn the fastener (D) 1/4 of a turn until it stops. 1/4 C D 4. Push the plastic catch (E) with a screwdriver until it goes above the heel. Turn the fastener (D) 1/4 of a turn until it stops. 1/4 E 5. Use a screwdriver to carefully remove the fastener from the handle. Then remove it from the cables together with the O-ring. 6. Remove the 5 screws and remove the right handle half. 7. Remove the handle stop (F) and the spring (G) from the handle. 8. Remove the power trigger (H). H G F 620 - 002 - 29.01.2019 Repair instructions - 17

cables from the handle. 5.11.2 To assemble the rear handle WARNING: Make sure that the spring does not eject out and causes injury. Put on protective goggles. CAUTION: The flat cable to the keypad is very easily damaged. Note: Make sure that cables and such are set correctly. It must be easy to put together the handle halves. Note: The fastener can only be pressed onto the handle when the groove and the heel on the handle engage. Make sure that the O-ring is set correctly in the fastener. 1. Put the keypad, main switch and cables in the handle. Make sure the cables and clips are set correctly in the grooves in the handle. 2. Put the power trigger (H) into the handle followed by the handle stop (F) and spring (G). H G F 3. Put the right handle half in position and attach with the 5 screws. 18 - Repair instructions 620 - 002 - 29.01.2019

Lubricate the O-ring lightly with grease to make the assembly easier. 5. Press the fastener onto the handle. 6. Pull out the handle stop (C) and turn one half revolution clockwise (D) until the handle stop comes into position. 1/2 C D 7. Put the handle in the chassis and connect with the 4 screws. 8. Connect the plug (A) and put the cables with clips (B) in the chassis. B A 620 - 002 - 29.01.2019 Repair instructions - 19

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. A B 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. 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. Defective battery. Press 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. Defective connection in keypad con- nector. Make sure that the keypad connector is correctly assembled, dry, not dam- aged and that there is no corrosion. Broken keypad. Replace keypad. Cables between control unit and key- pad/main switch are damaged. Repair/replace the cables if you can see damages. Short circuit in control unit. Replace control unit. Electrical motor makes sudden move- ment when you push the power trig- ger, then stops. Short circuit in control unit. Replace the control unit. Product stops when you apply work load. Defective connection in keypad con- nector. Make sure that the power connectors between battery and product are clean and not damaged. Keypad lights flash. Defective connection in keypad con- nector. Make sure that the keypad connector is correctly assembled, dry, not dam- aged and that there is no corrosion. Short circuit in keypad. Replace keypad. 20 - Troubleshooting 620 - 002 - 29.01.2019

Defective connection in main switch signal connector. Make sure that the keypad connector is correctly assembled, dry, not dam- aged and that there is no corrosion. Damaged or worn main switch. Replace keypad. A warning sign on keypad flashes continuously. 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. Front handle safety switch is caught in engaged position. Disassemble front handle and re- move dirt. A warning sign on the keypad flashes after start. The product then stops. Power trigger is pushed during start. Do not push the power trigger when you start the product. Water in main switch signal connec- tor. Disassemble and dry the stop signal connector and then assemble it. Short circuit in keypad. Replace the keypad. Short circuit in main switch. Replace the main switch. A warning sign on the keypad flashes after start. The product hangs up with the green led on. The signal between battery and prod- uct is defective. Make sure that the power connectors between the battery and the product are not dirty or damaged. Make sure that the small cables be- tween connector and the control unit are not loose or damaged. Product works but there is no indica- tion light on the keypad. Defective connection in keypad con- nector. 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. Broken keypad. Replace the keypad. Product starts immediately when bat- tery is added, without pressing the keypad. Short circuit in keypad. Replace the keypad. A warning sign on keypad shows a red light. Permanent error codes prevent the product from running. Erase error codes in diagnostic tool. Broken control unit. Replace control unit. Product shows red light after instal- ling a new control unit. Spare part comes without software. Use diagnostic tool to install software. 620 - 002 - 29.01.2019 Troubleshooting - 21

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. 22 - Troubleshooting 620 - 002 - 29.01.2019

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. Put the battery in a charger. If the same problem occurs, replace the battery. Defective charger. Put a battery in the charger. If the same problem occurs, replace the charger. 6.6 Troubleshooting of the battery connector 6.6.1 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. 3. Pull out the wires and connectors to the positive and negative terminals. 4. Lift the plastic fastener and pull out the communication cable, if installed. 620 - 002 - 29.01.2019 Troubleshooting - 23

CAUTION: The pin in the connector of the wire is loose and can fall out. 1. Push the communication cable connector into the plastic housing, if the battery connector has a communication cable. 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. 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 through the housing and the connectors. CAUTION: Make sure that the holes in the connections align with the holes in the housing before you push in the pins. 24 - Troubleshooting 620 - 002 - 29.01.2019

7.1 Technical data BHT250PD60 Motor Motor type PMDC (4-brush) Weight Weight without battery, kg/lb 3.8/8.4 Cutting equipment Type Double sided Blade length, mm/in 600/23.6 Blade speed, cuts/minute with SavE activated 3200 Blade speed, cuts/minute with SavE deactivated 4000 Water protection level IPX4 1 Yes Noise emissions Sound power level, measured dB (A) 89 Sound power level, guaranteed LWA dB (A) 94 Sound levels Sound pressure level at the operator’s ear, measured accord- ing to EN 60745 and EN 60745-2-15, dB(A): 78 Vibration levels2 Vibration levels (ah) at handles, measured according to EN 60745 and EN 60745-2-15, m/s2: Front/Rear handles 1.6/2.5 1 The Husqvarna Handheld Battery products marked with IPX4 fulfils these requirements on product approval lev- el 2 Reported data for vibration level has a typical statistical dispersion (standard deviation) of 1.5 m/s2. 620 - 002 - 29.01.2019 Technical data - 25