Husqvarna Automower 405X Workshop Manual
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Husqvarna Automower 405X Workshop Manual

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Workshop manual
Husqvarna Automower
405X, 415X
®

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Summary of Contents for Husqvarna Automower 405X

  • Page 1 Workshop manual Husqvarna Automower 405X, 415X ®...

  • Page 2: Table Of Contents

    Contents 1 Introduction 6 Repair instructions 1.1 Document description..........3 6.1 Product overview..........18 1.2 Servicing tools............3 6.2 To mount screws..........18 1.3 Technical data............3 6.3 To remove and install the top cover..... 19 6.4 To remove and install the body......19 6.5 To remove and install the upper chassis .....20 2 Safety 6.6 To replace the rear bumper........21...

  • Page 3: Introduction

    1 Introduction 1.1 Document description The Workshop manual is intended for dealers and service personnel, and is a supplement to the Operator’s manual. The following system is used in Workshop manual to make it easier to use: italics is a text that is shown on the •...

  • Page 4: Safety

    2 Safety 2.1 Safety definitions 2.3.3 Battery safety Warnings, cautions and notes are used to point out WARNING: Lithium-ion batteries can explode or specially important parts of the manual. cause fire if disassembled, short-circuited, exposed to water, fire, or high temperatures. WARNING: Used if there is a risk of injury or Handle carefully, do not dismantle, open the death for the operator or bystanders if the...
  • Page 5 The chassis contains components which are sensitive to electrostatic discharge (ESD). The chassis must also be resealed in a professional manner. For these reasons the chassis shall only be opened by authorized service technicians. A broken seal can result in the entire or parts of the guarantee no longer being valid.

  • Page 6: Product And Installation

    3 Product and installation 3.1 Main components for installation 3.4 Boundary loop The robotic system involves 4 main components: The strength of the A signal varies depending on the distance. The strength of the signal is high close to the •...

  • Page 7: Charging Station

    3.7 Circuit boards and sensors always goes from the guide wire to the left in the connection between guide wire and boundary loop. The circuit boards and sensors in the product: The strength of the guide signal varies like the A signal depending on the distance to the guide loop.

  • Page 8: To Do A Test Of The Installation

    3.10 Safe operation in slopes detect the signals if it has been paired with the charging Loop signal on page 49 . station. Refer to The product adjusts its operation automatically based on factors such as the slope angle and travel direction. 3.7.4 STOP sensor If the slope is too steep, the product moves rearwards There is a magnet and a Hall sensor that detects if the...

  • Page 9: Special Menus

    4 Special menus 4.1 Tools menu overview Tools History, trip Test Special settings Info History, total Calibrate General Key data Wheel Demo Key data Motors Tilt sensor motor calibration Battery Installation Search Reset trip Cutting lock times values Cutting height motor Loop calibration...

  • Page 10: Tools Menu (Expert Mode)

    4.4.1.2 Tools - Info - Battery Note: The product will operate as usual with the Tools - Info - Battery menu shows: hatch open. Voltage : The voltage level of the battery. About 20.5 • 4. Push the STOP button to stop the product. V indicates a fully charged battery and about 17 V indicates a flat battery.
  • Page 11 • blocked. The serial number of the Info - Motors - Cut height menu shows: communication circuit board is not registered on Husqvarna server. Replace the communication Cutting height : The blade disc height setting • circuit board. measured in steps.
  • Page 12 Total mowing : The total time in hours that the • 4.4.4 Tools - Test cutting motor has been running. Note: The battery voltage should be at least 18 V when Total search time : The total time in hours that the •...

  • Page 13: Quick Info (Limited Tools Menu)

    4.4.4.2 Tools - Test - User interface Note: The installation settings lock must be Tools - Test - User interface menu shows: deactivated to change any of the installation settings in the main menu. Keypad : • 1. Push the OK button to start the keypad test. 4.4.6 Tools - Calibrate 2.
  • Page 14 Calibrate : It has the same submenus as in Tools - • Calibrate . Refer to Tools - Calibrate on page 13 . 14 - Special menus 1582 - 001 - 23.12.2020...

  • Page 15: Autocheck Service Tool

    5.2.1 To connect the product with USB service Autocheck 3 is a PC tool developed for the service of the robotic lawn mowers from Husqvarna Group. It is a cable tool for troubleshooting as well as a database of sold 1.

  • Page 16: How To Use Autocheck 3

    5.3 How to use Autocheck 3 signal between the product and the charging station). The program’s main functions are grouped in a number Unit replacement : Has the functionality to set the • of menus: product serial number if the application circuit board Home •...

  • Page 17: Demo Mode

    Select product from the Log book and the serial number and operating data is transferred automatically to the new application circuit board. This requires that the product previously has been connected to Autocheck. • Enter the serial number manually in Autocheck If the product never was connected to Autocheck, the serial number must be entered manually in the Actions - Unit replacement menu.

  • Page 18: Repair Instructions

    6 Repair instructions 6.1.3 The lower chassis This chapter describes how to repair and change spare parts. Refer to the Illustrated parts list (IPL) at the The lower chassis is structured mechanically around the manufacturer's support website. modules that follow: 1.

  • Page 19: To Remove And Install The Top Cover

    Note: Read the section about how to mount screws in CAUTION: Clean dirt and grass from the plastic before starting any maintenance. Refer to product before you remove the parts. mount screws in plastic on page 34 . 1. Remove the top cover. Refer to To remove and install the top cover on page 19 .

  • Page 20: To Remove And Install The Upper Chassis

    6.5 To remove and install the upper chassis 6. Disconnect the power cable (A) from the motor control circuit board. To remove and 1. Remove the top cover. Refer to install the top cover on page 19 . To remove and install 2.

  • Page 21: To Replace The Rear Bumper

    6.7 To replace the front bumper Note: Attach a new warranty seal. The warranty seal must be included and unbroken for the warranty to be To remove and install 1. Remove the body. Refer to valid. the body on page 19 . 2.

  • Page 22: To Replace The Rear Body Suspension Parts

    5. Pull the cable and the headlights through the hole in Note: Make sure to put the cables in the cable the body. holders. To put the cables into position in the body: 6. Remove the screw for the holder of the charging 6.9 To replace the rear body suspension parts plates.

  • Page 23: To Replace The Keypad

    3. Lift up the front body suspension parts by using a 4. Disconnect all cables from the application circuit small flat screwdriver. Pull the screwdriver gently board. backwards. 5. Push the 2 clips to release the application circuit To replace the application circuit board.

  • Page 24: To Replace The Stop Button

    4. Push the clips inwards and lift up to remove the 3. Pull out one side of the stop button. support. 4. Pull the STOP rearward to remove it. 5. Remove the damaged ventilation filter. 5. Install in the opposite sequence. 6.

  • Page 25: The Circuit Boards And Sensors

    6.15 The circuit boards and sensors 5. Open the hatch and bend it over. These are the circuit boards in the product: 6. Remove the hatch. 1. Motor control circuit board (tilt sensor) 2. Communication circuit board 3. Rear sensor circuit board (rear loop sensor and stop sensor) 4.
  • Page 26 6.15.1 To replace the motor control circuit board 6.15.2 To replace the application circuit board To remove and 1. Remove the top cover. Refer to The operating information of the product is saved in the install the top cover on page 19 . application circuit board.
  • Page 27 3. Slide the hatch to the SIM card holder and open the Note: The communication circuit board contains an e- hatch. SIM. For some markets a separate SIM card is used. 1. Remove the top cover. Refer to To remove and install the top cover on page 19 .
  • Page 28 4. Disconnect the cable to the front loop sensor circuit 5. Push down the clip and remove the circuit board. board. 6. Install in opposite sequence. 6.15.7 To replace the rear loop sensor circuit board To remove and 1. Remove the top cover. Refer to install the top cover on page 19 .

  • Page 29: The Battery System

    7. Push to detach the 2 clips and pull up. The battery is maintenance-free, but has a limited life span. The battery is expected to last for 3000 - 4000 charging cycles. The normal charging current is 1.3 A. 6.16.1 To replace the battery To remove and 1.
  • Page 30 9. Remove the 4 screws and the frame. CAUTION: Always disconnect the power cable first to prevent current spikes that may harm the circuit boards or the battery. 5. Disconnect the cutting motor cable and the height adjustment motor cable from the motor control circuit board.

  • Page 31: Wheels And Wheel Motors

    Accessories > Terrain kit and 13. Install in the opposite sequence. Connect the cables motor. Enter the menu and position them in the cable holders. enable Terrain kit. 1. Remove the hub cap. Note: Make sure that the bellows are installed correctly to get a sufficient seal.

  • Page 32: Charging Station

    To replace the rear 5. Remove the wheel. Refer to 3. Insert the wheel brush in the slot from below in an wheels on page 31 . angle (A) and push it down into position (B). As an alternative, insert the wheel brush from the above in 6.
  • Page 33 4. Remove the 2 screws on the front of the charging 8. Disconnect the cables to the cable plate. station. 5. Carefully lift the charging cover forward and upward from the charging tower. 9. Remove the charging tower from the baseplate. 10.

  • Page 34: To Mount Screws In Plastic

    6.19.3 To replace the contact plates in the charging To ensure the threads in plastic parts are not damaged: station 1. Carefully turn the screw counter-clockwise until it 1. Remove the charging tower and charging station engages the existing threads in the plastic. The To remove and install the charging cap.

  • Page 35: To Replace The Sealing Strip

    3. Make sure the plug is screwed in completely so that a good seal is obtained. CAUTION: Tighten by hand so as not to damage the plastic. 4. Fit the plastic parts with the accompanying screw instead of the old plastic screw. 6.22 To replace the sealing strip There is one sealing strip in the product between the upper and lower chassis.

  • Page 36: Service

    7 Service 7.1 Service schedule The table below contains a checklist of points and actions to be taken when servicing the product. Every Every Action Explanation year 3rd year Firmware on page 16 . Firmware update Refer to If firmware is available in Autocheck, update the product with the newest firmware.

  • Page 37: Screw Fasteners

    Every Every Action Explanation year 3rd year Chassis screws Refer to Screw fasteners on page 37 . Do a check of the tightening torque of chassis screws. Maintenance - Replace the blades in Blades Refer to the Operator's manual. Replace blades and blade screws. Skid plates Make sure that the skid plate can rotate freely and that the ball bearing does not make a...
  • Page 38 Fastener Hardware Tool Tightening torque (Nm) Bearing cover, skid plate Screw gray, 4 x 14 mm Torx 20 Cutting motor to lower chassis Screw, 5 x 16 mm Torx 20 Clamp for battery, weight and rear loop Screw, 5 x 16 mm Torx 20 sensor circuit board.

  • Page 39: Troubleshooting

    8 Troubleshooting 8.1 Messages The table below contains fault and information messages which can appear in the product. There are references to menus in the product, but Autocheck can also be used in many cases. Note: Refer to the Operator's manual for more information about how to rectify errors. Messages Number Message...
  • Page 40 Messages Number Message Cause Action No loop signal Boundary wire broken. Check the signal given by the LED on the charging station. If the LED indicates a break in the boundary wire, find out where the break is. Replace the damaged section of the loop with a new loop wire and splice using an original coupler.
  • Page 41 Messages Number Message Cause Action Loop sensor problem, rear The cabling to the sensor circuit Check the cabling and refit the board is faulty or has come loose. cable or replace if necessary. Electronic or software related Check the levels for the A signal. Loop signal on page 49 .
  • Page 42 Messages Number Message Cause Action Charging station blocked There is an object in the way of Remove the object. the product preventing it from en- tering the charging station. The baseplate is bent. Ensure that the baseplate is placed on level ground. The contact between the charging Put the product in the charging plates and contact plates may be...
  • Page 43 Messages Number Message Cause Action Settings restored When restoring user settings af- If the fault occurs repeatedly, pro- ter, e.g circuit board replacement, gram the product with the most user settings failed to save and recent main program. Refer to Firmware on page 16 .
  • Page 44 Messages Number Message Cause Action Electronics problem Communication problems with the Restart the product. cutting system. Replace the motor control circuit To replace the board. Refer to motor control circuit board on page 26 Update the firmware via Autoch- eck. 40 - Limited cutting height range The cutting height adjustment Remove the chassis and check...
  • Page 45 Messages Number Message Cause Action Temporary battery problem Wrong type of battery. Use only original batteries recom- mended by the manufacturer. Temporary battery problem Battery temperature sensor de- Replace the battery. Refer to replace the battery on page 29 . fective.

  • Page 46: Symptoms

    Messages Number Message Cause Action Cutting system imbalanced Too few or too many blades. Check the blades on the blade disc. Safety function faulty Status LED malfunctioning. Restart the product. If the prob- lem remains, replace the keypad, application circuit board or ca- To replace the key- bling.
  • Page 47 8.2.1 Symptoms during mowing Symptom Cause Action Uneven mowing results The product works too few hours per day. Increase the working hours. Work area too large. Try to limit the work area or extend the working time. Blunt blades. Replace all the blades and screws so that the rotating parts are balanced.
  • Page 48 8.2.2 Symptoms during searching Symptom Cause Action The product runs, but the The product is searching for the charging This behaviour is normal and no action is blade disc does not rotate station. The blade disc does not rotate required. when the product is searching for the charging station.

  • Page 49: Loop Signal

    8.2.4 Symptoms during charging Symptom Cause Action Battery test to determine the Both the mowing and charging Low battery capacity. Perform a Auto test on times are shorter than usual battery’s capacity. Refer to page 16 . The product never leaves the The parking mode is activated.
  • Page 50 8.3.1 To troubleshoot the loop signal 8.3.1.3 Blue flashing light A blue flashing light is most likely a break in the Always start by checking the LED in the charging boundary loop. station. This usually provides a good indication of where troubleshooting should begin.

  • Page 51: To Find A Break In The Boundary Loop

    8.4 To find a break in the boundary loop perform a battery test in connection with the product’s normal operation or in connection with it having recently A break in the loop wire is normally due to physical been in operation. damage to the wire, e.g.

  • Page 52: Transportation, Storage And Disposal

    9 Transportation, storage and disposal 9.1 Transportation • Keep the product with all wheels on level ground during storage, or use an original wall hanger. The supplied Li-ion batteries obey the Dangerous Goods • If you keep the charging station indoors, disconnect Legislation requirements.
  • Page 53 1582 - 001 - 23.12.2020 Transportation, storage and disposal- 53...
  • Page 54 54 - Transportation, storage and 1582 - 001 - 23.12.2020 disposal...
  • Page 55 1582 - 001 - 23.12.2020 Transportation, storage and disposal- 55...
  • Page 56 ORIGINAL INSTRUCTIONS We reserve the right to make changes without prior notice. Copyright © 2021 Husqvarna AB. All rights reserved. 114 13 60-26 www.husqvarna.com 2021-01-04...

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Automower 415x

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