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Husqvarna Automower 435X AWD Workshop Manual

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Workshop manual

Husqvarna: Automower
435X AWD, 535 AWD
®

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  Summary of Contents for Husqvarna Automower 435X AWD

  • Page 1: Workshop Manual

    Workshop manual Husqvarna: Automower 435X AWD, 535 AWD ®...
  • Page 2: Table Of Contents

    Contents 1 Introduction 7 Troubleshooting 1.1 Document description..........3 7.1 Messages.............64 1.2 Servicing tools............3 7.2 Symptoms............70 7.3 Loop signal............72 7.4 To find a break in the boundary loop....74 2 Safety 2.1 Safety definitions............4 8 Transportation, storage and disposal 2.2 General safety instructions........4 2.3 Special safety instructions........4 8.1 Transportation............
  • 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 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.
  • Page 5: Symbols On The Product

    2.4 Symbols on the product The low voltage cable must not be shortened, extended or spliced. These symbols can be found on the product. Study them carefully. Do not use a trimmer nearby the low voltage cable. Be careful when trimming WARNING: Read the user in- edges where the cables are placed.
  • 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: Guide Loop

    3.5 Guide loop 3.7 Circuit boards and sensors The guide wire, together with the part of the boundary There are several types of circuit boards and sensors in loop that comprises the return to the charging station, is the product: called the guide loop.
  • Page 8: Testing The Installation

    Auto mode or in connection with the rearwards and then turns to continue in a different occasion, either in direction. start-up sequence. • The angle sensor - The angel sensor measures the angle of the rear unit in relation to the front unit. The Test out and Test in function is used to test if the signals are used to control the product when it turns product can follow the guide wire at the selected corridor...
  • Page 9: Autocheck Service Tool

    4.2 Connect to the product Autocheck 3 is a PC tool developed for the service of the robotic lawn mowers from Husqvarna Group. It is a 1. Start Autocheck on your computer. tool for troubleshooting as well as a database of sold products and service history.
  • Page 10: Programming A New Application Board

    Manual test • LED indication Status Firmware • Steady White New software is available. Actions • Confirm to start the soft- • Log book ware update. Documents • Pulsating White Software update is ongo- Customers • ing. 4.3.1 Home ® Pulsating Red/White Bluetooth software: In-...
  • Page 11 • Use Service mode - If the application board is replaced when troubleshooting, and you are not sure if the application board will be kept in the product, it is possible to temporarily skip to enter the serial number and use the application board in a so-called Service mode .
  • Page 12: Repair Instructions

    5 Repair instructions This chapter describes how to repair and change spare parts. Refer to the Illustrated parts list (IPL) at the manufacturer's support website. 5.1 Product overview 1. Front body 10. Rear body 2. Front top cover 11. Rear upper chassis 3.
  • Page 13: Front Unit

    The screw dimension is Torx 20 when there is no other 5. Hold the front top cover above the lights and pull it information. Note: Read the section about how to mount screws in plastic before starting any maintenance. Refer to mount screws in plastic on page 59 .
  • Page 14 5.3.2 To remove and install the front bumper tail 4. Pull out the grommets on the cables for the ® ultrasonic sensors and the headlights (Automower To remove and 1. Remove the front top cover. Refer to 435X AWD). install the front top cover on page 13 . 2.
  • Page 15 6. The front body is attached to the chassis at 4 5.3.4 To remove and install the front upper chassis positions. At each position, hold the chassis with one To remove and 1. Remove the front top cover. Refer to hand and loosen the front body with a quick and install the front body on page 14 .
  • Page 16 7. Remove the HMI lid. 9. Remove the 11 screws for the front upper chassis. 8. Remove the waranty seal at the point of seperation 10. Carefully lift the front upper chassis. between the front upper and lower chassis. 11. Disconnect the cable from the application board. 16 - Repair instructions 1061 - 001 -...
  • Page 17 12. Remove the front upper chassis. 5.3.5 To remove and install the center console To remove and 1. Remove the front top cover. Refer to install the front top cover on page 13 . To remove 2. Remove the front bumper tail. Refer to and install the front bumper tail on page 14 .
  • Page 18 6. Remove the waranty seals at the point of seperation 9. Disconnect all cables from the application board. between the center console and the front upper chassis. 7. Remove the 4 screws. 10. Remove the center console. 8. Carefully lift the center console. 11.
  • Page 19 5.3.7 To replace the front snap locks To remove and 1. Remove the front top cover. Refer to install the front top cover on page 13 . To remove 2. Remove the front bumper tail. Refer to and install the front bumper tail on page 14 . 3.
  • Page 20 5. Push the barb of the clip with a flat screwdriver. 7. Install the new clips. Make sure that the clips are oriented correctly. 6. Remove the 8 clips. Note: Make sure that the clips click into place. 8. Install in opposite sequence. ®...
  • Page 21 6. Compress the cable holder clips and push the cable 9. Remove the headlights and the cables. holder through the front body. 7. Turn the front body right side up. 8. Remove the cable holder. 10. Install the new headlights in opposite sequence. 5.3.10 To replace the front joysticks 1.
  • Page 22 ® 5. Remove the joysticks. 5.3.12 To replace the display (Automower 435X AWD) 6. Install in opposite sequence. To remove and 1. Remove the front top cover. Refer to install the front top cover on page 13 . 5.3.11 To replace the jog wheel To remove and 1.
  • Page 23 8. Remove the display from the display holder. 5. If the ventilation filter is not damaged. a) Push the display past the clips. b) Lift the display. a) Carefully clean the ventilation filter with a brush. 9. Remove the display. b) Install in opposite sequence.
  • Page 24: Rear Unit

    5.4 Rear unit 6. Remove the link arm cover. 5.4.1 To remove and install the rear unit 1. Push the STOP button on top of the product. 7. Remove the 2 cable clamp screws (Torx 27). 2. Remove the product from the charging station. 3.
  • Page 25 Servicing tool 9. Disconnect the main cable from the main cable link 11. Put the mandrel on the shaft. Refer to on page 61 . arm. CAUTION: Make sure that the lock spring in 12. Support the link arm with one hand and hit the pushed when pulling out the cable.
  • Page 26 13. Remove the mandrel. 5.4.2 To remove and install the rear top cover Note: If the rear unit is removed, do step 3 and 4. 1. Turn the rear unit. 14. Remove the rear unit. 2. Put a cloth between the rear top cover and the link arm to protect the rear top cover.
  • Page 27 4. Pull out the rear top cover. 3. Pull out the grommet. 5. Install in opposite sequence. 5.4.3 To remove and install the rear body To remove and install 1. Remove the rear unit. Refer to 4. Disconnect the charging cable. the rear unit on page 24 .
  • Page 28 5. Remove the rear body. 3. Remove the pivoting arm bolt (hex key 4). 4. Remove the pivoting arm. 6. Install in opposite sequence. Note: Make sure that the grommets seal properly against moisture. 5.4.4 To remove and install the pivoting arm To remove and install 1.
  • Page 29 7. Disconnect the battery cable (A). 5.4.5 To remove and install the rear upper chassis To remove and install 1. Remove the rear unit. Refer to the rear unit on page 24 . To remove and 2. Remove the rear body. Refer to install the rear top cover on page 26 .
  • Page 30 5.4.7 To replace the rear snap locks Note: Replace the sealing strip every time you To replace the assemble the rear chassis. Refer to To remove and install 1. Remove the rear unit. Refer to sealing strips on page 23 . the rear body on page 27 .
  • Page 31 4. Remove the joysticks. 4. Remove the main cable holder. 5. If the ventilation filter is not damaged. 5. Install in opposite sequence. 5.4.9 To clean or replace ventilation filter for the rear unit Note: The ventilation filter must be cleaned regulary and must be replaced if it is damaged.
  • Page 32: Link Arm

    5.5 Link arm 9. Remove the 2 screws (Torx 27) for the handle support. 5.5.1 To replace the handle To remove and install 1. Remove the rear unit. Refer to the rear unit on page 24 . To remove and 2.
  • Page 33 12. Remove the upper handle from the bracket. 7. Remove the link arm. 8. Install in opposite sequence. 13. Install in opposite sequence. 5.5.3 To remove and install the switch plate 5.5.2 To remove and install the link arm To remove and install 1.
  • Page 34: Cutting Unit

    8. Remove the 4 screws (Torx 27) that hold the switch Note: Make sure that the grommets seal properly plate. against moisture. 5.6 Cutting unit 5.6.1 To remove and install the blade disc WARNING: Do not use a powertool when you remove the screws.
  • Page 35 5. Remove the skid plate. 8. Remove the 3 screws that hold the blade disc. 6. Remove the screw (hex key 4) that hold the bearing. 9. Remove the blade disc. 10. Install in opposite sequence. 5.6.2 To remove and install the cutting module To remove and 1.
  • Page 36 7. Disconnect the cables to the cutting module and the 9. Put the cables into the area inside the sealing strip height adjustment motor from the front motor control groove. circuit board. 10. Remove the 4 screws that are screwed into plastic. 11.
  • Page 37: Main Cables

    12. Remove the cutting module. 5.7 Main cables 13. Remove the 3 screws that hold the hight adjustment 5.7.1 To replace the front main cable motor. To remove and 1. Remove the front top cover. Refer to install the front top cover on page 13 . To remove 2.
  • Page 38 5. Disconnect the front main cable from the front motor 4. Pull out the main cable grommet. control circuit board. 5. Disconnect the main cable. To remove and install 6. Remove the rear unit. Refer to the rear unit on page 24 . 6.
  • Page 39 11. Remove the link arm main cable. 4. Remove the 2 screws on the main cable holder. 5. Remove the main cable holder. 12. Install in opposite sequence. Note: Make sure that the grommets seal properly seal properly against moisture. 6.
  • Page 40: Circuit Boards And Sensors

    7. Twist and push the grommet out from the hole. 11. Attach the cable holder to the upper chassis. CAUTION: The cable routing is important to not disturb the loop sensor board. Use the cable holders and place the cables into correct position.
  • Page 41 To remove 3. Remove the front bumper tail. Refer to 9. Remove the application board. and install the front bumper tail on page 14 . To remove and 4. Remove the front body. Refer to install the front body on page 14 . To remove and 5.
  • Page 42 6. Remove the cable from the cable clip. 5.8.3 To remove and install the front circuit board bracket CAUTION: Always protect the product from electrostatic discharge, ESD, before you start to work on electrical components. CAUTION: If the circuit board is to be checked in order to evaluate the guarantee, it should be placed in a bag with protection against ESD (electrostatic discharge).
  • Page 43 6. Push the clip with a flat screwdriver. placed in a bag with protection against ESD (electrostatic discharge). To remove and 1. Remove the front top cover. Refer to install the front top cover on page 13 . To remove 2.
  • Page 44 To remove 9. Remove the communication circuit board. 4. Remove the front upper chassis. Refer to and install the front upper chassis on page 15 . 5. Remove the front circuit board bracket. Refer to remove and install the front circuit board bracket on page 42 .
  • Page 45 5.8.6 To replace the ultrasonic sensors 7. Remove the ultrasonic sensors. To remove and 1. Remove the front top cover. Refer to install the front top cover on page 13 . To remove 2. Remove the front bumper tail. Refer to and install the front bumper tail on page 14 .
  • Page 46 6. Disconnect the cable. CAUTION: Always protect the product from electrostatic discharge, ESD, before you start to work on electrical components. CAUTION: If the circuit board is to be checked in order to evaluate the guarantee, it should be placed in a bag with protection against ESD (electrostatic discharge).
  • Page 47 7. Remove the 2 screws. 10. Remove the 3D circuit boards from the holders. 11. Install in opposite sequence. 12. Connect the product to Autocheck. 8. Twist the holders counterclockwise around the steering pins (A). 13. Configure and calibrate the new circuit board. 5.8.9 To replace the front motor control circuit board CAUTION: Always protect the product from...
  • Page 48 6. Disconnect all cables from the front motor control 5.8.10 To remove and install the rear circuit board circuit board. bracket CAUTION: Always protect the product from electrostatic discharge, ESD, before you start to work on electrical components. CAUTION: If the circuit board is to be checked in order to evaluate the guarantee, it should be placed in a bag with protection against ESD (electrostatic discharge).
  • Page 49 6. Push the clip with a flat screwdriver. placed in a bag with protection against ESD (electrostatic discharge). To remove and install 1. Remove the rear unit. Refer to the rear unit on page 24 . To remove and 2. Remove the rear body. Refer to install the rear body on page 27 .
  • Page 50 7. Remove the rear motor control circuit board. 6. Disconnect the 3 CAN cables. 7. Remove the 3 screws on the holders. 8. Install in opposite sequence. 9. Connect the product to Autocheck. 10. Configure and calibrate the new circuit board. 5.8.12 To replace the rear 3D circuit boards for the angle sensor and the rear collision/lift sensors CAUTION: Always protect the product from...
  • Page 51 9. Remove the holders from the steering pins. 4. Remove the battery cable from the cable holder. 5. Remove the rear circuit board bracket. Refer to remove and install the rear circuit board bracket on page 48 . 6. Disconnect the CAN cable. 10.
  • Page 52: Wheels And Wheel Motors

    5.9 Wheels and wheel motors ® 4. Remove the wheel cover (Automower 435X AWD). 5.9.1 To remove and install the wheels 1. Remove the hub cap. 5. Remove the inside cover with a flat screwdriver. 2. Remove the nut (24 socket spanner) and the washer.
  • Page 53 7. Disconnect the motor cables from the motor control 10. Install in opposite sequence. circuit board. 5.9.3 To replace the rear wheel motors To remove and install 1. Remove the rear unit. Refer to the rear unit on page 24 . To remove and install the 2.
  • Page 54 9. Remove the wheel motor. 4. Remove the front wheel brushes. 10. Install in opposite sequence. 5.9.4 To replace the wheel brushes Note: The brush holders prevent dirt to enter the body. 5. Install the new wheel brushes. They must be used even if there are no brushes. 6.
  • Page 55: Battery And Charging

    7. Remove the rear wheel brushes. 4. Remove the battery cover. 5. Remove the 2 screws for the battery bracket. 8. Install the new brushes in the opposite sequence. 5.10 Battery and charging 5.10.1 To replace the battery 1. Switch off the product. 2.
  • Page 56 7. Disconnect all the cables from the battery. 4. Remove the battery cable from the bracket clip. 5. Disconnect the battery cable from the motor control circuit board. 8. Remove the battery. 6. Remove the battery cable. 9. Install in opposite sequence. 5.10.2 To remove and install the battery cable To replace the battery 1.
  • Page 57: Charging Station

    5. Tilt the charging plates. Note: Make sure to put the cable in the clip and pull it away from the loop sensor. 5.10.3 To replace the charging plates To remove and install 1. Remove the rear unit. Refer to the rear unit on page 24 .
  • Page 58 3. Disconnect all cables from the charging station. 8. Disconnect the cables to the cable plate. 4. Remove the 2 screws on the front of the charging station. 9. Remove the charging tower from the baseplate. 5. Carefully lift the charging cover forward and upward from the charging tower.
  • Page 59: To Mount Screws In Plastic

    5. Install in opposite sequence. To ensure the threads in plastic parts are not damaged: 1. Carefully turn the screw counter-clockwise until it 5.11.3 To replace the circuit board in the charging engages the existing threads in the plastic. The station screw will fall slightly by itself when the threads are 1.
  • Page 60 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. 60 - Repair instructions 1061 - 001 -...
  • Page 61: Service

    6 Service 6.1 Servicing tool Item Description Use for Article number Mandrel To remove the rear body 577 90 66-01 6.2 Service schedule The table below contains a checklist of points and actions to be taken when servicing the product. Complete service plans can be found in Autocheck.
  • Page 62: Screw Fasteners

    The tightening torque must be attained, otherwise there is not a satisfactory seal against moisture etc. Fastener Hardware Tool Tightening torque (Nm) ® ® Husqvarna Automower 435X AWD, Automower 535 AWD Bumpers to body Screw, 5 x 16 mm Torx 20 Holder charging plate Screw, 5 x 16 mm...
  • Page 63 Fastener Hardware Tool Tightening torque (Nm) Blade disc Screw, M4 x 8 mm Cross screwdriver Bearing, blade disc Screw, M6 x 8 mm Hex key 4 Blades Screw, M4 x 10 mm Flat/Cross screwdriver Bearing cover, blade disc Screw, Gray, 4 x 14 mm Torx 20 Charging station, lid Screw, Gray, 4 x 14 mm...
  • Page 64: Troubleshooting

    7 Troubleshooting 7.1 Messages This chapter will guide how to troubleshoot 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 65 Messages Number Message Cause Action MOTORS 20/21 Front wheel motor Grass or other object has wrapped Check the drive wheel and remove any blocked around the drive wheel. objects. 82/83 Rear wheel motor Grass or other object has wrapped Check the drive wheel and remove any blocked around the drive wheel.
  • Page 66 Messages Number Message Cause Action INSTALLATION No loop signal Boundary wire broken. Check the signal given by the LED on To trou- the charging station. Refer to bleshoot the loop signal on page 73 . The boundary wire is not connected to Check that the boundary wire connec- the charging station tors are fitted properly to the charging...
  • Page 67 Messages Number Message Cause Action INSTALLATION Mower lifted The lift sensor has been activated due Free the product and rectify the reason. to the product getting stuck. One of the lift sensor magnets is inver- Check the magnets placed in the front To replace ted or missing.
  • Page 68 Messages Number Message Cause Action INTERNAL DIAGNOSTICS 18/19 Collision sensor prob- Collision sensor is malfunctioning. Switch off/on the product. Replace the lem rear/front circuit board if needed. Loop sensor problem The cabling to the loop circuit board is Check the levels for the A signal. Refer To measure the loop signal strength faulty or has come loose.
  • Page 69 Messages Number Message Cause Action INTERNAL DIAGNOSTICS Invalid system configu- Wrong configuration of the circuit Redo the configuration via Autocheck. ration boards after replacing a circuit board. Messages Number Message Cause Action CHARGING STATION Charging station An object is obstructing the product. Remove the object.
  • Page 70: Symptoms

    7.2 Symptoms The most commonly occurring symptoms are described below. All symptoms are grouped by the situation where they occur most often. 1. Mowing 5. Charging 2. Searching 6. Miscellaneous 3. Following the guide wire 4. Docking Note: Refer to the Operator's manual for more information about how to rectify errors. 7.2.1 Symptoms during mowing Symptom Cause...
  • Page 71 7.2.2 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 72: Loop Signal

    7.2.4 Symptoms during charging Symptom Cause Action Battery test to determine the Both the mowing and charging Low battery capacity. Perform a Autocheck times are shorter than usual battery’s capacity. Refer to service tool on page 9 . The product never leaves the The PARK mode is activated.
  • Page 73 7.3.2 To troubleshoot the loop signal 7.3.2.3 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 74: To Find A Break In The Boundary Loop

    A wire break can be found by using Husqvarna’s break detection tool or with the manual method that is described in the Operator's manual.
  • Page 75: Transportation, Storage And Disposal

    8 Transportation, storage and disposal 8.1 Transportation • If you keep the charging station indoors, disconnect and remove the power supply and all the connectors The supplied Li-ion batteries obey the Dangerous Goods from the charging station. Put the end of each Legislation requirements.
  • Page 76: Technical Data

    9 Technical data 9.1 Technical data For the technical data, refer to Operator's manual and the manufacturer's website. 76 - Technical data 1061 - 001 -...
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  • Page 80 We reserve the right to make changes without prior notice. Copyright © 2019 Husqvarna AB. All rights reserved. 114 13 57-26 www.husqvarna.com 2019-05-08...

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