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Husqvarna 967187001 Workshop Manual

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Rider Battery
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  Summary of Contents for Husqvarna 967187001

  • Page 1 Workshop manual Rider Battery English...
  • Page 3: Table Of Contents

    12 CST-Drive Mode Logging ......115 13 Manual CST Tests ........125 14 Batteries and Maintenance ......137 Husqvarna AB has a policy of continuous product development and therefore reserves the right to modify the design and appearance of products without prior notice. English –...
  • Page 4: Index

    Index 1 Index 1 Index ................4 7.16 Changing Microswitch, Forward Drive ....54 7.17 Changing Speed Potentiometer ....... 56 7.18 Changing Recoil Spring in Pedal Plate ..... 57 2 Introduction and Safety Regulations ......7 7.19 Calibrating Speed Potentiometer ...... 59 7.20 Calibrating Speed ..........
  • Page 5 14.13 What Does a Battery Contain and 12.16 Cutting Motor Signals ........124 Where Can it Be Disposed Of? ......141 14.14 Husqvarna's Battery Charger ....... 141 13 Manual CST Tests ........... 125 14.16 Lead Sulfate, What is It? ......142 14.17 Charge Voltages for...
  • Page 6 Revision ledger Enter any revisions and corrections to the workshop manual into the table below. Revision can be notified by Husqvarna AB as service information or the equivalent. Enter the service notes into the troubleshooting software Common Service Tool (CST)
  • Page 7: Introduction And Safety Regulations

    Usage is made evident in each section. are designated A, B, etc. The figures are numbered 1, 2 etc. 2.6 Parts and Accessories The position references and figure numbers restart Always use original Husqvarna in each new section. • Spare parts • Service tools • Accessories or you may invalidate the warranty and risk your personal safety.
  • Page 8: Symbols On Rider

    Introduction and safety regulations 2.9 Symbols on Rider Clutch in. These symbols can be found on the ride-on mower and in the manual. WARNING! Careless or incorrect Clutch out. use can result in serious or fatal injury to the operator or others. Please read the Operator’s Parking brake.
  • Page 9: Special Safety Instructions

    Introduction and safety regulations 2.11 Risk of Sparks This Workshop Manual contains the following warning boxes in relevant places. WARNING! WARNING! Never short circuit the batteries! The warning box warns of the Never unscrew the batteries! Never risk of personal injury if the use a damaged battery! Always instructions are not followed.
  • Page 10: Cutting Power

    Introduction and safety regulations 2.12 Cutting Power WARNING! Working on a live machine can cause lethal injury The power must be disconnected from the machine when conducting some of the tests. Observe great care during these procedures. Power to the machine must also be disconnected when carrying out other work to reduce the risk of short circuits.
  • Page 11: Special Tools

    Special Tools 3 Special Tools The following are used when working on the ride- on mower. DIGITAL TACHOMETER 535 41 32-02 Mandrel for assembling the bushings on the pendulum shaft. 502 28 80-01 Tachometer 578 92 62-01 Adjustment tool for wheel speed. USB ‘‘type A’’...
  • Page 12 Special Tools Laser tachometer Security • Class 1 laser product. • Take care whenever the laser beam is on. • Do not look straight into the beam. Do not aim the beam towards anyone else's eyes, either people or animals. •...
  • Page 13 Special Tools Hydrometer and refractometer Multimeter Clip-on ammeter The voltage tester enables measurement of insulated cables by penetrating the cable sheath. Battery fluid/distilled water. English –...
  • Page 14: Technical Data

    Technical Data 4 Technical Data Dimensions Vibration levels Length without cutting deck, cm/in 174/5.7 (see note 3) Length with cutting deck, cm/in 208/6.8 Vibration level in steering Width without cutting deck, cm/in 79/2.6 wheel, m/s² Width with cutting deck, cm/in 89/2.92 Vibration level in seat, m/s².
  • Page 15: Design And Function

    Design and Function 5 Design and Function Table of contents 5.1 Administration ............................15 5.2 Wheels..............................15 5.3 Serial Number............................16 5.4 Steering ...............................17 5.5 Cutting Deck ............................18 5.6 Service Position for Cutting Deck ......................18 5.7 Removing the BioClip Plug ........................18 5.1 Administration Complete the sales certificate, customer register, etc.
  • Page 16: Serial Number

    • The machine’s type designation (Model). • The manufacturer’s type number (PNC). • The machine's serial number (Serial Number) Please provide the type designation and serial number when ordering spare parts. Husqvarna AB S - xxx xx Husqvarna SWEDEN Model Serial Number Rider Battery xxxxxxx-xx...
  • Page 17: Steering

    Design and Function 5.4 Steering All ride-on mowers in the Rider range have articulated steering. The force from the steering wheel is transferred to the rear carriage via cables and a chain. This makes the ride-on mower easy and precise to steer.
  • Page 18: Cutting Deck

    Design and Function 5.5 Cutting Deck The whole Rider range is equipped with front- mounted cutting deck to mow efficiently even in confined spaces. Rider Battery has a Combi Deck with a cutting width of 850 mm (33.5") Combi Deck 5.6 Service Position for Cutting Deck Service Position means the cutting deck is removed (see "6.5"...
  • Page 19: Basic Dismantle/Assembly

    Basic dismantle/assembly 6 Basic Dismantle/Assembly Table of contents 6.1 Wheels..............................20 6.2 Covers ..............................21 6.3 Front Batteries .............................25 6.4 Rear Battery ............................27 6.5 Exploded View Drawing Cutting Deck ....................28 6.6 Removing the Cutting Deck .........................29 6.7 Assembling the Cutting Unit ........................31 English –...
  • Page 20: Wheels

    Basic dismantle/assembly 6.1 Wheels IMPORTANT INFORMATION Take care not to damage the drive chain or gears when placing the stands. Use a jack assembly to raise the rear carriage. Use stands to support the machine. Suitable stand locations are shown here. Remove hubcap, circlip and washer.
  • Page 21: Covers

    Basic dismantle/assembly 6.2 Covers The steps described below are the basic steps that must be carried out before any service or repair work or final assembly is possible. Turn off the machine and remove the ignition key. Loosen the snap locks and lift off the cover on the rear carriage.
  • Page 22 Basic dismantle/assembly Loosen both side panels on the rear carriage. Loosen the cover over the articulated steering. English –...
  • Page 23 Basic dismantle/assembly Tilt forward the seat. Loosen the two snap locks. Unhook and lift of the battery cover. Loosen the front panel. In most cases, hanging the cover to one side will be sufficient for access. Otherwise, the steering column must be removed. English –...
  • Page 24 Basic dismantle/assembly Loosen the left side cover. Loosen the right side cover. The control panel and the key switch must also be disconnected here, see "8.2" steps 1 and 2. The lever grip for lowering the cutting deck must also be unscrewed.
  • Page 25: Front Batteries

    Basic dismantle/assembly 6.3 Front Batteries WARNING! Working on a live machine can cause lethal injury. Disconnect the batteries, see Chapter 2.12 Turn off the machine and remove the ignition key. Tilt forward the seat. Loosen the two snap locks, unhook the battery cover and lift it off.
  • Page 26 Basic dismantle/assembly Loosen the cable from the seat switch. Loosen the two front screws on the locking arm and completely unscrew the rear one. Lift up the locking arm The batteries are now free and can be lifted using the straps that are inserted through the eyes on top of the battery.
  • Page 27: Rear Battery

    Basic dismantle/assembly 6.4 Rear Battery WARNING! Working on a live machine can cause lethal injury. Disconnect the batteries, see Chapter 2.12 Turn off the machine and remove the ignition key. Loosen the snap locks and remove the cover. Loosen the rear cover. Loosen the cables on the battery terminals.
  • Page 28: Exploded View Drawing Cutting Deck

    Basic dismantle/assembly 6.5 Exploded View Drawing Cutting Deck English –...
  • Page 29: Removing The Cutting Deck

    Basic dismantle/assembly 6.6 Removing the Cutting Deck To dismantle the cutting deck proceed as follows: Put the machine in a level position. Turn off the machine and remove the ignition key. Apply and secure the parking brake. Check that the lever for setting the cutting height is in the S position.
  • Page 30 Basic dismantle/assembly WARNING! Always disconnect cables from the cutting deck before removal Loosen the snap locks, lift off the cover and disconnect the cables. Grasp the upper pipe framework in the cutting deck while holding in the baffle plates and pull out the cutting deck.
  • Page 31: Assembling The Cutting Unit

    Basic dismantle/assembly 6.7 Assembling the Cutting Unit To assemble: Push the cutting deck in and make sure the guide bolts fit into the grooves on the tool frame, one on each side. Fit the cutting deck's pipe together with the tool frame's pipe.
  • Page 32 Basic dismantle/assembly Push the cutting deck until the pipes bottom. Connect the cables and fit the cover. Put the cutting height control to one of the positions 1-5. English –...
  • Page 33: Repair Work

    Repair Work 7 Repair Work Table of contents 7.1 Replacing the Steering Cables ......................34 7.2 Removing/Fitting the Steering Shaft ....................35 7.3 Removing/Assembling the Cable Pulley....................36 7.4 Replacing Brake Cable ........................37 7.5 Checking and Adjusting the Brake Cable ....................37 7.6 Changing Articulated Steering Bearing....................37 7.7 Removing the Pendulum Shaft ......................40 7.8 Replacing the Pendulum Shaft Bushings ....................41 7.9 Assembling the Pendulum Shaft......................41...
  • Page 34: Replacing The Steering Cables

    Repair Work 7.1 Replacing the Steering Cables Note. Loosen the rear fastening of the steering If the old cables are whole, the new ones can be cables (1). attached to them as they are drawn out through the frame. The new cables will then automatically follow the correct route.
  • Page 35: Removing/Fitting The Steering Shaft

    Repair Work 7.2 Removing/Fitting the Steering Shaft Loosen the rear fastening of the steering cables (1). Pull the steering wheel shaft (11) upwards and move the lower part of the shaft backwards to pull off the steering chain (12). Move the upper bearing (10) upwards until it moves freely from the steering wheel shaft (11).
  • Page 36: Removing/Assembling The Cable Pulley

    Repair Work 7.3 Removing/Assembling the Cable Pulley Ensure that the cables are properly placed in the Loosen the rear fastening of the steering steering cable pulleys (7). cables (1). Ensure that the steering wheel is in the center position when the rear wheels are centered. Re- set the chain on the steering column's sprocket or Remove the screw (6) and the cable pulley (3).
  • Page 37: Replacing Brake Cable

    Repair Work 7.4 Replacing Brake Cable For accessing the front and rear attachments, dismantle any necessary covers, see "6.2" Unhook the spring in the front part of the brake cable. Loosen the rear part and remove the brake cable. Assemble the new wire in reverse order to dismantling.
  • Page 38 Repair Work Put the machine on stands and then loosen the wheel. See "6.1" Dismantle the covers on the rear carriage according to "6.2" Remove the rear attachments of both steering cables. Support the front and rear carriage independently before separating. Use a slide hammer size M8 to loosen the articulated shaft.
  • Page 39 Repair Work Loosen the articulated shaft's screw from below. Tap out the bearings and the sleeve with a mandrel. The lower bearing is tapped out from above. The upper bearing is tapped out from below. Press new bearings in by using a bearing assembly kit.
  • Page 40: Removing The Pendulum Shaft

    Repair Work 7.7 Removing the Pendulum Shaft Follow steps 1 to 12 in "7.6 Changing Articulated Steering Bearing". Dismantle the front left cover Remove all the cables laid out between the front and the rear carriage, in their rear attachments. Note their routing.
  • Page 41: Replacing The Pendulum Shaft Bushings

    Repair Work 7.8 Replacing the Pendulum Shaft Bushings When the pendulum shaft has been removed (follow "7.6 Removing the pendulum shaft"), the bushings in the rear frame must be changed. Remove the bushings (1), (2) one from each direction. New bushings are fitted with the mandrel, refer to "3 Special tools".
  • Page 42 Repair Work Assemble the articulated shaft with its key slot down. Make sure the key slot corresponds with the key slot in the frame. Fasten the cables in their respective positions between the front and the rear carriage. Refit the wheels, see "6.1". Assemble according to "7.6 Changing Articulated Steering Bearing", in reverse order.
  • Page 43: Removal Of Blades And Blade Adapter

    Repair Work 7.10 Removal of Blades and Blade Adapter The cutting deck should be in service position, see "5.6". WARNING! Use gloves and protective goggles when working on the cutting deck. WARNING! Always disconnect cables from the cutting deck before removal Lock the blade with a wooden block.
  • Page 44: Grinding And Balancing Blades

    Repair Work Blades are refitted in reverse order. Blade screw (1) tightening torque is 45-50 Nm (32-36 lbft), (Hand drawn) Screws securing the blade adapter (2) must be tightened to the flat surface of the motor shaft. 7.11 Grinding and Balancing Blades WARNING! Use glove to protect hands when working on the blades.
  • Page 45: Removing The Blade Motor

    Repair Work 7.12 Removing the Blade Motor The cutting deck should be in service position, see "5.6". WARNING! Always disconnect cables from the cutting deck before removal Remove blades and blade adapter in accordance with "7.10". Loosen the bolts holding the tool frame. Lift away the tool frame.
  • Page 46 Repair Work Loosen the circlip and pull the stay from the attachment. Unscrew the five screws and lift off the cover. Disconnect the cables between the motors and the control unit. English –...
  • Page 47 Repair Work Loosen the four screws on each motor. (Motors are now loose) Remove the cutting motors from below. Assembly is done in reverse order to removal. English –...
  • Page 48: Loosen The Pedal Plate

    Repair Work 7.13 Loosen the Pedal Plate WARNING! Working on a live machine can cause lethal injury. Disconnect the batteries, see Chapter 2.12 Turn off the machine and remove the ignition key. Loosen the front cover for better accessibility. Dismantle the cutting deck, see "6.6". Tilt forward the seat.
  • Page 49 Repair Work Unscrew and remove the left side cover. Unscrew and remove the left wing cover. Pull out the pin for the lifting chain. Fasten the pin to the chain to ensure the chain stays in place. English –...
  • Page 50 Repair Work Disconnect the cable to the speed potentiometer. Disconnect the cable to the microswitches. Loosen the steering column. English –...
  • Page 51 Repair Work Undo the four screws underneath that secure the pedal plate. Release the pin. Cut the cable tie holding the cables to the speed potentiometer and the microswitches. The pedal plate is now loose and can be lifted out from below to access the components.
  • Page 52: Changing Microswitch, P-Brake

    Repair Work 7.14 Changing Microswitch, P-brake Dismantle the cables from the switch. Dismantle the attachment with switch by loosening the screw and nut. Loosen the switch by drilling out the pop rivets with a 5 mm bit. Fit new microswitch by riveting it onto the attachment.
  • Page 53: Changing Microswitch, Reverse Drive

    Repair Work 7.15 Changing Microswitch, Reverse Drive Dismantle the cables from the switch. Loosen the switch by drilling out the pop rivets with a 5 mm bit. Fit new microswitch by riveting it onto the attachment. Refit the cables. Check that the microswitch is activated when the reverse pedal is pressed lightly.
  • Page 54: Changing Microswitch, Forward Drive

    Repair Work 7.16 Changing Microswitch, Forward Drive Drill out the pop rivets with a 5 mm bit. Dismantle the attachment with switch. Dismantle the cables from the switch. English –...
  • Page 55 Repair Work Loosen the switch by drilling out the pop rivets with a 5 mm bit. Fit new microswitch by riveting it onto the attachment. Refit the cables. Check that the microswitch is activated when the reverse pedal is pressed lightly. English –...
  • Page 56: Changing Speed Potentiometer

    Repair Work 7.17 Changing Speed Potentiometer Changing the speed potentiometer assumes the pedal plate has been loosened, if this has not been done, follow "7.13". Dismantle the two bolts and nuts, and lift away the attachment plates for the potentiometer and the switches.
  • Page 57: Changing Recoil Spring In Pedal Plate

    Repair Work 7.18 Changing Recoil Spring in Pedal Plate Changing the recoil spring assumes the pedal plate has been loosened, if this has not been done, follow "7.13". Loosen the screw for the pedal attachment. Put in place the spring and refit the screw loosely. English –...
  • Page 58 Repair Work Tighten the screw. Make sure the pedals are not sticking. Check the position of the recoil spring. Move the end of the recoil spring to in front of the drive disc. Calibration may be necessary after changing, see 7.17. English –...
  • Page 59: Calibrating Speed Potentiometer

    Repair Work 7.19 Calibrating Speed Potentiometer Sit on the seat. Hold in the power and savE buttons. Turn the key to position 1. SaveE is on, power and battery indicator flash. Press the accelerator pedal to bottom and release again. Press the reverse pedal to bottom and release again.
  • Page 60: Calibrating Speed

    Repair Work 7.20 Calibrating Speed The test below assumes that points 1-5 in 7.17 have been completed. IMPORTANT INFORMATION Calibration may only be carried out with fully charged batteries, rear wheel tire pressure of 1.0 bar and the machine standing on a roller bench. Hold in the power button and then press the savE button.
  • Page 61: Assemble New Baffle Plate

    Repair Work 7.21 Assemble New Baffle Plate Loosen the left wing cover for better access, see "6.2". Loosen the contact for the switch and unhook the spring. Remove the existing plate. English –...
  • Page 62 Repair Work Assemble the new baffle plate. Refit the spring and contact. English –...
  • Page 63: Changing Microswitch, Baffle Plate

    Repair Work 7.22 Changing Microswitch, Baffle Plate Loosen the left wing cover. Dismantle the cables from the switch. Loosen the switch by drilling out the pop rivets with a 5 mm bit. Fit new microswitch by riveting it onto the attachment.
  • Page 64: Repair Work Electrical Components

    Repair work electrical components 8 Repair Work Electrical Components Table of contents 8.1 Changing Seat Switch .........................65 8.2 Changing Control Panel ........................67 8.3 Changing Key Switch .........................68 8.4 Changing Drive Motor..........................69 8.5 Changing Control Unit (CCU) ......................74 8.6 Changing Fuses ..........................76 English –...
  • Page 65: Changing Seat Switch

    Repair work electrical components 8.1 Changing Seat Switch WARNING! Working on a live machine can cause lethal injury. Disconnect the batteries, see Chapter 2.12 CCU must be updated after replacing an old version of seat switch with a new one. Turn off the machine and remove the ignition key.
  • Page 66 Repair work electrical components Dismantle the integrated switch if it is still in the connector. Use a flat blade screwdriver to remove the plastic impacting the switch in the center of the connector as illustrated. Assemble the new seat switch. Refit the battery cover and fasten with snap locks.
  • Page 67: Changing Control Panel

    Repair work electrical components 8.2 Changing Control Panel WARNING! Working on a live machine can cause lethal injury. Disconnect the batteries, see Chapter 2.12 Turn off the power and remove the ignition key. Disconnect and unscrew the existing control panel. Assemble in reverse order.
  • Page 68: Changing Key Switch

    Repair work electrical components 8.3 Changing Key Switch WARNING! Working on a live machine can cause lethal injury. Disconnect the batteries, see Chapter 2.12 Turn off the machine and remove the ignition key. Remove the nut and lift out the key switch from below.
  • Page 69: Changing Drive Motor

    Repair work electrical components 8.4 Changing Drive Motor WARNING! Working on a live machine can cause lethal injury. Disconnect the batteries, see Chapter 2.12 Loosen the snap locks and remove the upper cover. Remove the wheels, see "6.1". Remove covers from the rear, see "6.2". Remove the brake wire.
  • Page 70 Repair work electrical components Unscrew the hex screw in the hub of the brake device. Unscrew the three bolts holding the attachment plate for the brake device. Lift away the entire attachment plate with brake device. English –...
  • Page 71 Repair work electrical components Loosen the master link in the drive chain. Remove the chain to free the top gear. Remove the top gear. Unscrew the four hex screws for the motor. English –...
  • Page 72 Repair work electrical components Loosen the negative cable from the electric motor. Cut the cable ties keeping the cables in place. Loosen the ground cable. English –...
  • Page 73 Repair work electrical components 13 Loosen the positive motor cables and the signal cables. Loosen the remaining four screws holding the motor. 9/16” Remove the motor. Assemble the motor in the reverse order. Calibration is necessary after changing, see "7.19". The brake wire may require adjustment after refitting, see "7.5".
  • Page 74: Changing Control Unit (Ccu)

    Repair work electrical components 8.5 Changing Control Unit (CCU) WARNING! Working on a live machine can cause lethal injury. Disconnect the batteries, see Chapter 2.12 Loosen the snap lock and remove the upper cover on the rear carriage. Uncouple all four connectors from the CCU. Unscrew and remove the existing CCU.
  • Page 75 Repair work electrical components Fit new CCU with the four screws. Refit all four connectors to the CCU. Refit the cover with snap locks. After changing the CCU, the software must be updated via Common Service Tool, followed by speed calibration accoarding to section 7.20. English –...
  • Page 76: Changing Fuses

    Repair work electrical components 8.6 Changing Fuses WARNING! Working on a live machine can cause lethal injury. Disconnect the batteries, see Chapter 2.12 IMPORTANT INFORMATION The fuses are intended to protect the electrical system. If the new fuse blows again shortly after replacement, it is due to a short circuit, which must be fixed before the machine can be put into operation again.
  • Page 77: Troubleshooting With Common Service Tool

    Troubleshooting with Common Service Tool 9 Troubleshooting with Common Service Tool Table of contents 9.1 Common Service Tool (CST) .......................78 9.2 Connecting CST ..........................78 9.3 Component Locations, Electrical System ....................79 9.4 Electrical Components.........................80 English –...
  • Page 78: Common Service Tool (Cst)

    Troubleshooting with Common Service Tool 9.1 Common Service Tool (CST) The Common Service Tool is for the Husqvarna Rider Battery. It is intended for use with a laptop computer (PC not included). The software is available for download from the Husqvarna website and is compatible with Windows XP and later.
  • Page 79: Component Locations, Electrical System

    Troubleshooting with Common Service Tool 9.3 Component Locations, Electrical System 1. Cutting motor 8. Microswitch "forward" 17. Charge connector 25. Single-action power 2. Control panel 9. Microswitch baffle 18. Blade motor control - relay 3. Blade motor control - plate ver.
  • Page 80: Electrical Components

    Troubleshooting with Common Service Tool 9.4 Electrical Components 1. Cutting motor 8. Microswitch "forward" 17. Charge connector 25. Single-action power 2. Control panel 9. Microswitch baffle 18. Blade motor control - relay 3. Blade motor control - plate ver. 2 26.
  • Page 81: Description Of Electrical System

    Description of electrical system 10 Description of Electrical System Table of contents 10.1 Cable Drawing ...........................82 10.2 Wiring Diagram (cutting motor control ver. 1) ..................84 10.3 Wiring Diagram (cutting motor control ver. 2) ..................86 10.4 Description of CCU ..........................88 10.5 Contacts ............................92 10.6 Description of Cables ........................93 English –...
  • Page 82: Cable Drawing

    Description of electrical system 10.1 Cable Drawing Connector indicator panel Cuttingdeck 1:GND unit v2 2:BATTERY 100% 3:BATTERY 75% 4:BATTERY 50% 5:BATTERY 25% 6:BATTERY LOW LED 7:ERROR TRIANGLE 8:ECO LED 9:+5 VOLT 10:START SWITCH LED 11:ECO MODE SWITCH Reverse switch 12:START SWITCH Reverse ON = +5V to CCU Speed demand rotary potentiometer...
  • Page 83 Description of electrical system Connector A at CCU Connector B at CCU Connector C at CCU Connector D at CCU A1:LIFT_SW B1:SPEED FEEDBACK C1:NC D1:P-brake A2:START_SW B2:SPEED DEMAND C2:NC D2:SEAT SWITCH A3:ECO_SW B3:MOTOR ERROR C3:NC D3:FORWARD A4:CHARGER_IN B4:MOTOR TEMP C4:NC D4:REVERSE A5:START_LED B5:MOTOR ENABLE...
  • Page 84: Wiring Diagram (Cutting Motor Control Ver. 1)

    Description of electrical system 10.2 Wiring Diagram (cutting motor control ver. 1) P-brake Speed potentiometer 5K Forward Diode Reverse Shifting power relay Fuse Brake resistor 22R 100W Diode Seat switch Cutting deck Drive motor on switch 2 BATT+ BATT- Power relay S peed feedback S peed IN 0-4,5V E rror out...
  • Page 85 Description of electrical system INDIC ATION A1:LIF T_S W A7:B ATTE R Y 100% B ATTE R Y 100% Cutting deck Cutting deck A8:B ATTE R Y 75% B ATTE R Y 75% A9:B ATTE R Y 50% B ATTE R Y 50% safety switch on switch 1 A10:B ATTE R Y 25%...
  • Page 86: Wiring Diagram (Cutting Motor Control Ver. 2)

    Description of electrical system 10.3 Wiring Diagram (cutting motor control ver. 2) P-brake Speed potentiometer 5K Forward Diode Reverse Shifting power relay Fuse Brake resistor 22R 100W Diode Seat switch Cutting deck Drive motor on switch 2 BATT+ BATT- Power relay S peed feedback S peed IN 0-4,5V E rror out...
  • Page 87 Description of electrical system INDIC ATION A1:LIFT_S W A7:BATTE R Y 100% BATTE R Y 100% Cutting deck Cutting deck A8:BATTE R Y 75% BATTE R Y 75% A9:BATTE R Y 50% BATTE R Y 50% safety switch on switch 1 A10:BATTE R Y 25% BATTE R Y 25% A11:B ATTE R Y 25%...
  • Page 88: Description Of Ccu

    Description of electrical system 10.4 Description of CCU CCU is a control unit that manages signals in the Rider Battery and controls the machine. The CCU unit has four connectors with 12 pins each. These connectors are marked A, B, C and D. Connector A Function Output...
  • Page 89 Description of electrical system Connector B Function Output Max in/output (Black) Input for speed signal from drive 4000 ohm motor. Output for speed limiter to drive motor. Input for fault indication 1000 ohm from drive motor. Input temperature signal from 22000 ohm drive motor.
  • Page 90 Description of electrical system Connector C Function Output Max in/output (Green) Connection of future internal functions in CCU, reserve 1. +5 V reserve, short-circuit pro- +5 V 50 mA tected output 50mA. Input: (ISP_Re- set_1) signal used for any program- ming problems.
  • Page 91 Description of electrical system Connector D Function Output Max in/output (Pink) Input signal from parking brake. Input signal from seat switch. 50 mA Input signal from +5 V direction switch for forward. Input signal from direction switch for backward. Input signal 1 from motor control 1 on cutting deck.
  • Page 92: Contacts

    Description of electrical system 10.5 Contacts These connectors are used for coupling the cutting deck and control unit (CCU), In order to loosen the cables from the connector, a screwdriver can be used to open the orange front. Then lift a small hook that is keeping the connector in place.
  • Page 93: Description Of Cables

    Description of electrical system 10.6 Description of Cables At the same time as one of the switches is activated, a potentiometer is also affected that The machine's electrical system is split into two requests the desired speed of the machine. The large cables (Cable 1 and Cable 2) and also some potentiometer is turned manually from the pedal smaller cables.
  • Page 94 Description of electrical system A safety switch for the cutting deck is also con- nected to Cable 1. This switch detects if the cutting From this switch, the start signals then go via two deck is in place and that the hook that secures the yellow leads down to the four pole connectors and cutting deck in place on the machine is locked.
  • Page 95 Description of electrical system Cable 2 connections to front part of the battery charger also has a fuse which may have machine blown if there is a problem with charging. Cable 2 goes to the control panel with the battery Drive motor connection to machine status indicator, buttons, key, seat switch and the two switches for activating the cutting deck.
  • Page 96 Description of electrical system The single-action power relay is now activated, which in turn powers the drive motor via the thick Connector A at CCU red lead. This lead has a 150 A fuse before the power relay. To protect the drive motor electronics, A1:LIFT_SW there is a diode mounted between the 150 A and A2:START_SW...
  • Page 97: Cst Autotest

    CST Autotest 11 CST Autotest Table of contents 11.1 Power Supply ....................... 98 11.1.1 Test of +36 V ..........................98 11.1.2 Test of +5 V ..........................99 11.2 Switches ......................107 11.2.1 Test of Cutting Deck ........................107 11.2.2 Test of Seat Switch ........................108 11.3 Pedals .........................
  • Page 98: Power Supply

    CST Autotest 11.1 Power Supply 11.1.1 Test of +36 V Power supply Description of 36 V test and batteries 36V power supply The first CST test is an autotest. This tests that 5V power supply there is +36 V in to the CCU unit. None of the test will work if the CCU unit is not receiving +36 V.
  • Page 99: Test Of +5 V

    CST Autotest 11.1.2 Test of +5 V The machine must be activated for this test and if a fault indication is received during the test of +5 V, the fault must be found before continuing with the other tests. (When trouble shooting without CST, a multimeter must first be used to see if +5 V is being delivered by CCU, connector D11, orange lead.) This is because this +5 V feeds all the microswitches,...
  • Page 100 CST Autotest The orange lead goes from CCU D11 to a first cou- pling with flat pin in Cable 1. This flat pin is coupled Connector D at CCU with a flat pin receptacle, the cable of which goes into Cable 2 to supply it with +5 V. In Cable 1, this +5 V goes to the microswitches for reverse, for- D2: Seat switch ward, P-brake and the microswitch for detecting...
  • Page 101 CST Autotest In Cable 2, +5 V goes to the microswitch for cutting deck activation, which is mounted by the cutting deck lifting lever. The microswitch is activated when the cutting deck is lowered. +5 V also goes to the seat switch, control panel and battery connector in the charger.
  • Page 102 CST Autotest Troubleshooting autotest for fault on +5 V sup- The +5 V supply has an automatic fuse that trig- gers if the output current from CCU exceeds 1 A. When this overcurrent consumption ceases, the fuse will reset automatically and +5 V will return. In case of a fault indication in the test software, there will be no +5 V supply to the machine from CCU.
  • Page 103 CST Autotest If the machine has cutting motor control version 2, the machine chassis will be connected to GND and if the machine has cutting motor control version 1, GND will not be connected to the chassis. The Reverse switch three microswitches that are mounted on the pedal Reverse ON = 5V to CCU plate were disconnected when the connector was...
  • Page 104 CST Autotest Still in Cable 1 is +5 V to the safety switch for detecting that the cutting deck is mounted. It is activated when the cutting deck has been correctly fitted. Loosen the connection with the orange leads from the switch and see if +5 V is OK.
  • Page 105 CST Autotest In order to test for faults on +5 V in Cable 2, recon- nect the flat pin and receptacle so that Cable 2 shall have +5 V. Start by checking that +5 V is not short circuited in the battery charger connector.
  • Page 106 CST Autotest Remaining in this cable is the seat switch, which Seat switch is also supplied with +5 V. Here, the orange cable must be checked to see that it is not in contact with GND at the seat switch, if the machine has version 2 of the cutting motor control, so that the chassis is connected to GND.
  • Page 107: Switches

    CST Autotest During this trouble shooting we assume that Switches +5 V is OK. Cutting deck 11.2 Switches Seat 11.2.1 Test of Cutting Deck If the test fails, check that the switch turns on when the cutting deck is activated. If there is +5 V at the microswitch on the gray lead, Cuttingdeck on switch 1 the gray lead must be measured where it goes into...
  • Page 108: Test Of Seat Switch

    CST Autotest 11.2.2 Test of Seat Switch The switch that detects occupancy of the seat is Seat switch also supplied with +5 V on one side. The other side leads +5 V to CCU D2 via a green lead if the driver sits on the seat.
  • Page 109: Pedals

    CST Autotest During this trouble shooting we assume that +5 V is OK. Pedals 11.3 Pedals Forward speed pedal Reverse speed pedal P-brake 11.3.1 Test of Switch for Forward Pedal Connector D at CCU When the driver depresses the pedal, +5 V is fed to the green lead.
  • Page 110: Test Of Switch For Reverse Pedal

    CST Autotest 11.3.2 Test of Switch for Reverse Pedal When the driver depresses the pedal, +5 V is fed Connector D at CCU to the white lead in the pedal plate connector. If CCU cannot read this input signal during the test, D4: Reverse the switch may be defective.
  • Page 111: Keypad

    CST Autotest 11.4 Keypad 11.4.1 Test of LED During this trouble shooting we assume that +5 V is OK. Keypad While testing the LEDs, all the possible states of Leds the LED indicators are stepped through while see- ing that they are turned on and off as they should. Buttons If any of these LEDs does not come on or go off, or two LEDs or more are on at the same time, then...
  • Page 112 CST Autotest Tests if control panel is changed but faults still present during the test Test of switch on control panel. The two switches on the control panel each send a +5 V signal to CCU when one of the buttons is pressed. When the switch for savE is pressed, a +5 V signal is sent to CCU connector A:3.
  • Page 113: Miscellaneous

    CST Autotest 11.5 Miscellaneous 11.5.1 Test of Charger Manual test without CST can also be carried out with the help of the text below. Miscelaneous Test with CST check of signal with charger connected. Charger CCU A:4 is an input signal indicating that the bat- tery charger is connected.
  • Page 114 CST Autotest If +5 V is on the orange lead, couple the connector from the battery charger and measure on the back of the green lead connection. If +5 V is not on the green, go to the next item. Common point Battery charger connector Wire connections inside the...
  • Page 115: Cst-Drive Mode Logging

    CST-drive mode logging 12 CST-Drive Mode Logging Table of contents 12.1 Manual Drive Mode Logging......................116 12.2 Keypad Buttons ..........................116 12.3 Main Relay............................116 12.4 Troubleshooting the Main Relay ......................116 12.5 Electrical Circuit Diagram .......................117 12.6 Troubleshooting with Circuit Diagram ....................118 12.7 Switches ............................119 12.8 Pedals..............................121 12.9 Keypads LEDs ..........................121 12.10 Miscellaneous ..........................122...
  • Page 116: Cst-Drive Mode Logging

    CST-drive mode logging 12.1 Manual Drive Mode Logging 12.4 Troubleshooting the Main Relay Using CST drive mode logging, the machine can Inside CCU is a drive circuit that couples one side be operated while looking at what is happen- of the relay's activation coil to GND. This circuit is ing with the various signals on the screen.
  • Page 117: Electrical Circuit Diagram

    CST-drive mode logging Connector at CCU GND via CCU C7: Main relay on/off Key switch to CCU Alternating power relay Key switch to motor 36+V from motor 500mS after key switch on Free wheeling diodes Drive motor Main relay +36V from key switch 12.5 Electrical Circuit Diagram these relays have a freewheeling diode across its The key switch is always supplied with +36 V...
  • Page 118: Troubleshooting With Circuit Diagram

    CST-drive mode logging 12.6 Troubleshooting with Circuit Diagram A brown lead runs from CCU connector C:7 to one pole of the switching relay coil. On the other side of the relay coil is a gray lead running to the single-action power relay coil. On the other side of the coil on the single-action relay is a brown lead running to the drive motor.
  • Page 119: Switches

    CST-drive mode logging 12.7 Switches Manual drive mode logging in CST can indicate breaks and short circuits. A short circuit is the Switches when the drive stage If the drive circuit inside CCU Lift switch attempts to drive a higher current than it can han- Seat switch Driver not seated dle (1 Ampere), it will turn off its output at the same...
  • Page 120 CST-drive mode logging Now take a reading on the brown lead's connec- should read battery voltage, about 36 V. tion to the microswitch, it should be around battery If not and the 80 A fuse is intact, there is probably voltage (36 V) measured to GND blue lead (GND a break between the fuse and the connector, but connection on rear carriage).
  • Page 121: Pedals

    CST-drive mode logging 12.8 Pedals The P-Brake pedal is indicated by P-Brake en- gaged and P-Brake not engaged. This screen indicates if the microswitch that detects the P- Pedals Brake pedal position is in working order. If not, it Speed potentiometer is not possible to activate the machine as CCU Forward pedal Inactive...
  • Page 122: Miscellaneous

    CST-drive mode logging 12.10 Miscellaneous 12.11 Total Battery Current This graph shows the current flowing out from the Miscelaneous machine to the various consumers, this signal is Speed feedback used if version 1 of the cutting motor control is fit- Total battery current ted and savE mode has been activated.
  • Page 123: Drive Motor Error

    CST-drive mode logging 12.12 Drive Motor Error 12.13 Cutting Motor Signals If this symbol is green, it indicates that it is OK. If it Cutting motor signals is red, the drive motor is sending out a fault signal. Cutting deck status Not locked This fault signal goes to the CCU unit, which then Lift switch...
  • Page 124: Activating The Cutting Unit

    CST-drive mode logging 12.15 Activating the Cutting Unit The signal to CCU A:1 is the signal that in the test is called Lift Switch. If the cutting deck's two mo- tors start as intended, CST down is indicated and other signal as below: After activating the cutting deck by lowering it, a +5 V signal is sent to CCU from the microswitch to Cutting motor 1 signal 1.
  • Page 125: Manual Cst Tests

    Manual CST tests 13 Manual CST Tests Table of contents 13.1 Manual CST Tests ...........................126 13.2 Lift Switch ............................126 13.3 Seat Switch............................127 13.4 Cutting Deck Status .........................127 13.5 Pedals..............................128 13.6 Speed Potentiometer ........................128 13.7 Forward Pedal Switch........................129 13.8 Forward Pedal Switch........................129 13.9 P-brake Pedal Switch ........................130 13.10 Main LED’s ............................131 13.11 Test Activation LED on ........................131...
  • Page 126: Manual Cst Tests

    Manual CST tests 13.2 Lift Switch WARNING! During manual trouble shooting This shows the state of the microswitch that sends the batteries must be connected a signal to CCU when the cutting deck is lowered. and the machine powered. With the cutting deck raised, the Lift Switch row will say Up and with the cutting deck lowered, it Take extra care when working on the machine.
  • Page 127: Seat Switch

    Manual CST tests 13.3 Seat Switch 13.4 Cutting Deck Status This shows that state of the seat switch. If it says This signal shows whether the cutting deck is "Driver not seated" on the row for Seat Switch, mounted. If CCU does not receive the signal that it means the seat switch is not activated when the cutting deck is in place, it will not be possible nobody is in the seat or pressing down the switch.
  • Page 128: Pedals

    Manual CST tests 13.5 Pedals In this connector there are three leads, one orange, one gray and one blue. If the connector is This box shows the signal from the speed unplugged from the potentiometer and the orange potentiometer, the signal from the Forward pedal cable coupled with the gray cable, "max"...
  • Page 129: Forward Pedal Switch

    Manual CST tests Try measuring in connector D on CCU by inserting 13.7 Forward Pedal Switch a thin wire through the rubber on the back of the connector so it make contact with the receptacle Conducting this test shows whether the inside the connector.
  • Page 130: P-Brake Pedal Switch

    Manual CST tests This green lead goes via Cable 1 to CCU and P-brake switch to connector D:4. If there is no change when activating the microswitch for forward, first check P-brake switch signal to CCU that there is +5 V on the orange lead that is connected to the microswitch.
  • Page 131: Main Led's

    Manual CST tests 13.10 Main LED’s 13.12 Test SavE LED on This test is used to check that all the LEDs on the To activate the savE LED, press the savE LED control panel are in working order. on button in CST and then the LEDs (two) inside the savE button light up.
  • Page 132: Test Error Led On

    Manual CST tests 13.13 Test Error LED on 13.15 Battery 100 % LED on To activate the Error LED, press the Error LED on To activate 100 % LED, press the Battery 100 % button in CST and then the two LEDs inside the LED button on in the test and then the LED for Error symbol should come on (red triangle).
  • Page 133: Battery 75 % Led On

    Manual CST tests 13.16 Battery 75 % LED on 13.17 Battery 50 % LED on To activate 75 % LED, press the Battery 75 % LED To activate 50 % LED, press the Battery 50 % LED button on in the test and then the LED for 75 % in button on in the test and then the LED for 50 % in the battery symbol will light up (rectangle second the battery symbol will light up (rectangle second...
  • Page 134: Battery 25 % Led On

    Manual CST tests 13.18 Battery 25 % LED on 13.19 Battery Low LED on To activate 25 % LED, press the Battery 25 % LED To activate Low LED, press the Battery Low LED button on in the test and then the LED for 25 % on button in the test and then the LED for Low in in the battery symbol will light up (rectangle at the the battery symbol will light up (rectangle at the...
  • Page 135: Keypad Buttons

    Manual CST tests 13.20 Keypad Buttons 13.22 SavE This test checks the buttons (switches) that are on Press the "e" button on the control panel and the the control panel. The first button this test shows color changes to blue. If this does not happen, (activation (I)) is for indicating that the machine is make sure the control panel has +5 V with a being activated.
  • Page 136: Miscellaneous

    Manual CST tests 13.23 Miscellaneous If this does not work, a voltage reading must be taken with a multimeter set to measure volt on pin 3 in the machine's connector for coupling This test checks that the battery charge coupling a battery charger and the machine should be signal to CCU is correctly connected and is activated.
  • Page 137: Batteries And Maintenance

    14.12 When Does a Battery Freeze? ......................141 14.13 What Does a Battery Contain and Where Can it Be Disposed Of? ..........141 14.14 Husqvarna's Battery Charger ......................141 14.16 Lead Sulfate, What is It? .......................142 14.17 Charge Voltages for Three Series Connected Lead-Acid Batteries ..........142...
  • Page 138: Battery Maintenance

    Batteries and maintenance 14.1 Battery Maintenance WARNING! Take care when handling battery It is very essential to maintain the batteries. This acid. Acid on the skin can cause serious corrosive injuries. In case applies particularly if the machine is left unused for of contact with the skin, wash long periods, as a lawn mower often does during immediately with water.
  • Page 139: Battery Information

    Batteries and maintenance 14.4 Battery Information A lead accumulator (popularly called "lead battery") is the most common type of battery and the battery type used in this machine. Batteries are heavy and can store a large amount of energy. In order to attain the voltage required in the machine, three batteries have been couple in series.
  • Page 140: When Is A 12V Battery Fully Charged

    Batteries and maintenance 14.6 When is a 12V Battery Fully Charged? A fully charged battery keeps the rest potential (unloaded) over 12.7 volts. Specific gravity is then 1.28. A battery that is principally empty holds a rest potential of about 12 volts. Specific gravity is then 1.20.
  • Page 141: How To Take Care Of Batteries

    12V battery is charged with a voltage of 14.4 V winter season. (14.3 V-14.5 V). Husqvarna's charger uses a charge voltage of 14.4 V (14.3 V-14.5 V). 4. Inspect the ventilation, make sure there is no...
  • Page 142: Lead Sulfate, What Is It

    Batteries and maintenance 14.15 Theory and Facts on Car has been fully charged in warm conditions. Cold Batteries therefore considerably reduces the service life of a battery if current is take out of it in the cold. However, it is fully possible to store a fully charged In winter and cold conditions, the battery capacity battery in cool or cold conditions as long as it is is considerably reduced.
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