100 h Service ������������������������������������������������������������������������������������������������������������������������������������������������22 250 h Service ������������������������������������������������������������������������������������������������������������������������������������������������23 500 h Service ������������������������������������������������������������������������������������������������������������������������������������������������24 Yearly Service �����������������������������������������������������������������������������������������������������������������������������������������������25 10. HMI Display Display Text �������������������������������������������������������������������������������������������������������������������������������������������������26 FS 5000D Fault Codes �������������������������������������������������������������������������������������������������������������������������������28 Service Menu �����������������������������������������������������������������������������������������������������������������������������������������������29 Setting Menu �����������������������������������������������������������������������������������������������������������������������������������������������29 11. Fault Codes Error Messages������������������������������������������������������������������������������������������������������������������������������������� 30 - 33...
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TABLE OF CONTENTS 12. Function Test Function Test �����������������������������������������������������������������������������������������������������������������������������������������������34 13. Fault Tracing Blade Depth sensor ������������������������������������������������������������������������������������������������������������������������������������37 Lowering �������������������������������������������������������������������������������������������������������������������������������������������������������39 Neutral ����������������������������������������������������������������������������������������������������������������������������������������������������������41 Blade Speed Sensor �������������������������������������������������������������������������������������������������������������������������������������43 Water Pressure Switch ���������������������������������������������������������������������������������������������������������������������������������45 14. Repair Instructions 14.1. Covers Removing the Front Cover ������������������������������������������������������������������������������������������������������������������������48 Removing the Side Covers �������������������������������������������������������������������������������������������������������������������������48 Removing the Fan Protection �������������������������������������������������������������������������������������������������������������������48 14.2.
Parts Cataloge (EPC)� '(02/,7,21 52%276 These electronic catalogs include all ';5 9DOLG IRU PDFKLQH the spares for Husqvarna FS 5000D The catalogs contain complete exploded drawings for each product and the location, spare part number, and appearance of each component is...
LITERATURE Operator’s Manual The operator’s manual describes how the machine is to be used, the functions of the machine, and the maintenance the operator normally carries out� This manual also contains important instructions for the safe handling of the machine� It is extremely important that service Oper ator ′...
General • No one may repair the FS 5000D unless they have read and understood the contents of this workshop manual� • No one may repair the FS 5000D unless they have read and understood the contents of the engine literature service manual�...
SAFETY INSTRUCTIONS Machine Stop Button The FS 5000D is equipped with an machine stop button which will quickly shut down power to the FS 5000D� Always engage the machine stop button before performing maintenance on the machine� Welding work on the machine General Only qualified welders should carry out welding operations on the machine.
SPECIFICATION 5. SPECIFICATION Technical Data TECHNICAL DATA Technical data FS5000 D Saw feature 350/14 500/20 650/26 750/30 900/36 Blade guard capacity, mm/inch 350/14 500/20 650/26 750/30 900/36 Maximum cutting depth, mm/inch 118 (4,75) 193 (7,75) 262 (10,5) 312 (12,5) 374 (15) Blade shaft, rpm 3197 2400...
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SPECIFICATION TECHNICAL DATA Battery FS5000 D FS7000 D Terminal type Standard SAE Standard SAE Voltage, V CCA, A Maximum size (LxWxH), mm/inch 280x175x175 / 11x6-7/8x6-7/8 316x175x190 / 12x6-7/8x7-1/2 Hydraulic fluid and lubricants Hydraulic fluid Quality Standard API Class SE SAE 15W40 API Class CC API class CD Lubricants...
TOOLS AND SPECIAL TOOLS 6. TOOLS AND SPECIAL TOOLS In the list below you will find the tools and the special tools used in this workshop manual. Tools Tool Tool no. Description Ratchet Wrench Wrench Lift strap Allen Key, Kit 2�5 - 10 mm Big Puller Socket, 37/38 mm Universal Pliers...
FUNCTION TEST 8. FUNCTION TEST Function Test Follow these steps to make sure that every function of the flat saw works properly before service and maintenance is carried out� • Start the Engine� • Turn the throttle knob and verify that the engine rev up� •...
SERVICE AND MAINTENANCE 9. SERVICE AND MAINTENANCE The following lists contains service procedures to be performed on the FS 5000D by the servicing workshop� Maintenance procedures normally performed by the owner (daily service) are described in the Operator’s manuals� For all services related to the engine, see engine manufacturer Yanmar’s service manual�...
SERVICE AND MAINTENANCE Daily Service/Checks Oil Level First see Removing the Side Covers (p. 48). Only left side needed. 1� First make sure that the engine is leveled� On the left side of the saw, remove the dipstick and wipe it clean with a cloth before reinserting the dipstick�...
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SERVICE AND MAINTENANCE Drain Fuel Filter/Water Separator First see Removing the Side Covers (p. 48) (Only left side needed) and Removing the Battery (p. 49). 1� Position an approved container under the fuel filter/water separator to collect the contaminants� 2� Close the fuel valve� 3�...
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SERVICE AND MAINTENANCE Safety Guards 1� Make sure all safety guards are in place and in good condition� Check Radiator Coolant Level First see Removing the Side Covers (p. 48) (Only right side needed) and make sure the the coolant is cold. 1�...
SERVICE AND MAINTENANCE 50 h Service Engine oil and Filter First see Removing the Side Covers (p. 48). Only left side needed. 1� Remove the top from the hose and bend it down to empty the system� 2� Unscrew and replace the filter, make sure to fill the new filter with oil and lubricate the seal with a few drops of oil prior to...
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SERVICE AND MAINTENANCE Blade Drive V-belt tension First see Removing the Front Cover (p. 48). 1� Check blade drive V-belt tension by plucking the edge of the belt, like a string� The V-belt should make a tone, not a thump� 2�...
SERVICE AND MAINTENANCE Front Wheel Bearings First see Replacing the Wheels (p. 77). 1� Lubricate the Front Wheel Bearings by using the grease nipples� Hydraulic System Filter 1� Replace hydraulic system filter. Fill the new filter with oil and lubricate the seal with a few drops of oil before assembly�...
SERVICE AND MAINTENANCE Wheels and Rear Wheel 1� Check wheels for wear or damage� Replace if necessary� 2� Check rear wheel hubs and wheels for looseness� Engine air cleaner hose and clamps 1� Check the engine air cleaner hose and clamps� 250 h Service Hydraulic System Filter 1�...
SERVICE AND MAINTENANCE Blade Shafts 1� Grease blade shaft� Two pumps at each end� Image shows the saw from underneath� 500 h Service Engine Gearbox Fluid 1� Open the hole on the gearbox� 2� Use an oil extractor and suck the oil out from the gearbox�...
SERVICE AND MAINTENANCE Hydraulic System Fluid 1� Unscrew the window on the hydraulic reservoir� 2� Use an oil extractor to suck the fluid out from the hydraulic reservoir� 3� Replace hydraulic system filter. Fill up the new filter before attaching it� 4�...
HMI DISPLAY 10. HMI DISPLAY Display Text 1� Machine in emergency stop state (Release emergency stop and cycle ignition to regain full functionality�) Turned on when machine stop is pressed� Turned off when all of the following 3 conditions are met: •...
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HMI DISPLAY 8� Amber Warning lamp� Turned on by ECU CAN message DM1 if Engine has minor fault codes� Same message as DM1 that contains fault codes� HMI does not make any decision on its own� It only displays information coming from the ECU� 9�...
HMI DISPLAY FS 5000D Fault Codes 1� Active fault codes� Turn on if there are active non 2� Engine fail lamp� Turned on by ECU CAN message engine fault codes� DM1 if Engine has any fault codes� Same message that contain the fault codes�...
HMI DISPLAY Service Menu To access the Service Menu, hold the “Menu” button down for 2 seconds� To exit the menu, hold the “Menu” button down for 2 seconds� Setting Menu To access the Setting Menu press the “Menu” button and “Display of blade speed, rpm” down at the same time�...
FAULT CODES 11. FAULT CODES Error Messages Code Message Description Action Check damage to HMI and ECU connector and chassis harness� If found, repair and restart system, reset fault No CAN communica- U100187 Engine ECU code� If problem still exists contact HCP SERVICE for tion further information�...
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FAULT CODES Code Message Description Action 1: Check damage to HMI and ECU connector and Engine starter can not be harness� If found, repair and restart system, reset fault C1D0115 Starter controlled� Cutting can code� not continue� 2: It problem still exists, contact your service agent for further information�...
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FAULT CODES Code Message Description Action 1: Check relay in relay/fuse box Circuit Short To Battery C1D0815 AUX1 2: Check damage to HMI connector and harness to or Open relay/fuse box� 1: Check relay in relay/fuse box C1D0811 AUX1 Circuit Short To Ground 2: Check damage to HMI connector and harness to relay/fuse box�...
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FAULT CODES Code Message Description Action E-track Position C1E0511 Circuit Short To Ground Check damage to actuator, connector and harness� Sensor E-track Position C1E0512 Circuit Short To Battery Check damage to actuator, connector and harness� Sensor 1: Disconnect E-track and reset fault code� If fault code no longer exist check damage to E-track actuator harness C1F0112 E-track Motor A...
TECHNICAL FUNCTIONS 12. FUNCTION TEST Function Test Follow these steps to make sure that every function of the flat saw works properly before service and maintenance is carried out� • Start the Engine� • Turn the throttle knob and verify that the engine rev up� •...
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FAULT TRACING 13. FAULT TRACING Blade depth sensor Error: Value of depth do not change on the display when the saw is lowered. Action: Is all contacts properly Make sure everything connected? is properly connected. Action: Are any fault Read and follow the codes active? recommended action in the fault code section.
FAULT TRACING Lowering Error: The saw can not be lowered. Action: Is the lowering Make sure that the hydraulic valve speed valve opened? is open half a turn. Action: Are any fault Read and follow the recommended codes active? action in the fault code section. Action: Measure the harness by the coil when you engage the lowering switch.
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FAULT TRACING Neutral Error: Engine doesn’t crank when Speed Control in Neutral. Action: Are all contacts Make sure everything is connected properly connected? properly. Action: Measure between pin 28-1 and 28-2 on the switch. Do you have continuity Replace the switch. when the Speed Control is in Neutral? Action: Connect breakout harness (BH) to the HMI2.
FAULT TRACING Blade Speed Sensor Error: Tachometer doesn’t move when engine revs up. Action: Is all contacts properly Make sure everything connected? is properly connected. Action: Connect breakout harness (BH). Measure between cable 13 and cable Action: 26 in BH. Do you have 12 V? When Reinstall software/ ignition is on, cable 14 should measure change HMI.
FAULT TRACING Water pressure switch Error: Engine stops when Water Safety System is turned on. Action: Is all contacts properly Make sure everything connected? is properly connected. Disconnect the harness from Action: the switch. Measure the voltage Change sensor. between cable H2; 26-1 and H2; 14-2.
REPAIR INSTRUCTIONS 14. REPAIR INSTRUCTIONS Table of Content 14.1. Covers Removing the Front Cover ������������������������������������������������������������������������������������������������������������������������48 Removing the Side Covers �������������������������������������������������������������������������������������������������������������������������48 Removing the Fan Protection �������������������������������������������������������������������������������������������������������������������48 14.2. Electrics /Hydraulics Removing the Battery �������������������������������������������������������������������������������������������������������������������������������49 Removing the Wiring Harnesses ��������������������������������������������������������������������������������������������������������������49 Change Lift Cylinder ���������������������������������������������������������������������������������������������������������������������������������52 Dismantling the Rear Axle - Hydraulic Motor ���������������������������������������������������������������������������������������53 14.3.
14.1 COVERS 14.1. COVERS Removing the Front Cover 1� Open the front cover on each side by rotating the turn slot� 2� Lift the cover up and outwards� Removing the Side Covers 1� Open the side covers on each side by rotating the two turn slots�...
ELECTRICS / HYDRAULICS 14.2 14.2. ELECTRICS / HYDRAULICS Removing the Battery First see Removing the Side Covers (p. 48) (only left side needed). 1� Loosen bolt at the minus terminal� Use a safety key� 2� Loosen bolt at the plus terminal� 3�...
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14.2 ELECTRICS / HYDRAULICS 5� Remove four clips on the right side� 6� Remove six clips on the right side 7� Remove three clips located behind the hydralic pump� 8� Open the hatch on the right side (2 screws) and remove the two clips�...
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ELECTRICS / HYDRAULICS 14.2 15� Unplug the depth sensor contact located behind the battery� 16� Unplug the Proximity Sensor� 17� Disconnect the clutch wire (if the saw is equipped with clutch) from the wiring harness located behind the gear box bracket� 18�...
14.2 ELECTRICS / HYDRAULICS Change Lift Cylinder First see Lifting the Road Saw (p. 72), Removing the Rear Axle (p. 74) Removing the Front Axle (p. 75) 1� Cover the ground beneth the hydraulic connectors with a carpet to reduce spill� Then remove hydraulic hose from the undercarriage�...
ELECTRICS / HYDRAULICS 14.2 Dismantling the Rear Axle - Hydraulic Motor First see Removing the Rear Axle 74). The steps below are applicable for both engines. 1� Secure the rear axis vertical in a vise� 2� Remove the hydraulic hoses� 3�...
14.3 COWLING 14.3. COWLING Changing the radiator filter First see Removing the Battery 49). 1� Unlock the back cover by turning the screws� 2� Open the back cover� 3� Remove the filter from behind the springs� 4� Rinse the radiator with water� Do not use a pressure washer! 5�...
COWLING 14.3 5� Refilling. Close the valve and remove the extension� 6� Fill with coolant mix until the level is according to recommendations� See daily service� Removing the HMI Board 1� Unplug the connector by turning it counterclockwise� 2� Remove the 4 screws around the display 3�...
14.3 COWLING Removing the ECU First see Removing the HMI Board (p. 55) and steps 4 & 6 in Removing the Lift Bail (p. 72). 1� Remove the four screws and lift the panel� 2� Remove the plastic cover� 3� Remove the six screws and lift up the bracket�...
COWLING 14.3 4� Flip the top off� 5� Remove the screw located underneath� 6� Pull the top off� 7� Remove the nut� 8� Remove the lowering speed valve� Reverse steps for assembly� Removing the Speed Control First see Removing the Battery (p.
14.3 COWLING 7� Remove the screws on the speed control with a Phillips screwdriver and pull the button out� 8� Remove cables by loosening the screws� 9� Remove the bolt holding the speed control� 10� Cut the clip apart� 11� Pull the speed control up� 12�...
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COWLING 14.3 3� Detach fuel coolant hose from the fuel filter. 4� Put a plug in the hose and in the filter. 5� Pull down the hose to the lowest point of the saw and drain the fuel system in a container (also see next step)�...
14.4 ENGINE 14.4. ENGINE Engine Lift First see Removing the Front Cover (p. 48), Removing the Side Covers (p. 48), Emptying/ Refilling the Radiator (p. 54), Removing the Battery (p. 49), Removing the Fan Protectzion 48), Removing the Lift Bail 72), Removing the Wiring Harnesses (p.
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ENGINE 14.4 9� Disconnect the two fuel hoses from the upper and lower fuel filter. 10� Insert screws as plugs and tighten the clamp� 11� Attach the straps from a traverse through the holes shown in the picture� 12� Slowly lift and secure the engine� Make sure the straps are tensioned�...
14.4 ENGINE Replacing the Fan First see Removing the Side Covers (p. 48) Emptying/ Refilling the Radiator (p. 54). 1� Remove the lower cover by unscrewing the two screws� 2� Remove the bolts on each side of the cowling� 3� Unscrew the two rear bolts� 4�...
ENGINE 14.4 Replacing the Fan Belt First see Removing the Side Covers (p. 48) Emptying/ Refilling the Radiator (p. 54) and step 1-5 in Replacing the Fan 62). 1� Loosen the belt tension� 2� Loosen the bolt holding the generator in place� 3�...
14.5 GEARBOX / CLUTCH / BLADE SHAFT 14.5. GEARBOX / CLUTCH / BLADE SHAFT Blade Shaft Drive Belts First see Removing the Front Cover (p. 48) Removing the Side Covers (p. 48). Removing the Blade Shaft Drive Belts 1� Remove the flange protection and outer pulley protection, two screws each�...
GEARBOX / CLUTCH / BLADE SHAFT 14.5 5� Reinstall the inner pulley protection with three screws each� 6� Reinstall the flange protection and outer pulley protection with four screws each� Changing the Pulleys First see Removing the Front Cover (p. 48) Removing the Blade Shaft Drive Belts (p.
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14.5 GEARBOX / CLUTCH / BLADE SHAFT off the tapered shafts� For Assembly 7� [Gearbox pulleys] Mount the new pulley with washer and screw� 8� The Gearbox pulleys should be in line with the Blade shaft pulleys� 9� [Gearbox pulleys] Attach the pulley cover by fastening the two screws connecting it to the gearbox�...
GEARBOX / CLUTCH / BLADE SHAFT 14.5 Gear Box First see Removing the Blade Shaft Drive Belts (p. 64). Removing the Gear Box 1� Disconnect the water hoses and drain fittings from the gearbox. 2� Slip a short 2x4 under the bell housing of the engine�...
14.5 GEARBOX / CLUTCH / BLADE SHAFT 11� Remove the two nuts at the upper part of the gearbox at the same time as you use a screwdriver to disconnect the gearbox and slide it away from the engine� 12� Use the overhead crane to lift the gearbox off�...
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GEARBOX / CLUTCH / BLADE SHAFT 14.5 5� Fasten the nob� 6� Mount the gear selector� 7� If there is a clutch, then reconnect the clutch wire from the wiring harness� 8� Insert the two horizontal bolts but do not fasten them� 9�...
14.5 GEARBOX / CLUTCH / BLADE SHAFT The Clutch First see Removing the Gear Box 67). Disassembling the Clutch 1� Remove the snap ring 2� Remove the eight bolts retaining the rotor assembly� 3� Remove the two socket head cap screws�...
GEARBOX / CLUTCH / BLADE SHAFT 14.5 5� Insert the remaning seven screws and tighten all eight screws� 6� Attach a new snap ring� Replacing the Clutch Armature First see Removing the Gear Box 67). 1� Remove the four bolts� 2�...
14.6 BASEPLATE / FRAME 14.6. BASEPLATE / FRAME Lifting the Road Saw 1� Use a travers and attach it to the hole on top of the lift bail and lift it up� 2� Put four axle stands beneth the saw and Lower the saw on top of the axle stands�...
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BASEPLATE / FRAME 14.6 9� Cut of all clips located on the lift bail� 10� Remove the two screws connecting the expansion tank to the lift bail� 11� Unscrew the two screws connecting the fuel filter to the lift bail� 12�...
14.7 FRONT- / REAR AXLE / LIFT CYLINDER 14.7. FRONT-/ REAR AXLE / LIFT CYLINDER Rear Axle First see Lifting the Road Saw (p. 72). Removing the Rear Axle 1� Remove the two weels with 4 screws each� (Must not be done, but the axle will be lighter�) 2�...
FRONT- / REAR AXLE / LIFT CYLINDER 14.7 3� Remove the plugs and reconnect the hydraulic hoses 4� Mount the weels with 4 screws� 5� Put the saw back on the ground by Reversing the steps in Lifting the Roadsaw� Replacing the Blade Depth Sensor First see...
14.7 FRONT- / REAR AXLE / LIFT CYLINDER 5� [Left side] Loosen the two screws holding the left bearing� Either use a wrench or move the Hydraulic pump for easier reach� 6� Lower the front axle� 7� Remove the two bolts holding the shaft�...
FRONT- / REAR AXLE / LIFT CYLINDER 14.7 Replacing the Wheels 1� Remove circlips with a circlip pliers� 2� Remove washer� 3� Pull off the wheel� Clean and grease inside of wheel and the front axle before reassemble with the steps revesed� Make sure to use new circlips�...
14.7 FRONT- / REAR AXLE / LIFT CYLINDER Changing the Blade Shaft First see Removing the Front Cover (p. 48) Removing the Side Covers (p. 48). Only left side needed. 1� Lower the front end as much as possible� 2� Disconnect the proximity sensor wire�...
FRONT- / REAR AXLE / LIFT CYLINDER 14.7 Replacing the Saw Axis Bearings First see Changing the Blade Shaft (p. 78) Changing the Pulleys (p. 65). 1� Remove the four screws holding the bearings� 2� Remove the bearings� 3� Use a presser from the opposite side from the proximity sensor�...
SOFTWARE 15. SOFTWARE Software update FS HMI Entering programming mode HMI software is loaded via USB with Freescale MfgTool� To download the software the HMI must be put in pro- gramming mode� Mounted in machine If HMI is mounted in the machine then programming mode is entered by the following steps: 1�...
SOFTWARE Connections The HMI must be powered by an external 12V power supply that can source 1A or more, unless it is mounted on the machine� The following external connections have to be made to the HMI� Function Connector HMI-1 HMI-1 Ignition switch signal HMI-2...
If this happens repeat the process. HMI software is supplied by Husqvarna at http://support.husqvarnacp.com/ as a zip file that contains both the HMI software and MfgTool. Start MfgTool by executing file MfgTool.exe. The MfgTool looks like the image below.
SOFTWARE When software download is complete, the message Operation Complete is displayed section A and the status bar turns green� MfgTool now looks like this: Then press the red Stop button to end software download and close MfgTool and then remove the USB cable from the HMI�...