Technical Information · issue 51 of 2010
New analyzer STIHL ADG 2
IssueTI 51/2010
Full text
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STIH)
Technical Information 51.2010
New analyzer STIHL ADG 2 – Series 4850
Overview
1. Technical description
2. Safety instructions
3. Diagnosis of cordless machines
4. Specifications
5. Service notes
TI_51_2010_30_01_01.fm englisch / English
)m~ge 2 Technical Information 51.2010
1. Technical description Instruction Manual.
The new STIHL analyzer ADG 2 makes it possible 1.2 Light-emitting diode (LED) on analyzer
to test the electrical components of all STIHL
cordless machines with an EC (electronically
commutate / brushless) motor.
Testing requires a STIHL type AP battery that is
suitable for the cordless machine to be tested and
has a charge status of at least 80 %.
1 1
3
4
007TI003 AM
The light-emitting diode (1) on the analyzer can be
continuous or flashing green, yellow or red.
Continuous green light
007TI001 AM
2 – Cordless machine and/or function OK
Continuous yellow light
The battery (1) supplies the cordless machine (2)
– Temporary fault in the cordless machine in the
with the power required for testing. The connection
past (e. g., loose contact), cordless machine is
to the cordless machine is made via the adapter (3)
operational at the moment – the fault is
of the analyzer (4).
displayed in the fault memory of the cordless
Batteries cannot be tested using the analyzer machine
ADG 2. The STIHL battery analyzer ADG 1 is still
A continuous red light
required for testing batteries.
... may have the following meanings:
1.1 Instructions for use – Active fault in cordless machine, cordless
machine is not operational at the moment –
a damage code may be displayed
– Malfunction, see b 3.10
A flashing red light
... may have the following meanings:
– Observe safety instructions on display – see
1 b2
– Fault in analyzer (analyzer display is blank) –
007TI002 AM
software update required
The analyzer is controlled using two pushbuttons (1):
– Confirmation of actions during the test
procedure
– Browsing between the display screens during
the test procedure
– Language selection
– Deleting the fault memory
For additional instructions on using the device – see
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Technical Information 51.2010 Page 3
2. Safety instructions
The motor of the cordless machine
starts during the test. Before the start
of the test, always rule out injuries by
the tool on the cordless machine –
risk of accident!
Varying measures are necessary depending on the
cordless machine:
STIHL cordless brushcutter STIHL cordless chain saw
007TI004 AM
007TI005 AM
. Removing the mowing head . Removing the bar and chain
STIHL cordless blower
007TI006 AM
. Position the machine so that no objects, people
or pets come in contact with the stream of air
For additional information and safety instructions – see Instruction Manuals of the respective cordless machine
and the ADG 2 analyzer.
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3. Diagnosis of cordless machines
3.1 Troubleshooting chart
Machine does not run or only hums
Check battery for state of charge, proper installation
and damage (housing, seal, contacts)
Battery
Charge / properly install /
- charged, properly installed, replace battery
undamaged?
yes
no Does yes
Check light-emitting diodes (LEDs) on battery machine run?
no LED light up or flash
red?
yes
3 LEDs flash 4 LEDs flash 3 LEDs light up 1 LED lights up
Fault in machine, Fault in battery, Machine is too hot Battery too hot /
check machine check with ADG 1 – allow it to cool cold, allow it to
and replace if off cool off / warm up
necessary
Does no
machine run?
1 2 yes 3
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Technical Information 51.2010 Page 5
1 2 3
Check machine for external damage:
- Tools
- Operating elements
- Housing
Is machine Replace damaged parts
yes
damaged?
Check electrical components for damage and
function with ADG 2 no Does yes
machine run?
and replace if necessary
no Does yes
machine run?
Repair procedure
completed
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3.2 Connecting the analyzer The test procedure continues automatically after
. Electrically connect the analyzer – see insertion of the battery. If the test procedure does
Instruction Manual not continue, this may be caused by the following:
After the analyzer is connected to the power supply, – no contact between battery and analyzer –
the display will read (with gray background in the remove the battery and reinsert it
following text): – Fault in battery – if necessary, check with STIHL
battery analyzer ADG 1
Analyzer If the state of charge of the battery is too low, this will
ADG 2 be indicated on the display:
Afterwards a self-test will take place. During this
process, the light-emitting diode on the analyzer State of charge too low
turns green, yellow and then red for
approx. 1 second and then goes out again.
. Use a battery with a sufficient state of charge
Self test 3.2.2 Insert adapter
Through insertion of the adapter, the cordless
machine is connected with the battery. The cordless
Once the self-test is completed: machine is operational.
. select language if necessary – see Instruction The motor of the cordless machine
Manual starts during the test. Before the start
of the test, always rule out injuries by
3.2.1 Insert battery the tool on the cordless machine –
risk of accident!
Insert battery
The following instructions appear on the display:
Eliminate risk from tool
. Eliminate risk from tool on cordless machine –
see b 2
2
. Press lower pushbutton to confirm
007TI008 AM
Insert adapter
. Slide the battery (1) into the analyzer (2) until
you start to feel resistance – then push it in until
it engages 1
007TI009 AM
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. Insert adapter (1) in the compartment of the 3.3 Data transfer
cordless machine – adapter slides into the The cordless machine and the analyzer exchange
compartment – press gently until it audibly information with one another. The analyzer can only
snaps into place. The adapter must end flush test the cordless machine if data transfer is working.
with the top edge of the housing
. Press lower pushbutton to confirm
Switch on unit
CAUTION! Motor may start
. Switch on cordless machine – see Instruction
Manual of the respective cordless machine
. Press lower pushbutton to confirm
Data transfer
If no data transfer takes place between the cordless
machine and the analyzer, there is a malfunction in
the connection to the cordless machine. This can be
for the following reasons:
– Fault in adapter of the analyzer – check
connecting cable and adapter for external
damage and replace if necessary, see b 5.1
– Fault in operating elements – troubleshooting,
see b 3.4.2
– Fault in wiring harness or electronics module of
the cordless machine – troubleshooting, see
b 3.6.3, b 3.6.4
Switch unit on again
. Switch the cordless machine on again for
3 seconds – the test procedure starts
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3.4 Check correct operation of operating Switch (hand guard)
elements (STIHL cordless chain saw only)
The operating elements may vary depending on the
cordless machine being tested. Operate hand guard
The state of the operating element is always shown OFF
in the display, see b 3.4.1.
. Operate hand guard
If the switch is functioning properly, when the
operating element is pressed, the display will
change and the light-emitting diode on the analyzer Operate hand guard
will light up green. ON
If the display does not change and/or the value is
not 100 % attained when the operating element is
pressed all the way:
3.4.2 Troubleshooting chart, operating
. Test switch according to flow chart – see elements
b 3.4.2
3.4.1 Switch state display
Display does not change and/or the
value is not attained
Switch (trigger switch)
Operate trigger switch
OFF
. Operate trigger switch Examine operating element for signs
of damage, replace if necessary
Operate trigger switch
Switch (trigger switch) with infinitely adjustable Check wiring harness and plug
control of the speed connection
of the switch, replace if necessary
Operate trigger switch
OFF 0%
. Operate trigger switch
Replace switch if necessary
Operate trigger switch
ON XXX %
In cordless machines with infinite control of the
speed, the currently selected power level (in
percent) can be read in the display (represented in
the description with XXX %).
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3.5 Fault indicator Remove adapter
The adapter must be removed from the cordless
3.5.1 No fault in cordless machine
machine before beginning to make repairs.
No fault
Remove adapter before
End of test
repair
The light-emitting diode on the analyzer is
permanently green.
Pressing the lower pushbutton restarts the test.
2
3.5.2 Fault in cordless machine 1
Depending on the type of fault, the light-emitting 1
diode in the analyzer is continuously yellow or red:
– A continuous red light: active fault, cordless
007TI010 AM
machine is not operational – a damage code
may be displayed
– Continuous yellow light: temporary fault in the
past (e. g., loose contact), cordless machine is . Press both safety catches (1) simultaneously –
operational – the fault can be retrieved in the adapter (2) is unlocked
fault memory of the cordless machine . Remove adapter (2) from the housing
The display first shows active faults (if present), then . Press lower pushbutton to confirm
entries in the fault memory. It is possible to browse
The data of the cordless machine remains
back and forth between the displays using the
preserved afterwards in the analyzer for approx.
pushbuttons of the analyzer.
30 min
After removal of the adapter, active faults and
Damage code
entries in the fault memory – if present – are listed,
For some active faults, first a damage code is see b 3.6 and b 3.7.
displayed:
Fault memory
Damage code If entries are stored in the fault memory, the
XX following message appears on the display:
The two-digit code in the display (represented in the
description with XX) indicates the cause for the fault Fault memory
in the cordless machine.
Always state the code in the warranty claim form
. Press lower pushbutton to view the entries in the
when making a complaint.
fault memory
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3.6 Faults (components)
2 6
007TI011 AM
4 1
Fault (display ADG 2) Remedy
Electronic module . Replace the electronic module (1)
Electric motor . Replace electric motor (2)
Sensor lead . Test sensor lead (3) according to flow chart –
see b 3.6.1
Motor lead The plug connectors on the electric motor are
marked YLW (yellow), BLU (blue) and RED (red).
. Clip the correspondingly colored leads to the
plug connections
. Test motor lead (4) according to flow chart –
see b 3.6.2
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2 6
007TI011 AM
4 1
Fault (display ADG 2) Remedy
Motor lead / The plug connectors on the electric motor are
Sensor lead marked YLW (yellow), BLU (blue) and RED (red).
. Clip the correspondingly colored leads to the
plug connections
. Test motor lead (4) according to flow chart –
see b 3.6.2
. Test sensor lead (3) according to flow chart –
see b 3.6.1
Wiring harness / . Test wiring harness (5) and contact plate (6)
contact plate according to flow chart – see b 3.6.3
Wiring harness / . Test wiring harness (5) and switch (7) according
switch to flow chart – see b 3.6.4
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3.6.1 Troubleshooting chart "sensor lead"
Check sensor lead to en-
sure that it is firmly seated,
plug in if necessary
yes Are wires / plugs no
of the sensor lead
damaged?
Replace electronic Replace electric
module motor
In rare cases, the fault may also
be in the electronic module if the
sensor lead is undamaged,
replace electronic module
if necessary
3.6.2 Troubleshooting chart "motor lead"
Check motor lead to en-
sure that it is firmly seated,
plug in if necessary
yes One or more motor leads no
damaged?
Replace electronic Replace electric
module motor
In rare cases, the fault may also
be in the electronic module if the
motor leads are undamaged,
replace electronic module
if necessary
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3.6.3 Troubleshooting chart
"wiring harness/ contact plate"
Check plug connections
of the wiring harness on
electronic module to
ensure that they are firmly
seated,
plug in if necessary
(red, black and
yellow-green lead to
contact plate)
Check battery
compartment for dirt and
damage, clean if
necessary
Wiring harness
(red, black and
yellow-green lead to
contact plate)
yes or contact plate no
damaged?
Replace wiring Replace electronic
harness module
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3.6.4 Troubleshooting chart
"wiring harness / switch"
Check plug connection of
the wiring harness on
electronic module to
ensure that it is firmly
seated,
plug in if necessary
(leads
to switches)
Check plug connections
of the wiring harness
to the switches
for secure fit,
plug in if necessary
Wiring harness
(leads
to switches)
yes damaged? no
Replace wiring Replace electronic
harness module
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3.7 Faults (external influences)
No damage code exists for these fault memory
entries.
Fault (display ADG 2) Remedy
Unit too hot . Let the machine cool off
Recommendation for users:
Observe light-emitting diodes (LEDs) on battery:
3 LEDs are continuously red
Battery less suitable The unit cannot perform to full capacity with this
battery.
. Use a battery with the battery power (Wh)
recommended for operating the cordless
machine
Automatic cut out Cut out due to environmental influences, e. g.,
moisture or dust
. Check the machine mechanically
Recommendation for users:
Remove battery from unit and clean battery
compartment.
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3.8 Clear fault memory 3.9 After the test
Once the cordless machine has been repaired, the . Remove the battery from the analyzer
fault memory can be cleared: Removing the battery causes the data of the
. After viewing the last entry in the fault memory, cordless machine tested to be cleared from the
press the lower pushbutton analyzer. Afterwards the analyzer can be used to
test other cordless machines.
Clear memory?
Press both buttons
. Press and hold both pushbuttons
simultaneously for approx. 3 seconds
Clear: no
Clear: yes
. Confirm clearing of the fault memory by
pressing the lower pushbutton
Insert adapter,
switch on unit
. Insert adapter in the cordless machine
. Switch on cordless machine – see Instruction
Manual of the respective cordless machine
The fault memory is cleared.
To avoid damage to the electronic
module, the adapter must not be
removed from the cordless machine
and the battery must not be removed
from the analyzer during the clearing
procedure.
Do not remove unit
After successful completion, clearing will be
confirmed on the display of the analyzer:
Memory cleared
End of test
Pressing the lower pushbutton restarts the test.
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3.10 Malfunctions
The following messages may appear on the display
of the analyzer during the test procedure. If this
occurs, follow the corresponding instructions.
Malfunction (display ADG 2) Remedy
State of charge too low . Use a battery with a sufficient state of charge
Internal fault . Remove the battery from the analyzer
. Unplug analyzer and plug it in again. If the fault
occurs again – replace analyzer
ADG 2 too hot . Let the analyzer cool off until the message no
longer appears in the display
Battery too hot . Let the battery cool off until the message no
longer appears in the display or use a different
battery
Short circuit . Remove the battery from the analyzer
Remove battery . Remove the adapter from the cordless machine
. Restart test – see b 3.2. If the fault occurs
again – carry out troubleshooting according to
flow chart, see b 3.10.1
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3.10.1 Troubleshooting plan, short circuit 4. Specifications
4.1 Analyzer 4850 840 0202 (US)
Check adapter and connecting cable
of the ADG 2 analyzer for damage,
replace if necessary Mains voltage: 120 V
Frequency: 50-60 Hz
Power consumption: 8W
Protection class: II, E
Check wiring harness with contact 4.2 Battery
plate
in cordless machine
Type: Lithium ion
for damage,
replace if necessary
The analyzer can only be used with STIHL type AP
batteries.
Replace electronic module if
necessary
5. Service notes
1
5.1 Removing the wiring harness
. Unplug analyzer
1 1
2 2
007TI013 AM
3 2
. Disconnect plug (1) of the black lead
1 1
2 2 . Disconnect plug (2) of the red lead
007TI012 AM
. Disconnect plug (3) of the green-yellow lead
. Pry plugs (1) out of the underside of the
analyzer
. Remove screws (2)
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1 3 1
2 1
2
4
007TI014 AM
007TI016 AM
3
. Remove screws (1) . Remove screws (1)
. Remove cable clamp (2) . Remove cable clamp (2)
. Pull wiring harness (3) out of the top of the . Pull wiring harness (3) out of the cover
housing through the opening (4)
007TI022 AM
. Remove screws in adapter cover
. Remove cover
2
1
007TI015 AM
. Unlock and disconnect plug (1) of the yellow-
green lead
. Disconnect plug (2) of the red lead
. Disconnect plug (3) of the black lead
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5.2 Installing the wiring harness
1 2
1 2
1 a
007TI019 AM
2
007TI017 AM
. Position wiring harness (1) in top part of housing
. Slide the bushing (1) onto the cable (2) so that so that the cable insulation ends flush with the
the distance from the bushing to the edge of the guide (2)
cable insulation is a = 1.2 in. (30 mm) . Slide bushing on the cable, if necessary
. Thread wiring harness into the cover of the . Position cable clamp at the opening of the
adapter bushing and screw in screws
. Position cable clamp at the opening of the
bushing and screw in screws 1
1 2
007TI020 AM
3 2
007TI018 AM
007TI015
. Connect plug (1) of the black lead
. Connect plug (2) of the red lead
. Connect plug (1) of the yellow-green lead
. Connect plug (3) of the green-yellow lead
. Connect plug (2) of the red lead
. Connect plug (3) of the black lead
Do not pinch leads when closing the cover.
. Close cover and screw in screws
007TI023 AM
. Thread contacts in the lower part of the housing
into the openings (arrows) in the upper part of
the housing
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)qechnic~l=fnform~tion=RNKOMNM==================================================================================m~ge=ON
5.4 Tightening torques
2 2
1 1 Part(s) Thread Tightening
torque
Cover / adapter M3x25 0.9 lbf. ft.
housing (1.2 Nm)
2 2 Cable clamp / cover P3.5x12 0.9 lbf. ft.
007TI021 AM
1 1 (1.2 Nm)
Upper / lower part of P3x18 0.6 lbf. ft.
. Insert power cord in the housing housing (0.8 Nm)
. Screw in screws (1)
. Press in plugs (2) on the underside of the Cable clamp / lower P4x8 0.6 lbf. ft.
analyzer part of housing (0.8 Nm)
5.3 Electronic module
Use only an appropriate electronic module for the
unit when replacing the electronic module.
XXXX-XXX-XXXX
007TI024 AM
. Observe the part number on the underside of
the electronic module
© ANDREAS STIHL AG & Co. KG, 2010 Technical Documentation
D1/MTK-ro
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Extracted from the manufacturer's 2012 service catalogue. Most of these PDFs embed fonts with a shifted character map, so the text above was recovered rather than copied — read it as a faithful but imperfect transcription, and treat the page image above each block as the authority where the two disagree — the figures exist only there, because they are vector drawings that text extraction cannot keep.