Husqvarna K 1260 Workshop Manual Download

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HUSQVARNA CONSTRUCTION PRODUCTS

Workshop manual

K 1260

Summary of Contents for K 1260

Page 1: ...HUSQVARNA CONSTRUCTION PRODUCTS Workshop manual K 1260 ...

Page 2: ... 6 5 STARTER 10 6 IGNITION SYSTEM 13 7 FLYWHEEL 16 8 AIR FILTER 18 9 INLET SYSTEM 19 10 FUEL SYSTEM 21 11 CARBURETTOR 24 12 DECOMPRESSION VALVE 29 13 CYLINDER PISTON 30 14 CRANKCASE 36 15 CLUTCH 41 16 CUTTING HEAD 44 17 WET SYSTEM 49 18 HANDLE 50 19 TOOLS 53 CONTENTS Page HUSQVARNA K 1260 ...

Page 3: ...ns there is generally two columns of text The left hand text column is a concise and is suitable for experienced mechanics the right hand column gives a more detailed description and is targeted at mechanics with less experience of repair work on the power cutter Contents The manual is divided into numbered chapters together with chapter headings that are stated in bold at the top of each page The...

Page 4: ...d for track cutting together with the fixture RA10 K1260 Rail has a custom front bearing housing with connection for the track cutting fixture The blade guard is chrome plated to withstand high temperatures The blade guard has no kit for wet cutting The Rail version is also available for blade diameters 14 350 mm and 16 400 mm The blade guard belt pulleys and front belt guard are different for the...

Page 5: ...handle 9 Starter 5 4 1 2 3 6 8 7 9 10 12 13 14 15 19 20 21 16 18 11 17 23 24 10 Tool bracket with combination wrench 11 Front belt guard 12 Belt adjuster screw 13 Locking screws for belt adjustment 14 Rear belt guard 15 Throttle 16 Rear handle 17 Throttle lock 18 Decompression valve 19 Water valve 20 Water connection 21 Choke 22 Fuel tank 23 Starter throttle lock 24 Stop switch 22 ...

Page 6: ...ribed in detail in respective chapters Cutting head 1 Loosen the screws to the cutting head 2 Loosen the tension of the belt with the adjuster screw Remove the screws to the cutting head 3 Detach the hose clip 4 Remove the front belt guard by pushing it forward 5 Lift off the belt from the belt pulley and remove the cutting head 6 Remove the rear belt guard bolts 7 Lift off the guard At this stage...

Page 7: ... filter so that dust does not fall into the carbu rettor inlet Cylinder cover 1 Loosen the cylinder cover s five screws 2 Lift off the cylinder cover Carburettor 1 Loosen the two screws at the inlet elbow 2 Unscrew the screws to release the carburettor 3 Turn the carburettor and remove the choke and fuel hose 4 Loosen the wire nipple on the opposite side 5 Note the channel and corresponding holes ...

Page 8: ...re minimised 1 The rubber pipe is pushed onto the plastic frame which also serves as a hol der of the throttle wire Note the impulse channel in the rubber pipe bottom left which connects the crankcase to the car burettor pump diaphragm Dismantling 2 Press the rubber pipe together and pull out the plastic frame 3 Remove the two screws to the cylinder and remove the inlet pipe 4 Examine the componen...

Page 9: ...asures for replacement Detach the fuel hose and the throttle wire at the car burettor Remove the outer screws at dampers 3 and 5 and movement limiter 6 The machine body can then be tilted forwards Remove the springs using the Allen key 4 mm 3 Below the flywheel 4 Above the ground support 5 Next to the cylinder 6 Remove the screw Measures for replacement To replace the spring 4 and dampers 3 and 5 ...

Page 10: ... and then out through the notch for the cord Pull out virtually the whole cord length until sufficient cord remains to tie a knot as illustrated 2 Insert the other end through the cover and on through the handle Tie a double knot as illustrated Loading the return spring 1 Fit the starter cord in the cut out 2 Wind the starter cord 4 turns around the hub 3 Pull out the starter handle so the cord ro...

Page 11: ... New return spring supplied in a holder to facilitate assembly Note that the holder has three slots used for assembly 6 Place the spring with holder above the spring housing and fit so that the loop fits in the bracket in the spring housing Press the spring down using a screw driver all around at the three slots a little at a time It is important that the screwdriver is applied so that the spring ...

Page 12: ...a shoulder screw Note the position of the springs in relation to the flanges on the flywheel so that they are fitted correctly NOTE Do not forget the washer A that should lie under the starter pawls against the flywheel Assembly It is important that the spring does not get caught between the starter pawls and the flywheel The following method is recommended when assembling 1 Press the spring into ...

Page 13: ... the engine piston is just below the upper turning point At the breaking instant the voltage in the primary coil rises from 5 V volt to approximately 200 V through induction At the same time a high voltage approximately 20 000 volt is transformed in the secondary coil to the spark plug Spark plug The spark plug s electrode gap should be 02 in 0 5 mm The electrodes should be free of soot deposits a...

Page 14: ...op switch If the spark plug does not spark replace the ignition module 502 71 13 01 1 4 5 2 3 Faulty spark plug Replace the spark plug with the test spark plug 502 71 13 01 If there is spark now the spark plug is defective Replace the spark plug If there is no spark the next step is to check the ignition lead Faulty ignition lead 1 2 Pull up the rubber seal by the igni tion module and unscrew the ...

Page 15: ...h magnets is turned towards the ignition module Place air gap gauge 01 in 0 3 mm 502 51 34 02 against the magnets and fit the new module in position The screws should be tightened to a torque of 3 7 4 4 lbf ft 5 6 Nm Test the short circuit cable and stop switch Test using a measurement instrument or the following simple solution Connect a battery in series with a test lamp to the short circuit cab...

Page 16: ...cluded in the tool kit 502 50 70 01 can be used Fit the piston stop Remove the centre nut Remove the flywheel centre nut Note the washer between the nut and flywheel Striking tools must never be used for removing or fitting the nut Remove the centre nut Fit the plate Centre the plate on the crankshaft Select the appropriate screw supplied with the tool and fit the screws in the holes for the start...

Page 17: ...sher and nut Tightening torque 28 33 lbf ft 38 45 Nm Use a torque wrench to tighten the nut Remove the tool and hook up the springs on the start hooks Fit the flywheel The crankshaft and the centre of the flywheel must be free from grease when assembling Align the key in the flywheel with the keyway on the cranks haft Fit the washer and nut Tightening torque 28 33 lbf ft 38 45 Nm Use a torque wren...

Page 18: ...and any deposits removed in connection with filter replacement Dust from dry cutting is blown clean using compressed air Material from wet cutting normally needs to be scraped off mechanically Paper filter The paper filter must not be cleaned as it should be replaced whenever necessary with a new filter The replacement frequency is highly dependent on the material to be cut and if the cutting is t...

Page 19: ...oke s link rod from the carburettor Turn the carburettor so that the throttle wire nipple is accessible Loosen this from the carburettor Loosen the fuel hose and choke Loosen the throttle wire Dismantling Remove the whole air filter unit and the cylinder cover Start by cleaning the cylinder flanges and the area around the carburettor thoroughly with compressed air Remove the two screws that hold t...

Page 20: ...inder SmartCarb The channel marked by arrows connects the carburettor s measurement chamber with inlet air in the inlet elbow Pressure equalisation between these allows the carburettor to provide the right fuel air mixture regardless of how fouled the filter may be This is the operating principle of SmartCarb Make sure the gasket between the carburettor and inlet elbow is fitted with the hole faci...

Page 21: ... filter Check that the filter is not cracked or in any other way defective Fouled filters are replaced with new ones Leakage testing Pressure tester 501 56 27 01 Use the pressure tester 501 56 27 01 to test the tightness of the fuel system The pressure tester is supplied with an adapter for small hose sizes this should be used on the fuel hose Make the hose between the adapter and the pressure tes...

Page 22: ...iver to push out the air vent from the tank Replacing the fuel hose Remove the hose by pushing the hose down into the tank little by little while pulling it out through the tank filling The new hose is fed into the tank from above by hand Lubricate the hose to facilitate installation Replacing the fuel hose The fuel hose is removed and fitted in the same direction from the top to the tank filling ...

Page 23: ... a maximum of 10 kPa in the direction of the tank The opening pressure from the direction of the tank to the sintered filter must be about 30 kPa Filter function test Detach the rubber hose with the sintered filter Blow by mouth through the hose and observe whether air can slowly pass Filter replacement Clogged filters should not be blown clean but replaced Use a pin punch to press the filter out ...

Page 24: ...ction 13 Measuring chamber measuring chamber diaphragm above 14 Needle valve 15 Pump diaphragm top side of the connection with the crankcase via the impulse line fuel under the diaphragm 16 Fuel pump valve tongues Carburettor versions The carburettor technology is being continuously developed and refined The carburettor version can be read from the marking as shown in the illustration for example ...

Page 25: ...run out through the venturi Not until air emerges from the venturi can the function of the needle valve be tested as set out below If the needle valve does not open at 250 kPa max permitted pressure test the needle valve has jammed This can usually be forced open by blowing gently through the hole for filter compensation A Test the needle valve s function as follows Pump a pressure to 100 250 kPa ...

Page 26: ... holding the axle and remove the components Needle valve Perform a pressure test as pre viously described If the test indicates a leaking needle valve it must be dismantled Check that the spring is not deformed and that the lever runs easily on the axle When reassembling Note that the lever has two forks where the needle valve and measurement chamber diaphragm fit Check that the spring is not defo...

Page 27: ...e valve flaps closed tightly against the carbu rettor housing Fuel strainer There is a fine meshed strainer located on the fuel inlet to the carburettor Inspect this with a magnifying glass Loose dirt particles can be blown away from the needle valve s seating If there are depo sits that are hard to remove or the mesh is damaged the strainer must be replaced The strainer is dismantled using a need...

Page 28: ...crew to an idle speed of approximately 2500 rpm The cutting blade must not rotate at this speed If the cutting blade rotates the clutch is defective and must be fixed Tachometer 502 71 14 01 The instrument is induction sensing and does not need to be connected directly to the ignition lead The air filter cover can be fitted when testing The supplied antenna cable does not normally need to be used ...

Page 29: ...es Carbon removing chemicals or a light oil diesel oil can help a jammed valve to work again Blown clean the valve with compressed air Carbon deposits on the valve and the seating can be removed using fine emery cloth Service Check that the valve moves Clean any soot or deposits from the valve Assembly Clean the sealing washer and check that this is not damaged before assembling the the decompress...

Page 30: ...e gauge Evacuate the pressure and repeat the procedure a few times Note the average value from the attempts The average value for a new and run in engine is approximately 7 5 bar 110 psi Values below 5 5 bar 80 psi indicate defects in the cylinder piston or piston rings Compression test The test indicates leakage from the combustion chamber Close the decompression valve or fit the sealing plug 503...

Page 31: ...ort plate to the right is placed between the piston and crankcase to facilitate the work Tool kit 502 50 70 01 The tool kit contains piston ring compressors piston stop and base plate for the piston Remove the cylinder base gasket Seal with a cloth or paper so as not to risk anything falling down into the crankcase Seal with a cloth or paper so as not to risk anything falling down into the crankca...

Page 32: ...e piston ring away from you so that it can be lifted out of the slot at the rear edge Assemble in reverse order Piston rings Remove the piston rings 505 38 17 05 1 2 Important when assembling The piston ring groove has a guide pin that prevents the piston rings from rota ting Fit so that the open part of the piston ring aligns with the guide pin Turn the piston ring with the bevelled edge towards ...

Page 33: ...rn com pletely smooth by the ports you should consider replacement Piston ring groove Measure the piston ring groove using feeler gauges If the piston ring groove is greater than 06 in 1 6 mm the piston must be replaced Fit a complete piston kit with piston rings needle bearing and gudgeon pin Piston ring groove If the piston ring groove is greater than 06 in 1 6 mm the piston must be replaced Fit...

Page 34: ... the machine works at short intervals and has not been run completely warm Scoring Damage of this type is always the result of overheating The cores are usually on the exhaust side which is the hottest Inlet side can show similar damage Check whether the machine has broken down due to an incorrect oil mixture or no oil at all The oil on the overheated piston has probably carbonized Check instead w...

Page 35: ...nkcase Carefully clean any old gasket residue from the surfaces that are in contact with the gasket Note the gasket s assembly to the cylinder Turn the gasket ensuring the impulse channel remains open to the crankcase Cylinder foot gasket Clean the surfaces thoroughly from old gasket residue Note the gasket s assembly to the cylinder Start by fitting the cylinder foot gasket Add the support plate ...

Page 36: ...he cylinder space for the decompression valve Inlet port 3 Remove the carburettor and inlet pipe 4 Fit the sealing washer 502 71 38 01 Exhaust port 5 Remove the cutting deck and muffler as shown on Pages 6 and 8 respectively 6 Fit the sealing washer 502 71 39 01 with the screws belonging to the muffler Test the tightness Connect the pressure tester to the nipple on the inlet seal Pump up a pressur...

Page 37: ...rocedure on the flywheel side Fitting CLUTCH SIDE 1 Lubricate the axle at the taper for the clutch drum 2 Carefully press down the sealing ring over the taper and down towards the seating 3 Knock down the sealing ring into its seating with the assembly punch Fitting FLYWHEEL SIDE 1 Lubricate the axle 2 Press the sealing ring towards the seating 3 Knock down the sealing ring into its seating with t...

Page 38: ...e crankcase 1 Remove the ten screws connecting the crankcase halves Note the screw at the rear of the crankcase FLYWHEEL SIDE 2 Install grab plate 544 06 00 02 in the screw holes on the flywheel side 3 Press out the crankshaft with a puller CLUTCH SIDE 4 Heat the bearing seat on the clutch side to about 200 F 100 C 5 Support the crankcase with wooden blocks as close to the crankshaft as possible K...

Page 39: ... max 300 F 150 C Place the sleeve in the tool kit against the bearing and knock this out with a large plastic mallet Assembly Use the tool kit 506 37 61 02 for bearing assembly in both crankcase halves Place the bearing on the support plate and hold it under the crankcase half Insert the screw through the washer and fit the screw in the support plate Lock the screw and turn the nut until the beari...

Page 40: ...rankcase half Make sure that the connecting rod is not held against the crankcase half Picture 5 Fit the guides Picture 6 Fit the new crankcase gasket Picture 7 Fit the second crankcase half using the same method as the first Use the fitting M10x1 Support the crankcase half in position with a long screw at the rear attachment point Fit the crankcase bolts as soon as possible to ensure that the gas...

Page 41: ...uller this will damage the piston Even dis mantling without the piston stop using a striking tool results in a risk of damage to the flywheel s locking mechanism keyway key Assembly Piston stop Lock the crankshaft s travel using the piston stop 504 91 06 05 instead of the spark plug Tightening torque 26 30 lbf ft 35 40 Nm For reasons of safety it is important that the clutch is assembled with the ...

Page 42: ... pin punch Assembly Pre fit the springs in the part of the shoes that have the narrow space Turn the springs with the hook to the side marked Off Turn the clutch and turn the springs in place using an awl Clean the clutch When the springs have been removed the clutch can be dismantled Check that the shoes can move easily in their races Clean if necessary Do not lubricate the clutch Note that the c...

Page 43: ...ange reaches the bottom of the belt pulley Tools Replacing the needle bearing is most easily done by using a hydraulic press The bearings can also be replaced using a screw vice You will need the following to remove the bearing socket 27 mm 1 1 8 in M8 bolt about 4 in 100 mm and nut washer external diameter slightly less than 19 mm 7 in Whatever the method the belt pulley centre is supported with ...

Page 44: ...h the bea ring seal Check that the seal is intact Dirt under this indicates defective seals and these should be replaced Remove the spacer together with the bearing seal Check that the seal is intact The washer and the three screws hold the blade guard against the bearing housing Remove the screws and the washer Remove the screws that hold the blade guard against the bearing housing Remove the was...

Page 45: ...uard Turn the bearing housing so that the screw holes are accessible from above with the tool Fit the blade guard tighten the screws alternately The soft rubber ring under the washer is pressed together when the plate washer is fitted The three screws must then be tigh tened alternately to avoid deforming the plate washer Fit the seal ring Press the seal ring fully down onto the plate washer The a...

Page 46: ...s Note that there must be washers on both sides of the belt pulley partly to the centre screw and partly to the ball bearing The washers are identical Asymmetrical belt pulley Note that the belt pulley is asymmetrical The side with the elevation as shown on the left should be facing the ball bearing Assembly The screw must be tightened using a torque wrench 38 42 Nm Assembly Place one washer on th...

Page 47: ... from the axle Remove the bearings using a universal puller Remove the bearings from the axle Blade shaft bearings The blade shaft has a fixed machined spacer which the bearings inner rings must be in contact with after assembly in the bearing housing The bearing s inner rings are press fitted against the shaft and the outer rings are press fitted against the bearing housing It is very important n...

Page 48: ... Place the support on the first fitted bearing Fit axle with bearing Make the bearing housing horizontal using assembly support B Turn the axle correctly Put the axle with the fitted bearing in place in the bearing housing with the spacer downwards Put pressing device C above the axle The device provides support to both bearing rings during assembly Press or knock down the bearing to gether with t...

Page 49: ... on each side of the blade guard The water strikes a section of the cutting blade and the centrifugal force carries it out towards the blade s diamond segment The spray nozzles are available with several different hole diameters depen ding on the type of machine and application Find the right nozzle in the spare parts list Hose clips The hose clips in the wet cutting system are of the type that ca...

Page 50: ...structions to the letter Rear handle control The handle unit is permanently attached to the fuel tank This chapter deals with maintenance work on the rear handle control Maintenance work related to the fuel tank is described in the Fuel system chapter Work on the anti vibration elements is described on Page 9 In some of the pictures in this section the rear handle has been divided to show the asse...

Page 51: ...the handle Relatively strong force is needed Removed throttle Removed throttle lock Important If the white lever for the throttle wire is not included as shown below it can be pressed with a screwdriver as shown in the adjacent pictures The picture to the right shows a divided handle Throttle Pull up the throttle until it stops Raise the white lever for the throttle wire and place it in the positi...

Page 52: ...s the throttle lock down in the lower part of the handle 3 Press the throttle lock in the upper part of the handle It will be locked in position by the throttle 4 Fit the lower shaft for the throttle lock 5 Fit the upper shaft for the throttle lock By pulling the throttle wire the lever arm will come into the correct position for fitting the shaft 6 Knock in the shafts with a pin punch and small h...

Page 53: ...s Dismantling the flywheel 502 71 14 01 Tachometer Instrument for measuring the engine s speed Idle setting Checking the maximum speed 501 56 27 01 Pressure tester Test of carburettor functionality Test of fuel lines Test of non return valve in the tank ventilation 502 50 70 01 Kit for piston service Consisting of piston ring com pressor piston stop and support plate Piston service 504 91 06 05 Pi...

Page 54: ...justment of the idle speed 502 50 66 02 U Key Removal and fitting of vibration dampers 54 19 502 50 82 01 Assembly punch Assembly of the crankshaft s sealing rings in the crankcase 504 90 90 02 Universal puller Dismantling the clutch s sup port washer on the crankshaft Splitting the crankcase in com bination with 544 06 00 02 544 06 00 02 Grip plate Splitting the crankcase in com bination with 504...

Page 55: ...www husqvarnacp com 115 54 49 26 English 2012 10 ARNE PALMQUIST ...

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