Partner K 3500 Service Manual Download

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Summary of Contents for K 3500

Page 1: ......

Page 2: ...7 A Roller System 17 1 Roller 2 Roller Casing 19 3 Roller Adjustment 23 Subject Page B Controls 24 C Water Cooling Components 26 D Handles and Guard 27 E Hydraulic System 28 1 Hose 28 2 Hydraulic Motor 30 3 Hydraulic Valve 37 7 Troubleshooting 45 A Mechanical Troubleshooting 45 B Hydraulic System Troubleshooting 4g C Failed Parts Analysis 52 8 Maintenance Schedule 54 9 Parts System 56 ...

Page 3: ...WARNING Never modify a cut off saw without express written permission from the manufacturer Unauthorized modifications can cause death or severe injury to yourself or others 1 Install ring blade 1 Make sure shipping carton con tains the following Items Hydraulic Saw Wooden Carrying Case Tool Kit Instructional Materials Instruction Book Parts Drawing Set up NOTE Show customer how to do the followin...

Page 4: ... stops cutting to first check the condition of the drive disc before making other adjustments Advise him that blades are for wet cutting not dry cutting 5 CONTROLS Show the customer the correct starting position and how the controls work when cutting Stress the importance of keeping all controls clean to allow proper movement 6 WORKING TECHNIQUE Demonstrate approved cutting techniques with special...

Page 5: ... support rollers mounted in the cover hold the blade against the engagement rollers The support roller cover which contains the two support rollers is the top portion of the saw that is removed when installing the blade The drive disc alone drives the ring blade The inner edge of the blade rides in a v groove in the drive disc and forms a metal to metal contact This drive mechanism is mounted dire...

Page 6: ...ng on what material is to be cut Blades are designed to cut asphalt poured concrete block brick rebar stone and other masonry material Wet cutting blades demand a very good water supply Since the blade is driven by an inner V edge that rides in a V groove in the drive disc and since that V edge wears and narrows total retipping of the blade is not allowed see also Retipping Section 5 The narrowing...

Page 7: ...ameter against the V shaped groove of the drive disc The drive disc is mounted directly to the hydraulic motor When the hydraulic motor turns at 14 000 RPM the drive disc rotates the blade Blade rotation is 2500 RPM As the blade is used the inner diameter of the blade as well as the groove in the drive disc wear until the springs can no longer provide enough force on the roller to ensure proper en...

Page 8: ...PM 14 000 RPM Gear motor with open center valve 120 125 bar 1740 1850 psi 38 L min 10 US gpm 100 l 20 bar 1300 1500 psi 9 9 kg 21 8 Ibs 0 8 kg 1 8 Ibs height 430 mm 17 length 880 mm 34 3 4 width 210 mm 8 l 4 32 65 cSt 10 or 20 wt hydraulic oil within 10 or 50 F of ambient temperature Hose diameter ID 9 mm 3 8 TORQUE SPECIFICATIONS Saw housing bolts 7 3 Motor cover bolts 9 6 Drive disc 4 5 Roller c...

Page 9: ... blade is driven on the inner edge by the drive disc The four rollers do not drive the blade Their only purpose is to support and engage the blade 2 Check troubleshooting section for information on blade performance blade surface wear The blade core becomes thinner and the blade groove becomes wider which prevents the blade from being driven well by the disc Secondly the blade is exposed to stress...

Page 10: ...section for procedures to prevent roller seizure A Rotate roller handles and note the distance the rollers slide in and out Make cer tain rollers can move out approximately 5 mm 3 16 B If rollers do not slide they must be removed from their casings All dirt rust etc must be removed from the roller and its casing C Replace O ring in casing if necessary D Reapply grease to the casing E Reinstall rol...

Page 11: ...andles to rotate Excessive force can damage handles A Rotate the blade during installation B Hold the blade down against the engagement rollers and rotate handles to lock blade into drive disc 6 Check that steel bushings in support roller cover are firmly installed with Loctite to permit roller adjustment 7 Install roller cover and tighten 8 Check blade motion Rotate blade to check that it turns f...

Page 12: ...imental to blade life a WARNING Too much roller clearance too loose will cause wear on the sides of the diamond segments due to blade vibration It can also be unsafe by allowing the blade to jump off NOTE If the blade spins slowly or stops adjusting roller clearance will not help unless roller clearance is extremely tight Check the condition of the drive disc engagement rollers and engagement roll...

Page 13: ...Grip one support a time v i r Excessive tension can rlse blade to warp 4 Move vise grip pliers to the bottom support roller and check in the same manner as the top support roller Adjust roller clearance so that clearance of both rollers is the same Example Setting may vary between 4565N lo 14 Ibs but must be the same within 4 5N 1 lb on both upper and lower roller For example if the upper roller i...

Page 14: ... support roller cover bolt only for the roller that is out of adjustment 6 Loosen jam nuts around the adjustment bushing on the saw frame on roller being adjusted 7 Turn adjustment bushing in 118 turn increments either clockwise n to increase roller clear ance or counter clockwise n to decrease roller clearance 13 ...

Page 15: ...rance A Use scale and vise grip pliers to recheck tension B Check that adjustment bushings and jam nuts are almost flush This distance varies with wear NOTE It is important that the jam nuts are tightened before the cover bolts are tightened If not the adjustment bushing in the saw frame will rotate as the roller cover bolts are tightened or loosened 14 ...

Page 16: ... moderate finger pressure and rotate the blade with your hand Make a note of how tight this roller feels Do the same with the other support roller Once the proper tension of the rollers is felt it is easier to remember and using the pull scale may not be necessary 13 Remove all clamps Rotate the blade and inspect the rollers while spinning the blade All four rollers must rotate while blade is spin...

Page 17: ...t roller cover and blade from machine NOTE Drive disc has a left hand thread A 2 With the two 19 mm wrenches remove drive disc from saw motor shaft 3 Look across the driving edge of drive disc and inspect for wear If the driving surface is too badly worn the inner edge of the blade will bottom out in the drive disc and slippage of the blade will result Replace as needed Assembly Notes A Grease dri...

Page 18: ...g Pliers Hammer Bench Vise NOTE If a vacuum is created by pulling the roller loosen screw on handle to create an air bleed 1 Remove engagement rollers by Prying them out with a screw driver and then pulling them out by hand 2 Remove support rollers by loosening nut tapping out with plastic hammer then pulling out by hand 17 ...

Page 19: ...ring from roller shaft 6 With a drift punch drive roller shaft out of casing 7 Remove seal and bearing from casing 8 Inspect clean and replace com ponents as needed 9 On engagement rollers inspect the condition of the 18 spring washers and check that they stack to 24 mm 15 16 10 Reverse procedure for reassembly 11 Grease seal before assembly 12 Apply water proof grease to bear ing during reassembl...

Page 20: ...gagement Roller Casing NOTE The four roller casings are removed in a similar manner Since the bottom engagement roller casing is the most difficult to remove this procedure will be illustrated 1 Remove engagement roller assembly from casing Remove rubber splash guard and center stabilizer blade 2 Remove screw and remove roller handle from assembly ...

Page 21: ... all rubber components water and oil hoses 4 Insert narrow drift punch into handle screw hole and drive casing partially out of housing 5 Remove punch from screw hole slide cap outward and reinstall punch through the screw hole at end of the casing Reheat saw housing if necessary Tap casing out until cap touches saw housing 20 ...

Page 22: ...SYSTEM 6 With cap off remove casing with pliers 7 After parts cool inspect clean and replace any damaged or worn parts 8 To make installation easier remove stabilizer blade if not removed 9 Reheat both sides of saw housing ...

Page 23: ... casing into saw housing C Carefully drive casing into housing D Just as casing protrudes through the housing install cap to end of casing 11 To complete the reassembly of the roller casing reverse the procedure for removal of the casing 12 Place O rings inside casing and apply grease to inside of casing before inserting roller assembly 22 ...

Page 24: ...ace If removal is necessary use heat to loosen bushing then unscrew from cover BUSHING SURFACE 1 During installation of new bushings be careful not to damage mating surfaces of the bushings Remove any burrs on these surfaces Check bushings for looseness If loose apply Loctite for permanent locking only to the bushings in the roller cover 2 Apply grease only to the bushings 2 that are installed in ...

Page 25: ...and cable assembly 2 To remove the inner wire loosen screw on valve lever and on screw in nipple in trigger 3 Use an 8 mm wrench to loosen bolt and remove trigger 4 Loosen bolt that holds cable into valve lever NOTE Rust and debris may prevent easy removal of cable from the valve lever Clean this area if necessary 24 ...

Page 26: ...rts for wear Replace parts if necessary 8 Reverse procedure for reassembly 9 When making the cable connection at the valve lever or in the trigger the position of the cable must allow the valve lever to travel the full distance to achieve maximum RPM s of the saw motor The lever must also return to its original position to stop the saw motor from turning Check movement by working the throttle a co...

Page 27: ...ce to prevent water nozzle blockage The water system consists of the water valve below the saw housing and the water nozzle on the stabilizer blade Both must be kept clean and operable 1 Remove water valve from saw housing Disassemble inspect and clean Replace parts as needed 2 Remove roller cover with screw driver Remove the stabilizer blade and hose clamp Inspect water nozzles and clean nozzles ...

Page 28: ...ing two screws from both sides of saw housing 2 With an 8 mm wrench remove rear handle parts and replace as needed 3 With 10 mm wrench remove guard and replace parts as needed a WARNING To maintain safe control of the saw operate the saw only with handles provided by the manufacturer Holding or operating the saw in any other manner could result In serious injury to the operator 27 ...

Page 29: ...cement Hose replacement may be necessary when external oil leakage is detected 1 Use an 8 mm wrench and remove side cover Use an 8 mm 5 16 allen wrench to remove roller cover to expose hoses Remove blade 2 Remove water hose connection from stabilizer blade 28 ...

Page 30: ...ould result to the operator Relieve pressure by squeezing trigger on saw or opening flow control valve on Partner power pack counter clockwise n HOSE WITH FEMALE COUPLER s HOSE WITH MALE COUPLER 4 With an 18 mm wrench remove hoses Inspect and replace hoses as needed Inspect couplers for damage During reassembly use Hydraulic Loctite on all hose connections NOTE Connect hose with female coupler to ...

Page 31: ...ceeds the cost of the assembly Before disassembling the motor try turning the shaft manually The shaft should turn smoothly with light to moderate resistance If the shaft fails to turn is very hard to turn or turns roughly this may indicate internal damage misalignment etc Disassembly IMPORTANPI NOTE Before repairing the hydraulic NOTE Repair of the motor itself does not require motor clean it tho...

Page 32: ...sition of motor cover be fore removing it from motor hous ing Remove motor end cap by removing 8 screws I 3 Lift off gears noting their position and carefully set them aside Remove woodruff key from shaft 4 Remove snap ring from motor housing ...

Page 33: ...from shaft 8 Remove remaining snap ring and the aluminum disc with O rings Inspection Inspect all parts checking for scratches nicks pitting on gears shaft and motor housings Replace all worn parts Wash all parts thoroughly in a clean petroleum solvent and blow dry Do not use cloth to wipe off parts as lint and other material may cause binding of closely fitted components NOTE Replacement housings...

Page 34: ...them into place with a light hammer NOTE Using a small dowel pin on the inside of the new bearing will aid in keeping the bearing square as it enters the motor housing Reassembly 10 Place shaft into vise A Place the aluminum disc with O rings onto shaft Make certain the counter bored surface of the disc is facing up during reassembly B Coat shaft with grease CAUTION Fill lock ring grooves with gre...

Page 35: ...Complete shaft reassembly 34 11 Reassemble Shaft NOTE Use new snap rings when reassembling shaft components NOTE Snap rings have a top and bottom Install both snap rings so that the round edge is next to the bearing and the sharp square edge is away from the bearing CAUTION Do not open snap rings more than necessary or they will be damaged ...

Page 36: ...shaft assembly 13 Carefully tap shaft into housing until it protrudes 24 mm lWl6 beyond motor surface NOTE During assembly watch the aluminum disc seal closely to avoid damage Lightly tap the aluminum disc into motor housing with hammer and blunt punch and install large snap ring ...

Page 37: ...s tightening screws to 10 N m 85 in Ibs NOTE Check shaft frequently during assembly The motor shaft is designed to have light to moderately stiff resistance to turning by hand Shaft is easier to rotate with drive disc installed 15 Reverse procedure to complete motor reassembly Remember to keep all components clean and lubricated during reassembly 36 ...

Page 38: ...ith the motor and valve in the same body The valve is a rotary spool design one spool inside of another spool The spools are high quality highly polished steel components that demand care when handling For motor repair see page 30 in this Section 1 Use an 8 mm wrench to remove bolts and lift off side cover Remove support roller cover and blade to expose valve 2 Remove drive disc from motor shaft u...

Page 39: ...6 SERVICE E HYDRAULIC SYSTEM 24 zp P i 38 3 Using pliers disconnect valve 2 I return spring 4 Disconnect throttle cable with 7 mm wrench 5 Disconnect rubber water hose from stabilizer blade c ...

Page 40: ...tor valve from housing B Tap gently on the valve motor assembly until it comes clear of frame Tap on both the valve body and on the end of the motor shaft to prevent binding as assembly is removed from saw housing 10 Place valve motor assembly into bench vise With a blunt tool force the rotary spools out of the valve body 40 ...

Page 41: ...nnected to the top work port stamped IN Return line has male hose coupler 6 Using an 18 mm wrench disconnect hydraulic hoses 7 Remove allen head bolts that hold saw valve motor assembly to saw frame 8 On later model saws insert screw driver into slot provided and twist to separate saw motor valve from saw frame housing ...

Page 42: ...nt tool force the inner spool from the outer spool Inspection 12 Inspect all parts O rings spools and valve body for nicks tears scratches and broken parts All parts must be free of imperfections to ensure no internal leakage during operation Replace parts as needed Reassembly 13 Before reassembly wash all parts and blow dry Use only lint free cloth for cleaning hydraulic parts Use care when worki...

Page 43: ...alves A Apply oil to all valve com ponents before reassembly Install O rings B Install inner valve spool in outer spool C If both snap rings were removed install top snap ring first position inner spool and then install the lower snap ring 42 ...

Page 44: ...d secure with 5 mm nut PEN LOSED 16 Install O rings on outer spool Oil spool assembly and place into valve body 17 Install valve motor assembly A On earlier models carefully reheat saw housing to install valve motor assembly into saw housing Align guide pins while installing 43 ...

Page 45: ...6 SERVICE E HYDRAULIC SYSTEM a _ v B On later models align pins and install motor a embly into saw housing 18 To complete installation of valve motor assembly reverse disassembly procedure 44 ...

Page 46: ... interference inside hydraulic motor Replace hydraulic motor Blade segment rubbing saw frame Repair blade if damaged Valve lever on motor stuck Inspect and clean Stretched trigger cable on saw Replace trigger cable Faulty bearing on roller s Replace roller bearings Hose connection to power pack incorrect Reconnect hoses Blade slipping or turning Roller handles not locked too slowly into position L...

Page 47: ...k is slow Check for hydraulic leaks Make sure power pack meets specifications Internal motor valve leaks Repair motor valve Blade jumping off Roller clearance too great Adjust roller clearance Roller handles not locked in position Lock roller handles Worn engagement rollers Replace rollers Blade not installed on engagement rollers correctly Reinstall blade Engagement rollers stuck in their casings...

Page 48: ...ow Use power pat that meets Specifications Blade cutting too slowly Faulty seal Blade turning too slowly Replace seal Check remedies under Blade Turning Too Slowly Wrong blade for material Change blade Insufficient water Make certain proper amount of water is supplied to blade Difficulty in making roller adjustment Adjustment bushing stuck Remove clean and grease adjustment bushings Loose steel bu...

Page 49: ...e core B wear o Rapid engagement roller C or drive disc D wear The following are the most common causes of blade slippage o Worn Drive Disc D How long a drive disc will last depends on how abrasive the material is and on how well it is flushed away o Worn out Shoulder E on Engagement Rollers If the width of the shoulder E is more than 50 percent worn the blade will slip prematurely o Worn Inner Ed...

Page 50: ...USE REMEDY Loss of hydraulic power or hydraulic pressure Valve lever not traveling full distance Stretched throttle valve cable Clean debris from valve lever _ Relief valve set too low Inspect throttle cable for damage Replace if necessary Pressure check relief valve setting Adjust or replace valve Relief valve spring broken Chip under relief valve or damaged seat Replace spring and readjust Remov...

Page 51: ...rheating exists Motor should be warm but not hot Erratic hydraulic drive power or hydraulic pressure Low oil level Add oil Foreign material floating in reservoir partially blocking off suction line Inspect reservoir suction line and pump inlet for restriction and remove Air suction Tighten suction line connections and check oil level in reservoir Blocked reservoir vent Inspect filler cap for plugg...

Page 52: ...l thinner weight oil in colder conditions Power Pack running when saw not in use Open water tap to cool oil Hydraulic oil cloudy Water in oil Inspect areas where water looking or foamy can enter reservoir Inspect heat exchanger and area around engine base Low oil level Add oil Suction line leaking Inspect suction line connection for tightness 51 ...

Page 53: ...lade overheating Rollers not adjusted Blade pinched in workpiece Warped or cupped blade Roller adjustment too tight zs 2 c Blade cracking Insufficient water supply blade overheating FCRACKED Short blade life Wrong blade for material lnsufficient water supply Excessive number of reinforcing rods Rollers misadjusted Blade speed too slow due to wrong power pack speed Bad working technique Rollers stu...

Page 54: ... PARTS ANALYSIS FAILED PART POSSIBLE CAUSE Hydraulic motor shaft Saw motor running backward I seal blown Hose disconnected during operation Excessive oil flow Rollers chipping Defective material Rollers wearing Normal condition ...

Page 55: ...Every 3 Months Support Rollers Check support roller for wear Support roller cassette maintenance Clean grease X X Support roller bearing Clean and grease X Engagement rollers Check engagement roller for wear X Engagement roller cassette removal Clean grease X Engagement roller bearing maintenance Clean grease X Engagement roller tension spring Check height of washer stack X ydraulic System Inspect...

Page 56: ... a Week Once MZnt h Every 3 Months Water System Inspect clean water nozzles X Water control valve Cable X Check trigger cable assy Motor X Clean motor valve area _ Inspect blade guard area Blade X X Adjustment bushing blade adjustment Clean grease Check blade stabilizer alignment X X 55 ...

Page 57: ... 61 01 1 SEAL 1 CASSETT GUIDE 1 GUIDE ROLLER SPRING kR 1 SUPPORT ROLLER ASSV 1 SUPPORT ROLLER 506 10 62 01 1 CASSETTE SUPPORT 306 PD 6541 1 PIN htR 506 RV BER GUARQ 22 W 29 738 32 01 00 140 43 07 00 1 O RING NR 740 44 u9 DC1 20 o RltiG 740 44 QT 50 LO Q RING M 2 II Part numbers are listed on the exploded view in numerical order with letters to identify their location in the exploded view 3 A separ...

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Partner K 3500, Service Manual

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