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HUSQVARNA CONSTRUCTION PRODUCTS

Workshop manual

K 3600 Mk II, K 2500

Содержание K2500

Страница 1: ...HUSQVARNA CONSTRUCTION PRODUCTS Workshop manual K3600 Mk II K2500 ...

Страница 2: ...NT OF ENGAGEMENT ROLLER BEARING SOCKET 15 10 CONTROLS 17 K2500 11 COMPONENTS ORIENTATION 19 12 BELT TRANSMISSION 20 13 CUTTING HEAD 21 14 CONTROLS 26 HYDRAULIC MOTOR 15 HYDRAULICS PRINCIPLES OF OPERATION 27 16 HYDRAULIC MOTOR PRINCIPLES OF OPERATIONS 30 17 TESTING 31 18 TROUBLESHOOTING PROCEDURES 33 19 REMOVAL 35 20 INSPECTION 37 21 DRIVESHAFT 39 22 SLIDE BEARINGS 43 23 VALVES 45 24 TOOLS CONVERSI...

Страница 3: ... of hydraulics Layout pictures and text In addition to the diagrams and illustrations there are generally two columns of text The left hand text column is concise and is suitable for experienced mechanics whilst the right hand column gives a more detailed description and is targeted at mechanics with less experience of power cutter repair work Contents The manual is divided into numbered chapters ...

Страница 4: ...interference from the spring force the direction of the arrows so as to provide the correct pressure against the drive disc Corrosion or dirt that blocks movement will cause the blade to slip against the drive disc A properly greased bearing housing will redu ce the risk of operational disruption There must be zero clearance in the adjustment of the engagement and support rollers against the sides...

Страница 5: ...disc 17 Water adjustment valve 18 Type plate 19 Lubrication channel outlet 1 10 9 7 8 7 5 5 11 4 1 1 2 2 15 17 2 3 19 4 12 13 13 14 14 5 6 6 18 16 6 NB The position of the engagement and support rollers on the Husqvarna K950 Ring is reversed on the K3600 MkII The direction of blade rotation in rela tion to the machine is the same for both models pulling blade but the rotation of the cutting blade ...

Страница 6: ... Hydraulic motor Rotate the drive disc a few turns by hand Quick inspection Roller bearings When replacing the blade it is appro priate and easy to perform a quick inspection of the condition of the engagement and support rollers Feel that the rollers rotate evenly and easily Any bearing damage must be corrected refer to Chapter 8 Hydraulic motor Rotate the drive disc a few turns by hand There mus...

Страница 7: ...g blade in the drive disc and then in both engagement rollers Fix the blade in position by turning both knobs one turn Fit the guard Fit the guard and tighten the screws lightly Screw the knobs back out Check the position of the adjuster screws Check that the adjuster screws are suffi ciently screwed out to create clearance between the blade and the rollers as fol lows Rotate the blade by hand The...

Страница 8: ...de against the drive disc Correct adjustment It is very important that the rollers are correctly adjusted in order to ensure machine function and to minimise wear To be correctly adjusted the rollers must be set to the blade with no clearance Excessive contact increases roller wear and results in deformation on the blade that will in a worst case scenario lead to the blade breaking Insufficient co...

Страница 9: ...6 in Support rollers The support rollers must be replaced if they have no grooves Min 1 5 mm 06 in Engagement rollers The engagement roller unit assembly A comprises bearing brackets which hold double roller bearings and the engage ment roller itself which is fitted on the shaft The spring which provides pressure to the drive disc is pre tensioned and fixed in the bearing bracket The plastic cylin...

Страница 10: ...Wipe the bearing bracket and check that it is not damaged Check the integrity of the engagement roller bearings Grease characteristics The grease used in the service proce dures set out below must be stiff and afford good resistance to water pene tration The original grease used during assembly in the factory is Shell Alvania RL3 lithium grease where the figure 3 indicates the NLGI grade of the gr...

Страница 11: ...inst the tool in the vice and tighten the socket head cap screw firmly Fit the wear part Fit a new socket head cap screw with thread lock Position the roller against the tool in the vice and tighten the socket head cap screw firmly Grease the bearing housing The cutting blade must be fitted and the knobs screwed in Put the grease gun against the nipples A and pump grease in until clean grease runs...

Страница 12: ...n position thread on the lock nut and fit a new socket head cap screw with thread lock Position the roller against the tool in the vice and tighten the socket head cap screw firmly Fit the wear part Use a new socket head cap screw with thread lock during installa tion Tighten the socket head cap screw firmly Support rollers Inspection Check the integrity of the support roller bearings Check that t...

Страница 13: ...above Press the pin down a little Twist the handle and ease the pin out of the bearing socket Remove seals Lift off the cap A Push up the sealing ring B using an awl The sealing ring must be replaced Remove the wear ring C from the shaft Remove the circlip D Remove the bearing unit Secure the bearing tool in a vice Position the disassembly socket on the bearing tool with the shoulder facing upward...

Страница 14: ... Lift off the cap A Push up the sealing ring B using an awl The sealing ring must be replaced Remove the wear ring C from the shaft Remove the circlip D 8 13 Fit new bearings 1 Locate the shaft with the screw head in the hole on the bearing tool Fit a roller bearing and position the assembly punch on the shaft Press the bearing down until the punch touches the shaft 2 Fit the inner and outer space...

Страница 15: ...ve the bearing unit Secure the bearing tool in a vice Position the disassembly socket with the shoulder facing upwards and turn the bearing arm so that the tool s screw meets the bearing arm screw Press the bearing unit out through the bearing arm Tap the shaft out of the bearing in the same way as shown on page 12 7 Fit the circlip Fill the inside of the new sealing ring with grease and fit using...

Страница 16: ... 0 5 inch Tip Removing the water disc facili tates the procedure Tip Removing the water disc facilitates the procedure Remove the 4 screws holding the water disc in place and the screw holding the water connection 506 37 53 01 Replaceable seals Remove the seals using a sharp pointed awl The stripper plate A comprises two components an O ring and a plastic ring The O ring is fitted first and positi...

Страница 17: ...he tool and lightly tighten the socket by hand Turn the socket so that it correctly lines up the outlet channel with the bearing socket distribution channel the lubrication nipple with the bearing socket hole Line up the bearing socket Fit the tool and lightly tighten the socket Turn the socket so that it correctly lines up the outlet channel with the bearing socket distribution channel the lubric...

Страница 18: ... of the controls Fit a 5 mm Allen key as shown in the picture to hold the units together Remove the start control shaft with a pair of pliers Pull the start control link rod to opera tional position Lift the controls out of the handle half and unhook the controls from the link rod First separate the handle at the rear by the controls to release the control shafts from the handle half Then move the...

Страница 19: ...ater valve The water valve is fitted in the handle half by two screws After removal the knob can be un screwed and the valve cleaned Note the water valve s hose routing Hydraulic hoses in the picture have been turned out of the way Hose clips Remove the hose clips by cutting them with pliers as shown in the picture Fit new hose clips using pliers as shown in the picture on the right Hose clips Use...

Страница 20: ... screw 7 Lock screws for belt adjustment 8 Water connector 9 Rear handle 10 Throttle trigger 11 Throttle trigger lockout 12 Hydraulic motor 13 Water valve 1 5 8 7 9 11 13 12 14 15 10 6 2 4 3 14 Pressure hose 15 Return hose HUSQVARNA K2500 Hydraulic pressure max 150 bar 2200 psi Hydraulic flow min max 35 42 l min 9 11 US gpm Hydraulic oil ISO VG 46 11 19 ...

Страница 21: ...ighten both nuts firmly 22 lbf ft 30 Nm Belt adjustment Tighten the nuts by hand Screw in the adjuster screw until the square nut is centred in the mark on the guard Tighten the nuts firmly 22 lbf ft 30 Nm Then remove the nuts and take off the belt guard Lift the belt off the belt pulley Pull the water hose off the valve The cutting head can now be lifted out of the machine The rear belt guard is ...

Страница 22: ...y and the bearing Tip Tie on the belt pulley so that it is not lost or forgotten when reassembling Press up bushing with two open ended spanners Now remove the inner flange washer The centre bush for the blade can be replaced and is available in different diameters Press up the centre bush with two open ended spanners Now remove the inner flange washer Remove the spacer together with the bearing s...

Страница 23: ...off the bearing housing Check that the grooved rings for the blade guard s locking mechanism are intact Also check that the rubber ring under the grooved ring is in good condition The rubber ring acts as a spring to keep the gears engaged The bearing housing grooved ring is secured by two screws Check that the grooved rings are intact Also check that the rubber ring is in good condition Remove the...

Страница 24: ...eating in the cutting arm are not damaged If the bearing is seriously damaged so that it has been scored in all probability the axle or cutting arm must be replaced due to the damage a seized bearing causes to the bearing seating or the axle Check Check that the axle and the bearing seating in the cutting arm are not damaged Prepare bearing replacement The bearing housing must be secured so that t...

Страница 25: ...entre the washer on the top side of the bearing housing Place the bearing on the round support plate on the underside of the bearing housing Screw the screw into plate for its entire thread length Fitting the outer bearing Position the bearing and spacer on the support plate and hold it under the bearing housing Press in the outer bearing until the spacer ring touches Fitting the shaft Screw in th...

Страница 26: ...Bearing housing blade guard Check that the rubber seal is fitted properly against the bearing housing and blade guard Turn the bearing housing so that the screw hole becomes accessible from the top with the tool Tighten the three screws crosswise so that the washer is not unevenly loaded and risks being deformed Tighten the screws fully Fit the seal with spacer ring Centre bush Never hit the centr...

Страница 27: ...the hydraulic motor The UP marking on the torsion disc must be turned outwards from the motor Removal of torsion plate Relax the return spring at the motor housing support point Use a large screwdriver to pre vent torsion plate movement during removal and fitting Removal of torsion plate Lift the sprung end at the motor housing support point in order to eliminate spring force Use a large screwdriv...

Страница 28: ...tem The term hydraulic refers to the trans fer of power using some form of fluid The fluid that is used in this context is oil which apart from serving as the medium for transferring power also lubricates and cools the system s com ponents Hydraulic power transfer nor mally operates in a sealed system that is to say the fluid medium that is used is returned to a container from where it is reused A...

Страница 29: ...either the pump s speed or displacement volume By leading some of the fluid directly to the return side the flow to the tool can be varied This principle is used for throttle control in Husqvarna hydraulic cutters When the machine is not operating the entire flow passes virtually without pressure through the bypass valve When the throttle control is pressed in the bypass valve is closed and the hy...

Страница 30: ...side that is to say the side to which the hydraulic unit provides flow and pressure and which drives the power cutter FLOW PRESSURE 0 140 Bar 0 40 L min FLOW PRESSURE 0 140 Bar 0 40 L min FLOW PRESSURE 0 140 Bar 0 40 L min FLOW PRESSURE 0 140 Bar 0 40 L min Idling The hydraulic unit is operational and provides its preset 40 l min 10 gpm The throttle on the cutter is at the stop setting so the thro...

Страница 31: ...tween the gears and the motor hous ing the outsides to reach the return side One gear has an output shaft linked to the cutter blade s driving wheel Since the gears are mechanically linked to one another power is transferred to the shaft by both gears The hydraulic motor and the structure of the servo system are identical for both the K3600 MkII and the K2500 However because the two machines use c...

Страница 32: ...t work in environments with variable temperatures ISO L HV VG 46 The graph illustrates how the viscosity of hydraulic oil typically changes at various temperatures At ope rating temperature a viscosity of between 20 and 50 cSt is recommended Dimension Pressure loss Hydraulic hose 3 8 2 0 bar m 9 psi ft 1 2 0 5 bar m 2 psi ft 5 8 0 16 bar m 1 psi ft Coupling each 3 8 1 3 bar 19 psi 1 2 0 4 bar 6 ps...

Страница 33: ...move the belt pulley Screw the belt pulley washer and screw back in position The lock requires a fixed 12 mm combination open ended box spanner Fit the open ended spanner to the driveshaft and secure the box spanner using an M8 screw in the cutting head attachment WARNING The hydraulic motors have a high in the case of the K2500 very high torque Don t use manual force as resistance during the test...

Страница 34: ... Low motor output Cause Action Locked main valve Once the hydraulic unit is shut off the main valve is compressed into operating position by the spring above When the hydraulic unit is started the main valve is forcibly compressed to the spring The reason why the motor does not start may be that dirt or corrosion prevent the spring from compressing the main valve into operational position If the m...

Страница 35: ...t is likely that the main valve has locked in this position Remove the hydraulic motor cover and check the movement of the main valve Leaking main valve The following faults may cause sufficient leakage to prevent the main valve opening to the return side Damaged gasket around the main valve Bad seal between the main valve and the white plastic hat Alternatively the plastic hat may be deformed or ...

Страница 36: ... ensure that the link rod is not deformed It is important to preserve the shape of the link rod in order to ensure starter function K3600 MkII Release link rod from control Remove the drive disc and the washer below Loosen the water valve Lift the valve to release the link rod Remove the hydraulic motor Remove the four screws Tightening torque for re fitting 10 Nm 7 lbf ft Pull out the motor unit ...

Страница 37: ...e movement when removing and re fitting the nut Remove the belt pulley Prevent belt pulley rotation using a pin spanner Alternatively angled needle nose pliers may be used Unscrew the centre screw remove the belt pulley and the washer below When re fitting Note that the washer to the left must be turned with the flat side up The belt pulley must be turned with the raised centre section facing up D...

Страница 38: ... This is also where bearing wear is greatest Damaged drive disc bearing If the driveshaft shaft on the left exhibits play it may be the result of the drive disc bearing being damaged which in turn will damage the slide bearings in the motor housing and the cover Dismantling for inspection Remove cover screws Identical design The hydraulic motors used in the K3600 MkII and K2500 are identical in al...

Страница 39: ...that is manufactured with very small dimensional tolerances in order to ensure minimal leakage and a high level of efficiency Motor damage The wear damage described above is uncommon Generally speaking there are the following causes The hydraulic motor has operated for many hours beyond that estimated to be the normal operating life of the machine If wear occurs on a hydraulic motor with fewer ope...

Страница 40: ...fore it is recommended that the entire unit be replaced as shown in picture This is available as a complete spare part Removal K 3600 MkII 1 Remove the drive disc see page 6 2 Remove water disc this facilitates the procedure K 2500 Remove the belt pulley see page 34 K 3600 MkII and K 2500 Remove the motor cover the gears the non driving shaft and the spring as shown in the picture Remove the wedge...

Страница 41: ... F 100 C Ideally the shaft unit should be cooled in a freezer before fitting Heat the bearing housing Heat the bearing housing to approximately 200 F 100 C Ideally the shaft unit should be cooled in a freezer before fitting Fit the shaft unit Once the bearing housing is heated and the shaft unit is cooled fitting can nor mally be done by hand If necessary make a few light taps with a plastic malle...

Страница 42: ...age replace the shaft Fit a new outer sealing ring Lift the old sealing ring using an awl or similar and fit a new sealing ring Fit a new outer sealing ring Thread the sealing washer on the shaft Grease the shaft Grease the shaft thoroughly where it touches the roller bearing The main reason for doing this is to protect the inner sealing ring as it is fed over the sharp edges of the stop where the...

Страница 43: ...roller bearing on the shaft and push until it touches Place the shaft in a vice which must have soft jaws to prevent damaging the shaft surface Tighten the jaws to the point at which they support the roller bearing ring Tap the shaft down towards the roller bearing recess Fit the roller bearing Place the roller bearing on the shaft Tighten the vice jaws to the point at which they support the rolle...

Страница 44: ...It is rarely necessary to replace slide bearings as damage to these parts is a very infrequent occurrence If in spite of everything these bearings do suffer damage the first sign will be a loss of motor power which in turn means that the motor housing and or the cover will have suffered damage as the result of deficient control on the part of the gears In such instances the motor must be replaced ...

Страница 45: ...essed air after removal 22 Fitting Driveshaft slide bearings in motor housing Fit the new bearing on the driveshaft as shown in the picture Tap down the bearing using a plastic mallet on the shaft until the bearing is 0 5 1 0 mm 02 04 in below the sealing plane Sealed bearing housing Fitting of both non driving shaft slide bearings and the driveshaft bearing in the cover is done in the following w...

Страница 46: ...the start control Important for the function The main valve must be able to move without hindrance and the sealing rings must be intact It is very important that the small hole in the centre of the plastic hat is open If it is blocked the motor will not start It is also impor tant that the plastic hat is kept in position relative to the main valve by the O ring with a certain amount of resistance ...

Страница 47: ...erside Blow the servo shaft channel and hole clean Re fitting Fit the return spring on the opposite side in the correct position before fitting the e clip refer to the pictures above Removal Remove the e clip and pull out the servo shaft Cleaning Blow the fixed section of the valve clean in the same way as during the inspection Block off the underside Blow the servo shaft channel and hole clean Re...

Страница 48: ...m the position of the main valve Push the valve towards the spring Removal The brake valve has an M5 screw thread in the end towards the hydraulic hose Screw a long screw into the brake valve and pull out the complete unit If the spring does not come out this can easily be removed using a magnetic driver Removal The brake valve has an M5 thread and is pulled out using a screw Inspection The valve ...

Страница 49: ...n those we have used in this workshop manual VOLUME 1 US gallon 3 785 litres 1 litre 0 264 US gallon In terms of volume there is also the British gallon British Imperial System 1 Imp gallon 4 546 litres 1 litre 0 220 Imp gallon FLOW gpm US gallons per minute 1 gpm 3 785 litre minute 1 litre minute 0 264 gpm TORQUE For conversion of screw tightening torques 1 lbf ft 1 356 Nm 1 Nm 0 738 lbf ft PRESS...

Страница 50: ...www husqvarnacp com 502 53 06 26 English 2007 08 ARNE PALMQUIST Print Risbergs ...

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