Husqvarna K3600 Mk II Gebrauchsanweisung

HUSQVARNA CONSTRUCTION PRODUCTS

Workshop manual

K 3600 Mk II, K 2500

1. LITERATURE 2

K3600 MkII

2. BASIC FUNCTION 3

3. COMPONENTS – ORIENTATION 4

4. REPLACEMENT OF BLADE 5

5. ROLLERS – ADJUSTMENT/INSPECTION 7

6. ENGAGEMENT AND SUPPORT ROLLERS 8

7. REPLACEMENT OF ENGAGEMENT

AND SUPPORT ROLLERS 9

8. REPLACEMENT OF ROLLER BEARINGS 12

9. REPLACEMENT 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, CONVERSION TABLES 48

CONTENTS Page

HUSQVARNA

K3600 Mk II

K2500

502 53 06-26

LITERATURE1

Workshop Manual

The Workshop Manual covers virtually all workshop

procedures concerning the Husqvarna K3600 MkII and

K2500. Some very simple and self-evident repair proce-

dures have been omitted.

Outline

The Workshop Manual begins by addressing servicing

and repair procedures for the K3600 MkII and K2500,

in individual sections. These sections address all repair

procedures except those relating to the hydraulic motor

itself.

Both machines have identically designed hydraulic

motors; only a few components separate the two

models. Because of this similarity, servicing and repair

procedures for the hydraulic motor are covered in a

single chapter for the K3600 MkII and K2500, located

at the end of the manual.

It is essential to know how pressure and flow

work together in order to be able to understand how

hydraulics work and, more importantly, to understand

problems when things don't work. Because of this, we

decided to start the manual with a section dedicated to

the way in which hydraulics work, written specifically

for those with little or no experience 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 together

with chapter headings that are stated in bold at the top

of each page.

The contents list also shows page references to the

start of each chapter.

Spare parts

K3600 MkII and K2500

The folders cover all spare parts available for the power

cutters.

The folders contain complete exploded views of the

entire machine that allow each component's location,

spare part number and appearance to be easily identified.

502 53 06-26

HUSQVARNA CONSTRUCTION PRODUCTS

Workshopmanual

K3600 Mk II, K 2500

IPL, K2500, 2007-01, 544 93 63-01

K2500

Reservdelar

Spare parts

Ersatzteile

Pieces de rechange

Piezas de repuesto

Ricambi

Peças sobresselente

HUSQVARNA CONSTRUCTION PRODUCTS

544 93 63-01

IPL, K3600 MkII, 2007-01,544 93 58-01

K3600 MkII

Reservdelar

Spare parts

Ersatzteile

Pieces de rechange

Piezas de repuesto

Ricambi

Peças sobresselente

HUSQVARNA CONSTRUCTION PRODUCTS

544 93 58-01

BASIC FUNCTION 2

The blade’s drive and control systems

Eccentric drive

The unique concept behind the K3600 MkII is its

eccentric drive (outside the centre) and control of the

cutter blade (A).

Function

The drive disc (B) which is powered by a belt driven off

the engine, has a groove into which the blade slots.

The two engagement rollers (C) exert pressure against

the blade (from the engagement roller springs, when the

knob is tightened), causing the blade to press against

the drive disc. The lower picture shows how the engage-

ment roller flanges grip in the cutter blade’s groove.

The only function of the support roller (D) is to exert

counter-pressure so that the blade is located properly

against the rollers without any play or clearance.

With this design, the cutter blade can be controlled

in both the radial and axial directions (rotating and

lateral movements). Three points (at the two engagement

and support rollers and at the drive disc) guide the

blade at the same time as the pressure against the drive

disc generates sufficient friction to drive the blade.

Important for good function

The description of the function indicates that it is parti-

cularly important that the engagement rollers can move

axially without 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 of the

blade. The adjustment is to be changed when the blade

is replaced and must be checked at least once during the

life of the blade. Because the adjustment is mechanically

locked, there is no movement once the locknuts have

been set and tightened.

Wear

In comparison with a traditional centre-driven machine,

the blade’s drive and engagement systems are subjected

to harder wear since the mechanical parts work con-

stantly in an environment of water and slurry.

Parts subject to wear

The wear-prone parts are the drive disc, engagement

rollers and support rollers (B, C and D in the figure).

These parts can be quickly and easily replaced and this

job is normally carried out by the user.

IMPORTANT

In all control and adjustment work on the engagement and

support rollers, the knobs that tensions the blade against

the drive disc must be unscrewed to its end position.

NB: The knobs must not be fully screwed to the end

position as this restricts engagement roller rotation.

HUSQVARNA K3600 MkII

COMPONENTS – ORIENTATION3

Components

1. Cutting blade – ring shaped cutting

blade with diamond segment

2. Water disc

3. Blade guard

4. Knobs for tensioning the blade against

the drive disc

5. Adjuster screws for support roller

adjustment against blade

6. Locknuts for roller adjuster

7. Support rollers (behind guard)

8 Drive disc (behind guard)

9. Adjustable handle

10. Throttle trigger lockout

11. Throttle trigger

12. Splash guard

13. Engagement rollers (behind guard)

14. Lubrication nipples

15. Hydraulic motor

16. Lock to prevent rotation of the

drive disc

17. Water adjustment valve

18. Type plate

19. Lubrication channel outlet

15 17

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 is reversed.

Therefore, the same cutting blade

should not be used on both machines as

this will result in the blade suffering

increased wear.

1. Support rollers

2. Engagement rollers

3. Pressure hose

4. Return hose

5. Water hose

Hydraulic pressure, max 150 bar

2200 psi

Hydraulic flow, min–max 35–42 l/min

9–11 US gpm

Hydraulic oil ISO VG 46

REPLACEMENT OF BLADE

Removal

Move the handle to the back-

ward position.

Removal

Pull out the handle lock and move the

handle to the rearmost position to secure

the best possible accessibility.

Unscrew the knobs (A).

Undo the locknuts (B).

Unscrew the adjuster screws (C)

at least two turns.

First unscrew both knobs (A);

this ensures that the blade exerts no

pressure against the drive disc.

Undo both locknuts (B) to the support

rollers.

Unscrew the adjuster screws (C) at least

two turns.

Remove the guard

Undo the three socket head cap

screws.

Lift off the guard.

Remove the blade.

Remove the support roller guard

The support roller guard is fixed in

position by three socket head cap screws.

Undo these.

Lift off the guard.

Remove the blade.

Quick inspection

Roller bearings

Check that the engagement and

support rollers rotate easily.

For details of how to replace

bearings, refer to Chapter 8.

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 must be even resistance.

Flange and waist

Check roller flanges and grooves.

Replace if necessary. Refer to

Chapters 6 and 7.

Bearing bracket – mobility

Check the mobility of the

engagement and support rollers’

bearing brackets.

Flange and waist

Also check that the engagement roller

flange and the support roller groove

(circled) is within permitted tolerances;

refer to Chapter 6.

If necessary, replace engagement and

support rollers in accordance with

Chapter 7.

Bearing bracket – mobility

Mobility of engagement roller bearing

brackets is checked by turning the knobs

between end positions.

It must be possible to move support

roller bearing brackets between end posi-

tions by hand.

REPLACEMENT OF BLADE

Replacement of drive disc

Blade and drive disc replaced at the same time

A new blade must be installed along with a new drive disc. If replacing with a

used blade, the drive disc associated with that blade must also be installed.

A used blade can be used with a new drive disc, never vice versa.

Remove the drive disc

Push in the rotation lock.

Remove the drive disc.

Install a new drive disc

Remove the drive disc

Press in the drive disc rotation lock on

the opposite side above the hydraulic

motor.

Remove the centre screw and lift off the

washer and drive disc.

Install a new drive disc

Fit the new drive disc and the tappet.

Fit the centre screw, press in the rotation

lock and tighten the centre screw firmly.

Fit the blade

The knobs must be screwed out!

Fit the cutting 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 rol-

lers must now not rotate or be easy to

slow down. Otherwise, unscrew the

adjuster screws.

Tighten the guard

Screw the guard firmly in position.

Adjust roller contact

Before the machine can be used, the

rollers must be adjusted as set out in

Chapter 5.

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 sufficiently screwed out to

create clearance between the

blade and the rollers.

Firmly screw the guard in

position

Adjust roller contact

Adjust in accordance with

Chapter 5.

ROLLERS – ADJUSTMENT/INSPECTION 5

Adjustment

Important –

knobs screwed out

The knobs must be screwed out.

Undo the locknuts (B).

Rough adjustment

Rotate the blade by hand and

screw in the adjuster screws (A)

until the rollers rotate.

Fine adjustment

Fine adjust until you reach a

position where you can easily

stop the rotation of the support

rollers with your thumb (lower

picture).

Tighten the locknuts –

final inspection

Tighten the locknuts firmly and

perform a final inspection of

the adjustment.

Screw in the knobs

Adjustment

Important – knobs screwed out

Roller adjustment must always be per-

formed with the knobs screwed out.

Undo the locknuts (B).

The best way to inspect the adjustment

is to tighten the locknuts slightly before

starting the adjustment process.

Rough adjustment

Rotate the blade by hand and screw in

the adjuster screws (A) until the rollers

rotate.

Fine adjustment

Fine adjust until you reach a position

where you can easily stop the rotation of

the support rollers with your thumb

(lower picture).

Tighten the locknuts – final

inspection

Tighten the locknuts (B) firmly and per-

form a final inspection of the adjustment.

Screw in the knobs

Finish by screwing in the knobs to

tension the blade 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 contact will result in the

blade being unstable. In extreme cases,

this may lead to the blade leaving its

track.

Function

The support rollers are fitted on levers in

the support roller guard. The position of

the lever is determined by the adjuster

screws (A). The locknuts (B) lock the

lever in position.

The rollers must always be adjusted following:

– changeover to a new blade

– changeover to another used blade

– replacement of guide or support roller

Always check the adjustment whenever the support roller guard has

been removed and refitted.

IMPORTANT: When adjusting the rollers, the knobs must be

screwed out – but not out fully to its end position as this will stop the

engagement roller rotation.

Inspection

At least once during the

life of the blade

The inspection is conducted in

the same way described above.

Inspection

At least once during the life of

the blade

The inspection is conducted in the same

way described above.

Remember – the knobs must be

unscrewed during the inspection!

ENGAGEMENT AND SUPPORT ROLLERS6

Replaceable wear parts

The engagement and support rollers, as well

as the drive disc, are exposed to extreme

wear due to the dirty conditions in which

they operate. As a result, wear parts have

been made easy to replace. The lifespan of a

set of engagement and support rollers can

vary considerably depending on the material

cut and the cutting technique employed.

Using insufficient water during cutting

increases wear. A set usually rolls approxi-

mately 2–6 blades.

Same roller type replaced in pairs

In order for the blade to sit straight in the

drive disc, the same roller type must be

replaced in pairs.

Upper and lower rollers may be

swapped

It is common for the flange of the upper

engagement roller to experience more wear

due to the additional load exerted on it by

the feed pressure. You can swap the upper

and lower engagement rollers in order to get

the full operational life out of both rollers.

Wear limit

Engagement rollers

The engagement rollers must have a flange

width of at least 1.5 mm/.06 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

cylinder in the centre of the spring limits

movement of the bearing bracket when

the cutting blade is exposed to extreme

loads.

The bearing bracket moves in the

machine’s bearing housing. Lubrication

is applied via the grease nipple (B) and

lubrication channels in the bearing

housing carry grease to the outlet channel

(C), which indicates when clean grease

comes out.

NB: The bearing housing must be

lubricated with the blade fitted and the

knobs in operational position!

Knobs

Operational position (1)

The knobs must always be fully screwed

in when the machine is put in operation.

Service position (2)

The knobs must be screwed out when

changing the blade and adjusting the

rollers.

Disassembled knob (3)

Screwing the knob past the service

position releases the snap-on fastener

from the cam, allowing the bearing

bracket to be pressed out.

REPLACEMENT OF ENGAGEMENT AND SUPPORT ROLLERS

Engagement rollers

Remove the support roller guard

and the blade.

Unscrew the knob.

Engagement rollers

Remove the support roller guard and the

blade.

When replacing the engagement roller,

the bearing bracket assembly must be

removed for inspection and service.

Force the knob from the snap-on fastener

by screwing the knob past the end stop.

Unscrew the knob.

Replace engagement rollers

Secure the tool in a vice

The simplest way of removing the wear

part is to place a box spanner in a vice.

Lock the nut using the spanner and

unscrew the socket head cap screw.

Never put the roller in the vice!

Inspection, cleaning

Pull or press out the bearing bracket.

If the bearing bracket is defective

(wear/corrosion damage), the simplest

thing to do is to replace the entire bea-

ring bracket assembly with bearings.

Replace the bearings as described in

Chapter 8.

Clean all traces of old grease from the

bearing housing.

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 grease.

If you opt to use a different brand,

the grease used must be of the same

NLGI grade.

(The NLGI grade indicates the stiff-

ness of the grease. The higher the

NLGI grade, the stiffer the grease.)

IMPORTANT!

Worn engagement and support rollers

have a smaller diameter than new rol-

lers. Unscrew the adjuster screws two

turns if only one type of roller is to be

replaced, and four turns if all rollers are

to be replaced before the guard is fitted.

Inspection, cleaning

Pull or press out the bearing

bracket.

Clean the bearing housing.

Wipe the bearing bracket and

check that it is not damaged.

Inspect the engagement roller

bearings.

Replace engagement

rollers

Secure the tool in a vice

Lock the nut using the box

spanner and unscrew the socket

head cap screw.

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