Husqvarna K4000 Workshop Manual
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Husqvarna K4000 Workshop Manual

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Workshop manual
K4000
English
474 - 002 - 27.06.2018

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Summary of Contents for Husqvarna K4000

  • Page 1 Workshop manual K4000 English 474 - 002 - 27.06.2018...

  • Page 2: Table Of Contents

    3 Servicing data 3.1 Symbols in the diagrams........5 3.2 K4000 Wet/Cut-n-Break......... 6 3.3 K4000 Wet............. 7 3.4 K4000 Wet............. 8 3.5 K4000 Cut-n-Break ..........9 3.6 K4000 Cut-n-Break..........10 3.7 K4000 Cut-n-Break..........11 4 Servicing tools 4.1 Servicing tools overview........12 5 Product overview for repair and servicing 5.1 Components overview K4000Wetwet....

  • Page 3: Introduction

    1.5 Servicing tools The manual gives information about necessary servicing tools. Always use original tools from Husqvarna. 474 - 002 - 27.06.2018 Introduction - 3...

  • Page 4: Safety

    2 Safety 2.1 Safety definitions 2.3 Symbols on the product The definitions below give the level of severity for each WARNING: Careless or incorrect use can signal word. result in injury or death to the operator or others. WARNING: Injury to persons. Read the manual carefully and make sure you understand the instructions before CAUTION: Damage to the product.

  • Page 5: Servicing Data

    3 Servicing data 3.1 Symbols in the diagrams Bolt Tightening torque Phillips Grease Pozidrive Thread lock Track Torx Allen 474 - 002 - 27.06.2018 Servicing data - 5...

  • Page 6: K4000 Wet/Cut-N-Break

    3.2 K4000 Wet/Cut-n-Break 6.5-7 2.5-3 2.5-3 6.5-7 1-1,2 2-2.5 6 - Servicing data 474 - 002 - 27.06.2018...

  • Page 7: K4000 Wet

    3.3 K4000 Wet 33-35 25-30 6.5-7 474 - 002 - 27.06.2018 Servicing data - 7...

  • Page 8: K4000 Wet

    3.4 K4000 Wet 5-10 2.5-3 9-9.5 8 - Servicing data 474 - 002 - 27.06.2018...

  • Page 9: K4000 Cut-N-Break

    3.5 K4000 Cut-n-Break 10-12 33-35 10-12 6.5-7 474 - 002 - 27.06.2018 Servicing data - 9...

  • Page 10: K4000 Cut-N-Break

    3.6 K4000 Cut-n-Break 8-10 20-25 10 - Servicing data 474 - 002 - 27.06.2018...

  • Page 11: K4000 Cut-N-Break

    3.7 K4000 Cut-n-Break 25-30 10-15 7-10 474 - 002 - 27.06.2018 Servicing data - 11...

  • Page 12: Servicing Tools

    4 Servicing tools 4.1 Servicing tools overview Pos. Designation Used for Order No./Source Service Center General 502 71 27-02 key Torx T10, T20, T27 Bearing press To put the gear housing bearing 506 37 61-02 Hex keys kit General (Hex keys: 3, 4, 5 and 6 mm. 504 90 00-06 Socket: 8 mm ) Universal puller Wet: To install crown gear and bear-...

  • Page 13: Product Overview For Repair And Servicing

    5 Product overview for repair and servicing 5.1 Components overview K4000Wetwet 1. Cutting blade (not supplied) 8. Circuit breaker 2. Blade guard 9. Spindle lock 3. Spray nozzle on each side 10. Water coupling with valve 4. Front handle 11. PRCD (Portable Residual Current Device) (Not for UK and Ireland) 5.

  • Page 14: Components Overview K4000Cut-N-Break

    5.2 Components overview K4000Cut-n-Break 1. Cutting blades (not supplied) 9. Circuit breaker 2. Blade guard 10. PRCD (Portable residual Current Device) (Not for UK and Ireland) 3. Spray guard 11. Water coupling 4. Water valve 12. Locknuts for belt adjustment 5.

  • Page 15: Basic Structure

    5.3 Basic structure K4000Wet and Cut-n-Break have the same motor unit that makes wet cutting possible with small quantities of water. The workshop manual has the same sections for the motor and different sections for each type of machine. 1. Motor. The same unit for the two machines. Available for 230 V (220–240 V) and 120 V (100 - 120 V).

  • Page 16: Repair And Servicing

    6 Repair and servicing 6.1 Carbon brushes 6.1.2 To remove the carbon brushes 1. Remove the screws and the inspection cover. The carbon brushes transmit electric current to the rotor. The carbon brushes are wear parts and must be examined regularly. 6.1.1 To examine the carbon brushes The illustration shows a brush that is worn but can be used.

  • Page 17: Carbon Brush Holders

    6.2 Carbon brush holders 6.1.3 To install the carbon brushes 1. Clean the holder. 6.2.1 To remove the carbon brush holders 2. Install the new carbon brushes. To remove the carbon 1. Remove the brushes. See brushes on page 16 2.

  • Page 18: Circuit Board

    4. Remove the locking button and spring. 8. Remove the screws. 9. Remove the carbon brush holders. 5. Remove the switch. 6.3 Circuit board 6. Remove the two screws for the left handle. The circuit board has two functions, Softstart and ™...

  • Page 19: Electrical Cables

    short circuit there will be more current going in through 6.5.1 To examine the electrical cables, contact - the coil than going out. If the current in the coil is more PRCD than 10mA, a circuit breaker will stop the current to the The PRCD only let through current when it is connected product.
  • Page 20 4. Measure between the contact pins, ground and the 4. Measure between the contact pins and their contact related contact points on the PRCD. points on the switch. 6.5.2 To examine the electrical cables, contact - 6.5.3 To examine the electrical cables, switch - switch motor The PRCD only let through current when it is connected...

  • Page 21: Rotor

    to examine the cables by measuring them in series with 1. Remove the inspection cover to the carbon brushes. the stator. Use the resistance setting, not the buzzer. To remove the carbon brushes on page 16 1. Measure between the switch and the carbon 2.

  • Page 22: Stator

    6.6.2 To remove the rotor 3. Cut the cables from the circuit board to the stator at the splices. To disassemble the gear To remove the rotor, see housing on page 27 . 6.6.3 To install the rotor To install the gear To install the rotor, please see housing on page 32 .
  • Page 23 7. Open the gear housing with a screwdriver. 11. Remove the gear housing and the rotor. 8. Remove the gear set housing 12. Remove the two screw holding the stator. 9. Remove the four screws to the gear housing. 13. Remove the stator. 10.
  • Page 24 from the multimeter in order to decrease the inductance 4. Remove the screws to the right handle. and get more accurate result. 1. Remove the inspection cover to the carbon brushes. 5. Remove the right handle. 2. Move away the springs holding the brushes. 6.
  • Page 25 7. Cut the two cables going to the stator at the splices. When a test is made with the stator on the product, the inductance must be 40 mH. Resistance must be around 8 Ω. If the stator is broken, an inductance test gives 0 mH. A resistance test gives a maximum value.
  • Page 26 4. Remove the screws to the right handle. 1. Remove the inspection cover to the carbon brushes. 2. Move away the springs holding the brushes. 5. Remove the right handle. 3. Pull out the brushes until they are not in connection with the rotor.

  • Page 27: Gear Housing Wet

    7. Cut the cable going to the stator at the splice. 6.8 Gear housing Wet 6.8.1 To disassemble the gear housing 1. Remove the screws and the inspection cover. 8. Connect one of the multimeter probes to the cable for the carbon brush. Connect the other one to the cut off cable going to the stator.
  • Page 28 4. Remove the screws for the gear set housing. 8. Remove the screw for the ground wire. 9. Remove the gear housing and the rotor. 5. Open with a screwdriver. 10. If the rear bearing does not come out of the motor housing, use a hammer and hit it lightly.
  • Page 29 Servicing tools overview you can use a slide hammer. Note: The nut must be loosened in a clockwise on page 12 direction. 1. Remove the circlip. 12. Remove the drive pinion and the spacer. 13. Put the rotor in a vice with soft jaw guards. 14.
  • Page 30 2. Remove the crown gear bearing with a universal puller. 6.8.6 To install the gear cover bearing To install the gear cover bearing, use Husqvarna Servicing tools overview on page 12 . bearing press 1. Add a large washer to help the nut. Pull the bearing into position by turning the nut.
  • Page 31 6.8.7 To install the crown gear and bearing 6.8.8 To install the gear housing bearing To install the gear cover bearing, use bearing press and To install the gear housing bearing, use Husqvarna Servicing tools overview on page mounting sleeve. See bearing press and Husqvarna mounting sleeve.
  • Page 32 6.8.9 To install the gear housing 4. Put the gear housing and the rotor half into the motor housing. 1. Push the rotor in to the gear housing. 5. Tighten the screw for the ground wire from the motor housing. 2.

  • Page 33: Gear Housing Cut-N-Break

    6.9 Gear housing Cut-n-Break 8. To apply grease, use Husqvarna grease. See Servicing tools overview on page 12 . It has the correct type and quantity of grease. You can also 6.9.1 To disassemble the gear housing apply 100g of Eco 100gr Bevel gear grease or Note: The crown gear unit cannot be disassembled.
  • Page 34 4. Remove the screws for the crown gear unit. 8. Remove the screw for the ground wire. 9. Remove the gear housing and the rotor. 5. Open with a screwdriver. 10. If the rear bearing does not come out of the motor 6.
  • Page 35 an alternative to the counter stay device you can use a Note: The nut must be loosened in a clockwise Servicing tools overview on page 12 slide hammer. direction. 1. Remove the circlip. 12. Remove the drive pinion and the spacer. 13.
  • Page 36 6.9.5 To install the gear housing bearing 1. Remove the bearing with a counter stay device. If To install the gear housing bearing, use Husqvarna necessary, use a hot air gun below the bearing seat bearing press and Husqvarna mounting sleeve.
  • Page 37 6.9.6 To install the gear housing 4. Put the gear housing and the rotor half into the motor housing. 1. Push the rotor in to the gear housing. 5. Tighten the screw for the ground wire from the motor housing. 2.

  • Page 38: Blade Guard

    6.10 Blade guard 8. To apply grease, use Husqvarna grease, 25g. See Servicing tools overview on page 12 . Do not use other types of grease. Apply it to the drive pinion and 6.10.1 To remove the blade guard fill the needle bearing.

  • Page 39: Cut-N-Break

    6.11 Cut-n-Break 6.10.2 To install the blade guard The screws must be tightened gradually in sequence as 6.11.1 Blades in the illustration. This is in order not to damage the rubber ring below the washer. 6.11.1.1 To remove the blade Cut-n-Break 1.
  • Page 40 6.11.1.2 To install the blade Cut-n-Break 6.11.2 Belt 1. Push the belt out from the center of the blade. 6.11.2.1 To tighten the belt Cut-n-Break 1. Loosen the nuts that hold the cutting arm and the screw that locks the adjustment washer. 2.
  • Page 41 6.11.2.2 To remove the belt Cut-n-Break 4. Remove the plates. 1. Remove rubber guard from the screw. 2. Move the spray guard to the side. 5. Lock the nut and remove the center screw. Remove the pulley wheel and the belt. 3.
  • Page 42 3. Put the front guard. 6.11.3 Bearing 6.11.3.1 To remove the bearing Cut-n-Break To remove the bearing, use Husqvarna wrench. See Servicing tools overview on page 12 1. Remove the belt guard. 4. Put the pulley wheel. 2. Put it in a vice.
  • Page 43 4. Put the wrench as in the illustration. Push out or hit 6.11.3.2 To install the bearing Cut-n-Break the bearing with a socket. To install the bearing, use Husqvarna wrench. Servicing tools overview on page 12 1. To put the new bearing, use a press. Apply press force to the outer ring of the bearing.

  • Page 44: Water System

    6.11.4 Cutting unit Cut-n-Break 4. Remove the screws on the spray guard, on the handle and at the bottom of the gear housing. 6.11.4.1 To remove the cutting unit The cutting unit can be disassembled to make repairs easier. For example if you are repairing the gear housing or if you are dividing the motor.
  • Page 45 6.12.4 Hose clips The hose clip can be used again after it has been removed. 1. Open the hose clip with a screwdriver. 6.12.1 Water coupling ® The water coupling is adapted to the Gardena system. 2. Close the hose clip using pliers. The flow control adjusts a constant and low flow when the water pressure changes.

  • Page 46: Cables

    nozzle has a smaller diameter compared to the gasoline 6.13.2 To put cables into the terminal bar cutters in order to limit the quantity of water. 1. Put the cables all the way to the bottom of the terminal bar. Note that the cables must not be stripped.
  • Page 47 6.13.4 To install splices and sleeves 1. Remove the cable insulation by approx. 7 mm at the two ends of the cable. Put the cables in the splice sleeve. 2. Push together the splice sleeve with a pliers for cable clips. Pull the cables to make sure they are locked against the splice sleeve.

  • Page 48: Diagrams

    7 Diagrams 7.1 Wiring diagram 230V 1. To mains plug 2. Live cables 3. Emc filter 4. Emc filter 5. Ground cable: mains input - terminal bar 6. Ground cable: terminal bar - circuit board 7. Ground cable: terminal bar - front of machine 8.

  • Page 49: Wiring Diagram 120V

    7.2 Wiring diagram 120V 1. To mains plug 2. Live cables 3. Ground cable: mains input - terminal bar 4. Terminal bar 5. Ground cable: terminal bar - front of machine 6. Live cable: circuit board - stator 7. Live cable: stator - rotor 8.

  • Page 50: Wiring Diagram 120V Uk And Ireland

    7.3 Wiring diagram 120V UK and Ireland 1. To mains plug 2. Live cables 3. Emc filter 4. Ground cable: mains input - terminal bar 5. Terminal bar 6. Ground cable: terminal bar - front of machine 7. Live cable: circuit board - stator 8.
  • Page 51 474 - 002 - 27.06.2018 Diagrams - 51...
  • Page 52 596432402 2018-06-27...

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