Husqvarna K3600 Mk II Workshop Manual
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Husqvarna K3600 Mk II Workshop Manual

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Workshop manual
K3600 Mk II, K2500
HUSQVARNA CONSTRUCTION PRODUCTS

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Summary of Contents for Husqvarna K3600 Mk II

  • Page 1 Workshop manual K3600 Mk II, K2500 HUSQVARNA CONSTRUCTION PRODUCTS...

  • Page 2: Table Of Contents

    CONTENTS Page HUSQVARNA LITERATURE K3600 Mk II K3600 MkII K2500 2. BASIC FUNCTION COMPONENTS – ORIENTATION 4. REPLACEMENT OF BLADE 5. ROLLERS – ADJUSTMENT/INSPECTION 6. ENGAGEMENT AND SUPPORT ROLLERS 7. REPLACEMENT OF ENGAGEMENT AND SUPPORT ROLLERS 8. REPLACEMENT OF ROLLER BEARINGS 9.

  • Page 3: Literature

    LITERATURE 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.

  • Page 4: Basic Function

    BASIC FUNCTION HUSQVARNA K3600 MkII 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.

  • Page 5: Components - Orientation

    5. Water hose Hydraulic pressure, max 150 bar The position of the engagement and 2200 psi support rollers on the Husqvarna K950 Ring is reversed on the K3600 MkII. Hydraulic flow, min–max 35–42 l/min The direction of blade rotation in rela- 9–11 US gpm...

  • Page 6: Replacement Of Blade

    REPLACEMENT OF BLADE Removal Removal Move the handle to the back- Pull out the handle lock and move the ward position. handle to the rearmost position to secure the best possible accessibility. Unscrew the knobs (A). First unscrew both knobs (A); this ensures that the blade exerts no Undo the locknuts (B).
  • Page 7 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.

  • Page 8: Rollers - Adjustment/Inspection

    ROLLERS – ADJUSTMENT/INSPECTION Correct adjustment It is very important that the rollers are The rollers must always be adjusted following: correctly adjusted in order to ensure – changeover to a new blade machine function and to minimise wear. – changeover to another used blade To be correctly adjusted, the rollers –...

  • Page 9: Engagement And Support Rollers

    ENGAGEMENT AND SUPPORT ROLLERS Replaceable wear parts Upper and lower rollers may be Min. 1.5 mm swapped .06 in. The engagement and support rollers, as well It is common for the flange of the upper as the drive disc, are exposed to extreme engagement roller to experience more wear wear due to the dirty conditions in which due to the additional load exerted on it by...

  • Page 10: Replacement Of Engagement And Support Rollers

    REPLACEMENT OF ENGAGEMENT AND SUPPORT ROLLERS Grease – characteristics the figure ‘3’ indicates the NLGI The grease used in the service proce- grade of the grease. IMPORTANT! dures set out below must be stiff and If you opt to use a different brand, Worn engagement and support rollers afford good resistance to water pene- the grease used must be of the same...
  • Page 11 REPLACEMENT OF ENGAGEMENT AND SUPPORT ROLLERS Remove the wear part Remove the wear part Lift off the engagement roller. Once the socket head cap screw has been removed, the wear part can be lifted out. Clean and apply grease under the washer and on the engage- Clean and apply grease under the washer ment roller seat.
  • Page 12 REPLACEMENT OF ENGAGEMENT AND SUPPORT ROLLERS 7 Support rollers Support rollers Inspection Inspection Check the integrity of the Check the integrity of the support roller support roller bearings. Check bearings – the rollers must be able to that the bearing arms can move rotate freely, with even movement and and that they do not have zero play.

  • Page 13: Replacement Of Roller Bearings

    REPLACEMENT OF ROLLER BEARINGS Tools Tool 506 38 85-01 The bearing tool, with assembly punch and disassembly socket, is used to fit and remove engagement and support roller bearings. The inner diameter of the twist grip is specifically adapted for the bearing bracket pin.
  • Page 14 REPLACEMENT OF ROLLER BEARINGS 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.
  • Page 15 REPLACEMENT OF ROLLER BEARINGS Remove 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.

  • Page 16: Replacement Of Engagement Roller Bearing Socket 9

    REPLACEMENT OF ENGAGEMENT ROLLER BEARING SOCKET 9 Removal Tool A special tool produced by Husqvarna is required in order to replace the bearing socket. Item no. 506 37 53-01. 506 37 53-01 Removing the water disc facili - Removing the water disc facilitates the tates the procedure.
  • Page 17 REPLACEMENT OF ENGAGEMENT ROLLER BEARING SOCKET Fitting Fitting Grease the tool Grease the tool When the bearing socket is When the bearing socket is screwed in screwed in there is a tendency using the tool there is a tendency for the for the socket to turn in the socket to turn in the screwing direction.

  • Page 18: Controls

    CONTROLS Remove the handle halve Remove the handle halve Remove the screws. Move the handle to the forward position. Remove the handle half screws. First, separate the handle at the rear, by the controls, to release the control shafts from the handle half. Then move the handle half back to release it from the front section of the machine.
  • Page 19 CONTROLS Return spring Return spring The picture shows a correctly The return spring is fitted on the under- fitted return spring. side of the controls and usually comes loose when the controls is removed from the handle half. The picture shows how the return spring should be fitted when the control unit is in position.

  • Page 20: Components - Orientation

    COMPONENTS – ORIENTATION HUSQVARNA K2500 K2500 – components Hydraulic pressure, max 150 bar (2200 psi) 1 Cutting blade Hydraulic flow, min–max 35–42 l/min (9–11 US gpm) Hydraulic oil ISO VG 46 2. Blade guard 3. Adjustable handle for the blade guard 4.

  • Page 21: Belt Transmission

    BELT TRANSMISSION Belt guard Belt guard Removal Removal Undo the nuts (A) and release Undo both nuts on the front belt guard the belt tension using the (A). adjuster screw (B). Slacken the belt tension by unscrewing the adjuster screw (B) until there is no spring tension.

  • Page 22: Cutting Head

    CUTTING HEAD Dismantling Dismantling Dismantle the cutting head Dismantle the cutting head from the from the machine. machine. This chapter describes dismantling of the cutting head components and has instructions for replacing the blade shaft bearing at the end. Lock the belt pulley with a Lock the belt pulley with a pin punch pin punch and dismantle the and dismantle the centre screw.
  • Page 23 CUTTING HEAD Lift the blade guard off the Lift the blade guard off the bearing bearing housing. housing. Check that the grooved rings are Check that the grooved rings for the intact. blade guard's locking mechanism are Also check that the rubber intact.
  • Page 24 CUTTING HEAD Bearing unit The complete bearing unit consists of the axle, two ball bearings with spacer ring for the inner bearing races and a spacer washer against the belt pulley. Split the bearing unit Split the bearing unit Fit the screw on the special tool Use the vice as a counterhold.
  • Page 25 CUTTING HEAD Tool use Lubricate the slide surfaces and the screw. Centre 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.
  • Page 26 CUTTING HEAD Fit the belt pulley Note that the axle and the belt pul ley have a profile that means that the belt pulley must be turned cor rectly when assembling. Do not forget the washer between the bearing and the belt pulley! 1.

  • Page 27: Controls

    CONTROLS Separate the handle Separate the handle First, remove the cutting head In order to gain access to separate the and the rear belt guard. handle, the cutting head and rear belt guard must first be removed; see previous Remove the three screws as chapters.

  • Page 28: Hydraulic Motor

    In with an area of 10 cm and the the case of Husqvarna hydraulic cutters, the hydraulic unit must other just 1 cm . We place a provide a flow of 40 l/min (10 gpm) and a pressure of up to 150...
  • Page 29 We will now see a few common solutions that are applied in hydraulic systems and for Husqvarna Compressed air system: hydraulic power cutters.
  • Page 30 We will now see how pressure and flow interact in prin ciple in a Start variety of situations with the Husqvarna K3600 MkII/ K2500 and Work is about to begin, the throttle is pressed in so the throttle the Husqvarna hydraulic unit. Measuring equipment for pressure valve closes.

  • Page 31: Hydraulic Motor - Principles Of Operations

    HYDRAULIC MOTOR – PRINCIPLES OF OPERATION Hydraulic motor The solution is the spring-loaded valve by the motor that forces The hydraulic motor is of the the oil to pass through the main valve. gear-driven type. The two gears When the starter is activated, pressure increases, the valve opens form a seal where they grip one and gives the oil a free path to the motor.

  • Page 32: Testing

    TESTING Build your own measurement equipment Measurement equipment with the appropriate specification to test hydraulic cutters and hydraulic units is generally available for pur- chase as a finished product from specialist hydraulic equipment retailers. It is also relatively easy to build measure- ment equipment, as shown in the picture opposite.
  • Page 33 TESTING Testing hydraulic units Testing cutting machine Connection Hydraulic motor The function and output of both the hydraulic unit and the cut - This test will show whether internal leakage in the hydraulic ting machine can be tested using the connection circuit shown motor is the cause of reduced power.

  • Page 34: Troubleshooting - Procedures

    TROUBLESHOOTING – PROCEDURES Symptom: Low motor output Cause: Action: Worn motor Internal leakage allows hydraulic oil to pass the top and bottom Connect the machine to a hydraulic unit and test run the cutting side of the gears due to wear. This sort of wear can be totally machine with the motor shaft locked in accordance with the normal for a motor that has had a long operating life.
  • Page 35 TROUBLESHOOTING – PROCEDURES Symptom: Motor does not stop – control in stop position Cause: Action: Deformed link rod Dirt locking the torsion plate The servo valve, on which the torsion plate is mounted, has a This test is to be done with the cutting machine connected to a very definite position where the servo valve is open to the return hydraulic unit.

  • Page 36: Removal

    REMOVAL Removal of complete hydraulic motor For inspection and standard servicing purposes, the hydraulic motor need not be removed from the machine. The motor must be removed in the following instances: – Complete hydraulic motor replacement If there is wear damage in the motor housing or cover, the entire hydraulic motor should be replaced with a new unit.
  • Page 37 REMOVAL K2500 K2500 Remove the cutting head Remove the cutting head See description in Chapter 12. Remove the rear belt guard Remove the rear belt guard See description in Chapter 12. Remove the belt pulley Remove the belt pulley Prevent belt pulley rotation and Prevent belt pulley rotation using a pin remove the centre screw.

  • Page 38: Inspection

    INSPECTION Identical design The hydraulic motors used in the K3600 MkII and K2500 are identical in all but one respect. That difference is in the gear height, which affects the speed of the output shaft at identical flows from the hydraulic unit. This is due to the totally dif - ferent cutting blade transmission systems used.
  • Page 39 INSPECTION Motor housing/cover Damaged motor housing Damaged bearings cause the gears to be positioned obliquely to the sealing surfaces of both the motor housing and the cover. Damage manifests as circular grooves following the movement of the gears and leads to reduced motor power due to internal leakage.

  • Page 40: Driveshaft

    DRIVESHAFT Driveshaft bearing/shaft seal If external leakage comes from the drive shaft, it is a sign that the shaft seal is damaged. Worn roller bearings may be indirectly responsible for the leak. Recommendation – replace bearing, shaft and seal On machines that have many operational hours on the clock, the shaft seal may cause damage to the surface of the driveshaft, reducing the integrity of the seal.
  • Page 41 DRIVESHAFT Remove the shaft unit Remove the shaft unit Tap out the complete shaft unit. Tap out the complete shaft unit with bearings and seals. Fitting Fitting Fitting the complete shaft Fitting the complete shaft unit Clean the bearing housing in the unit Clean the bearing housing in machine.
  • Page 42 DRIVESHAFT Shaft seal If the roller bearing and the shaft do not exhibit signs of damage, the shaft seal may be replaced separately in accordance with the description below. Important Remember that the shaft has two bearing surfaces to the gear motor slide bearing in addition to the roller bearing.
  • Page 43 DRIVESHAFT Fit a new inner sealing ring Fit a new inner sealing ring Carefully press the sealing ring Carefully press the new sealing ring over over the roller bearing stop edge the sharp stop edges of the roller bearing. down to its seat. Press the sealing ring down into its seat.

  • Page 44: Slide Bearings

    SLIDE BEARINGS Slide bearings Gear shafts, the driveshaft and the non-driving shaft are all fitted with slide bearings. These four bearings are identical. Replacement of slide bearings – rarely necessary It is rarely necessary to replace slide bearings as damage to these parts is a very infrequent occurrence.
  • Page 45 SLIDE BEARINGS Removal Removal Closed bearing housing Closed bearing housing Place a nut or washer as support Removal of both non-driving shaft slide in the bottom of the bearing bearings and the driveshaft bearing in housing. the cover is done in the following way: Screw in the screw tap.

  • Page 46: Valves

    VALVES Main valve Function The main valve manages the start and stop function of the hydraulic motor by guiding the oil flow to the gears or the return side. The position of the main valve is dictated by the servo valve, which is directly connected to the start control.
  • Page 47 VALVES Servo valve Function The servo valve is mechanically connected to the start control. It hydraulically controls the start and stop function of the main valve. Its design ensures that the start control can be operated with minimal force. The fixed and the movable part of the servo valve has two small holes through which hydraulic oil can pass whenever the holes are lined up.
  • Page 48 VALVES Brake valve Function The main task of the brake valve is to quickly slow the rotation of the blade once the start control has been released. This function is particularly impor- tant on the K2500 with its practically friction-free transmission system. Without a functioning brake valve, the blade on the K2500 would rotate even with the start control in stop position.

  • Page 49: Tools, Conversion Tables

    TOOLS, CONVERSION TABLES ● = Service action Conversion tables There are measurements for volume, pressure and flow other than 506 38 85-01 those we have used in this workshop manual. Press tool for roller bearings, K3600 MkII ● Removal and fitting of engage- VOLUME ment and support roller bearings.
  • Page 50 www.husqvarnacp.com 502 53 06-26 English 2007-08...

This manual is also suitable for:

K2500

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