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Husqvarna K6500 Ring Workshop Manual

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Workshop manual
K6500 Ring
HUSQVARNA CONSTRUCTION PRODUCTS

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Summary of Contents for Husqvarna K6500 Ring

  • Page 1 Workshop manual K6500 Ring HUSQVARNA CONSTRUCTION PRODUCTS...

  • Page 2: Table Of Contents

    CONTENTS Page HUSQVARNA 1. DOCUMENTATION 2. BASIC FUNCTION K6500 Ring 3. COMPONENTS – NAVIGATION 4. REPLACING BLADE 5. ROLLERS – ADJUSTMENT/INSPECTION 6. ENGAGEMENT AND SUPPORT ROLLERS 7. REPLACING ENGAGEMENT AND SUPPORT ROLLERS 8. REPLACING ROLLER BEARINGS 9. REPLACING ENGAGEMENT ROLLER BEARING SLEEVES 16 10.

  • Page 3: Documentation

    DOCUMENTATION Workshop manual This workshop manual covers virtually all work in the workshop that involves the K6500 Ring. Some very simple and rather obvious repair work has been omitted. Arrangement – illustrations and text This manual is divided into numbered chapters as well as chapter headings that are specified in bold at the top of each page.

  • Page 4: Basic Function

    BASIC FUNCTION The blade’s drive and guiding system Eccentric drive The unique concept behind the K6500 Ring is its eccentric drive (outside the centre) and guiding of the cutter blade (A). Function The drive wheel (B) which is powered by a belt driven off the engine, has a groove into which the blade slots.

  • Page 5: Components - Navigation

    18. Starter inhibitor 19. Lubricating duct outlets NOTE In comparison to the hydraulically driven cutter ring, Husqvarna K3600, the engagement and support rollers have a reverse position on K6500 Ring. The blade's rotational direction relative to the machine is the same for both...

  • Page 6: Replacing Blade

    REPLACING BLADE Dismantling Remove the support roller cover Screw out the knobs at the outer position – the blade then has no tension on the drive wheel. The support roller cover is secured with four screws. Loosen these. Lift off the cover. Lift out the blade Remove the blade from the engagement roller and the blade from the drive wheel groove.
  • Page 7 REPLACING BLADE Remove the drive wheel Push in the drive wheel rotary latch on the opposite side. Remove the centre screw, lift off the carrier and the drive wheel. Fit the new drive wheel, 18–20 Nm/13–15 lbf·ft. Fit the new drive wheel and carrier. Fit the centre screw, push in the rotary latch and tighten the centre screw: 18–20 Nm.

  • Page 8: Rollers - Adjustment/Inspection

    ROLLERS – ADJUSTMENT/INSPECTION Correct adjustment Correctly adjusted rollers are essential for The rollers must always be adjusted following: the operation of the machine and to – changeover to a new blade minimise wear. – changeover to another used blade Correctly adjusted means that the –...

  • Page 9: Engagement And Support Rollers

    ENGAGEMENT AND SUPPORT ROLLERS Replaceable wear parts Upper and lower rollers may be Min. 1.5 mm swapped The engagement and support rollers, as well It is common for the flange of the upper as the drive wheel, 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 REPLACING ENGAGEMENT AND SUPPORT ROLLERS Grease – characteristics The grease used in the service procedures set out below must be stiff and IMPORTANT! afford good resistance to water penetration. Worn engagement and support rollers The original grease used during assembly in the factory is Shell Alvania RL3 have a smaller diameter than new rol - (lithium grease), where the figure ‘3’...
  • Page 11 REPLACING ENGAGEMENT AND SUPPORT ROLLERS Remove the roller When the nut is removed, lift off the carrier and roller. Lift off the washer to the ball bearing. Clean and apply grease under the washer and the engagement roller seat. (The grease prevents the penetration of concrete slurry.) Note that the washer must be turned with the recess closest to the shaft facing down.

  • Page 12: Replacing Engagement And Support Rollers

    REPLACING ENGAGEMENT AND SUPPORT ROLLERS Support rollers Checking Make sure that the roller bearings are intact – the rollers must rotate easily, with a smooth motion and no play. The support rollers are mounted on arms which change position when adjusting the roller.

  • Page 13: Replacing Roller Bearings

    REPLACING ROLLER BEARINGS Tool Bearing press 506 38 85-02 Bearing press (A), with removal sleeve (B) and mounting device (C), are used for the removal and installation of engagement and support roller bearings. Note that one end of the removal sleeve has a shoulder which is to face the engagement and support rollers' bearing holders.
  • Page 14 REPLACING ROLLER BEARINGS Fit new bearings 1. Place the shaft with the flange facing the hole on the bearing press. Add a ball bearing and place the mounting device on the bearing. Press down the bearing until the device is in contact with the shaft. 2.
  • Page 15 REPLACING ROLLER BEARINGS Remove the bearing unit Secure the bearing press in a vice. Place the removal sleeve with the shoulder up and turn the bearing arm so that the tool screw meets the bearing arm screw. Press out the bearing unit from the bearing arm. Knock the shaft out from the bearings in the same way as shown on page 13.

  • Page 16: Replacing Engagement Roller Bearing Sleeves

    REPLACING ENGAGEMENT ROLLER BEARING SLEEVES Dismantling Tool The special tool 506 37 53-01 is needed to replace the bearing sleeve. Remove the water disc The work is facilitated if the water disc is removed. Page 18 has a description of how this is done. 506 37 53-01 Lubricate the tool This is particularly important when the bearing sleeve is fitted for the...
  • Page 17 REPLACING ENGAGEMENT ROLLER BEARING SLEEVES Line the lubrication duct Put the sleeve in place by hand. Turn the sleeve so that the lubrication duct is aligned with the outlet duct in the chassis, or a millimetre lower (opposite to the tool's screw direction, as shown below) to compensate for any rotation during assembly.

  • Page 18: Replacing Drive Wheel Bearings

    REPLACING DRIVE WHEEL BEARINGS Tool A special tool is needed to replace the wheel bearing: 506 37 61-02. Parts of the tool kit are used both for removal and installation of the drive wheel bearing. It is important that the tool's sliding surfaces – threads, washers – are lubri- cated in order for the tool to function optimally.
  • Page 19 REPLACING DRIVE WHEEL BEARINGS Drive wheel Press in the rotary latch and remove the centre screw. Remove the carrier and drive wheel. Carrier Lift off the drive wheel carrier. Sealing collar Remove the sealing collar's three screws and remove the sealing collar. Radial seal/holder Lift out the sealing ring with holder.
  • Page 20 REPLACING DRIVE WHEEL BEARINGS Assemble bearings Perform the following operations with the machine horizontal. The transmission side should be facing up and the underside should be accessible. Support washer Parts of tool kit 506 37 61-02 are used for bearing assembly. Note that the tool kit washer cannot be used as a support when the inner bearing is assembled.
  • Page 21 Install the drive shaft Hold the drive shaft on the underside and screw in the tool's screw, through the triangle, into the base of the shaft. Pull in the drive shaft using the nut on the tool until the shaft comes into contact with the domed underside of the triangle.

  • Page 22: Cutting Unit

    CUTTING UNIT Cutting unit Dismantling The cutting unit is a separate unit that can be replaced. Remove the first water hose at the water valve. Remove the four screws that hold the cutting unit to the crankcase. Lift off the cutting unit. Lock washers The cutting machine is subjected to large vibration forces during operation.
  • Page 23 CUTTING UNIT Spray guard The spray guard is replaced as per the description below. Replacing the spray guard is made with the machine in an inverted position. Dismantling Remove the plugs The plugs, one on each side, are of foamed plastic and can easily be removed with pointed pliers.

  • Page 24: Wet System

    WET SYSTEM Hose clips Oetiker system The machine is originally fitted mainly with a single-use Oetiker ear clip. This type of clip has the advantage of being able to give small- dimension hoses even clamping force all round with a minimal risk of leakage.
  • Page 25 WET SYSTEM Water valve The water valve is accessible when the rear motor guard and controller unit has been removed, see page 26. Function The motor requires water cooling so as not to overheat. Water is carried from the hose connection, which has a Gardena hose connector, to the inlet side of the motor and on from the motor to the water valve and then to the water disc where the water flows out onto the blade.
  • Page 26 CONTROLS, ELECTRICAL COMPONENTS Removal Rear motor guard Remove the screws indicated with arrows, then remove the guard. (7 x MT5x14, 3–4 Nm. 1 x MT5x40, 3–4 Nm) When the guard has been removed, most components are accessible, such as the control unit with electrical connections, the water valve and hoses.

  • Page 27: Controls, Electrical Components

    CONTROLS, ELECTRICAL COMPONENTS 1. The yellow cable on the right is removed by undoing the locking screw on the top. 2. The grey cable on the left is locked with a spring. Insert a small screwdriver in the recess just to the right of the cable and pull this out.

  • Page 28: Motor

    MOTOR Removal Starting position Remove the blade as described on Page 6. Remove the rear motor guard as described on Page 26. Remove the transmission housing and belt as illustrated and descri- bed on Page 18. The front motor guard must be removed to access the motor itself and its electrical connections.
  • Page 29 MOTOR 5. Separate the 2 connectors for the motor. 6. Remove the hose clip and pull off the hose that runs from the water connection to the motor. 7. Remove the hose clip and pull off the hose that runs from the motor to the water valve.
  • Page 30 MOTOR Function Working method The way in which the high frequency motor works differs signifi- cantly from a traditional motor with rotor windings and collec- tor/carbon brushes. The rotor in the high frequency motor consists of permanent magnets with high magnetic force, known as neodymium magnets. In other words, the rotor has no windings or electrical components.
  • Page 31 Defective HF unit or cutting machine? When troubleshooting, it is important to remember that the fault may be in either the cutting machine K6500 Ring or the unit PP65. If you have access to another working PP65 and machine, these can be used in order to identify the faulty unit.

  • Page 32: Troubleshooting

    TROUBLESHOOTING Motor Dismantle the cutting machine so that the motor's connectors are accessible. The motor does not need to be removed from the machine. Short-circuit testing Check first to make sure that the motor does not have shorted windings to earth (motor material). This is easy to do using a multimeter on the contact X1.
  • Page 33 If measured values are outside the tolerance ranges, the ther- mistor is defective. Cable between PP65 and K6500 Ring Supply cables which have been “driven over” or abused are a relatively common cause of interference. Carry out a visual check of the outside of the cable for damage due to trapping.
  • Page 34 TROUBLESHOOTING Signal cables, connection testing and insulation testing This test is used to check whether any cable is broken and whether there is any damaged insulation which is causing the wires to come into contact with one another. This test is carried out with a multimeter set for connection testing with a buzzer signal.

  • Page 35: Tools

    Checking of the electric motor's Fitting of support rollers' ● functions. sealing collar. The special tools below are needed for servicing the K6500 Ring, 506 37 53-01 Press tool for the engage- but are not sold by Husqvarna: ment roller bearing sleeves...
  • Page 36 www.husqvarnacp.com 115 61 52-26 English 2013-09...

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