Husqvarna K 4000 Cut-n-Break Instruction manual

Workshop manual
K4000
English
474 - 002 - 27.06.2018

Contents
1 Introduction
1.1 Document description............................................ 3
1.2 Target group...........................................................3
1.3 Revisions................................................................3
1.4 Safety..................................................................... 3
1.5 Servicing tools........................................................3
2 Safety
2.1 Safety definitions....................................................4
2.2 General safety instructions.....................................4
2.3 Symbols on the product......................................... 4
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.................. 13
5.2 Components overview K4000Cut-n-Break...........14
5.3 Basic structure..................................................... 15
6 Repair and servicing
6.1 Carbon brushes....................................................16
6.2 Carbon brush holders...........................................17
6.3 Circuit board.........................................................18
6.4 PRCD (Portable Residual Current Device).......... 18
6.5 Electrical cables................................................... 19
6.6 Rotor.................................................................... 21
6.7 Stator....................................................................22
6.8 Gear housing Wet................................................ 27
6.9 Gear housing Cut-n-Break................................... 33
6.10 Blade guard........................................................38
6.11 Cut-n-Break........................................................39
6.12 Water system..................................................... 44
6.13 Cables................................................................ 46
7 Diagrams
7.1 Wiring diagram 230V............................................48
7.2 Wiring diagram 120V............................................49
7.3 Wiring diagram 120V UK and Ireland...................50
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1 Introduction
1.1 Document description
This manual gives a full description of how to do
maintenance and repair on the product. It also gives
safety instructions that the personnel must obey.
1.2 Target group
This manual is for personnel with a general knowledge
of how to do repair and do servicing. All personnel that
do repair or do servicing on the product must read and
understand the manual.
1.3 Revisions
Changes to the product can cause changes to the
maintenance work and spare parts. Separate
information is sent out for each change.
Read the manual together with all received information
about changes to maintenance and spare parts for the
product.
1.4 Safety
WARNING: All personnel that repair or do
servicing on the product must read and
understand the safety instructions in this
workshop manual.
1.5 Servicing tools
The manual gives information about necessary servicing
tools. Always use original tools from Husqvarna.
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2 Safety
2.1 Safety definitions
The definitions below give the level of severity for each
signal word.
WARNING: Injury to persons.
CAUTION: Damage to the product.
Note: This information makes the product easier to use.
2.2 General safety instructions
• You must not repair the product unless you have
read and understood this workshop manual.
• The service center where the product is repaired
must have safety equipment approved by local
bylaws.
• The product is examined and approved only with the
equipment given or recommended by the
manufacturer.
• Service personnel must make sure that the service
and repairs in this manual are done following legal
requirements. This in order to avoid health and
safety risks of the personnel doing the work.
• When possible, disconnect the power cable and
make sure it cannot be connected until the service is
completed.
• If you keep the product running during service, do
not touch the wires. Electrical shock can cause
injury.
• Follow the local waste regulations.
• Always make sure all nuts and bolts are correctly
tightened.
• Do not lift the machine by holding the cable and do
not pull the plug by pulling the cable.
• Check that the cables are not damaged and in good
condition.
• Do not use the product if a cable is damaged.
• Use protective gloves and eye protection. Goggles
must follow the ANSI Z87.1 for US or EN166 for EU
countries.
• When using compressed air, do not point it to your
body. Air can go in to the blood stream.
• Wear ear protection when test running.
• The product can make sparks and cause ignition of
flammable materials.
• If a warning symbol decal on the product is
damaged or missing, replace the warning symbol
decal.
2.3 Symbols on the product
WARNING: Careless or incorrect use can
result in injury or death to the operator or
others.
Read the manual carefully and make sure
you understand the instructions before
using the product.
Always put on personal protective
equipment:
• Hearing protection
• Protective goggles or a visor
• Breathing mask.
This product in compliance with applicable
EC directives.
WARNING! Dust from cutting can cause
breathing problems. Use breathing
protection. Do not breathe exhaust fumes.
Always make sure there is good airflow.
WARNING! Sparks from the cutting blade
can cause a fire in materials such as,
gasoline, wood, fabric and dry grass.
WARNING! Kickbacks can be sudden,
fast and can cause injuries. Read and
understand the instructions in the manual
before using the product.
Make sure the cutting disc is not
damaged.
WARNING! Do not use circular saw
blades.
Note: Other symbols/decals on the product refer to
special certification requirements for some markets.
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3 Servicing data
3.1 Symbols in the diagrams
Tightening torque
Grease
Thread lock
Torx
Allen
Bolt
Phillips
Pozidrive
Track
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3.2 K4000 Wet/Cut-n-Break
1-1,2
T20
2.5-3
T27
1
2-2.5
T27
2
T27
T10
2
T27
3-4
T27
6.5-7
T27
2.5-3
T27
6.5-7
T27
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3.3 K4000 Wet
6.5-7
T27
1
33-35
25-30
22
7
13
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3.4 K4000 Wet
9-9.5
T27
2.5-3
T27
5-7
T27
2-3
T27
5-10
13
T27
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3.5 K4000 Cut-n-Break
6.5-7
T27
10-12
T27
10-12
T27
1
7
13
33-35
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3.6 K4000 Cut-n-Break
A
A
20-25
22
2-4
T27
8-10
T27
T27
T27
T27
PH2
PH2
T27
T27
3-4
T27
4-6
T27
PH2
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3.7 K4000 Cut-n-Break
10-15
25-30
7-10
T27 7-9
T27
2-3
PH2
PH2
13
13
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4 Servicing tools
4.1 Servicing tools overview
1 2 3
8 9 10 11
4 5 6 7
Pos. Designation Used for Order No./Source
1 Service Center
key Torx T10,
T20, T27
General 502 71 27-02
2 Bearing press To put the gear housing bearing 506 37 61-02
3 Hex keys kit General (Hex keys: 3, 4, 5 and 6 mm.
Socket: 8 mm )
504 90 00-06
4 Universal puller Wet: To install crown gear and bear-
ing
504 90 90-02
5 Wrench Cut-n-Break To remove and install
the blade bearing
502 53 15-01
6 Torque wrench Sockets sizes 7, 13, 22 mm There are many manufacturers
7 Counter stay
device
To remove the ball bearing and nee-
dle bearing in the gear housing
There are many manufacturers, for example:
Kukko (Germany), Snap-On (USA)
8 Mounting
sleeve
Wet To put the crown gear and seal
ring
525 30 02-01
9 Multimeter To control the functions of the electri-
cal system
Amprobe 37XR-A or other model that can
measure inductance
10 Grease To lubricate the gear housing 503 97 64-01 - Wet / 574 20 30-01 Cut-n-Break
11 Slide Hammer To remove the gear housing bearing There are many manufacturers
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5 Product overview for repair and servicing
5.1 Components overview K4000Wetwet
11
10
9
1
2
3
4
5
6
8
7
1. Cutting blade (not supplied)
2. Blade guard
3. Spray nozzle on each side
4. Front handle
5. Inspection cover for carbon brushes
6. Starter lock
7. Rear handle
8. Circuit breaker
9. Spindle lock
10. Water coupling with valve
11. PRCD (Portable Residual Current Device) (Not for
UK and Ireland)
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servicing - 13

5.2 Components overview K4000Cut-n-Break
1
4
5
2
2
3
6
7
8
11
9
10
12
13
14
1. Cutting blades (not supplied)
2. Blade guard
3. Spray guard
4. Water valve
5. Front handle
6. Inspection cover for carbon brushes
7. Starter lock
8. Rear handle
9. Circuit breaker
10. PRCD (Portable residual Current Device) (Not for
UK and Ireland)
11. Water coupling
12. Locknuts for belt adjustment
13. Locknut for belt tensioner
14. Belt tensioner
14 - Product overview for repair and
servicing
474 - 002 - 27.06.2018

5.3 Basic structure
12
3
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).
2. Wet. Blade water coolant. Blade diameter 350 mm
3. Cut-n-Break. Cutting unit with two blades. Blade
water coolant. Blade diameter 230 mm, cutting
depth 400 mm.
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servicing - 15

6 Repair and servicing
6.1 Carbon brushes
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. The brush and the collector only have small
scratches in the direction of turning. The illustration also
shows the results when the brush is worn. The spring no
longer gives the brush the correct pressure. Sparks
occurs which causes damage to the brushes and the
collector in a very short time. Sparks can also occur if
the brushes cannot move. This can be because of dirt.
Running in new brushes can also cause sparks.
1. Examine the brush using a Vernier caliper.
Replace the brushes when there is more than
10mm/.4in between the brush holder and the top of the
brush.
>10 mm (.4”)
6.1.2 To remove the carbon brushes
1. Remove the screws and the inspection cover.
2. Loosen the screw one turn and remove the cable
lug.
3. Lift the spring and remove the carbon brush.
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6.1.3 To install the carbon brushes
1. Clean the holder.
2. Install the new carbon brushes.
3. Install the cable lug and tighten the screw.
4. Install the inspection cover and screws.
You must break in new carbon brushes. Run the
machine for 30 minutes without a load.
6.2 Carbon brush holders
6.2.1 To remove the carbon brush holders
1. Remove the brushes. See
To remove the carbon
brushes on page 16
2. Remove the screws to the right handle.
3. Remove the right handle.
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4. Remove the locking button and spring.
5. Remove the switch.
6. Remove the two screws for the left handle.
7. Remove the screw. Move the circuit board to the
side.
8. Remove the screws.
9. Remove the carbon brush holders.
6.3 Circuit board
The circuit board has two functions, Softstart and
Elgard™. Softstart gives a soft start with less current.
Elgard™ gives a warning by changing the speed if there
is an overload.
6.3.1 To examine the circuit board
1. To examine the circuit board, special equipment is
necessary. As an alternative you can use a process
of exclusion. Examine the Power supply, cables,
switches, stator and rotor. If they are operating, the
problem is with the circuit board. It must then be
replaced.
6.4 PRCD (Portable Residual Current Device)
The current that comes in through the phase conductor
must also go through the 0 conductor. The conductors
run through a coil. If the same current goes in the two
directions, there will be no current in the coil. If there is a
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short circuit there will be more current going in through
the coil than going out. If the current in the coil is more
than 10mA, a circuit breaker will stop the current to the
product.
6.4.1 To examine the PRCD
Each time the power plug is connected to the mains, the
RESET button must be pressed. A relay connects the
current and is held in position while there is mains
current. A red light above the button shows that the
current is connected. The TEST button is used to control
that the PRCD works.
1. Start the machine and press the TEST button. The
PRCD must stop the machine.
6.5 Electrical cables
WARNING: Do not make any controls when the
product is connected to a mains socket.
The electrical function is controlled with a multimeter.
6.5.1 To examine the electrical cables, contact -
PRCD
The PRCD only let through current when it is connected
to the mains. To access the connection points to control
the mains cable with a multimeter, pull apart the ends of
the PRCD.
1. Remove the two screws on each end.
2. Pull out the ends.
3. Turn the PRCD.
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4. Measure between the contact pins, ground and the
related contact points on the PRCD.
6.5.2 To examine the electrical cables, contact -
switch
The PRCD only let through current when it is connected
to the mains. To examinel the mains cable with a
multimeter, pull apart the ends of the PRCD. Then you
can measure at the connection points.
1. Open the ends of the PRCD. See To examine the
electrical cables, contact - PRCD on page 19
2. Remove the switch. See To remove the carbon
brush holders on page 17
3. Divide the gear and motor housing See To
disassemble the gear housing on page 27
4. Measure between the contact pins and their contact
points on the switch.
6.5.3 To examine the electrical cables, switch -
motor
The cables from the switch to the motor goes through
the circuit board. A probe from the multimeter cannot get
in contact with a cable on the circuit board. The best is
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