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
2474 - 002 - 27.06.2018

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.
474 - 002 - 27.06.2018 Introduction - 3

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.
4 - Safety 474 - 002 - 27.06.2018

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

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
6 - Servicing data 474 - 002 - 27.06.2018

3.3 K4000 Wet
6.5-7
T27
1
33-35
25-30
22
7
13
474 - 002 - 27.06.2018 Servicing data - 7

3.4 K4000 Wet
9-9.5
T27
2.5-3
T27
5-7
T27
2-3
T27
5-10
13
T27
8 - Servicing data 474 - 002 - 27.06.2018

3.5 K4000 Cut-n-Break
6.5-7
T27
10-12
T27
10-12
T27
1
7
13
33-35
474 - 002 - 27.06.2018 Servicing data - 9

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
10 - Servicing data 474 - 002 - 27.06.2018