Husqvarna K3600 Mk II Instruction manual

HUSQVARNA CONSTRUCTION PRODUCTS
Workshop manual
K 3600 Mk II, K 2500

1
1. LITERATURE 2
K3600 MkII
2. BASIC FUNCTION 3
3. COMPONENTS – ORIENTATION 4
4. REPLACEMENT OF BLADE 5
5. ROLLERS – ADJUSTMENT/INSPECTION 7
6. ENGAGEMENT AND SUPPORT ROLLERS 8
7. REPLACEMENT OF ENGAGEMENT
AND SUPPORT ROLLERS 9
8. REPLACEMENT OF ROLLER BEARINGS 12
9. REPLACEMENT OF ENGAGEMENT ROLLER
BEARING SOCKET 15
10. CONTROLS 17
K2500
11. COMPONENTS – ORIENTATION 19
12. BELT TRANSMISSION 20
13. CUTTING HEAD 21
14. CONTROLS 26
HYDRAULIC MOTOR
15. HYDRAULICS – PRINCIPLES OF OPERATION 27
16. HYDRAULIC MOTOR – PRINCIPLES OF
OPERATIONS 30
17. TESTING 31
18. TROUBLESHOOTING – PROCEDURES 33
19. REMOVAL 35
20. INSPECTION 37
21. DRIVESHAFT 39
22. SLIDE BEARINGS 43
23. VALVES 45
24. TOOLS, CONVERSION TABLES 48
CONTENTS Page
HUSQVARNA
K3600 Mk II
K2500
502 53 06-26

2
LITERATURE1
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. These sections address all repair
procedures except those relating to the hydraulic motor
itself.
Both machines have identically designed hydraulic
motors; only a few components separate the two
models. Because of this similarity, servicing and repair
procedures for the hydraulic motor are covered in a
single chapter for the K3600 MkII and K2500, located
at the end of the manual.
It is essential to know how pressure and flow
work together in order to be able to understand how
hydraulics work and, more importantly, to understand
problems when things don't work. Because of this, we
decided to start the manual with a section dedicated to
the way in which hydraulics work, written specifically
for those with little or no experience of hydraulics.
Layout – pictures and text
In addition to the diagrams and illustrations, there are
generally two columns of text. The left-hand text
column is concise and is suitable for experienced
mechanics, whilst the right-hand column gives a more
detailed description and is targeted at mechanics with
less experience of power cutter repair work.
Contents
The manual is divided into numbered chapters together
with chapter headings that are stated in bold at the top
of each page.
The contents list also shows page references to the
start of each chapter.
Spare parts
K3600 MkII and K2500
The folders cover all spare parts available for the power
cutters.
The folders contain complete exploded views of the
entire machine that allow each component's location,
spare part number and appearance to be easily identified.
502 53 06-26
HUSQVARNA CONSTRUCTION PRODUCTS
Workshopmanual
K3600 Mk II, K 2500
IPL, K2500, 2007-01, 544 93 63-01
K2500
Reservdelar
Spare parts
Ersatzteile
Pieces de rechange
Piezas de repuesto
Ricambi
Peças sobresselente
HUSQVARNA CONSTRUCTION PRODUCTS
544 93 63-01
IPL, K3600 MkII, 2007-01,544 93 58-01
K3600 MkII
Reservdelar
Spare parts
Ersatzteile
Pieces de rechange
Piezas de repuesto
Ricambi
Peças sobresselente
HUSQVARNA CONSTRUCTION PRODUCTS
544 93 58-01

BASIC FUNCTION 2
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.
The two engagement rollers (C) exert pressure against
the blade (from the engagement roller springs, when the
knob is tightened), causing the blade to press against
the drive disc. The lower picture shows how the engage-
ment roller flanges grip in the cutter blade’s groove.
The only function of the support roller (D) is to exert
counter-pressure so that the blade is located properly
against the rollers without any play or clearance.
With this design, the cutter blade can be controlled
in both the radial and axial directions (rotating and
lateral movements). Three points (at the two engagement
and support rollers and at the drive disc) guide the
blade at the same time as the pressure against the drive
disc generates sufficient friction to drive the blade.
Important for good function
The description of the function indicates that it is parti-
cularly important that the engagement rollers can move
axially without interference from the spring force (the
direction of the arrows), so as to provide the correct
pressure against the drive disc. Corrosion or dirt that
blocks movement will cause the blade to slip against the
drive disc. A properly greased bearing housing will redu-
ce the risk of operational disruption.
There must be zero clearance in the adjustment of the
engagement and support rollers against the sides of the
blade. The adjustment is to be changed when the blade
is replaced and must be checked at least once during the
life of the blade. Because the adjustment is mechanically
locked, there is no movement once the locknuts have
been set and tightened.
Wear
In comparison with a traditional centre-driven machine,
the blade’s drive and engagement systems are subjected
to harder wear since the mechanical parts work con-
stantly in an environment of water and slurry.
Parts subject to wear
The wear-prone parts are the drive disc, engagement
rollers and support rollers (B, C and D in the figure).
These parts can be quickly and easily replaced and this
job is normally carried out by the user.
IMPORTANT
In all control and adjustment work on the engagement and
support rollers, the knobs that tensions the blade against
the drive disc must be unscrewed to its end position.
NB: The knobs must not be fully screwed to the end
position as this restricts engagement roller rotation.
3
A
B
B
C
CD
C
A
A
B
DC
HUSQVARNA K3600 MkII

4
COMPONENTS – ORIENTATION3
Components
1. Cutting blade – ring shaped cutting
blade with diamond segment
2. Water disc
3. Blade guard
4. Knobs for tensioning the blade against
the drive disc
5. Adjuster screws for support roller
adjustment against blade
6. Locknuts for roller adjuster
7. Support rollers (behind guard)
8 Drive disc (behind guard)
9. Adjustable handle
10. Throttle trigger lockout
11. Throttle trigger
12. Splash guard
13. Engagement rollers (behind guard)
14. Lubrication nipples
15. Hydraulic motor
16. Lock to prevent rotation of the
drive disc
17. Water adjustment valve
18. Type plate
19. Lubrication channel outlet
1
10
97
8
7
5
5
11
4
1
1
2
2
15 17
2
3
19
4
12
13
13
14
14
5
6
6
18
16
6
NB
The position of the engagement and
support rollers on the Husqvarna K950
Ring is reversed on the K3600 MkII.
The direction of blade rotation in rela-
tion to the machine is the same for both
models (pulling blade), but the rotation
of the cutting blade is reversed.
Therefore, the same cutting blade
should not be used on both machines as
this will result in the blade suffering
increased wear.
1. Support rollers
2. Engagement rollers
3. Pressure hose
4. Return hose
5. Water hose
3
4
5
Hydraulic pressure, max 150 bar
2200 psi
Hydraulic flow, min–max 35–42 l/min
9–11 US gpm
Hydraulic oil ISO VG 46

REPLACEMENT OF BLADE
Removal
Move the handle to the back-
ward position.
Removal
Pull out the handle lock and move the
handle to the rearmost position to secure
the best possible accessibility.
5
Unscrew the knobs (A).
Undo the locknuts (B).
Unscrew the adjuster screws (C)
at least two turns.
First unscrew both knobs (A);
this ensures that the blade exerts no
pressure against the drive disc.
Undo both locknuts (B) to the support
rollers.
Unscrew the adjuster screws (C) at least
two turns.
Remove the guard
Undo the three socket head cap
screws.
Lift off the guard.
Remove the blade.
Remove the support roller guard
The support roller guard is fixed in
position by three socket head cap screws.
Undo these.
Lift off the guard.
Remove the blade.
Quick inspection
Roller bearings
Check that the engagement and
support rollers rotate easily.
For details of how to replace
bearings, refer to Chapter 8.
Hydraulic motor
Rotate the drive disc a few turns
by hand.
Quick inspection
Roller bearings
When replacing the blade, it is appro-
priate and easy to perform a quick
inspection of the condition of the
engagement and support rollers. Feel that
the rollers rotate evenly and easily. Any
bearing damage must be corrected; refer
to Chapter 8.
Hydraulic motor
Rotate the drive disc a few turns by
hand. There must be even resistance.
Flange and waist
Check roller flanges and grooves.
Replace if necessary. Refer to
Chapters 6 and 7.
Bearing bracket – mobility
Check the mobility of the
engagement and support rollers’
bearing brackets.
Flange and waist
Also check that the engagement roller
flange and the support roller groove
(circled) is within permitted tolerances;
refer to Chapter 6.
If necessary, replace engagement and
support rollers in accordance with
Chapter 7.
Bearing bracket – mobility
Mobility of engagement roller bearing
brackets is checked by turning the knobs
between end positions.
It must be possible to move support
roller bearing brackets between end posi-
tions by hand.
A
B
C
4

6
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.
Remove the drive disc
Push in the rotation lock.
Remove the drive disc.
Install a new drive disc
Remove the drive disc
Press in the drive disc rotation lock on
the opposite side above the hydraulic
motor.
Remove the centre screw and lift off the
washer and drive disc.
Install a new drive disc
Fit the new drive disc and the tappet.
Fit the centre screw, press in the rotation
lock and tighten the centre screw firmly.
Fit the blade
The knobs must be screwed out!
Fit the cutting blade in the drive disc and
then in both engagement rollers. Fix the
blade in position by turning both knobs
one turn.
Fit the guard
Fit the guard and tighten the screws
lightly. Screw the knobs back out.
Check the position of the
adjuster screws
Check that the adjuster screws are suffi-
ciently screwed out to create clearance
between the blade and the rollers as fol-
lows: Rotate the blade by hand. The rol-
lers must now not rotate or be easy to
slow down. Otherwise, unscrew the
adjuster screws.
Tighten the guard
Screw the guard firmly in position.
Adjust roller contact
Before the machine can be used, the
rollers must be adjusted as set out in
Chapter 5.
Fit the guard
Fit the guard and tighten the
screws lightly. Screw the knobs
back out.
Check the position of the
adjuster screws
Check that the adjuster screws
are sufficiently screwed out to
create clearance between the
blade and the rollers.
Firmly screw the guard in
position
Adjust roller contact
Adjust in accordance with
Chapter 5.
!
4
!

ROLLERS – ADJUSTMENT/INSPECTION 5
Adjustment
Important –
knobs screwed out
The knobs must be screwed out.
Undo the locknuts (B).
Rough adjustment
Rotate the blade by hand and
screw in the adjuster screws (A)
until the rollers rotate.
Fine adjustment
Fine adjust until you reach a
position where you can easily
stop the rotation of the support
rollers with your thumb (lower
picture).
Tighten the locknuts –
final inspection
Tighten the locknuts firmly and
perform a final inspection of
the adjustment.
Screw in the knobs
Adjustment
Important – knobs screwed out
Roller adjustment must always be per-
formed with the knobs screwed out.
Undo the locknuts (B).
The best way to inspect the adjustment
is to tighten the locknuts slightly before
starting the adjustment process.
Rough adjustment
Rotate the blade by hand and screw in
the adjuster screws (A) until the rollers
rotate.
Fine adjustment
Fine adjust until you reach a position
where you can easily stop the rotation of
the support rollers with your thumb
(lower picture).
Tighten the locknuts – final
inspection
Tighten the locknuts (B) firmly and per-
form a final inspection of the adjustment.
Screw in the knobs
Finish by screwing in the knobs to
tension the blade against the drive disc.
Correct adjustment
It is very important that the rollers are
correctly adjusted in order to ensure
machine function and to minimise wear.
To be correctly adjusted, the rollers
must be set to the blade with no clearance.
Excessive contact increases roller wear
and results in deformation on the blade
that will, in a worst case scenario, lead to
the blade breaking.
Insufficient contact will result in the
blade being unstable. In extreme cases,
this may lead to the blade leaving its
track.
Function
The support rollers are fitted on levers in
the support roller guard. The position of
the lever is determined by the adjuster
screws (A). The locknuts (B) lock the
lever in position.
7
The rollers must always be adjusted following:
– changeover to a new blade
– changeover to another used blade
– replacement of guide or support roller
Always check the adjustment whenever the support roller guard has
been removed and refitted.
IMPORTANT: When adjusting the rollers, the knobs must be
screwed out – but not out fully to its end position as this will stop the
engagement roller rotation.
A
B
B
Inspection
At least once during the
life of the blade
The inspection is conducted in
the same way described above.
Inspection
At least once during the life of
the blade
The inspection is conducted in the same
way described above.
Remember – the knobs must be
unscrewed during the inspection!
A
A
BA

8
ENGAGEMENT AND SUPPORT ROLLERS6
Replaceable wear parts
The engagement and support rollers, as well
as the drive disc, are exposed to extreme
wear due to the dirty conditions in which
they operate. As a result, wear parts have
been made easy to replace. The lifespan of a
set of engagement and support rollers can
vary considerably depending on the material
cut and the cutting technique employed.
Using insufficient water during cutting
increases wear. A set usually rolls approxi-
mately 2–6 blades.
Same roller type replaced in pairs
In order for the blade to sit straight in the
drive disc, the same roller type must be
replaced in pairs.
Upper and lower rollers may be
swapped
It is common for the flange of the upper
engagement roller to experience more wear
due to the additional load exerted on it by
the feed pressure. You can swap the upper
and lower engagement rollers in order to get
the full operational life out of both rollers.
Wear limit
Engagement rollers
The engagement rollers must have a flange
width of at least 1.5 mm/.06 in.
Support rollers
The support rollers must be replaced if they
have no grooves.
Min. 1.5 mm
.06 in.
Engagement rollers
The engagement roller unit assembly (A)
comprises bearing brackets, which hold
double roller bearings, and the engage-
ment roller itself, which is fitted on the
shaft. The spring, which provides pressure
to the drive disc, is pre-tensioned and
fixed in the bearing bracket. The plastic
cylinder in the centre of the spring limits
movement of the bearing bracket when
the cutting blade is exposed to extreme
loads.
The bearing bracket moves in the
machine’s bearing housing. Lubrication
is applied via the grease nipple (B) and
lubrication channels in the bearing
housing carry grease to the outlet channel
(C), which indicates when clean grease
comes out.
NB: The bearing housing must be
lubricated with the blade fitted and the
knobs in operational position!
B
C
A
Knobs
Operational position (1)
The knobs must always be fully screwed
in when the machine is put in operation.
Service position (2)
The knobs must be screwed out when
changing the blade and adjusting the
rollers.
Disassembled knob (3)
Screwing the knob past the service
position releases the snap-on fastener
from the cam, allowing the bearing
bracket to be pressed out.
12
3

REPLACEMENT OF ENGAGEMENT AND SUPPORT ROLLERS
Engagement rollers
Remove the support roller guard
and the blade.
Unscrew the knob.
Engagement rollers
Remove the support roller guard and the
blade.
When replacing the engagement roller,
the bearing bracket assembly must be
removed for inspection and service.
Force the knob from the snap-on fastener
by screwing the knob past the end stop.
Unscrew the knob.
9
Replace engagement rollers
Secure the tool in a vice
The simplest way of removing the wear
part is to place a box spanner in a vice.
Lock the nut using the spanner and
unscrew the socket head cap screw.
Never put the roller in the vice!
Inspection, cleaning
Pull or press out the bearing bracket.
If the bearing bracket is defective
(wear/corrosion damage), the simplest
thing to do is to replace the entire bea-
ring bracket assembly with bearings.
Replace the bearings as described in
Chapter 8.
Clean all traces of old grease from the
bearing housing.
Wipe the bearing bracket and check that
it is not damaged.
Check the integrity of the engagement
roller bearings.
Grease – characteristics
The grease used in the service proce-
dures set out below must be stiff and
afford good resistance to water pene-
tration.
The original grease used during
assembly in the factory is Shell
Alvania RL3 (lithium grease), where
the figure ‘3’ indicates the NLGI
grade of the grease.
If you opt to use a different brand,
the grease used must be of the same
NLGI grade.
(The NLGI grade indicates the stiff-
ness of the grease. The higher the
NLGI grade, the stiffer the grease.)
IMPORTANT!
Worn engagement and support rollers
have a smaller diameter than new rol-
lers. Unscrew the adjuster screws two
turns if only one type of roller is to be
replaced, and four turns if all rollers are
to be replaced before the guard is fitted.
Inspection, cleaning
Pull or press out the bearing
bracket.
Clean the bearing housing.
Wipe the bearing bracket and
check that it is not damaged.
Inspect the engagement roller
bearings.
Replace engagement
rollers
Secure the tool in a vice
Lock the nut using the box
spanner and unscrew the socket
head cap screw.
7