Husqvarna K6500 Instruction manual

HUSQVARNA CONSTRUCTION PRODUCTS
Workshop manual
K6500 Ring

2
1. DOCUMENTATION 3
2. BASIC FUNCTION 4
3. COMPONENTS – NAVIGATION 5
4. REPLACING BLADE 6
5. ROLLERS – ADJUSTMENT/INSPECTION 8
6. ENGAGEMENT AND SUPPORT ROLLERS 9
7. REPLACING ENGAGEMENT AND SUPPORT ROLLERS 10
8. REPLACING ROLLER BEARINGS 13
9. REPLACING ENGAGEMENT ROLLER BEARING SLEEVES 16
10. REPLACING DRIVE WHEEL BEARINGS 18
11. CUTTING UNIT 22
12. WET SYSTEM 24
13. CONTROLS, ELECTRICAL COMPONENTS 26
14. MOTOR 28
15. TROUBLESHOOTING 31
16. TOOLS 35
CONTENTS Page
HUSQVARNA
K6500 Ring
Screws – dimensions and torques
Information on screw type and recommended tightening torque is
given in brackets – e.g. (M5x26, 7–8 Nm) – in a number of places
in this workshop manual.
M= standard millimetre thread for fitting in metal.
MT= coarse thread for fitting in plastic.
5x26 indicates the coarseness x the length in millimetres. Note
that the length is calculated minus the screw head.
7–8 Nm indicates the tightening torque in Newton metres.
Practically all screws of smaller dimensions have Torx T27 screw
heads.
L
T
27

3
DOCUMENTATION 1
HUSQVARNA CONSTRUCTION PRODUCTS
Workshop manual
K6500 Ring
CB100011
Language 1 (3)
SB, de Finibus Bonorum et Malorum, 2000-00
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id, posuere non felis.
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.
The list of contents at the beginning of the manual also has a
page reference to the beginning of each chapter.
Service bulletins
Service bulletins are issued when important design modifications
have taken place, for example, or when amended service actions
have been introduced. The service bulletins are available to down-
load from the Husqvarna website under “Service bulletins, SB”.
Operators manual
The operators manual describes how the machine is to be used,
the functions of the machine, and the maintenance the operator
normally carries out.
This manual also contains important instructions for the safe
handling of the machine.
It is extremely important that service personnel are well
acquainted with how the machine is used and follow the
instructions given in the manual.
AK6500 Ring
MOTOR
6
5
15
8
7
9
11
18
19
4
4
1
16
17
12
3
13
20
16
10
6
14
2
17
Spare parts
The folder includes all spare parts for Husqvarna K6500 Ring.
The folder contains complete exploded drawings for the whole
machine where the location, spare parts number and appearance of
each component is easy to identify.
Information on spare parts, called IPL (Illustrated Parts List),
can be downloaded from Husqvarna Construction Products'
website or from Husqvarna EPC.

BASIC FUNCTION2
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.
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 wheel. The lower picture shows how the enga-
gement 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 guided in
both the radial and axial directions (rotating and lateral
movements). Three points (at the two engagement and
support rollers and at the drive wheel) guide the blade
at the same time as the pressure against the drive wheel
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 wheel. Corrosion or dirt that
blocks movement will cause the blade to slip against the
drive wheel. A properly greased bearing housing will
reduce 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 wheel, 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 wheel must be screwed out to its end position.
NB: The knobs must not be fully screwed to the end
position as this restricts engagement roller rotation.
4
A
B
B
C
CD
C
A
A
B
DC

5
COMPONENTS – NAVIGATION 3
Components
1. Cutting blade – ring-shaped cutting
blade with laser welded diamond
segments
2. Engagement rollers (behind the
cover)
3. Blade guard
4. Spray guard
5. Hose for water connection
6. Cable for the HF unit
7. Water disc
8. Button for locking the rotation of
the drive wheel
9. Knob for tensioning the blade to the
drive wheel
10. Transmission housing
11. Grease nipples for lubricating the
bearing housings
12. Support rollers (behind cover)
13. Adjustment screws for adjusting the
contact of the rollers with the blade
14. Lock nuts for roller adjustment
15. Drive wheel (behind the cover)
16. Support roller cover
17. Throttle
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
machines (pulling blade), but the actual
rotation of the cutting blade is the oppo-
site.
The same cutting blade should there-
fore not be switched between the machines.
Changing the direction of rotation causes
increased wear of the blade.
1
2
4
8
56
9
9
15
2
2
12
12
16
13
12
12
13 14
14
10
7
2
3
17
11
11
18
19
13
14
11

REPLACING BLADE
6
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. Remove the blade.
Quick check
Check of blade replacement
In connection with the blade replacement it is appropriate and easy to make a
quick check of the condition of the engagement and support rollers.
Roller bearings
Check that the rollers rotate smoothly and easily. In the event of bearing
damage, this must be addressed, see Chapter 8.
Flange and groove
Also check that the engagement roller flange and support roller grooves
(circled) are within acceptable tolerances, see Chapter 6.
If necessary, replace the engagement and support rollers as per Chapter 7.
Bearing holders – engagement rollers
Check that the engagement roller bearing holders do not jam: unscrew the
knobs a few turns and make sure the bearing holders move smoothly and
without resistance.
4
Replacing the drive wheel
The blade and drive wheel are replaced together
A new blade is fitted with a new drive wheel. When replacing with a used
blade, the associated drive wheel must be fitted.
Used blades can be used with new wheels, but never fit a new blade with a
used drive wheel.

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.
Fit the blade
The knobs must be screwed out. Fit according to 1. – 2. – 3. below.
Fit the cover
Fit the screws and tighten them lightly. Screw out the knobs.
Check the position of the adjuster screws
Check that the adjuster screws are screwed out long enough to create play bet-
ween the blade and rollers, as follows: Rotate the support rollers by hand – the
blade should not now rotate with the rollers. Otherwise unscrew the adjuster
screws a little more.
Tighten the cover, 26–30 Nm/19–22 lbf·ft.
Now tighten the cover: 26–30 Nm. Use a torque wrench or the tool that
comes with the machine (506 36 36-01). A high torque is possible with this
tool.
Adjust the contact of the rollers
Before the machine can be used, the rollers must be adjusted as shown in
Chapter 5.
1. Align the cutting blade in the drive
wheel.
2. Align the groove of the cutting blade in
relation to the two engagement rollers.
3. Keep the blade in place by turning the
knobs at least one turn.
4
!506 36 36-01
Initial set-up of support rollers
Prepare the adjustment of the support rollers, as per Chapter 5, as follows:
– Unscrew the two adjuster screws (A) about 2 turns.
– Loosen the two lock nuts (B).
– Push the support roller arms against the adjuster screw.
– Tighten the lock nuts (B) slightly to ensure inertia in the movement.
AA
BB
18–20 Nm
26–30 Nm

ROLLERS – ADJUSTMENT/INSPECTION5
Adjustment and checking
Adjustment of the roller contact with the blade must
be made when the blade is mounted. Checking and
readjustment must also be done at least once during the
blade's life.
1. Screw out the knobs
Unscrew both knobs to the maximum position, then a
half turn in.
2. Slacken off the lock nuts
This should only be done when carrying out readjust-
ment when the blade is worn and has not been removed
from the machine. When blade replacement is being
carried out, according to the previous chapter, this has
already been done.
Slacken off the lock nuts (B). Then tighten the lock
nuts slightly before starting adjustment.
3. Adjustment
Place a wrench on one support roller, and rotate it back
and forth while screwing in the adjuster screw (A) slowly.
When the roller comes into contact with the blade and
this rotates, the adjustment is correct. Do the same for
the other support roller.
4. Tighten the lock nuts, 16–20 Nm/12–15 lbf·ft.
Tighten the lock nuts (B) at a torque of 16–20 Nm.
5. Checking
If the adjustment has been made correctly, it should be
possible to slow the roller rotation using your thumb
while the blade is rotated by hand.
If one of the rollers is adjusted incorrectly, steps 2–5
must be performed for the appropriate roller.
6. Screw in the knobs
Finish by tightening the knobs in operating position.
Correct adjustment
Correctly adjusted rollers are essential for
the operation of the machine and to
minimise wear.
Correctly adjusted means that the
rollers are in contact with the blade with-
out any play.
If the contact is too firm, this will
increase roller wear and cause deforma-
tion of the blade which, at worst, could
lead to a blade fracture.
If the contact is not firm enough, this
will mean that control of the blade will
be worse, which in extreme cases could
lead to the blade leaving the groove.
Function
The support rollers are mounted on the
arms of the support roller cover. The
position of the arms is determined by the
adjuster screws (A). The nuts (B) lock the
arms' position.
8
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 cover 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
A
A
A
B
B
B
1
3
5
2
4
6
16–20 Nm

9
ENGAGEMENT AND SUPPORT ROLLERS 6
Engagement rollers
– construction
The spring, which creates compressive
force on the blade's drive wheel, is pre-
tensioned and contained within the bea-
ring holder. The movement limiter, in
the middle of the spring, limits the en-
gagement roller movement in the event
of abnormal stresses, such as jamming.
A
B
Service position
The knobs are screwed out which elimi-
nates the spring force to the engagement
rollers and drive wheel. Service position
is used when replacing the blade and
adjusting the rollers.
Operating position
The knobs are screwed into bottom
position whereby the engagement rollers'
springs tighten the cutting blade to the
drive wheel.
Knob with snap fastener lock
The knob has a snap fastener lock on
the bearing holder pin. Removing the
knob releases the snap fastener lock from
the pin and the bearing holder can be
removed.
Lubrication – operating position
The bearing housing has lubricating
ducts that directs the grease from the
nipple (A) to the outlet duct (B) which
indicates when the correct amount of
grease has been filled. Lubrication is
done with the knobs in operating posi-
tion (knobs screwed in).
Service position Operating position
Replaceable wear parts
The engagement and support rollers, as well
as the drive wheel, 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

REPLACING ENGAGEMENT AND SUPPORT ROLLERS
Remove the knobs
Force off the knobs from the snap fasteners by unscrewing the knobs past the
end stop. Unscrew the knobs.
10
Secure the tool in a vice
The easiest way to remove the roller is to put a box wrench in a vice. Lock the
carrier with box wrench and remove the nut.
Never put the roller in the vice!
Checking, cleaning
Push or pull off the bearing holders.
Defective bearing holders (wear/corrosion damage) are best replaced with
new bearing holders complete with bearings.
Replace defective bearings as specified in Chapter 8.
Clean old grease from the bearing housing.
Wipe the bearing holders and make sure they are free from damage.
Check that the roller bearing feels intact.
Grease – characteristics
The grease used in the service procedures set out below must be stiff and
afford good resistance to water penetration.
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 stiffness 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 cover is fitted.
7
Replacement of engagement rollers
Remove the blade as specified in Chapter 4.