Husqvarna PG 530 Instruction manual

Workshop manual
PG 530
GB

Technical data
Feature Data
Model PG 530
Grinding width 530mm (21")
Grinding disc 3×240mm (9.5")
Weight 200kg (440lbs)
Grinding pressure total 134kg (295lbs)
Grinding pressure per disc 44.7kg (98lbs)
Motor Power 3.75kW (5.0hp)
Power per grinding disc 1.25kW (1.7hp)
Grinding disc speed 200—710rpm
Planetary head speed 50rpm
Direction of rotation FWD/RE with grinding discs.
Planetary head rotation in same direction (no
counter rotation).
Power supply 220—240 simple phase (12 amp).
(3 phase version available).

HUSQVA NA
PG 530
CONTENT
1. Literature 2
2. Service checks | Faults and troubleshooting 3
3. Special functional components 6
4. Components – orientation 7
5. ismantling into basic modules 8
6. Removing the satellite heads 11
7. Opening belt compartment 12
8. Removing belt parts and satellite motor 13
9. Fitting in internal components 15
10. Pulley service 17
11. Testing motor shaft alignment 20
12. Fitting on satellite motor and pulleys 22
13. Setting up a new belt 24
14. Mounting the satellite heads 29
15. Planetary seal installation 30
16. Planetary motor gearbox 31
17. Mounting the planetary motor 32
18. Tools 34
Page

1 Literature
1.Literature
2
115 11 93-26
“Dismantling into Basic Modules”
×2
Workshop Manual
The Workshop Manual includes virtually all
workshop procedures that can come into ques-
tion on the PG 530. Some very simple and self-
evident repairs have been omitted.
OUTLINE
Chapter 2 contains tables that the serviceman
can scan through to identify possible problems.
These may be resolved by checking the Faults and
troubleshooting table.
An introductory section with the title “Dismant-
ling into Basic Modules” shows how the machine
is dismantled into large component units, for ex-
ample, Chassis/Frame section, comprising;
handle bars, electrical cabinet, steel frame, wheels
and the Head, comprising; motors, cover, grind-
ing/satellite/planetary heads and internal com-
ponents.
The manual goes on to describe in detail
through the different chapters how work on the
basic modules should be carried out.
This arrangement means that as a mechanic, at
least until you have learnt the basic composition
of the machine, you need to start with the
chapter “Dismantling into Basic Modules” to
then move on to the chapter covering the specif-
ic service work.
LAYOUT – PICTU ES AND TEXT
The pictures are mostly enough to guide the
mechanic through the various procedures. The
text on the right hand column has further refer-
ences and explanations for the repair work on
the planetary grinder.
CONTENTS
The manual is divided into numbered chapters
with chapter headings that are stated in bold at
the top of each page.
The list of contents also has page references at
the start of each chapter.
Chemical substances
When performing service
tasks involving the use of
chemical substances (such as
silicone or retainer
compounds), please refer to
the instructions from the
manufacturer.

Service checks | Faults and troubleshooting 2
2.Service checks | Faults and
troubleshooting
3
Service & Maintenance check
MECHANICAL CHECKS | EXTE NAL
Description Time required
Tilt unit back check for and remove any Diamond tools 2 min
Check Shroud for damage affecting planetary rotation, satellite rotation, planetary seal efficiency and extrac-
tion efficiency.
5 min
Unplug the planetary drive to reduce operating noise and Run the discs through the range of speeds listen-
ing for any bearing noises that may be caused by bearings that are deteriorating
5 min
Unplug small motor and run discs at low speed to assess how true discs are running 5 min
Remove belt inspection cover plates to assess condition of belt, cleanliness of inside of machine and mois-
ture levels inside machine.
10 min
Check head locks for tightness and tighten where required using a medium bond thread retaining com-
pound / 3 per satellite
5 min
Check satellites for excess movement or inconsistent movement in relation to other satellites. If one or more
heads are not running true, disassemble all heads.
15 min
if dismantling required
Check spring steel leaf for cracking or inconsistent wear on each head, inspect spring cushion for tears or ex-
cess deterioration
10min
Reassemble Satellites 15 min
Check 70 dust seals for condition and wear. ( replace each service) 5 min
Unplug large motor and plug small motor back in. Run planetary head through a range of speeds to and
listen for smoothness of operation.
5 min
Remove planetary drive gearbox from gearbox mounting bracket and check condition of sprocket and chain-
ring.
5 min
Replace sprocket if required (abnormal wear or rounding teeth) 30 min
Replace chain ring if packed with debris or chain worn out (opening of rollers) 30 min
With planetary drive removed, check for presence of dust on top surface of machine. If large amounts of
dust is present, remove machine cover and check condition of planetary head seal and replace if necessary.
20 min
if cover needs removal
Reassemble 20 min
MECHANICAL CHECKS | INTE NAL
Description Time required
Tilt unit back check for and remove any Diamond tools 2 min
Check Shroud for damage affecting planetary rotation, satellite rotation, planetary seal efficiency and extrac-
tion efficiency.
5 min
Unplug the planetary drive to reduce operating noise and Run the discs through the range of speeds listen-
ing for any bearing noises that may be caused by bearings that are deteriorating
5 min
Unplug small motor and run discs at low speed to assess how true discs are running 5 min
Remove belt inspection cover plates to assess condition of belt, cleanliness of inside of machine and mois-
ture levels inside machine.
10 min
Check head locks for tightness and tighten where required using a medium bond thread retaining com-
pound / 3 per satellite
5 min
Check satellites for excess movement or inconsistent movement in relation to other satellites. If one or more
heads are not running true, disassemble all heads.
15 min
if dismantling required
Check spring steel leaf for cracking or inconsistent wear on each head, inspect spring cushion for tears or ex-
cess deterioration
10 min
Reassemble Satellites 15 min
Check 70 dust seals for condition and wear. (replace each service) 5 min
Unplug large motor and plug small motor back in. Run planetary head through a range of speeds to and
listen for smoothness of operation.
5 min
Remove planetary drive gearbox from gearbox mounting bracket and check condition of sprocket and chain-
ring.
5 min
Replace sprocket if required (abnormal wear or rounding teeth) 30 min
Replace chain ring if packed with debris or chain worn out (opening of rollers) 30 min
With planetary drive removed, check top surface of machine for presence of dust. If large amounts is present,
remove machine cover and check condition of planetary head seal and replace if necessary.
20 min
if cover needs removal

2 Service checks | Faults and troubleshooting
4
Service & Maintenance check
ELECT ICAL CHECKS
Description Time required
Follow all leads for damage, pulled or exposed wires be sure to check inside
both motor terminal boxes and lead hoods.
10 min
Inspect all glands- motor, drive cables , control panel, cabinet 5 min
Inspect control panel for damaged or broken switch gear. 5 min
With motors disconnected, power-up drives in standby mode (using power
button near handle bars).
Check both cooling fans are running on top of drives. 5 min
Set displays to Output Frequency mode and run drive using STOP/RUN
switch near handlebars. Small drive should ramp up to 120Hz with speed
dial set to full and large drive should ramp up to 80Hz with speed dial set to
full. Check in both directions.
5 min
Check fault history to assess recent faults to make sure there are no abnormal
faults in history (normal faults are F9 undervoltage & F16 motor overtemp).
5 min
Power down drives and blow out with compressed air.
Make sure airline is drained of moisture.
5 min
Re-check and operate all switch gear with unit tilted back and plugged in 10 min

Service checks | Faults and troubleshooting 2
5
Faults and troubleshooting
Fault indication Possible cause uggested action
[1] Over cur-
rent
Motor being worked too hard and drawing extra cur-
rent.
Check current being drawn when machine is running. Reduce speed setting
and current draw back into acceptable limits as described on previous page.
Short circuit on output side of variable speed drives
or frequency converters.
Check wiring in plugs connected to motor cables or inside connection boxes
on motors.
Motor failure (very rare) Have motor tested and replace if required.
Poor voltage supply to machine will result in excess
current draw
Poor mains supply (under 220 ) | Working off a generator
Using light duty power leads | Using more then 20m (65ft) power leads
[3] Earth fault Short circuit on output side of variable speed drives
or frequency converters.
Check wiring in plugs connected to motor cables or inside connection boxes
on motors.
Motor failure (very rare) Have motor tested and replace if required.
[9] Under
voltage
Insufficient voltage supply to machine. Check power supply and ensure correct voltage.
Power supply to variable speed drives or frequency
converters has been turned off.
Re-connect power to grinder.
[11] Output
phase
supervision
Short circuit on output side of variable speed drives
or frequency converters.
Check wiring in plugs connected to motor cables or inside connection boxes
on motors.
Motor failure (very rare) Have motor tested and replace if required.
[14] Unit over
temperature
ariable speed drives or frequency converter over
temperature due to high temperature working envir-
onment or faulty temperature sensor.
Open door on electrical cabinet to increase ventilation.
Have variable speed drives or frequency converter tested by service agent.
[15] Motor
stalled
Motor being worked too hard and drawing extra cur-
rent.
Check current being drawn when machine is running. Reduce speed setting
and current draw back into acceptable limits as described on previous page.
Mechanical jam preventing motor from turning. Try rotating grinding discs and planetary head by hand to see if jam exists
[16] Motor over
temperature
Motor being worked too hard and drawing extra cur-
rent.
Check current being drawn when machine is running. Reduce speed setting
and current draw back into acceptable limits as described on previous page.
Grinder is hard
to hold onto
Not enough diamonds under the machine (if grind-
ing thick glue or soft floors, too few diamonds un-
der the machine will greatly increase the load on
grinder and operator). Usually also accompanied by
high current draw by large motor.
Increase number of diamonds under machine to reduce load on grinder and
operator.
Large motor not working (this can be caused by fault
with motor, fault with wiring to motor, or fault with
large variable speed drive or frequency converter).
Check large motor is plugged in. Check there are no faults on larger variable
speed drive or frequency converter. Check that large variable speed drive or fre-
quency converter is on. Check that large variable speed drive or frequency con-
verter is functioning properly (unplug both motors, set display on keypad to
Output Frequency, switch machine to RUN, see if numbers on screen change
from zero and begin counting up. If numbers stay on zero, large variable speed
drive or frequency converter is not receiving run command from switch on
control panel. Machine needs to be checked by an electrician or by Husqvarna
Construction Products.
Drive belt is slipping. Remove belt tensioner cover plate on bottom of machine and check there is
no water or dust on the inside of the machine that may be causing the belt to
slip on the drive pulleys.
Drive belt is broken (try turning one of the grinding
heads by hand; if all rotate together, belt is not
broken, if only one turns, belt is broken).
Replace internal drive belt.
Grinder sounds
like it is over
revving
Small planetary drive motor not plugged in. Check small planetary drive motor is plugged in.
Small motor not working (this can be caused by
fault with motor, fault with wiring to the motor, or
fault with large variable speed drive or frequency
converter).
Check small motor is plugged in. Check there are no faults on small variable
speed drive or frequency converter. Check that small variable speed drive and
frequency converter is on. Check that small variable speed drive or frequency
converter is functioning properly (unplug both motors, set display on keypad
to Output Frequency, switch machine to RUN, see if numbers on screen
change from zero and begin counting up. If numbers stay on zero, small vari-
able speed drive or frequency converter is not receiving run command from
switch on control panel. Machine needs to be checked by an electrician or
Husqvarna Construction Products.
Grinder is jump-
ing around
Grinding heads may be worn-out or damaged. Check grinding heads for broken parts or excess movement.
Diamonds may not be fitted correctly or different
height diamonds may be on the grinding heads.
Check to ensure all diamonds are fitted correctly and are the same height.
Head locks may be loose or missing. Check to ensure all head locks are present and tight.

3 Special functional components
3.Special functional components
6
Dual Drive Technology™
•Dual Drive Technology™ – a unique patented twin motor arrange-
ment with separate motors for grinding discs and planetary system,
which enables total control of grinding performance.
1. SATELLITE HEADS – G INDING BY OTATION
(a) The diamond grinding tools are attached to the satellite heads.
These heads are grinding by rotation, and can be controlled to oper-
ate with variable speed in both directions.
(b) The satellite heads are working together as a planetary system. This
is achieved by rotating the entire planetary head to which the satel-
lites are attached.
2. SATELLITE OTATION – BELT T ANSMISSION
(a) Rotation to each of the three satellite head shafts is transmitted by a
belt.
(b) The entire planetary head is rotated to achieve a better controlled
grinding process.
(c) The satellite motor shaft is directly driving the belt. The motor can
operate in both directions.
3. PLANETA Y OTATION – SP OCKET T ANSMISSION
(d) The planetary motor power is transmitted by means of a sprocket
on the motor shaft.
(e) The sprocket drives a chain ring, which is fixed to the planetary
head, which will then rotate. The speed can be adjusted to achieve
optimum grinding results.

Components – orientation 4
4.Components – orientation
7
Components
1. Handle bars
2. Control panel
3. Handle bar release
4. Handle bar adjuster
5. Hour counter
6. Electrical power connector
7. Electrical cabinet
8. Chassis / frame
9. Planetary head motor
10. Grinding/satellite heads motor
11. Dust extraction port
12. Lifting lug (attached to frame with lift-
ing shafts with R-clips)
13. Cover / shroud
14. elcro for attaching skirt
15. Planetary head
16. Grinding / satellite head

5 Dismantling into basic modules
5.Dismantling into basic modules
8
THE CHASSIS / F AME UNIT
The chassis / frame unit is designed to carry,
control and manoeuvre the grinding unit,
which is attached by two shafts through the
lifting lugs.
DETACH THE G INDING UNIT
1. Unplug the power cables for the planet-
ary motor (a) and the satellite / grinding
motor (b).
2. Remove the R-clip (c) from the lifting
shaft on both sides.
3. Hold on to balance the chassis / frame
unit (d). Pull out the lifting lug shaft (e)
on both sides.
EMOVE THE PLANETA Y D IVE
UNIT
4. Remove the 4 planetary drive position-
ing bolts (f). Two on either side.
5. Lift off the planetary drive unit.
Basic modules
This chapter shows how the machine is built
up of basic modules, for example, the
chassis / frame unit and the grinding unit
and how the latter is set up in a service rack.
The purpose is to illustrate how you can
easily and effectively dismantle and assemble
the machine in its basic modules.
Service work on a component level, for ex-
ample, the satellite / grinding drive belt, is
described in detail in respective chapters.
×4 13mm
×2
×2

Dismantling into basic modules 5
9
THE COVE / SH OUD
The cover / shroud protects the interior from dirt and the user from moving parts. It
is fitted with high precision and a tight seal to ensure a clean environment for the
gear sprockets and other moving parts.
1. Remove the counter sunk screw with an
8mm Allen key.
2. Remove the following 18mm bolts:
(a) Two bolts with washers.
(b) Two gear plate bolts with washers.
3. Lift off the gear plate.
Remove the terminal box cover plate
4. Remove the two 18mm bolts.
5. Remove the cover plate.
6. Turn the motor around so that the elec-
tric box is straight over the slot. Lift off
the cover / shroud straight up.
THE CHAIN ING
7. Remove the six M10 chain ring nuts:
•Fit the tool kit 17mm chain ring sock-
et (c) through the socket hole (d).
•Rotate the motor plate to reach all the
chain ring nuts.
8. Use two crow bars to evenly work the
chain ring off the 6 locating threads.
9. Lift off the chain ring.
8mm
×4 18mm
×2 18mm

5 Dismantling into basic modules
10
MOUNTING THE G INDING UNIT IN A SE VICE ACK
The grinding unit is a complex piece of technology and requires various types of
high precision service. This is most easily done if the unit is mounted in a service
rack in which the grinding unit can be tilted around and fixed in an ergonomic posi-
tion.
Fit on the pivoting cradle
1. Place the pivoting cradle over the grind-
ing motor.
•The square should fit tightly around
the grinding unit's circular shape.
2. Secure cradle on the grinding unit using
the clamps (a) on either side.
•Tighten the clamp nuts with a span-
ner.
Use a power lift
Due to the weight of the unit, it should be
lifted by means of a power lift.
3. Attach a lifting cable to the lifting lugs
using two shackles (b).
•Hoist the cradle up.
4. Roll the service rack in position under
the grinding unit. so that the pivoting
pins (c) fit in the slots on either side.
•Lock the rack roller wheels and lower
the pivoting frame in position.
WO KING WITH THE SE VICE
ACK
5. Whenever the motor is on top, the
pivoting cradle is unstable due to the
weight of the motor.
(d) Secure the cradle with one of the two
corner lock pins to safely move the
rack or work on the machine.
6. The motor weight will cause the
pivoting cradle to tilt over rapidly
Counter this by pushing on the further
side of the cradle (e).
•Remove the lock pin. Hold on and
gently lower the near side of the
cradle.
•Reach forwards and hold on to the
further side of the cradle (e).
•Gently lower the approaching upper
cradle side (e) until the cradle reaches
the horizontal position.
Always draw the weight towards
yourself.
Never push the weight away as
a means to pivot the cradle.
7. Secure the cradle with one of the two
corner lock pins (d) to safely work with
the grinding unit.
×2 | 30mm
×2
Manual symbol: Flip unit
180°
Always start rotation by
pressing down the near cradle
side!

emoving the satellite heads 6
6. emoving the satellite heads
11
1. Remove the M16 centre bolt from each
of the three satellite heads.
•Take care of the spring washers.
2. Lift off the satellite heads.
EMOVE THE HEAD BOSS
In each head boss, there are two threaded
holes for the purpose of pressing the head
boss up and thus breaking the thread lock
compound.
3. Insert and screw down two M10·50mm
bolts.
4. Apply even pressure on the headboss by
alternating between the two bolts (a) and
(b).
•When the thread lock is broken and
the head boss has moved up, the two
bolts should be removed.
5. Use two crow bars to evenly apply pres-
sure to the head boss and lever it up.
6. Removal will expose three belt driving
pulleys extending through the belt cover
plate.
The satellite heads
Secure the diamond tools while in operation.
Must be in good condition to ensure a smooth floor when grinding.
×3 24mm
M10·50

7 Opening belt compartment
7.Opening belt compartment
12
1. Unclamp unit from cradle.
•This step is necessary when opening
up the belt compartment.
EMOVE ALL BOLTS, WASHE S
AND PLATES
2. Overview of all bolts, washers, seals and
plates to be removed:
(a) M6•12 ×3 | 10mm socket, belt ten-
sion cover plate with rubber seal.
(b) M6•12 ×2, belt inspection cover
plate with rubber seal.
(c) M8 | 13mm, with washer (idle
pulley).
(d) M8 ×4, centre bearing housing cover
and bearing plate.
(e) M8, with washer (space bar).
(f) M12 ×9 | 18mm, exterior bolts with
washers, bottom plate.
(g) 21mm ×12, with washers, 3 oil seal
housings and cover plates.
3. Use a soft mallet to knock off the silic-
one sealed centre bearing housing plate.
4. The centre bearing housing should be
lifted off evenly by means of two crow
bars.
5. Knock off silicone glued washers with a
blade screwdriver.
6. For easy removal: Use a soft mallet to
knock the oil seal housing corner, to
make it spin on its axis.
7. Remove excess silicone glue using a
razor scraper.
8. Remove the silicone compound sealing
all around the bottom plate.
9. Use three blade screw drivers to system-
atically break apart the silicone glued
surfaces all around the bottom plate.
10. Remove the bottom plate.
The belt drive compartment
Before proceeding with opening up the belt compartment; remove the satellite heads
as described in the previous chapter.
×2 30mm

emoving belt parts and satellite motor 8
8. emoving belt parts and satellite motor kg
13
EMOVE THE SATELLITE MOTO
1. Start with removing the belt, or what is
left of it.
•Lift out the following pieces:
(a) Belt tensioning assembly.
(b) Three satellite head pulley assem-
blies.
2. The belt compartment with the follow-
ing pieces left to be removed:
(c) Centre drive bearing.
(d) Idle pulley.
3. Undo the centre bearing screw with the
speciality tool: 8mm Allen hex driver.
4. Evenly lift off the centre bearing and
pulley by means of two crow bars.
Optionally, use a bearing puller (see
Tools chapter).
5. When the centre pulley is removed, the
motor drive shaft with key (e) is visible.
6. Clamp the unit to the cradle on both
sides.
•Tilt the cradle 180° (the opening
downwards) and secure it with a
corner pin.
7. Remove the four motor plate bolts.
8. Use a crow bar to apply enough pressure
to detach the motor plate from the rub-
ber seal.
9. Carefully lift the motor away.
Heavy weight – take proper pre-
cautions
The belt drive compartment
Before proceeding with cleaning up the belt compartment; open up the belt compart-
ment as described in the previous chapter.
Always check that the machine is secured in the cradle before turning
8mm tool
×4 18mm

8 emoving belt parts and satellite motor
14
EMOVE THE MOTO MOUNTING PLATE
1. Tilt the cradle 180° (the opening upwards) and secure it with a corner pin.
•Remove the cir-clip that holds the motor mounting plate shaft (a).
•Place a board under the cradle to catch the motor mounting plate (3a).
2. Use a sledge hammer and the following
tools to knock out the motor mounting
plate:
(b) Motor mounting plate tool
(c) Press tool 11
3. Motor mounting plate (a) will fall down
on the board placed underneath.
4. Tilt the cradle 180° (the opening down-
wards) and secure it with a corner pin.
•Remove the idle pulley shaft bolt.
5. Catch and remove the idle pulley from
beneath the cradle.
6. Knock off the silicone glued washer
with a slotted screwdriver.
7. Undo the six bolts in the main bearing
assembly (d).
8. Use a soft mallet to remove the main
bearing assembly (d).
9. Tilt the cradle 180° (the opening up-
wards) and secure it with a corner pin.
•Clean the interior well with a solvent
and compressed air.
•Overview of the stripped belt compart-
ment with:
(e) Top bearing housing (cast).
13mm
×6 13mm

Fitting in internal components 9
9.Fitting in internal components
15
MOUNT THE BEA ING HOUSING
1. Apply a fine bead of silicone seal com-
pound all around the contact surface of
the bearing housing (a) (with the deep
part of the housing facing down).
•Put the bearing housing into place,
keeping the bolt holes aligned.
2. From underneath the cradle, fit in each
of the six centre bearing housing M8
bolts.
3. Tilt the cradle 90° to more easily tighten
the 6 bolts, while holding the bearing
housing in position.
4. Secure the cradle with the opening up-
wards and smooth the excess silicone
compound.
FIT ON THE IDLE PULLEY
5. Clean and apply silicone seal compound
to:
(b) The idle pulley shaft contact surface
edge (the longer end).
(c) The idle pulley bolt washer (with the
bolt through.
6. Fit the silicone applied end of the idle
pulley into the mounting hole.
7. From underneath the cradle, fit on the
idle pulley bolt with the washer.
•Tighten the bolt.
•Smooth the silicone compound
around the pulley shaft.
8. Tilt the cradle 180° (with the opening
downwards) and secure it with a corner
pin. Smooth the silicone compound.
ATTACH THE MOTO PLATE
9. Put a 70 dust seal over the motor plate
shaft (d).
•Secure it well on the base ridge.
10. Apply a thin layer of bearing retainer to
the contact surfaces:
(d) The motor plate shaft.
(e) The two centre bearings.
•Fit the motor plate shaft into the
motor bearing housing.
Assembling
Before assembling or applying silicone sealing, thread lock compound or lubricants,
all the parts should be well cleaned with a solvent. Use compressed air to remove fine
particles and dust.
×6 13mm ×6 13mm
×1 13mm

9 Fitting in internal components
16
ATTACH THE MOTO PLATE
11. Use a soft mallet to knock down the motor plate shaft
(d).
•Knock until the seal reaches the main bearing hous-
ing.
12. From underneath; fit on the cir-clip to secure the mo-
tor mounting plate shaft (d).

Pulley service 10
10.Pulley service
17
Assembling
Before assembling or applying bearing adhes-
ive compound or lubricants, all the parts
should be well cleaned with a solvent. Use
compressed air to remove particles and dust.
FLY PULLEY ASSEMBLY
Fit bearing into bearing housing
1. Apply a layer of bearing retainer com-
pound to the contact surfaces:
(a) The outside of the bearing.
(b) The inside of the bearing housing.
2. Place the bearing housing in a press and
fit the bearing over the opening.
3. From tool kit; place on top of bearing:
(c) Bearing press tool.
(d) Multi purpose press tool.
4. If necessary, use the press tool (e) to fill
up the gap to the press.
•Press the bearing fully down inside the
bearing housing.
5. Secure the bearing by fitting an internal
circlip.
6. Check that circlip fits well into its slot.
Fit in the shaft
7. Apply a layer of bearing retainer com-
pound to the contact surfaces:
(f) The inside of the bearing (in the bear-
ing housing (6)).
(g) The fly pulley shaft.
•Fit in the shaft (with keyseat end)
down through the bearing.
8. Press down the shaft inside the mount-
ing plate bearing.
9. Turn the housing and shaft around.
•Secure the shaft by fitting an external
circlip.
10. Check that the circlip is properly fitted
in its slot.
Fly pulley - disassembled
Fly pulley

10 Pulley service
18
Fit fly pulley shaft through fly pulley
Apply a layer of bearing retainer compound
to the contact surfaces:
(a) The inside of the fly pulley (1).
(b) The end of the fly pulley shaft featur-
ing a key (2).
1. Place the fly pulley on top of the fly pul-
ley support press tool (c).
2. Insert the fly pulley shaft through the
fly pulley.
•Make sure that the key (d) is aligned
with the fly pulley keyway.
3. Start pressing the shaft down into the
pulley.
4. Check that the key and keyway align
and fit cleanly.
•Press the shaft fully down inside the
pulley.
5. Turn the pulley assembly around.
(e) Fill up keyway with retainer com-
pound.
6. Secure the pulley by fitting an external
circlip to the lowest slot (next to the pul-
ley).
Fit on the last bearing
7. Fit on another circlip over the second
slot.
8. Apply a layer of bearing retainer com-
pound to the contact surfaces:
(f) The bearing inside.
(g) Around the fly pulley shaft, above the
circlip.
9. Press the bearing down on the fly pulley
shaft:
(h) Use the top bearing assembly press
tool.
10. Secure the top bearing by fitting the last
external circlip.
11. Check that the circlip is properly fitted.