Husqvarna WS 482 HF Instruction manual

HUSQVARNA CONSTRUCTION PRODUCTS
Workshop manual
WS 482 HF

1. LITERATURE 3
2. COMPONENTS – NAVIGATION 4
3. FUNCTION TEST 5
4. BLADE FLANGE HUB 7
5. ELECTRICAL COMPONENTS
– dismantling 9
– assembly 13
6. FEEDING MOTORS
– dismantling 15
– gear housing 17
– bottom bearing, adjustment 19
– assembly 21
– HALL-sensor 22
7. PIVOTING ARM
– dismantling 25
– blade shaft, saw hub 28
– transmission 30
– slip clutch 35
– assembly 37
8. SAW HEAD
– dismantling 40
– friction linings, bearing replacement 42
– carriage feed slip torque 43
– pivoting arm feed shaft 45
– assembly 46
9. SAW MOTOR 49
10. SAW CARRIAGE 52
11. SERVICE 56
12. SPECIAL TOOLS 60
CONTENTS Page
2
HUSQVARNA
WS 482 HF

3
LITERATURE 1
HUSQVARNA CONSTRUCTION PRODUCTS
Workshop manual
WS 482 HF
HUSQVARNA CONSTRUCTION PRODUCTS
GB ES DE FR
Operator’s manual
Please read the operator’s manual carefully and make sure
you understand the instructions before using the machine.
Manual de
FR
GB
ES
DE
instrucciones
Lea detenidamente el manual de instrucciones y asegúrese
de entender su contenido antes de utilizar la máquina.
Bedienungsanweisung
Lesen Sie die Bedienungsanweisung sorgfältig durch und
machen Sie sich mit dem Inhalt vertraut, bevor Sie das
Gerät benutzen.
Manuel d’utilisation
Lire attentivement et bien assimiler le manuel d’utilisation
avant d’utiliser la machine.
WS 440 HF
WS 482 HF
Workshop manual
The workshop manual covers virtually all work in the
workshop that involves the WS 482 HF. Some very
simple and rather obvious repair work has been
omitted.
PP 480 HF
Driving the wall saw requires a high frequency unit,
PP 480 HF. A separate workshop manual is available
for this unit.
Arrangement – illustrations and text
The 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.
Spares
Spares WS 482 HF
The folder includes all spares for Husqvarna
WS 482 HF.
The folder contains complete exploded drawings
for the whole machine where the location, spares
number and appearance of each component is easy to
identify.
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.

COMPONENTS – NAVIGATION
4
2
HUSQVARNA CONSTRUCTION PRODUCTS
GB ES DE FR
Operator’s manual
Please read the operator’smanual carefully and make sure
you understand the instructions beforeusing the machine .
Manual de
FR
GB
ES
DE
instrucciones
Lea detenidamente el manual de instrucciones y asegúrese
de entender su contenido antes de utilizar la máquina.
Bedienungsanweisung
Lesen Sie die Bedienungsanweisung sorgfältig durchund
machen Sie sich mit dem Inhalt vertraut,bevor Sie das
Gerät benutzen.
Manuel d’utilisation
Lire attentivement et bien assimiler le manueld’utilisation
avant d’utiliser la machine.
WS 440 HF
WS 482 HF
1. Saw head
2. Pivoting arm
3. Saw motor
4. Electric socket
5. Socket cover
6. Saw frame
7. Water connection
8. Water hose
9. Blade flange hub
10. Outer flange
11. Blade guard guide
12. Blade guard
13. Track
14. Saw carriage
15. Locking handle
16. Mounting bracket
17. Track holder
18. Coupling link
19. Cleaning brush
20. Tool kit
21. Operators manual

123
FUNCTION TEST
5
Function test
In order to determine the status of the current item, it is
appropriate to begin by measuring the traction and tooth
flank play in the arm feed's worm gear.
The tests reveal the condition of the feeding motors, slip
clutches and gears, and from this you can determine what
action to take.
Preparations
The blade flange hub must be removed for the test.
1. Starting position (blade side).
2. Loosen the screw (motor side).
3. Pull out the stud.
4. Turn the water connection horizontally to the right
(blade side).
5. Lift off the blade flange hub.
Arm feed
Arrange the scales as shown in the illustration using an
appropriate load belt and a steel shaft that fits through the
arm hole. In order to get the right value for the force of the
pivoting arm, the angle between the pivoting arm and load
belt must be as close to 90° as possible.
The arm must be able to pull at least 290 kg (640 lb) in both
directions. The following cases may occur:
The force is different depending on which way the arm pulls.
– Adjust the position of the HALL sensor card, see Page 23.
It does not achieve 290 kg (640 lb).
– Adjust the position of the HALL sensor card, see Page 23.
– If the motor is working but the arm has stopped, adjust the
slip clutch arm, see Page 39, Paragraph 8.
The saw carriage moves when the force to the arm increases.
– The carriage's slip clutch must be adjusted, see Page 43.
Carriage feed
Arrange the scales as shown in the figure using appropriate
load belts.
The carriage must be able to pull at least 290 kg (640 lb) in
both directions. The following cases may occur:
The force is different depending on which way the carriage
pulls.
– Adjust the position of the HALL sensor card, see Page 23.
It does not achieve 290 kg (640 lb).
– Adjust the position of the HALL sensor card, see Page 23.
– If the feeding motor is running but the carriage is not
moving, adjust the carriage slip clutch, see Page 43.
4 5
3

FUNCTION TEST
6
3
Max 1,5 mm
.06 in.
Wear control
Check the worm gear play using a dial gauge
arranged as shown in the figure. Control
measurement should be made level with the
centre of the blade flange hub.
If the play exceeds 1.5 mm (.06 in.) when the
arm is pushed with a light press, the worm
wheel needs replacing.
Also check to see if the worm wheel's
wedging has too much play by pushing the
arm with greater force. If a play of 4–6 mm
(.15–.25 in.) can be measured, the keyway in
the worm wheel is deformed and the worm
wheel may need replacing.
These plays do not significantly affect the
sawing process, but could lead to a total
failure if the wear continues which is why it
is prudent to address these issues at a
scheduled service.

BLADE FLANGE HUB
7
Function
The obvious task of the blade flange nub is to
lock the blade between the flange washers with
the centre screw on the outer flange washer.
The blade flange hub also has a channel
system that supplies the blade with water on
both sides.
The inner flange washer is journalled to
the bracket and surrounded by sealing rings
to prevent water reaching the bearing. Make
sure the bearing is intact by turning the
inner flange washer.
Bearing replacement
Dismantling
1. Remove the two screws on the centre
bushing and lift this off.
2. Note the channels under the bushing that
direct the water to the upper flange washer.
Clean if necessary.
3. Turn the blade flange hub and remove the
six hexagonal screws.
4. Lift off the washer.
5. Press out the inner flange washer using a
standard puller as shown in the illustration.
6. Turn the blade flange hub.
Note that there are two radial seals above
the bearing. These must always be replaced
when changing the bearing.
7. Remove the two radial seals.
Pay attention to how these are to be turned
when reassembling.
It is particularly important that these are
thoroughly greased. Water flows between the
sealing rings that is transported to the inner
blade flange hub and on to the blade.
1
3
5
6
7
2
4
4

BLADE FLANGE HUB
8
Bearing – dismantling
The easiest way of removing the bearing is by
using a hydraulic press.
Bearing – assembly
When fitting, it is important that a press
force is applied to the outer bearing ring to
prevent damage to the bearing.
Note that the bearing must be pressed
slightly below the flat surface to reach the
stop under the bearing. Hint: use the old
bearing as a pressing device.
Lubricate and fit the seals
Lubricate the sealing rings carefully with
OG2. Also apply a little grease between the
ball bearing and the lower seal ring. Poorly
applied lubrication may cause water leaks on
the ball bearing!
1. Fit the inner flange washer
Fit the inner flange by pressing.
Hint: Use the replaced the ball bearing as a
support for the newly fitted bearing when
pressing the flange washer. In this way both
the bearing rings are supported and the
bearing load is not uneven.
2. Fit other components
Apply grease above the bearing and fit the
washer. Lubricate and fit the O-ring on the
shaft.
3. Fit the blade bushing
Blade guard bracket
To change the blade guard bracket, you must
first remove the flange washers.
1. Remove the two screws.
2. Divide the unit.
3. Remove the washer by simultaneously
turning and pulling it out.
4. Note the "water chute" and the channels
that direct the water towards the inner flange
washer and on towards the blade.
Clean and check that the water channels
are open.
1
3
2
1
3
2
4
4

ELECTRICAL COMPONENTS
9
1
3
5
2
4
6
5
Dismantling
1. Remove the four screws to the electric
socket.
2. Remove the four inner screws in the
electric socket.
3. Lift up the socket piece by the rear edge.
4. Pass the socket piece through the electric
socket and remove it.
5. Lift off the cover.
6. Socket piece after removed cover.
Dismantling the socket unit
To access more of the saw components the cover must be removed. To
remove this, first remove the socket piece on the top of the cover.
For work that does not directly affect the socket units, the most appro-
priate method is to remove the complete socket unit, as described on this
page.
In other cases, dismantle as described on the next and following pages,
when work mainly involves sockets and electronics, and where components
are dismantled piece by piece.

34
56
78
ELECTRICAL COMPONENTS
10
12
5
Dismantling of the socket components
This chapter deals with the removal of electrical components from
the machine, which are grouped around the electric socket on the saw
head. Releasing the power cables from the enclosure where all the electrical
connections converge is necessary for virtually all work on the saw head
and saw motor.
For jobs that include the pivoting arm, work on the electrical
components or cable system is unnecessary.
Preparations
To access the electronic devices it is advisable
to begin by doing as follows:
1. Set the arm horizontally using the feeding
motor.
Alternatively: Loosen the six screws that
hold the pivoting arm by one turn. The
pivoting arm can now be folded down to a
horizontal position to enable the removal of
the saw frame.
2. Remove the four screws to the saw frame.
Remove the electric socket
3. Remove the four screws to the electric
socket.
4. Remove the four inner screws in the
electric socket.
Mark the sockets
5. Lift up the socket unit. Note that the
right-hand socket module has thick cables
and supplies the saw motor. The other two
are for the feeding motors. The left, closest
to the pivoting arm, is for the arm motor.
The middle modules are for the carriage
motor.
6. Lift up the socket unit. and mark the
modules.
Release the sockets
7. The sockets are attached to a frame where
the side panels can be folded to free the
sockets.
8. Make sure that the rectangular studs for
the sockets release from the side panels.

13 14 15
ELECTRICAL COMPONENTS
11
9
11
10
12
5
16 17
18 19
9. The earth wire is secured with a screw in
the socket frame. Remove the earth wire.
10. Lift off the socket frame.
11. Lift off the socket enclosure.
12. Lift off the cover.
13. Remove the three outer screws.
14. Remove the four screws that are screwed
into the feeding motors.
15. Lift off the enclosure cover.
16. Remove the printed circuit board's two
screws.
17. Lift the circuit board straight up from
the sockets.
18. Note the markings: Two socket points
and two points on the board.
If the sockets are not already marked this
must be done to prevent confusion. Mark
the two-pole socket on the short side of the
board and the first socket on the long side
of the board. Also mark each socket.
19. Remove the printed circuit board's two
remaining sockets. Pull the tongue outwards
and pull off the two sockets.
Remove the printed circuit board.

ELECTRICAL COMPONENTS
12
25. Pull out the socket pin.
26. Push the cables with the socket pins out
of the enclosure. Be careful not to damage
the cables on sharp edges.
20
22
23
21
24
5
Tool
25 26
523 93 44-01
20. Before the next stage, the enclosure must
be lifted up slightly.
21. Pull up one socket to allow more room
for removal. Press the second socket down by
pushing aside the rubber seal using a small
screwdriver. Repeat with the other socket.
Motors' socket pieces
The two feeding motors have socket pieces
where the pin has to be released from the
socket in order to remove from the enclosure.
Tool for the socket pins
A special tool is needed for removing the
pins. This can be purchased from
Husqvarna: Part no. 523 93 44-01.
(Make: Harting: 09 99 000 0319.)
Remove the socket pins
22. Note that the socket has a marked con-
tour where the removal tool is inserted.
23. Push the removal tool into the socket
piece to open the pin lock.
24. Grip the cable with a finger.

4
ELECTRICAL COMPONENTS
13
1
3
2
56
5
BLACK
RED
BLUE
WHITE
BROWN
BLUE
A: for carriage motor
B: for arm motor
C: for temperature sensor
RED
YELLOW
RED
BLACK
BLACK
For HAL sensor – arm motor
For HAL sensor – carriage motor
1
6
2
3
4
5
Carriage motor (A)
BLUE
YELLOW
RED
WHITE
BLACK
1
6
2
3
4
5
Arm motor (B)
Circuit board A
B
C
4 and 5: Power supply to the circuit board 4 and 5: Communications to the circuit board
Reassembly
Wiring diagram
Check that cables and sockets are correctly
connected using the adjacent simplified
wiring diagram.
Avoid crushing damage to cables
Exercise care when assembling the cables to
ensure they do not jam causing damage to
the insulation as a result.
Assembly
Starting position
1. The saw motor and the two feeding
motors must be installed.
2. Push the saw motor and temperature
sensor cables through the seal. This
operation is made easier if the last cable is
fitted with heat shrink tubing, which is
removed later.
Seal to the bushing inside and out with
silicone.
3. Install the earth wire on the saw head.
Note that the earth wire has its own bushing.
4. Seal the feeding motor's bushing using
silicone.
Start by applying silicone under the cables.
Fold down the cables and apply silicone on
the top.
5. Pull up the cables from the feeding
motors through the enclosure. Be careful not
to damage the insulation to the enclosure.
6. Insert the HALL sensor cables through
the black plastic frame.

ELECTRICAL COMPONENTS
14
11. Fit the enclosure. Two screws in each
feeding motor and three extra.
The feeding motors' screws have Loctite
applied, primarily for sealing reasons.
12. Fit the cover.
7
9
11
8
10
12
5
15
1716
13 14
7. Remove the grey rubber seal from the
enclosure and push the sockets through the
enclosure and then through the seal.
8. Fit the bushing and press down the
sockets in this.
Clean the socket pins of any oxides and
lubricate with Electrolube.
9. Mount the PCB in the enclosure – two
screws.
Fit the three sockets to the circuit board.
Make sure that the two-pole sockets have not
been confused.
10. Fit the saw motor cables.
13. Put the electric socket in place.
14. Align the sockets in the socket frame.
15. Fit the earth wire to the socket frame.
16. Screw on the socket frame in the electric
socket.
17. Screw the electric socket on to the saw
head.

FEEDING MOTORS
15
Feeding motors
The machine has two feeding motors, one
for carriage feed (A) and one for the move-
ment of the pivoting arm (B).
The feeding motor's speed is changed in
the gear housing and the screw worm pro-
duces a slow motion, which in turn drives
the worm wheel of the saw head.
Note that the gear housings and the
motors' gear wheels are different for the
carriage and arm feed, and therefore must
not be confused.
At the screw's other end, there is a bearing
housing with axial and radial bearings.
A = carriage feed
B = arm feed
Dismantling
1. The sockets to the motors must be sepa-
rated from the socket pins to remove the
motor cables from the enclosure. Remove
the socket pins using special tool
523 93 44-01 as described on Page 12.
2. Remove the four screws to the motor.
3. Lift off the motor unit from the gear
housing.
4. Complete feeding motor with cables.
The three cables to the left are for power
supply to the feeding motor. The socket to
the right is the connection to the HALL
sensor.
1
AB
3
2
4
6
HALL sensor
Both feeding motors are fitted with a HALL-
sensor whose function is to regulate motor
speed.
The HALL sensor is set as described on
Page 22.

FEEDING MOTORS
16
6
12
34
5 6
Replacing the feeding motor
The feeding motors are identical for the
carriage and arm feed. Only the gear wheels
differ.
1. and 2. The cables have a silicone seal to
the motor housing. Carefully fold up the
cables and remove the seal from the cables
and the motor housing using a small screw-
driver.
Gear wheel
5. 5. The gear wheel unit is secured with
three screws. Loctite 243 must be used for
reassembly.
6. The gear wheel is replaceable and sits with
a press-fit into the holder. Knock out the
gear wheel with a pin punch.
When reassembling, apply Loctite 648 to
the gear wheel bracket (arrow).
3. Remove the screws.
(When reassembling, lock the screws with
Loctite 243.)
4. Pull out the motor while pressing in the
cables into the motor housing.
Motors: arm and carriage feed
Both motors have the same basic structure.
Note, however, the difference between the
feeding motors' gear wheels.
Left motor – arm feed.
Right motor – carriage feed.

FEEDING MOTORS
Gear housing
Dismantling
1. Use a pin punch and tap lightly on one
corner so that the gear housing releases from
the saw head. Under no circumstances must
the gear housing be deformed as this leads to
poor sealing.
The following stages are made easier if the
saw is mounted on the track.
2. ARM FEED
Press the pivoting arm down and pull the
gear housing from the saw head with a
twisting counter-clockwise motion.
3. CARRIAGE FEED
Push the saw carriage to the right and pull
the gear housing out of the saw head with a
twisting counter-clockwise motion.
4. Dismantled gear housing.
1
23
4
17
6
Gear housing – function
The gear housing's gear wheel changes gear
to reduce the motor's high speed to the slow-
moving screw worm which connects to each
worm wheel in the saw head for controlling
the pivoting arm and carriage feed
respectively.

FEEDING MOTORS
18
1
3
10 Nm
2
4
6
567
8
The screw worm's axial bearing
The axial bearing consists of a needle bearing
that is surrounded by bearing washers on
both sides.
On the opposite side there are three
washer springs that provide the axial bearing
with preload which is adjusted with the
screw.
Assembly
1. Fit the axial bearing with the surrounding
bearing washers.
2. Apply Loctite 243 threadlocker to the
threads on the screw. Hold the worm gear
vertically and insert the screw with washer
springs and tighten the screw in the shaft.
The figure shows how to reverse the washer
springs.
Axial bearing's preload
In the following stages the axial bearing's
preload must be set to the correct pressure.
3. Secure the gear housing in a vice. A long
extension with a 10 mm socket is needed.
Tighten the screw to a torque of 10 Nm
(7.5 lbf·ft.
4. Reverse the screw 90 degrees. The axial
bearing now has the correct preload.
Screw worm – dismantling
5. Start by removing the centre screw. Under
this there is a flat washer and three washer
springs.
6. Knock out the screw worm with a small
plastic hammer.
7. Lift out the screw worm. Note the axial
bearing for the screw worm. Bearing washers
surround the needle bearing on both sides.
8. Remove the wedge if this is to be replaced.
The wedge does not need to be removed to
lift the washers.

FEEDING MOTORS
19
3
abc d e
6
2. Lift out the bearing holder.
If no actions have been taken that change
the length of the gear assembly, the shim on
the bottom bearing does not need to be
measured or corrected.
1
2
Bottom bearing
Remove
The feeding motors' screw worms on the
opposite side are journalled with axial and
radial needle bearings.
1. Remove the four screws to the bearing
holder.
Remove the components
3. The bottom bearing components are
removed by knocking the bearing holder
using a vice.
Alternatively, you can place a screw in the
bearing journal and pull out the bearing
unit.
Bottom bearing components
a. Shim
b. Bearing washer
c. Axial needle bearing
d. Bearing journal
e. Needle bearing (radial bearing)
The screw worm's axial preload
In the following stage the screw worm's
preload must be adjusted axially. The screw
worm must not have any play and have a
light preload.
Shim
The Shim is 0.05 mm (.002 in.) thick and
bonded together in an assembly that is about
2 mm (.08 in.) thick. The shim is separated
with a knife to the desired thickness.

FEEDING MOTORS
20
6
b2 b1
a2 a1
Adjustment – axial application
Starting position
The motor housing must be mounted on the
opposite side.
The measurement must be made with a
fitted stud and axial needle bearing with
associated bearing washer.
Measurement A
First measure the distance between planes
a1 and a2. This is done by first resetting the
callipers to measure the bearing housing
flange and then by measuring the distance to
its internal plane.
This measurement is called A and in this
case is 2.49 mm. (The position of the bearing
is 2.49 mm (.098 in.) deeper than the flange.)
a1 –a2 = A
A = 2.49 mm (.098 in.)
Measurement B
Reset the callipers to one flat surface and
measure the distance between the b1 and b2
planes.
This measurement is called B and in this
case is 1.83 mm. (The washer is 1.83 mm
(.072 in.) above the saw head level.)
b1 –b2 = B
B = 1.83 mm (.072 in.)
Adjust the shim
The above measurements A and B are used
to calculate the thickness of the shim washer,
as follows:
A – B = Shim thickness
In the above case, the shim thickness must
therefore be:
2.49 – 1.83 = 0.66 mm (.026 in.)
The bearing must have a preload. Round the
measurement up so that the shim is 0.05 to
0.1 mm (.002 to .004 in.) more than the esti-
mated dimension. In this case, we choose the
thickness to the nearest 5/100 part above,
which means we adjust the shim thickness to
0.70 mm (.0276 in.).
Measuring device
The following measurements are made easier
using digital depth callipers. The greatest
advantage is that digital callipers can be reset
at a suitable (arbitrary) reference plane.