Husqvarna K6500 Instruction manual

HUSQVARNA CONSTRUCTION PRODUCTS

Workshop manual

K6500 Ring

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.

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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quam lobortis nunc. Fusce vel tortor magna, a posuere est.

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rices, tellus nunc pulvinar dui, a mollis orci leo quis nulla.

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stra, per incepto

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verra. Cum sociis natoque penatibus et magnis dis parturient

montes, nascetur ridiculus mus.

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Curabitur sapien nulla, tempus id luctus ac, tempus vel lacus.

Donec eget nibh sem. Ut dolor libero, pharetra sed imperdiet

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

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.

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.

13 14

REPLACING BLADE

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.

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.

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.

!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.

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.

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.

16–20 Nm

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.

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.

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.

Replacement of engagement rollers

Remove the blade as specified in Chapter 4.

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