Husqvarna Welding Consumables k2500 User Manual

Operators manual  
K2500  
Please read the operator’s manual carefully and make sure you understand the  
instructions before using the machine.  
English  
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CONTENTS  
Contents  
KEY TO SYMBOLS  
Key to symbols .............................................................  
CONTENTS  
4
Contents ......................................................................  
WHAT IS WHAT?  
What is what on the power cutter? ...............................  
SAFETY INSTRUCTIONS  
Steps before using a new power cutter. .......................  
Personal protective equipment .....................................  
Machines safety equipment ........................................  
Checking, maintaining and servicing the machines  
safety equipment ..........................................................  
General safety precautions ..........................................  
General working instructions .......................................  
Cutting blades ..............................................................  
ASSEMBLY  
Assembly ..................................................................... 11  
Fitting the cutting blade ................................................ 11  
Guard for the blade ...................................................... 11  
STARTING AND STOPPING  
Starting and stopping ................................................... 12  
MAINTENANCE  
Maintenance ................................................................ 13  
TECHNICAL DATA  
Technical data .............................................................. 15  
Cutting equipment ........................................................ 15  
EC-declaration of conformity ........................................ 15  
English – 3  
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WHAT IS WHAT?  
16  
17  
What is what on the power cutter?  
1
2
3
4
5
6
7
8
9
Cutting blade  
10 Switch  
Guard for the blade  
Catch for the guard  
Front handle  
11 Hydraulic motor  
12 Flange washer  
13 Belt guard  
Water tap  
14 Belt tensioner  
15 Cutting arm  
Rating plate  
Switch lock  
16 Combination spanner  
17 Operators manual  
Water connection with filter  
Hydraulic hoses  
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SAFETY INSTRUCTIONS  
Breathing mask  
Steps before using a new power  
cutter.  
This machine is a hydraulically operated power cutter  
intended for free-hand cutting. The machine should be  
connected to a hydraulic unit with an oil flow of 35-42  
litres/min and a maximum pressure of 150 bar.  
Heavy-duty, rm grip gloves.  
Please read the operator’s manual carefully.  
Check the cutting blade’s mounting, see the chapter  
”Assembly”.  
Let your Husqvarna dealer check the power cutter and make  
essential adjustments and repairs.  
Tight-fitting, heavy-duty and comfortable clothing that  
permits full freedom of movement.  
WARNING! Under no circumstances may the  
design of the machine be modified without  
the permission of the manufacturer. Always  
use genuine accessories. Non-authorized  
modifications and/or accessories can result  
in serious personal injury or the death of the  
operator or others.  
!
WARNING! Use of products which cut, grind,  
drill, sand or shape material can generate  
dust and vapors which may contain harmful  
chemicals. Know the nature of the material  
being worked on and wear appropriate dust  
mask or respirator protection.  
!
Use leg-guards recommended for the material to be cut.  
Boots with steel toe-caps and non-slip sole  
WARNING! A power cutter is a dangerous  
tool if used carelessly or incorrectly and can  
cause serious, even fatal injuries. It is  
extremely important that you read and  
understand the contents of this Operator’s  
Manual.  
!
Always have a first aid kit nearby.  
Husqvarna Construction Products has a policy of continuous  
product development. Husqvarna reserves the right to modify  
the design and appearance of products without prior notice  
and without further obligation introduce design modifications.  
Machines safety equipment  
All information and all data in the Operator’s Manual were  
applicable at the time the Operator’s Manual was sent to print.  
This section describes the machines safety equipment, its  
purpose, and how checks and maintenance should be carried  
out to ensure that it operates correctly. See the ”What is  
what?” section to locate where this equipment is positioned  
on your machine.  
Personal protective equipment  
WARNING!You must use approved personal  
protective equipment whenever you use the  
machine. Personal protective equipment  
cannot eliminate the risk of injury but it will  
reduce the degree of injury if an accident  
does happen. Ask your dealer for help in  
choosing the right equipment.  
WARNING! Never use a machine that has  
faulty safety equipment! Carry out the  
inspection, maintenance and service  
routines listed in this section.  
!
!
Switch  
Protective helmet  
The switch is used to start and stop the machine.  
Hearing protection  
Protective goggles or a visor  
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SAFETY INSTRUCTIONS  
Switch lock  
Checking the switch lock  
The switch lock is designed to prevent accidental operation of  
the switch. When the lock (A) is pressed in this releases the  
switch (B).  
Check that the switch is locked when the switch lock is in its  
home position.  
A
B
Press the switch lock and check that it returns to its home  
position when released.  
The switch lock remains pressed as long as the switch is  
pressed.When you release your grip on the handle this resets  
both the switch and the switch lock. This takes place via two  
independent return spring systems. This position causes the  
machine to stop and the switch to be locked.  
Check that the switch and switch lock move freely and that  
their return spring systems function.  
Guard for the blade  
This guard is fitted above the cutting blade and is designed to  
prevent parts of the blade or cutting fragments from being  
thrown towards the user.  
Start the machine, release the switch, and check that the  
machine and blade stop.  
Checking the blade guard  
WARNING! Always check that the guard is  
correctly fitted before starting the machine.  
Check that the cutting blade is fitted  
correctly and does not show signs of  
damage. A damaged cutting blade can cause  
personal injury. See instructions under the  
heading Assembly.  
!
Checking,maintaining and servicing  
the machines safety equipment  
Check that the guard is complete and without any cracks or  
deformations.  
WARNING! All servicing and repair work on  
the machine requires special training.This is  
especially true of the machines safety  
!
equipment. If your machine fails any of the  
checks described below you must contact  
your service agent.When you buy any of our  
products we guarantee the availability of  
professional repairs and service. If the  
retailer who sells your machine is not a  
servicing dealer, ask him for the address of  
your nearest service agent.  
General safety precautions  
A power cutter is designed to cut hard materials, such as  
masonry. Observe the increased risk of kickback when  
cutting soft materials. See instructions under the heading  
How to avoid kickback.  
Checking the starting and stopping  
functions of the switch  
Do not use the power cutter until you have read the entire  
contents of this Operator’s Manual.  
All servicing, in addition to the points listed in the section  
”Control, maintenance and service of the power cutter’s  
safety equipment”, should be carried out by trained  
service specialists.  
Start the machine, release the switch, and check that the  
machine and blade stop.  
Never use the machine if you are tired, if you have drunk  
alcohol, or if you are taking medication that could affect  
your vision, your judgement or your co-ordination.  
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SAFETY INSTRUCTIONS  
Wear personal protective equipment. See instructions  
under the heading Personal protective equipment.  
when cutting that no material can become loose and fall,  
causing operating injury.Take great care when working on  
sloping ground.  
Never use a machine that has been modified in any way  
from its original specification.  
Make sure that no clothes or parts of the body come in  
contact with the cutting equipment when it is rotating.  
Never use a machine that is faulty. Carry out the checks,  
maintenance and service instructions described in this  
manual. Some maintenance and service measures must  
be carried out by trained and qualified specialists. See  
instructions under the heading Maintenance.  
Keep at a safe distance from the cutting equipment when  
it is rotating.  
The guard for the cutting equipment must always be on  
when the machine is running.  
Never allow anyone else to use the machine without first  
ensuring that they have understood the contents of the  
operator’s manual.  
Ensure that the working area is sufficiently illuminated to  
create a safe working environment.  
Do not move the machine when the cutting equipment is  
rotating.  
Transport and storage  
Always ensure you have a safe and stable working  
position.  
Do not store or transport the power cutter with the cutting  
blade fitted.  
Make sure that no pipes or electrical cables are routed in  
the area to be cut.  
Store the power cutter in a lockable area so that it is out of  
reach of children and unauthorised persons.  
All blades should be removed from the cutter after use and  
stored carefully. Store cutting blades in dry, frost free  
conditions.  
Cutting  
WARNING!The safety distance for the power  
cutter is 15 metres.You are responsible to  
ensure that animals and onlookers are not  
within the working area. Do not start cutting  
until the working area is clear and you are  
standing firmly.  
Special care should be taken with abrasive discs. Abrasive  
discs must be stored on a flat, level surface. If blades are  
supplied with a backing pad then a spacer should be used to  
keep them flat. If an abrasive disc is stored in humid  
conditions, this can cause imbalance and result in injury.  
!
Inspect new blades for transport or storage damage.  
General  
General working instructions  
Start cutting with the machine running at maximum  
speed.  
Always hold the machine in a firm grip with both hands.  
Hold it so that the thumbs and fingers grip round the  
handles.  
WARNING! This section describes basic  
safety directions for using a power cutter.  
This information is never a substitute for  
!
professional skills and experience. If you get  
into a situation where you feel unsafe, stop  
and seek expert advice. Contact your dealer,  
service agent or an experienced power  
cutter user. Do not attempt any task that you  
feel unsure of!  
WARNING! Overexposure to vibration can  
lead to circulatory damage or nerve damage  
in people who have impaired circulation.  
!
Contact your doctor if you experience  
symptoms of overexposure to vibration.  
These symptoms include numbness, loss of  
feeling, tingling, pricking, pain, loss of  
strength, changes in skin colour or  
condition.These symptoms normally appear  
in the fingers, hands or wrists.  
Basic safety rules  
Look around you:  
-To ensure that people, animals or other things cannot affect  
your control of the machine.  
-To make sure that none of the above come into contact with  
the cutting blade.  
Cutting technique  
Do not use the machine in bad weather, such as dense  
fog, rain, strong wind, intense cold, etc. Working in bad  
weather is tiring and can lead to dangerous conditions,  
e.g. slippery surfaces.  
The technique described below is of a general character.  
Check information for each blade regarding individual cutting  
characteristics (for example, diamond blades requires less  
feeding pressure than an abrasive discs).  
Never start to work with the power cutter before the  
working area is clear and you have a firm foothold. Look  
out for any obstacles with unexpected movement. Ensure  
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SAFETY INSTRUCTIONS  
Support the work piece in such a way that it is possible to  
predict what will happen, and so that the cut remains open  
while cutting.  
Sharpening diamond blades  
Diamond blades can become dull when the wrong feeding  
pressure is used or when cutting certain materials such as  
heavily reinforced concrete. Working with a blunt diamond  
blade causes overheating, which can result in the diamond  
segments coming loose.  
Sharpen the blade by cutting in a soft material such as  
sandstone or brick.  
Check that the blade is not in contact with anything when  
the machine is started  
Blade vibration  
The blade can become out-of-round and vibrate if an  
excessive feed pressure is used.  
Always cut at maximum speed.  
Start cutting smoothly, allowing the machine to work  
without forcing or pressing in the blade.  
A lower feed pressure can stop the vibration. Otherwise  
replace the blade. The blade must be of the recommended  
type for the material to be cut.  
Move the blade slowly forwards and backwards to achieve  
a small contact area between the blade and the material  
to be cut. This reduces the temperature of the blade and  
ensures effective cutting.  
How to avoid kickback  
WARNING! Kickback can happen very  
suddenly and violently; kicking the power  
cutter and cutting blade back at the user. If  
!
this happens when the cutting blade is  
moving it can cause very serious, even fatal  
injuries. It is vital you understand what  
causes kickback and that you can avoid it by  
taking care and using the right working  
technique.  
Feed down the machine in line with the blade. Pressure  
from the side can damage the blade and is very  
dangerous.  
What is kickback?  
The word kickback is used to describe the sudden reaction  
that causes the power cutter and cutting blade to be thrown  
from an object when the upper quadrant of the blade, known  
as the kickback zone, touches an object.  
The guard for the cutting equipment should be adjusted so  
that the rear section is flush with the work piece. Spatter  
and sparks from the material being cut are then collected  
up by the guard and led away from the user.  
General rules  
Never start to cut with the upper quadrant of the blade as  
shown in the figure, also known as the kickback zone.  
WARNING! Under all circumstances avoid  
grinding using the side of the blade; it will  
almost certainly be damaged, break and can  
cause immense damage. Only use the  
cutting section.  
!
Always hold the machine in a firm grip with both hands.  
Hold it so that the thumbs and fingers grip round the  
handles.  
Do not pull the power cutter to one side, this  
can cause the blade to jam or break  
resulting in injury to people.  
Keep a good balance and a firm foothold.  
Always cut at maximum speed.  
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SAFETY INSTRUCTIONS  
Stand at a comfortable distance from the work piece.  
Take care when inserting the blade in an existing cut.  
Never cut above shoulder height.  
Make sure that the right bushing is used for the cutting blade  
to be fitted on the machine. See the instructions under the  
heading Assembling the cutting blade.  
High-quality blades are often most economical. Lower quality  
blades often have inferior cutting capacity and a shorter  
service life, which results in a higher cost in relation to the  
quantity of material that is cut.  
Be alert to movement of the work piece or anything else  
that can occur, which could cause the cut to close and  
pinch the blade.  
Water cooling  
Pull in  
Pull in occurs when the disc’s lower section suddenly stops or  
when the cut closes. (To avoid, see the heading ”Basic rules”  
and ”Jamming/rotation”, here below.)  
WARNING! Water cooling, which is used  
when cutting concrete, cools the blade and  
increases its service life while also reducing  
the formation of dust. Disadvantages include  
difficulties at very low temperatures, the risk  
of damaging floors and other structural  
elements, and the risk of slipping.  
!
Pinching/rotation  
If the cut is pressed together this can lead to jamming. The  
machine can be pulled down suddenly with a very powerful  
jerk.  
After using an abrasive disc with water cooling, run the disc  
dry for about half a minute. If an abrasive disc is stored in  
humid conditions, this can cause imbalance and result in  
injury.  
How to avoid pinching  
Support the work piece in such a way that the cut remains  
open during the cutting operation and when the cut is  
finished.  
Hand-held, high-speed machines  
Our cutting blades are manufactured for high-speed, portable  
power cutters. If blades from other manufacturers are used,  
ensure that the blades conform to all regulations and  
demands that concern this type of power cutter.  
Special blades  
Cutting blades  
Some cutting blades are designed for stationary equipment  
and for use with attachments.Such cutting blades must not be  
used on portable power cutters.  
WARNING! A cutting blade may burst and  
cause injury to the operator.  
Always contact local authorities and make sure you are  
following applicable directives.  
!
Never use a cutting blade at a lower speed  
rating than that of the power cutter.  
Abrasive discs  
Never use a cutting blade for any other  
materials than that it was intended for.  
The cutting material on abrasive discs consists of grit bonded  
using an organic binder. ”Reinforced blades” are made up of  
a fabric or fibre base that prevents total breakage at maximum  
working speed if the blade should be cracked or damaged.  
WARNING! Cutting plastics with a diamond  
blade or rescue blade can cause kickback  
when the material melts due to the heat  
produced when cutting and sticks to the  
blade.  
A cutting blade’s performance is determined by the type and  
size of abrasive corn, and the type and hardness of the  
bonding agent.  
!
Abrasive discs, types and use  
Use  
General  
Disc type  
Material  
Water cooling  
Cutting blades are available in two basic designs; abrasive  
discs and diamond blades.  
Can be used to  
Concrete, asphalt,  
stone masonry, cast  
iron, aluminium,  
copper, brass, cables,  
rubber, plastic, etc.  
reduce dust. Run the  
disc dry for about a  
half minute after using  
an abrasive disc with  
water cooling.  
Concrete  
Steel, steel alloys and  
other hard metals.  
Metal  
NOT recommended  
Always remove the cutting blade when the machine is  
transported.  
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SAFETY INSTRUCTIONS  
Check that the blade is approved for the same or higher  
Diamond blades for wet cutting  
speed according to the aproval plate of the engine. Never use  
a cutting blade with a lower speed rating than that of the  
power cutter.  
WARNING! Cool diamond blades for wet  
cutting continuously with water to prevent  
overheating, which can cause the blade to  
break up and eject pieces that can cause  
injury.  
!
Diamond blades for wet cutting should have water poured  
over them during the cutting to cool the blade and bond the  
dust.  
Ensure the blade it not cracked or damaged in any other way.  
Diamond blades for dry cutting  
Diamond blades for dry cutting are a new generation of  
blades that do not require water cooling. However, the blades  
will still be damaged by excessive heat. It is most economical  
to allow the blade to cool by simply lifting it out from the cut  
every 30–60 seconds and letting it rotate in the air for 10  
seconds.  
Test the abrasive disc by hanging it on your finger and tapping  
it lightly with a screwdriver or the like. If the disc does not  
produce a resonant, ringing sound it is damaged.  
Diamond blades  
Diamond blades consist of a steel body provided with  
segments that contain industrial diamonds.  
Diamond blades ensure lower costs per cutting operation,  
fewer blade changes and a constant cutting depth.  
When using diamond blades make sure that it rotates in the  
direction indicated by the arrow on the blade.  
Always use a sharp diamond blade. Sharpen the blade by  
cutting in a soft material such as sandstone or brick.  
Diamond blades are available in several hardness classes. A  
"soft" diamond blade has a relatively short service life and  
large cutting capacity. It is used for hard materials such as  
granite and hard concrete. A "hard" diamond blade has a  
longer service life and reduced cutting capacity, and should  
be used for soft materials such as brick and asphalt.  
Material  
Diamond blades are ideal for masonry, reinforced concrete  
and other composite materials. Diamond blades are not  
recommended for cutting metal.  
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ASSEMBLY  
Checking the drive axle and flange  
washers  
Assembly  
Check that the threads on the drive shaft are undamaged.  
WARNING! Always disconnect the machine  
from the hydraulic hoses before cleaning,  
assembly and maintenance.  
Check that the contact surfaces on the blade and the flange  
washers are undamaged, of the correct dimension, clean,  
and that they run properly on the drive axle.  
!
Fitting the cutting blade  
Do not use warped, notched, indented or dirty flange  
washers. Do not use different dimensions of flange washers.  
Husqvarna’s blades are approved for hand-held power  
cutters. Blades are manufactured with three different  
diameters of centre holes: 20 mm (0.787"), 22.2 mm (7/8")  
and 25.4 mm (1"). Bushings can be fitted on the machine axle  
to adjust the machine to the centre hole of the blade. Use a  
bushing with the correct diameter! The blades are marked  
with the diameter of the centre hole.  
Cutting arm  
It is possible to turn the cutting arm 180° so that the blade  
comes on the other side of the cutting arm. This simplifies  
cutting close to obstacles such as walls and floors etc. The  
cutting arm and drive belt are released in the same way as  
when replacing the drive belt. See instructions under the  
heading Replacing the drive belt.  
The blade is placed on the bushing (C) between the inner  
flange washer (A) and the flange washer (B). The flange  
washer is turned so that it fits on the axle.  
Turn the arm 180°, replace the respective parts, and screw  
them secure in the same way as before.  
If you are using a diamond blade you must also turn it so that  
it rotates in the right direction. A diamond blade must rotate in  
the direction shown by the arrow marking on the blade.  
Guard for the blade  
The guard must always be fitted on the machine.  
Tightening torque for the bolt holding the blade is: 15-25 Nm  
(130-215 in.lb).  
The guard for the cutting equipment should be adjusted so  
that the rear section is flush with the work piece. Spatter and  
sparks from the material being cut are then collected up by  
the guard and led away from the user.  
The axle can be locked by inserting a screwdriver or the like  
in the hole in the belt guard.  
When a diamond blade is mounted on the power cutter make  
sure that the diamond blade will rotate in the direction  
indicated by the arrow on the blade.  
When the blade is replaced with a new one, check the flange  
washers and the drive axle. See instructions under the  
heading Checking the drive axle and flange washers.  
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STARTING AND STOPPING  
Starting and stopping  
WARNING! Note the following before  
starting:  
!
Make sure you have a secure footing and  
that the cutting blade cannot touch anything.  
Keep people and animals well away from the  
working area.  
Starting  
Grip the front handle with the left hand.  
Grip the rear handle with the right hand. When you grip  
the rear handle this releases the switch lock.  
Stopping  
The machine is stopped by releasing the switch.  
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MAINTENANCE  
Checking the drive axle and flange  
washers  
Maintenance  
Check that the threads on the drive shaft are undamaged.  
Check that the contact surfaces on the blade and the flange  
washers are undamaged, of the correct dimension, clean,  
and that they run properly on the drive axle.  
WARNING! Inspection and/or maintenance  
should be carried out with the hydraulic  
hoses disconnected.  
!
Tensioning the drive belt  
The drive belt is fully enclosed and well protected from dust  
and dirt.  
When the drive belt is to be tensioned, release the nuts  
holding the cutting arm.  
Do not use warped, notched, indented or dirty flange  
washers. Do not use different dimensions of flange washers.  
Water cooling  
Screw the adjuster screw so that the square headed nut  
comes opposite the marking on the cover.This automatically  
ensures that the belt has the correct tension.  
Check that the water tap functions.To open the water tap, turn  
the tap to open position.  
Tighten the two nuts holding the cutting arm.  
To turn off the water, turn the tap to closed position.  
Replacing the drive belt  
First release the nuts and then the adjuster screw to release  
the belt tension.  
Water filter  
Unscrew the nuts and lift off the front belt guard.  
Check and clean the filter if necessary.  
The cutting head is now loose and can be removed from the  
machine. Remove the rear belt guard by releasing the two  
screws holding the guard.  
Take off the old belt and fit the new one. Fit the cutting arm to  
the machine and tension the belt with the adjuster screw. A  
new drive belt should be re-tensioned after running for about  
30 minutes.  
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MAINTENANCE  
Daily maintenance  
Carry out the following checks daily before using the machine.  
1
2
Check that nuts and screws are tight.  
Check that the power source (the hydraulic unit) supplies  
the correct oil flow and oil pressure.  
3
4
5
Check that the hydraulic hoses and couplings are clean  
and undamaged.  
Connect the machine hoses with the hoses from the  
power source.  
Start the power source and check that the power cutter  
functions by starting the machine with the switch in the  
rear handle. Check that the blade stops when the switch  
is released.  
6
7
8
Checking the blade guard  
Check the condition of the cutting blade.  
Check the tension of the drive belt.  
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TECHNICAL DATA  
Technical data  
Technical data  
K2500  
Engine  
Hydraulic oil flow, l/min / gpm  
Working pressure, bar / psi  
Max. working pressure, bar / psi  
Max. speed of output shaft, rpm  
Drive system, V-belt  
35-42 / 9-11  
130-140 / 2000  
150 / 2200  
4300  
SPZ  
Weight  
Power cutter without cutting blade, kg  
Sound levels  
8,3  
Noise pressure level at the operators ear, max. speed,  
measured according to ISO/DIS 15744, ISO/DIS 11201,  
dB (A)  
85  
Noise emissions  
Sound power level, measured dB(A)  
106  
107  
Sound power level, guaranteed L  
Vibration levels  
dB(A)  
WA  
(see note 1)  
2
Front handle, m/s  
7,5  
5,2  
2
Rear handle, m/s  
Note 1: Handle vibrations are measured according to ISO 8662-4  
Cutting equipment  
Cutting blade  
Max. peripheral speed, m/s  
16"  
100  
EC-declaration of conformity  
(Applies to Europe only)  
Husqvarna Construction Products, SE-433 81 Partille, Sweden, tel: +46-31-949000, declares under sole responsibility that the  
power cutter K2500 from year 2006 serial numbers and onward (the year is clearly stated in plain text on the rating plate with  
subsequent serial number) conforms with the requirements of the COUNCILS DIRECTIVE:  
- of June 22, 1998 ”relating to machinery” 98/37/EC, annex IIA.  
The following standards have been applied: EN ISO 12100:2003, EN 982:1996, EN 792-7:2001  
SMP Svensk Maskinprovning AB, Fyrisborgsgatan 3, SE-754 50 Uppsala, Sweden, has performed voluntary type examination on  
behalf of Husqvarna AB. The certificates are numbered: 01/169/009 – K2500.  
Partille November 14, 2006  
Ove Donnerdal, Development Manager  
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1150293-26  
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2006-12-20  
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