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Husqvarna DSS 200 Workshop Manual

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Workshop manual
GB
DSS 200
v1.0

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  Summary of Contents for Husqvarna DSS 200

  • Page 1 Workshop manual DSS 200 v1.0...
  • Page 2 115 62 70 - 26...
  • Page 3: Table Of Contents

    HUSQVARNA CONTENTS Page DSS 200 1. Introduction Workshop Manual Spare parts General specifications Mountings & Tightening torque Service rules 2. Safety & symbols General precautions Occurring symbols in the manual 3. Checks/Troubleshooting/Specifications Maintenance guide Troubleshooting guide 4. Common service tasks...
  • Page 5: Introduction

    Please refer to the shearer's type plate to order DSS200 the correct spare parts. Accessory spare parts for DSS 200 are part of the latest tool IPL, available from the EPC (Elec- tronic Parts Catalogue). All components of the IPLs are illustrated in...
  • Page 6: General Specifications

    Introduction Service rules General specifications To ensure quality and consistency of Husqvarna workshop service, please follow these rules: Feature Data 1. Use genuine Husqvarna or Husqvarna re- Model DSS 200 commended parts and lubricants or their Suitable carrier DXR 140...
  • Page 7: Safety & Symbols

    Safety & symbols 2.Safety & symbols General precautions READ THE OPERATOR'S MANUAL • Familiarize yourself with the tool. Read the operator's manual. • The user's manual contains much information concerning basic service and maintenance, which is important in order to keep the machine safe and reliable. WARNING •...
  • Page 8: Occurring Symbols In The Manual

    Safety & symbols Occurring symbols in the manual Several graphical symbols occur in the manual to indicate standard actions to be taken, thus reducing the need to read through too much text. Chemical substances HEAT REQUIRED When performing service • Heat object concerned by means of e.g. a hot air gun to: tasks involving the use of chemical substances (such –...
  • Page 9: Checks/Troubleshooting/Specifications

    Checks/Troubleshooting/Specifications 3.Checks/Troubleshooting/Specifications Maintenance guide Item Check interval Service action Grease 10 hrs Add grease to all grease nipples (see Grease nipples overview lubrication below). Intense shearing requires shorter grease intervals. or after washing Ocular check for hydraulic leakage: If leakage occur, refer to Troubleshooting guide on next page.
  • Page 10: Troubleshooting Guide

    Checks/Troubleshooting/Specifications Troubleshooting guide Fault Probable cause Check / Solution Reference Steel shears Check all connections required for correct opera- DXR Workshop manual tion and quick couplings. Insufficient hydraulic Check that correct tool is selected in work mode Owner's manual of DXR ma- flow and/or pressure of the DXR remote terminal: “Steel shear”...
  • Page 11: Common Service Tasks

    Common service tasks 4.Common service tasks Handling with hoist Many service tasks are facilitated by means of a hoist pulley device (see chapter Tools). 1. Secure the shearer unit to hoist by means of a sling: • attach with two shackles to frame of adaptor plate •...
  • Page 12: Reassembling

    Common service tasks Reassembling Reassembling Grease – lubrication I. Clean parts to be reassembled thor- oughly: – use steel brush, solvents and compressed air II. Add grease to contact surfaces before reassembling – protect threads or parts to be sealed with thread-locking or retainer compounds, e.g.
  • Page 13: Functional Overview

    Functional overview 5.Functional overview DSS 200 Basic functional components A) Hydraulic connections to demolition robot: I. hydraulic steel shears cylinder (D) with max. pressure (250 bar) II. hydraulic orbital motor (B) with normal pressure (200 bar) B) Hydraulic orbital motor •...
  • Page 15: Dismantling Shear House And Jaws

    Dismantling shear house and jaws 6.Dismantling shear house and jaws 1. PREPARATIONS • Position hydraulic shears vertically with boom—stick structurally secured. • Shears jaws fully opened. Dismantling cutter house 2. Remove cover plates (a) Remove 16 fasteners (8 each & 26 Nm –...
  • Page 16: Dismantling Jaws And Links

    Dismantling shear house and jaws 6. Remove centre pin (c) • knock pin by means of a mallet 7. Fully remove centre pin (c) • pull out pin Reassembling: Fit grease (G) on pin shaft (not on threads) Remove remaining cast steel plate •...
  • Page 17: Shear House Parts And Jaws

    Dismantling shear house and jaws Shear house parts and jaws Prior to assembling; apply grease (G) to all contact surfaces. JAW/LINK PIN (×4) Each pin (d) is secured by means of a circlip ) grease nipple ) grease channel/grove LINK (×2) (f) grove for pin head on one side SHEAR JAW (×2) (e) replace jaw edge if blunt or broken...
  • Page 19: Dismantling Mounted Cylinder

    Dismantling mounted cylinder 7.Dismantling mounted cylinder PREPARATIONS • Remove shear house, jaws and links as in previous chapter. • Position shears unit vertically down- wards at a convenient hight optionally: – attached to boom—stick in a structurally secured manner – or, hanging by a strap and pulley system •...
  • Page 21: Cylinder Service

    Cylinder service 8.Cylinder service PREPARATIONS Remove cylinder from cylinder plate fol- lowing steps in previous chapter. Dismantling 1. Remove cylinder plate gasket • use an O-ring picker to remove (a) U-cup seal (b) O-ring 2. Loosen cylinder rod head • use a plastic mallet –...
  • Page 22 Cylinder service Continued from previous page... 9. Remove cylinder rod gland • use an O-ring picker to remove: I. rod wear ring (linear motion bearing) II. rod wiper 10. Cylinder piston and rod 11. Cylinder barrel – interior 12. Cylinder piston internal gland •...
  • Page 23: Hydraulic Swivel & Orbital Motor

    Hydraulic swivel & Orbital motor 9.Hydraulic swivel & Orbital motor 1. PREPARATIONS • Position shearers vertically, hanging or attached to stick of a DXR ma- chine. Cutting jaws may be mounted. • Clean unit thoroughly. • Remove two hydraulic hose coup- lings (I) for orbital motor: 22 mm –...
  • Page 24: Orbital Motor And Housing

    Hydraulic swivel & Orbital motor ...Continued from previous page HYDRAULIC SWIVEL HEAD 7. Remove swivel head fasteners • Allen key: 8mm Reassembling: use thread locking compound T2 (Hydraulic) to fasteners. Tightening torque: 51 Nm 8. Remove swivel head • evenly work off swivel head = 51 –...
  • Page 25: Swivel Flanges

    Hydraulic swivel & Orbital motor ...Continued from previous page 4. Removing interior flange fasteners (e) use marker to mark interior swivel flange to exterior swivel flange • use Allen key: 10mm – remove 14 × 4cm fasteners with = 89 friction washers –...
  • Page 26: Orbital Motor Service

    Hydraulic swivel & Orbital motor Orbital motor service 1. Orbital motor with service points (a) Orbital motor base (b) Relief valves – comprising: I. valve pin II. valve spring III. spring seat IV. copper washer/seal V. plugging VI. relief adjuster (Allen head) The two relief valves ensure that orbital motor will not get over-loaded.
  • Page 27: Hydraulic Swivel Piston

    Hydraulic swivel piston 10.Hydraulic swivel piston PREPARATIONS 8 mm • Remove orbital motor and flanges as de- scribed in previous chapter. Dismantling swivel piston 1. Remove piston clamping flange (I) • remove 9 × fasteners – 8 mm Allen wrench Reassembling: use thread locking compound T1 (Medium) to fasteners.
  • Page 28 Hydraulic swivel piston ...Continued from previous page 7. SWIVEL PISTON GLANDS, O- RING SEALS AND PINS (a) Removing piston glands • use an O-ring picker – gently remove the glands (b) Removing O-ring seals • use an O-ring picker and remove: –...
  • Page 29: Tools

    Tools 11.Tools ● = Service action Service tools – supplied Centre nut socket Kit of PO-plugs Art. No: 587 35 71 – 01 See DXR Workshop Manual ● Fit to shape: 55 (mm) Pressure proof metal plugs ● Selection of hose plugs of occur- ●...
  • Page 30 Tools Recommended tools – not supplied Heat gun Cir-clip pliers External ● Heating bolts and fasteners to fa- cilitate breaking thread-locking or ● Dismantling of cutter shafts etc. retaining compounds Plastic mallet ● knocking out shafts, breaking thread-locking and retaining com- Pulley hoist (or equiv.) pounds 250kg...
  • Page 31: Hydraulic Diagrams

    Hydraulic diagrams 12.Hydraulic diagrams...
  • Page 32 www.husqvarnacp.com English 115 62 70 - 26 2014-06...