Husqvarna DCR 100 Instruction manual

GB
v1.0
Workshop manual
DCR 100/300
GBGB

115 75 36 - 27

HUSQVARNA
DCR
100/300
CONTENTS
1. Introduction 1
Spare parts....................................................................1
Technical data.............................................................2
Mountings & Tightening torque.............................2
2. Safety & symbols 3
General precautions...................................................3
Occurring symbols in the manual..........................4
3. C ecks/Troubles ooting 5
Maintenance................................................................
Troubleshooting guide..............................................7
4. Common service tasks 9
Hydraulic lines/couplings........................................9
5. Components – orientation 11
Basic functional components................................11
6. Dismantling into basic modules 13
Jaw unit & cylinder—adaptor plate........................13
Adaptor plate & cylinder........................................14
7. Main and ydraulic swivel 15
Adaptor plate swivel.................................................1
Hydraulic swivel.......................................................16
8. Hydraulic manifold 17
Swivel—cylinder frame.............................................17
9. Cylinder 19
10. Jaws 21
Cutter pads................................................................22
11. Hydraulic pressure tuning 23
12. Components – orientation 25
Machine overview.....................................................2
Basic functional components................................2
13. Crus er jaw 27
Frame—jaw shaft........................................................27
Cylinder—jaw shaft...................................................27
14. Adaptor plate & connections 29
External hydraulic hoses.........................................29
Adapter plate.............................................................29
Adaptor plate swivel.................................................30
Hydraulic swivel.......................................................31
15. Cylinders 33
16. Internal ydraulics & booster 37
Hydraulic manifold.................................................39
Booster........................................................................40
17. Hydraulic pressure tuning 43
Testing booster pressure..........................................43
Valve tuning...............................................................4
18. Hydraulic diagrams 47
19. Tools 49
Service tools – supplied...........................................49
Recommended tools – not supplied.....................49
DCR 100
DCR 300
Page

Intro uction 1
1.Intro uction
DCR 100 | DCR 300 1
Spare parts
SPARE PARTS DCR 100 / DCR 300
Please refer to the shearer's type plate to order
the correct spare parts:
Serial Number (S/N) | Product Number (P/N)
NB: Serial No is shorter on older machines (as il-
lustraded for DCR300 to the left)
These documents include all spare parts for:
DCR 100
DCR 300
Link to EPC: http://parts.husqvarna. om
All components are illustrated in exploded
views of the entire machine, where each com-
ponent's position, spare part number and ap-
pearance can be easily identified. These docu-
ments and later revisions are available from the
Husqvarna support site.
Workshop Manual
The Workshop Manual includes virtually all rel-
evant workshop procedures on the DCR 100
and DCR 300. The page footer indicates which
model the content refers to. Some very simple
and self-evident repairs have been omitted.
In case of doubt on basic handling of these
DXR Crushers, please refer to the Operator's
manuals.
OUTLINE
The manual describes dismantling and reas-
sembling of various components through the
different chapters.
This means that as a mechanic, at least until
you are familiar with the basic composition of
the machine, you need to start with some earlier
chapters to allow for access to the service items
concerned. Each chapter begins with suggested
preparations before the service items concerned.
LAYOUT – PICTURES 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 machine.
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 has chapter references as
well as page references for relevant subtitles.
Operator's manual
The operator's manual describes how the ma-
chine is to be used, the functions of the ma-
chine, and the maintenance the operator nor-
mally carries out.
This manual also contains important instruc-
tions for the safe handling of the machine.
It is extremely important that service person-
nel are well acquainted with how the machine is
used and follow the instructions given in the
manual.
Dismantling in basic steps
×1 6mm

1 Intro uction
2 DCR 100 | DCR 300
Technical ata
Feature Data
Model DCR 100 DCR 300
Suitable carrier DXR 140 DXR 2 0/270/300/310
Hydraulic system
Max. incoming pressure, bar
(psi) 200 (2900)
Operating pressure, bar (psi) 200 (2900) 200— 00 (2900—72 0)
Max. flow, l/min (gal/min) 0— (0—1 ) 0— /100 (0—1 /26)
Dimensions
Heig t wit adapter plate, mm
(inc ) 1000 (39½) 112 (44 )¼
Weig t wit connection plate
and oses, kg (lb) 204 (4 0) 277 (611)
Widt , mm (inc ) 730 (28 )¾883 (34 )¾
Dept , mm (inc ) 330 (13)
Max. jaw opening (between tips),
mm (inc ) 42 (16 )¾1430 (17)
Min. jaw opening (between tips),
mm (inc ) 2 (1)2
Rotation angle Free rotation 360°
Performance
Jaws dept , mm (inc ) 18 (7 )¼19 (7 )¾
Closing time, (capacity) s ( 2 l/min) 3.7 (6 l/min) 2.8
Opening time, (capacity) s ( 2 l/min) 2.0 (6 l/min) 1.9
Max. tip power (fully opened
jaws), kN (t) 33 (34)1 / 317 (32)2440 (4 )
Max. tip power (near fully closed
jaws), kN (t) 1 (16)1 / 1 9 (16)2N/A
Max. rod cutting power, kN (t) 920 (94)21400 (143)
Max. rod cutting diameter, mm
(inc ) 28 (< 1⅛)230 (< 1¼)
1Jaw adjustment pins in outer position
2Jaw adjustment pins in inner position
Mountings & Tightening torque
Torque for occurring metric fasteners
Coarse
pitch
threads
SS—ISO 8981/1 rating
Type 8.8 [Nm] 10.9 [Nm] 1 .9 [Nm]
M ,7 8,1 9,7
M6 9,8 14 17
M8 24 33 40
M10 47 6 79
M12 81 114 136
M16 197 277 333
M20 38 41 649
M24 66 93 1120

Safety & symbols 2
.Safety & symbols
DCR 100 | DCR 300 3
General precautions
READ THE OPERATOR'S MANUAL
•Familiarize yourself with the machine. 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
•This symbol indicates that hazardous safety risks to persons must be avoided.
•This symbol indicates when risk of machine damage should be avoided.
WEIGHT
•This indicates that risky weights are to be considered. Take proper precaution!
HIGH PRESSURE
•This symbol indicates risk of spray from high pressure hydraulic fluid. Take pre-
cautions and wear protection.

2 Safety & symbols
4 DCR 100 | DCR 300
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.
HEAT REQUIRED
•Heat object concerned by means of e.g. a hot air gun to:
–loosen thread-locking compound
–expand object which fits tightly around another object
THREAD-LOCKING COMPOUND
•Apply thread-locking compound of recommended quality (see Tools section)
T1=Blue (medium)
T2=Blue (medium, hydraulics)
T3= Red (hard)
RETAINER
•Apply to secure all types and sizes of bearings, shafts, cylindrical parts (see Tools
section).
ANTI-SEIZE COPPER PASTE
•Apply copper based anti-seize high temperature lubrication, (see Tools section).
LUBRICATING GREASE
•Apply lubrication of recommended quality, (see Tools section).
LUBRICATION OF HYDRAULIC PARTS
•Before mounting; apply Hydraulic Fluid to flexible hydraulic parts, seals, O-
rings etc.
SCREWS OR FASTENERS (EXAMPLE)
•Quantity: 4
•Suitable tool: Allen wrench, size 2, mm
KEEP MACHINE AND WORK AREA TIDY
•Prior to service; thoroughly clean areas concerned
•Remove dirty grease and lubricants
•Wipe clean with suitable solvent or cleaning agent and use compressed air to re-
move any dust or debris
SPILL OF FLUIDS
•Keep vessels and absorbent sheets at hand.
COVER OPENINGS
•Protect exposed hydraulic parts from contamination.
•Cover opening wit plastic caps or wrap area in plastic bag.
C emical substances
When performing service
tasks involving the use of
chemical substances (such
as lubricants or retainer
compounds), please refer to
the instructions from the
manufacturer.

Checks/Troubleshooting 3
3.Checks/Troubleshooting
DCR 100 | DCR 300 5
Maintenance
The maintenance guide lists items that need
regular maintenance by the operator. The
intervals are based on daily use of the ma-
chine, and may differ depending on the
rate of usage.
Daily
CLEANING
•Clean with a rag or brush
•The tool can be cleaned more thoroughly
by washing it with water and detergent.
GENERAL INSPECTION OF:
•Tool, for damage and wear
•All couplings, connections and hydraulic
hoses. Replace if not in full working or-
der.
•Crusher jaw bolts – ocularly. Tighten if
necessary by means of a torque wrench.
CUTTER PADS
•When worn to one side, each cutter pad
should be turned around.
•Never use pads that are cracked or dam-
aged!
See chap. 10. DCR100 13. DCR300
LUBRICATION
Grease nipples
Apply to all crusher's nipples every 8 hours:
•use a grease gun to apply lithium loaded
grease (see Tools chapter) through all
nipples as illustrated below
Preparations
•Position machine with the concrete
crusher at a convenient working height
Lubrication of:
Weekly:
1. Hydraulic swivel
Daily:
2. Contact surfaces of orbital flanges
3. Cylinder shafts
4. Jaws pivoting shafts
Maintenance gui e
Daily maintenance Weekly maintenance Every 500 / Yearly
Cleaning C eck bus ings
of adapter plate swivel
Function test:
DCR100: Max. 200 bar
DCR300: Max. 500 bar
General inspection
Cutter pads Jaws
c eck bus ings
(brass wit yellow con-
tact surface)
DCR300:
Replace in-line ose filters
Lubrication

3 Checks/Troubleshooting
6 DCR 100 | DCR 300
Weekly
JAW UNIT BUSHINGS
Check for loose fit of jaw bushings and
shafts:
•Lift each jaw unit to verify a firm fit.
–If loose – replace bronze bushings with
yellow contact surfaces.
See chap. 10. DCR100 13. DCR300
JAW TIPS – DCR100 (FIXED)
•Check wear of crushing surfaces of jaws
and add filling material if necessary.
•Before adding filling material, remove all
remains of paint, as these can cause toxic
gases.
•Preheat the surface to 1 0—200°C.
•After adding filling material, let cool
slowly to room temperature.
Recommended welding wire
ESAB: OK 83.30 DIN 8 -E1 300
OK 83. 0 DIN 8 -E6-
SIEV-FRO: B- 00 or B-600
See chap. 10. DCR100 13. DCR300
JAW TIPS – DCR300
(REPLACEABLE)
If worn, the tips should be replaced or re-
moved for temporary welding work.
See chap. 13.
Yearly
IN-LINE HOSE FILTERS (DCR300)
Clogged filters will reduce the performance
of the crusher.
•Replace as shown in chapter 14 “Adaptor
plate & connections”.
See chap. 14.
ADAPTER PLATE SWIVEL
BUSHINGS
Check for loose fit of swivel bushings:
•If loose – replace the bronze bushings.
See chap. 7. DCR100 14. DCR300
FUNCTION TEST
Measure maximum pressure to make sure
that every function of the crusher works
properly before, and after, service and
maintenance is carried out.
•Close crusher jaws completely, while
holding them continuously closed:
DCR100: 200bar should be displayed
in the remote control terminal.
DCR300: 00bar should be displayed
on pressure dial connected to
lower measure port of booster.

Checks/Troubleshooting 3
DCR 100 | DCR 300 7
Troubleshooting gui e
Model Problem Possible cause Typical symptom C eck / Solution Reference
DCR100/
300
Reduced per-
formance
Insufficient hydraulic
flow and/or pressure
Make sure that all hydraulic
hoses and connections are in-
tact and correctly connected.
DXR owner's &
workshop manual
Check that correct tool is se-
lected in work mode of the
DXR remote terminal:
“Crusher”
DXR Owner's
manual
Check DXR machine max.
flow and pressure.
DXR Workshop
manual
Crusher closes/opens slowly. Check, replace in-line hose fil-
ters, if clogged. Chap. 14
Hydraulic pressure does
not reach maximum
pressure (200 & 00 bar)
Check DXR machine max.
flow and pressure.
DXR Workshop
manual
Hissing noise
Oil temperature increases
Valve temperature increases
Check/adjust max pressure
limiting valve.
DCR100: 23 bar
DCR300: 20bar
Chap.11 DCR100
Chap.17 DCR300
Hissing noise from cylinder when fully
closed.
Replace seals of jaw hydraulic
cylinder/s.
Chap. 9 DCR100
Chap. 1 DCR300
Hissing noise from swivel when fully
closed.
Replace seals of hydraulic
swivel.
Chap. 9 DCR100
Chap. 14 DCR300
Damaged or worn jaw tip N/A Replace or re-weld the two jaw
tips.
Chap. 10 DCR100
Chap. 13 DCR300
DCR 300
Pressure reducing valve is incor-
rectly set (to low).
200bar is delivered to crusher, but
booster can not intensify to max pressure
( 00bar).
Adjust pressure reducing valve
to 200bar. Chap.17 DCR300
Sequence valve is incorrectly set. Booster is not engaged, no ticking noise
is present.
Adjust sequence to open at
180bar. Chap.17 DCR300
Defect check valves in high
pressure block.
Continuous ticking noise from booster,
booster does not hold pressure.
Check, clean, and /or replace
check valves. Chap.16 DCR300
Damaged or contaminated
booster internal hydraulics.
Continuous ticking noise from booster,
booster does not hold pressure. Replace booster Chap.16 DCR300
DCR100/
300
Play in swivel
bearing Worn brass rings Crusher acts unstable against its adapter plate. Replace brass rings. Chap. DCR100 Chap. DCR300
The manoeuv-
ring of the
crusher is re-
versed
Reverse pressure and return
hose.
Connect inlet hose to tool in-
take and the return hose to
tool outlet.
Component orient-
ation
The jaws can
not
open/close
Insufficient hydraulic
flow and/or pressure
Check DXR machine max.
flow and pressure. DXR Workshop
manual
Jammed/contaminated quick
couplings Check/clean quick couplings
Contaminated in-line filters Check, and replace, in-line
hose filters if clogged. Chap. 14
DCR 300
The jaws close
but can not
open.
Defect or contaminated pilot
operated valve.
Check, clean or replace pilot
operated check valves and oc-
curring O-rings.
Chap.16 DCR300
DCR100/
300
Vibrations Screws and bolts are loose or
missing.
Check the tightening torque
of the screws or bolts. Replace
missing screws.
All chap.
External oil
leaks
Loose connections.
N/A
Tighten the connections.
Damaged hose and/or coupling Replace damaged hoses
and/or couplings.
Damaged rod wiper seal Replace damaged rod wiper(s). Chap.9 DCR100
Chap.1 DCR300
DCR 100 Damaged O-rings between hy-
draulic manifold and cylinder Replace damaged O-ring. Chap.8 DCR100

Common service tasks 4
4.Common service tasks
DCR 100 | DCR 300 9
HANDLING WITH HOIST
Virtually all service tasks are facilitated by
means of a hoist pulley device (see chapter
Tools).
1. Secure the crusher unit to hoist with
shackles and a loop:
DCR 300: attach the shackles to lifting
lugs – one on each side of the
adaptor plate
DCR 100: attach two shackles to frame
of adaptor plate
•hoist to vertical position:
–stabilise unit by slightly resting
jaw(s) on e.g. a wooden piece
•a vertical position facilitate good
reach from both sides:
–shafts of jaws and cylinders
–interior service
Hy raulic lines/couplings
Preparation
Make sure hydraulic coupling
areas are absolutely clean be-
fore opening!
•Take care of the spill; put a vessel or an
absorbent sheet under the coupling
THREADED COUPLINGS
2. Mark lines and hoses for your own ref-
erence and gently loosen the coupling.
Use two spanners not to twist hose.
Avoid hazardous spray! Use
eye-protection. Check that
hoses are pressure free.
3. Keep area clean and reduce spill
by plugging or covering all
openings:
(a) a tight fit plastic hat
(b) a nylon plug
Maintaining hydraulic operation
4. Use a metal PO-plug (c) when
maintaining operability of the
hydraulic system is desired.
Reassembling threaded couplings
. Check that the O-ring is positioned
correctly in its slot.
–replace O-rings with cracks or
signs of wear
Reverse the steps as in 1—2 above.
HOSES
Before removal: mark or document how
hose is lead to ensure proper remounting.
6. Check that hoses are in good condition
–replace worn or damaged hoses
–check that hoses run smoothly
without kinks, twists or contact
to sharp edges

4 Common service tasks
Reassembling
10 DCR 100 | DCR 300
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. by
means of tape
–remove tape once the part has
been mounted proceed with
step III. below
Threa -locking an
retainer compoun
Clean surface to be sealed with brush,
solvent and compressed air as in step I.
above.
III. Apply the recommended sealant:
•Thread-locking compound:
–T1, T or T3
•Retainer compound:
–R

Components – orientation 5
5.Components – orientation
DCR 100 11
DCR100
Basic functional
components
A) Hydraulic connection to demolition
robot DXR 140
•Hydraulic swivel with normal
pressure (200 bar) flow to cylin-
ders
B) Cylinder
•Open or close crusher jaws
C) Jaw links
•Two shaft positions on either side
for adjustable crusher depth
D) Crusher jaws
•Cutting with interior cutting pads
•Crushing with exterior jaw tip
–welded reshapable contact sur-
face
Machine overview
1. Adaptor plate:
•Attaches to stick of DXR 140
2. Swivel system:
•Adaptor plate swivel to permit full
passive rotation of the crusher
•Interior hydraulic swivel
3. Overpressure valve
4. Protector for cylinder piston
. Hydraulic hoses for inflow and return
flow
•Features quick couplings
6. Cylinder
7. Protective shield
8. Jaw link
•Two shaft positions on either side
for adjustable crusher width
Jaws
9. Jaw cutter
–for cutting rebar(s)
10. Jaw tip
•reshapable crushing surface

5 Components – orientation
12 DCR 100

Dismantling into basic mo ules 6
6.Dismantling into basic mo ules
DCR 100 13
Preparation
1. Secure the crusher unit vertically by
means of e.g. a hoist pulley (see chap.
Common service tasks):
(a) attach a strap to lifting lugs
(b) stabilise unit by slightly resting
jaw(s) on e.g. a wooden piece
PROTECTIVE SHIELDS
There is one shield on either side.
2. Remove the four fasteners:
–Allen wrench: 8mm
Reassembling, apply thread-locking
compound T1
CYLINDER PISTON PROTECTOR
3. Remove piston protector
•Spanner: 22mm
Reassembling, apply thread-locking
compound T1
Jaw unit & cylin er—
a aptor plate
Comprising crusher jaws and cutters.
4. Remove shaft nuts from both sides
•Special Tool No: 1 (see Tools)
or spanner: 36 mm
Reassembling, apply thread-locking
compound T1
•Tighten manually “hard”, until
free movement of jaw is limited –
then loosen slightly.
. Knock out shaft from one side
•use a mallet and e.g. a rod to knock
shaft through
Reassembling, apply a thin coat of
grease to shaft
6. Reposition jaw unit
•hoist slightly
•close jaws
7. Remove second shaft
•lower until cylinder rests on jaw unit
•neutralise load and remove shaft (see
step 4 above)
8. Separate cylinder—adaptor plate from
jaw unit
•hoist to fully separate the two basic
modules
REASSEMBLING
Reassemble by reversing the above steps of
disassembling.
Prepare shafts, contact surfaces and lock
screws following the principle described in
chapter “Common service tasks”:
I. Shafts: apply a thin coat of grease
II. Contact surfaces: apply a thin coat of
grease
III. Nuts: apply thread-locking compound
×4 8mm
×2 36mm
ST No. 1
×6 22mm
140 Nm
81 Nm

6 Dismantling into basic mo ules
14 DCR 100
A aptor plate & cylin er
Preparation
Remove jaw unit – see previous page and
(a) place cylinder foot on a flat surface
–stabilise unit; fill up small gap
on one side
EXTERNAL HYDRAULIC HOSES
1. Remove both hydraulic hoses
–Spanner: 30mm
ADAPTOR PLATE
For all adaptor plate fasteners:
–use heat gun to soften thread-
locking compound
Reassembling, apply thread-locking
compound T1
Tightening torrquw for all easily
reachable fasteners: 50Nm
2. Remove all 9 easily accessible fasteners:
–use hot air gun to soften thread-
locking compound
–Allen wrench: 8mm
3. Remove all three round headed fasten-
ers
–Allen wrench: 6mm
4. Remove all four corner fasteners
–Allen wrench: 8mm
–loosen with a shallow
wrench; ca 30mm deep
–use a balled end for
continued unscrewing
. Lift off adaptor plate
REASSEMBLING
Reassemble by reversing the above steps.
Follow advice on thread-locking compound
from chapter “Common service tasks”.
×2 30mm
6mm
8mm
8mm
50Nm
50Nm

Main an hy raulic swivel 7
7.Main an hy raulic swivel
DCR 100 15
DISMANTLING OF SWIVELS
Preparations
Follow instructions in previous chapter
“Dismantling in basic modules” and re-
move the adaptor plate.
A aptor plate swivel
This allows crusher unit to rotate 360°.
DISMANTLING
Swivel top
1. Remove swivel fasteners (16)
–Allen key: 10mm
–take care of the friction washers
HYDRAULIC HOSE ADAPTORS
Thoroughly clean areas con-
cerned to minimise risk of con-
taminating the hydraulic sys-
tem.
2. Remove adaptor couplings from hy-
draulic swivel head
–spanner: 32mm
Protect all hydraulic openings
with plugs or covers!
3. Lift off swivel top
–if necessary, use a bladed screw
driver to evenly lift up edge
Swivel bearing
4. Lift off swivel ring
5. Reassembling, apply a thin coat of grease
to all contact surfaces of swivel parts.
Replace brass rings if worn
- use heat gun and Allen key: 3mm
- tightening torque: 5Nm
REASSEMBLING
Reverse the above steps.
10mm
×2 32mm
86Nm
3mm
5 Nm

7 Main an hy raulic swivel
16 DCR 100
Hy raulic swivel
The hydraulic swivel comprises the visible
male unit, which rotates inside the female
unit.
Preparations
Remove swivel top, following step 1—3 on
previous page.
Disassembling
Thoroughly clean areas con-
cerned to minimise risk of
contaminating the hydraulic
system.
1. Remove the hydraulic swivel fastening
ring (a)
•Remove all ring fasteners (9)
–Allen key: 7mm
–take care of the friction washers
Reassembling, apply thread-locking
compound T1
2. Remove swivel and swivel washer
(b) lift out the hydraulic swivel
Channels:
P=Pressure, T=Tank, G=Grease
(c) two swivel seals may be removed by
means of a pick-tool
(d) take care of the swivel washer
Protect all hydraulic openings
with plugs or covers!
REASSEMBLING
Reverse the above steps.
47Nm
7mm

Hy raulic manifol 8
8.Hy raulic manifol
DCR 100 17
10mm
22mm
DISMANTLING
Preparations
Remove main swivel as described in previ-
ous chapter.
Swivel—cylin er frame
Use heat gun to soften thread-locking com-
pound.
1. Remove all fasteners from either side:
(a) 12 bolts with friction washers (6 on
either side)
–socket wrench: 22mm
Reassembling, apply hydraulic thread-locking
compound T1 to all 12 fasteners.
HYDRAULIC MANIFOLD VALVE
Thoroughly clean areas con-
cerned to prevent contaminat-
ing the hydraulic system.
2. Remove the valve (c)
–be prepared to collect spill of hy-
draulic fluid
–socket: 27mm
–check O-ring – change if defect
3. Remove the swivel—cylinder frame
–use a mallet to evenly knock off
4. Lift off swivel—cylinder frame
–cover valve opening
Hy raulic manifol
Thoroughly clean areas con-
cerned to prevent contaminat-
ing the hydraulic system.
. Remove all corner fasteners (4)
–Allen wrench: 6mm
6. Lift off hydraulic manifold
–cover all hydraulic openings
–check condition of O-rings,
change if defect.
7. Manifold & hydraulic swivel
–remove hydraulic swivel as de-
scribed in previous chapter
REASSEMBLING
Reverse the above steps.
27mm
×4 6mm
140Nm
50Nm
24Nm