Husqvarna DSS 200 Instruction manual

GB
v1.0
Workshop manual
DSS 200

115 62 70 - 26

1. Introduction 1
Workshop Manual 1
Spare parts 1
General specifications 2
Mountings & Tightening torque 2
Service rules 2
2. Safety & symbols 3
General precautions 3
Occurring sym ols in the manual 4
3. Checks Troubleshooting Specifications 5
Maintenance guide 5
Trou leshooting guide 6
4. Common service tasks 7
Handling with hoist 7
Hydraulic lines/couplings 7
Reassem ling 8
5. Functional overview 9
Basic functional components 9
6. Dismantling shear house and jaws 11
Dismantling cutter house 11
Dismantling jaws and links 12
Shear house parts and jaws 13
Remove edge piece (×4) 13
7. Dismantling mounted cylinder 15
8. Cylinder service 17
9. Hydraulic swivel & Orbital motor 19
Or ital motor and housing 20
Swivel flanges 21
Or ital motor housing seal 21
Or ital motor service 22
10. Hydraulic swivel piston 23
Dismantling swivel piston 23
11. Tools 25
Service tools – supplied 25
Recommended tools – not supplied 25
12. Hydraulic diagrams 27
HUSQVARNA
DSS 200
Page
CONTENTS

Introduction
.Introduction
1
Spare parts
SPARE PARTS DSS 200
Please refer to the shearer's type plate to order
the correct spare parts.
Accessory spare parts for DSS 200 are part of
the latest tool IPL, availa le from the EPC (Elec-
tronic Parts Catalogue).
All components of the IPLs are illustrated in
exploded views, where each component's posi-
tion, spare part num er and appearance can e
easily identified. The EPC is availa le from the
Husqvarna support site.
Workshop Manual
The Workshop Manual includes virtually all rel-
evant workshop procedures on the DSS 200.
Some very simple and self-evident repairs have
een omitted.
In case of dou t on asic handling of these
DXR Shearers, please refer to the Operator's
manuals.
OUTLINE
The manual descri es dismantling and reas-
sem ling of various components through the
different chapters.
This means that as a mechanic, at least until
you are familiar with the asic composition of
the machine, you need to start with some earlier
chapters to allow for access to the service items
concerned. Each chapter egins with suggested
preparations efore 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 tool.
CONTENTS
The manual is divided into num ered chapters
with chapter headings that are stated in old at
the top of each page.
The list of contents has chapter references as
well as page references for relevant su titles.
DSS200
DSS200 , 2013-10 ,

Introduction
2
General specifications
Feature Data
Model DSS 200
Suita le carrier DXR 140 DXR 250, 270 DXR 300, 310
Hydraulic system
Shear
cylinder:
incoming
pressure,
ar (psi)
250 (3626)
flow, l/m
(galus/min) 0—52 (0—13.7) 0—65 (0—17.2) 0—75 (0—19.8)
Or ital
motor:
incoming
pressure,
ar (psi) 200 (2900)
flow, l/m
(galus/min) 1.75—8 (0.46—2.11)
Dimensions
Height, mm (inch) 1019 (40 1/8)
Height with adapter
plate, mm (inch) 1212 (47 23⁄32)
Weight with adapter
plate and hoses, kg (l ) 185 (407)
Width, mm (inch) 330 (13)
Max. jaw opening
( etween tips), mm
(inch)
200 (7.9)
Performance
Jaw depth, mm (inch) 158 (6 7/32)
Closing time, (capa-
city) s 2.5 2.0 1.75
Opening time, (capa-
city) s 1.9 1.5 1.3
Max. rod cutting
power,
kN (tonUS)841 (85.7)
Max. jaw power (jaw
centre), kN (tonUS)490 (50)
Or ital motor
Relief valves Start opening y 180—190 ar
Fully opened y 210 ar
Or ital speed (rpm) 24 ±2
Hydraulic flow (l/m
(galus/min)1.75—8 l/m ±0.5 (0.46—2.11 ±0.13)
Continuous hydraulic
rotation 360°
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]
M5 5,7 8,1 9,7
M6 9,8 14 17
M8 24 33 40
M10 47 65 79
M12 81 114 136
M16 197 277 333
M20 385 541 649
Service rules
To ensure quality and consistency of Husqvarna
workshop service, please follow these rules:
1. Use genuine Husqvarna or Husqvarna re-
commended parts and lu ricants or their
equivalents. Parts that do not meat
Husqvarna's design specifications may
cause damage or performance issues.
2. Use recommended or special tools designed
for this product to avoid damage and incor-
rect assem ly.
3. Install new gaskets, O-rings, cotter-pins and
lock plates when reassem ling.
4. When tightening olts or nuts; egin with
the larger diameter or inner olts first.
Then tighten to the specified torque evenly,
using a diagonal pattern in incremental
steps, unless a particular sequence is spe-
cified.
5. Clean parts in cleaning solvent upon disas-
sem ly. Lu ricate any sliding surfaces e-
fore reassem ly using y Husqvarna recom-
mended lu ricant.
6. After reassem ly, check all parts for proper
installation and operation.

Safety & symbols 2
.Safety & symbols
3
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 asic service and
maintenance, which is important in order to keep the machine safe and relia le.
WARNING
•This sym ol indicates that hazardous safety risks to persons must e avoided.
•This sym ol indicates risk of tool damage should e avoided.
WEIGHT
•This indicates that risky weights are to e considered. Take proper precaution!
HIGH PRESSURE
•This sym ol indicates risk of spray from high pressure hydraulic fluid. Take pre-
cautions and wear protection.

2 Safety & symbols
4
Occurring symbols in the manual
Several graphical sym ols occur in the manual to indicate standard actions to e
taken, thus reducing the need to read through too much text.
HEAT REQUIRED
•Heat o ject concerned y means of e.g. a hot air gun to:
–loosen thread-locking compound
–expand o ject which fits tightly around another o ject
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 earings, shafts, cylindrical parts (see Tools
section).
ANTI-SEIZE COPPER PASTE
•Apply copper ased anti-seize high temperature lu rication, (see Tools section).
LUBRICATING GREASE
•Apply lu rication of recommended quality, (see Tools section).
SCREWS OR FASTENERS (EXAMPLE)
•Quantity: 4
•Suita le tool: Allen wrench, size 2,5mm
KEEP MACHINE AND WORK AREA TIDY
•Prior to service; thoroughly clean areas concerned
•Remove dirty grease and lu ricants
•Wipe clean with suita le solvent or cleaning agent and use compressed air to re-
move any dust or de ris
SPILL OF FLUIDS
•Keep vessels and a sor ent sheets at hand.
COVER OPENINGS
•Protect exposed hydraulic parts from contamination.
•Cover opening wit plastic caps or wrap area in plastic ag.
Chemical su stances
When performing service
tasks involving the use of
chemical su stances (such
as lu ricants or retainer
compounds), please refer to
the instructions from the
manufacturer.

Checks/Troubleshooting/Specifications 3
3.Checks/Troubleshooting/Specifications
5
GREASE NIPPLES
Apply to all shearers nipples every 10
hours:
•use a grease gun to apply lithium loaded
grease (see Tools chapter) through all
nipples as illustrated elow
Preparations
•Position machine with shearers at a con-
venient working height
•Fully close shearers jaws
Lubrication of:
1. Hydraulic swivel
2. Contact surfaces of or ital flanges
3. Shafts through cylinder head (×2)
4. Shafts through links and shearer jaws
(×2)
5. Jaws pivoting shaft
6. Cylinder head slide plates (×2)
7. Jaws to centre of high load plates con-
tact surfaces (×2)
8. Jaws to outer high load plates contact
surfaces (×2)
Maintenance guide
Item Check interval Service action
Grease
lu rication
10 hrs
or after washing
Add grease to all grease nipples (see Grease nipples overview
elow). Intense shearing requires shorter grease intervals.
Wear and
damage 10 hrs
Ocular check for hydraulic leakage: If leakage occur, refer to
Troubleshooting guide on next page.
Ocular check of high load plate olts (a).
I. Replace if damaged, II. Check with torque wrench if signs of
eing not fully tightened (position mark not aligned).
Jaw edges
10 hrs Ocular check of jaw edges ( ): Replace if lunt or damaged
(Make sure not to use shearers on concrete or hardened steel).
When a jaw edge is
to e replaced
Check condition of cylinder head slide plates (c): Replace slide
plate if worn.

3 Checks/Troubleshooting/Specifications
6
Troubleshooting guide
Fault Pro a le cause Check / Solution Reference
Steel shears
Low cutting
performance
Insufficient hydraulic
flow and/or pressure
Check all connections required for correct opera-
tion and quick couplings. DXR Workshop manual
Check that correct tool is selected in work mode
of the DXR remote terminal: “Steel shear”
Owner's manual of DXR ma-
chine
Check DXR machine max. flow and pressure. DXR Workshop manual
Hydraulic system does
not reach maximum
pressure (250 ar)
Check DXR machine max. flow and pressure. DXR Workshop manual
Replace glands and O-ring seals of hydraulic swiv-
el piston. Chapter 9 & 10
Replace glands, O-ring seals and gaskets of shear
cylinder. Chapter 8
Damaged jaw edges due
to cutting of inexpedient
materials
Replace jaw edges and check that suita le materi-
als are eing cut. Chapter 6
The shears do
not open or
close
No hydraulic flow
and/or pressure Check DXR machine max. flow and pressure.
DXR Workshop manual
Jammed/contaminated
quick couplings Check/clean quick couplings
Jaw – distor-
tion, discolour-
ation vi rations
Insufficient lu rication Check/clean grease nipples, grease channels and
groves Chapter 3 & 6
Shear rotor
Low rotating
performance
Insufficient hydraulic
flow and/or pressure
Check all connections required for correct opera-
tion and quick couplings.
DXR Workshop manual/Ex-
tra hydraulic function manual
Check DXR machine max. flow and pressure. DXR Workshop manual
Check that extra function 1/2 is selected in ser-
vice menu Owner's manual of DXR ma-
chine/Extra hydraulic func-
tion manual
Adjust max flow for extra function 1/2 in service
menu
Hydraulic system does
not reach maximum
pressure (200 ar)
Check DXR machine max. flow and pressure. DXR Workshop manual
Adjust max pressure for extra function 1/2 in ser-
vice menu
Owner's manual of DXR ma-
chine/Extra hydraulic func-
tion manual
Malfunctioning or ital
motor relief valve(s)
Check and adjust relief pressure. Clean and
check free movement of valve piston(s). Chapter 9
Sequence valve piston is
stuck
Dismantle sequence valve piston and springs and
clean or replace sequence valve lock if damaged.
Jammed/damaged swiv-
el piston roller earing
Dismantle swivel piston and check free move-
ment of earing, clean and replace when needed. Chapter 10
Common
Vi rations Loose or missing screws
or olts
Check the tightening torque of the screws or
olts.
Replace the missing screws.
Joystick control
have reversed
functions
Delivery line inter-
changed with return
line
Swap to correct hose for delivery (P) and return
(T) connections
External oil
leaks
Loose connector Tighten loose fittings
Damaged hose Replace damaged hoses Chapter 4
Damaged coupling Replace damaged couplings

Common service tasks 4
4.Common service tasks
7
Handling with hoist
Many service tasks are facilitated y means
of a hoist pulley device (see chapter Tools).
1. Secure the shearer unit to hoist y
means of a sling:
•attach with two shackles to frame of
adaptor plate
•hoist to vertical position:
–sta ilise unit y slightly resting
jaw(s) on e.g. a wooden piece
•a vertical position facilitate good
reach from oth sides:
–shafts of jaws and cylinders
–interior service
Hydraulic lines/couplings
Preparation
Make sure hydraulic coupling
areas are absolutely clean be-
fore opening!
•Take care of the spill; put a vessel or an
a sor ent 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
y plugging or covering all
openings*):
(a) a tight fit plastic hat
( ) a nylon plug
Maintaining hydraulic operation
4. Use a metal PO-plug*) (c) when
maintaining opera ility of the
hydraulic system is desired.
Reassembling threaded couplings
5. 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 a ove.
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
*) See Tools section of Workshop Manual

4 Common service tasks
Reassem ling
8
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
Cleaning & lubrication
•Clean with a neutral detergent and dry
thoroughly afterwards
•Add grease to all nipples (see previous
chapter)
•Apply a thin film of grease to protect
cleaned surfaces
Thread-locking and
retainer compound
Clean surface to e sealed with rush,
solvent and compressed air as in step I.
a ove.
III. Apply the recommended sealant:
•Thread-locking compound:
–T1, T or T3
•Retainer compound:
–R

Functional overview 5
5.Functional overview
9
DSS 200
Basic functional
components
A) Hydraulic connections to demolition
robot:
I. hydraulic steel shears cylinder (D)
with max. pressure (250 ar)
II. hydraulic or ital motor (B) with
normal pressure (200 ar)
B) Hydraulic orbital motor
•Hydraulic flow: 1.75—8 l/minute
–min. flow limitation eliminates
risk of jerky movement
–two relief valves ensure that
or ital motor will not get over-
loaded
–a sequence valve will alance a i-
directional flow through the
or ital motor
C) Swivel
•Continuous hydraulic rotation in
oth directions (±360°)
D) Shears cylinder
•Pulls links to open shear jaws
•Pushes links to close shear jaws
•Hydraulic flow:
–DXR 140: 0—52 l/minute
–DXR 250—270: 0—65 l/minute
–DXR 300—310: 0—75 l/minute
E) Shears links
•Linking cylinder force to shears jaws
F) Shear jaws
I. Open jaws when positioning over
o ject to e cut; steel tu es, rods etc.
II. As jaws close, o ject is drawn in-
wards for increased force
III. Jaw edges meet with high leverage
and a clean cut
CAPACITY
Steel
section
Max dimensions
mm (inch)
beam
IPE 120 120×64 (423⁄32×233⁄64)
square
bar 30×30 (1316×1316)
tube 75×5
(261⁄64×13⁄64)
rebar*)Ø 25 (63⁄64)
square
tube 60×60×5 (223⁄64×223⁄64 ×13⁄64)
channel tube
UPE 100 55×100 (211⁄64×315⁄16)
*) max. quality steel: 500 MPa 75 ksi

Dismantling shear house and jaws 6
6.Dismantling shear house and jaws
11
. PREPARATIONS
•Position hydraulic shears vertically with
oom—stick structurally secured.
•Shears jaws fully opened.
Dismantling cutter house
. Remove cover plates
(a) Remove 16 fasteners (8 each a1&a2)
–10 mm socket wrench
3. Remove centre pin nut (b)
•heat nut to melt thread-locking com-
pound
•use special tool 55mm “Centre nut
socket” (b1)
–use in conjunction with a 24mm
socket wrench
•Reassembling:
–Add Thread-locking compound T3 to
nut threads.
–After tightening to torque (140 Nm),
mark nut position as means for ocu-
lar service control.
4. Remove high load plate
Both side plates have to e removed in
order to remove oth cutting jaws.
•17 mm Allen wrench, 3/4”
5. Lift off high load plate
Continue dismantling on next page...
10 mm
×2 17mm
3 4”
380 Nm
24 mm
26 Nm
140 Nm
×16

6 Dismantling shear house and jaws
12
6. Remove centre pin (c)
•knock pin y 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
•apply step 4—5 to remaining plate
Dismantling jaws and links
Links (f) etween cylinder head and
each jaw is joined y two shafts (d)
each.
8. Remove jaw pin circlip
Jaw pin (d)
•use circlip pliers
9. Knock jaw pin through
•use mallet and a drift pin
–e careful with centre grease
nipple
10. Pull out jaw pin
•catch shear jaw (e)
•pull out jaw pin (d)
Reassembling: Apply grease (G) to pin
•apply step 8—10 for second jaw
11. Remove link (f)
•use principle of step 8—10
•catch link (f)
•remove remaining link
•slide surface of cylinder head (g)
Reassembling: Apply grease (G) to contact sur-
faces. Ensure that wedge shape of link mid sec-
tion is pointing inwards with flat side upwards.
REASSEMBLING
Apply grease (G) to all moving parts prior
to assem ling. Assem le parts y reversing
the a ove steps.

Dismantling shear house and jaws 6
13
Shear house parts and
jaws
Prior to assembling; apply grease (G) to all
contact surfaces.
JAW/LINK PIN (×4)
Each pin (d) is secured y means of a
circlip
(d1) grease nipple
(d2) grease channel/grove
LINK (×2)
(f) grove for pin head on one side
SHEAR JAW (×2)
(e) replace jaw edge if lunt or roken
e1: outer edge piece with wedge
e : inner edge piece
Remove edge piece (×4)
PREPARATIONS
This can e done without any previous dis-
mantling. Open and position jaws in a feas-
i le position.
Procedure
Use a heat gun to help reaking the thread-
locking compound.
1. e1 outer edge piece:
•loosen the two fasteners
–use a 6mm Allen wrench
2. Remove the wedge
•unscrew the wedge fasteners
–use a 4mm Allen wrench
3. Remove the outer and inner edge
pieces (e1 and e )
•unscrew each pair of fasteners
–use a 6 mm Allen wrench
REASSEMBLING EDGE PIECES
Simply reverse the a ove steps 1—3.
Use a thread-locking compound as indic-
ated in the illustrations.
HIGH LOAD PLATE (×2)
This takes the structural shear loads and
supports cylinder head movement
(h) cylinder head slide plate with fasten-
ers
(i) grease nipple with grease channel
×3 6 mm
9 Nm
×4 6 mm
×2 6 mm
×1 4 mm
24 Nm
6 Nm

Dismantling mounted cylinder 7
7.Dismantling mounted cylinder
15
PREPARATIONS
•Remove shear house, jaws and links as in
previous chapter.
•Position shears unit vertically down-
wards at a convenient hight optionally:
–attached to oom—stick in a
structurally secured manner
–or, hanging y a strap and pulley
system
•Carefully clean shearers ody to minim-
ise risk of contaminating hydraulic sys-
tem.
Dismantling
This chapter prepares for cylinder service
(chapter 8). For cylinder replacement, its
ase must e dismantled as in chapter 9—
10.
REMOVING CYLINDER LATCH
1. Remove × nuts with washers
•19mm socket key
–take care of nuts and washers
. Loosen the two latch bolts
•8mm Allen wrench
–unscrew olts until cylinder latch
can e removed
3. Prepare to collect spill
(a) position shears cylinder unit slightly
upwards, as illustrated
( ) place a spill vessel underneath
4. Unscrew cylinder barrel
•unscrew until hydraulic fluid is
pouring out in a controlled manner
5. Lift off empty cylinder barrel
For cylinder service – see next chapter.
REASSEMBLING
Apply copper paste (Cu) to barrel threads.
Otherwise, reverse the a ove steps.
×2 8mm
19mm
77 Nm