Husqvarna DSS 200 User Manual Download

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GB

v1.0

Workshop manual

DSS 200

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Summary of Contents for DSS 200

Page 1: ...GB v1 0 Workshop manual DSS 200 ...

Page 2: ...115 62 70 26 ...

Page 3: ...tional 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 Orbital motor and housing 20 Swivel flanges 21 Orbital motor housing seal 21 Orbital motor service 22 10 Hydrau...

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Page 5: ...ase 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 befo...

Page 6: ... Tightening torque Torque for occurring metric fasteners Coarse pitch threads SS ISO 8981 1 rating Type 8 8 Nm 10 9 Nm 12 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 lubricant...

Page 7: ...enance 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 risk of tool 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 cau...

Page 8: ...pply copper based anti seize high temperature lubrication see Tools section LUBRICATING GREASE Apply lubrication of recommended quality see Tools section SCREWS OR FASTENERS EXAMPLE Quantity 4 Suitable tool Allen wrench size 2 5mm 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 a...

Page 9: ...act surfaces 2 8 Jaws to outer high load plates contact surfaces 2 Maintenance guide Item Check interval Service action Grease lubrication 10 hrs or after washing Add grease to all grease nipples see Grease nipples overview below 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 ...

Page 10: ...d 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...

Page 11: ... 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 hydra...

Page 12: ...ds 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 be sealed with brush solvent and compressed air as in step I above...

Page 13: ...draulic rotation in both 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 object to be cut steel tubes rods etc II As jaws close object is drawn in wards for incre...

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Page 15: ...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 be removed in order to remove both cutting jaws 17 mm Allen wrench...

Page 16: ... use circlip pliers 9 Knock jaw pin through use mallet and a drift pin be 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 t...

Page 17: ...a feas ible position Procedure Use a heat gun to help breaking 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 e2 unscrew each pair of fasteners use a 6 mm Allen wrench REASSEMBLING EDGE PIECES Simply reverse the above steps 1 3 Use...

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Page 19: ...r cylinder replacement its base must be dismantled as in chapter 9 10 REMOVING CYLINDER LATCH 1 Remove 2 nuts with washers 19mm socket key take care of nuts and washers 2 Loosen the two latch bolts 8mm Allen wrench unscrew bolts until cylinder latch can be removed 3 Prepare to collect spill a position shears cylinder unit slightly upwards as illustrated b place a spill vessel underneath 4 Unscrew ...

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Page 21: ...nter clockwise direction 3 Unscrew cylinder rod head rotate manually in counter clockwise direction knock head loose in counter clockwise direction 4 Remove cylinder rod head Reassembling add thread locking compound T1 medium to rod head threads 5 Remove piston head gasket use an O ring picker 6 Remove cylinder rod with piston use a steel rod and a mallet knock cylinder rod through bar rel tube 7 ...

Page 22: ...ring linear motion bearing II rod wiper 10 Cylinder piston and rod 11 Cylinder barrel interior 12 Cylinder piston internal gland use an O ring picker for removal of a U cup ring b O ring 13 Cylinder piston external gland use an O ring picker for removal of c U cup ring d O ring REASSEMBLING Simply reverse the above steps ...

Page 23: ...rs Tightening torque 89 Nm 3 Place shearer unit on a sturdy work bench 4 Remove shearer cylinder hydraulic couplings II stabilise shearer unit by means of a piece of wood use two spanners 30 and 27 mm plug hydraulic openings REMOVING ADAPTOR PLATE 5 Remove centre round headed fasten er use hot air gun to loosen thread locking compound Allen key 8mm Reassembling use thread locking compound T1 Mediu...

Page 24: ...ixation plate Orbital motor and housing 1 Remove motor fasteners Allen key 6mm Reassembling use thread locking compound T1 Medium to fasteners Tightening torque 24 Nm 2 Remove motor housing Reassembling check alignment groves a 3 Mark and lift off orbital motor a motor housing alignment groves Use marker to mark b motor position to internal flange c external flange position to cylinder support d O...

Page 25: ...lange marking as in step 3b above Swivel flanges Preparations see previous steps 3 4 5 Remove swivel flanges f exterior swivel flange g interior swivel flange Reassembling Lubricate contact surfaces with grease G Align flange markings see step 4d above Orbital motor housing seal 6 Replacing O ring The O ring serves as means to protect roller bearing from water entering through the swivel head fixa...

Page 26: ...just relief pressure by means of a 4mm Allen wrench clockwise for higher relief pres sure counter clockwise for lower relief pressure b3 Remove relief valve by means of a 14mm socket wrench 2 Dismantling sequence valve block c Clean thoroughly before disassembling remove hollow fasteners by means of a 22mm spanner DISASSEMBLING SEQUENCE VALVE PISTON d sequence valve comprising I valve pin II valve...

Page 27: ...g flange II take care of radial shaft seal replace if worn or damaged III remove needle bearing with sup port washers one on either side 3 Gently pull out swivel piston 4 Swivel female unit hydraulic fluid openings and groves hydraulic fluid pressure hydraulic fluid return G grease flow from head nipple 5 Swivel male unit hydraulic fluid openings grease openings and groves 6 Principles for flow of...

Page 28: ...LANDS 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 hydraulic channels O rings 2 grease channel O ring c Remove piston head pins use pliers grasp pin end and pull straight out ...

Page 29: ...kage or contamination of hydraulic sys tem Centre nut socket Art No 587 35 71 01 Fit to shape 55 mm Centre shearer bolt nut for use with 24mm socket wrench Recommended tools not supplied Absorbents Absorbent sheets to collect spill from hydraulic fluid WRENCH TOOLS AND SPANNERS Workshop wrenches bits Allen 4 6 8 10 17 mm Occurring fasteners 8mm Low 30mm Spanners sockets Hexagonal 10 19 22 27 30 mm...

Page 30: ... out shafts and pins Shackles Two shackles to secure sling to ad aptor plate 2 GREASE AND COMPOUNDS Retaining compound e g Loctite 638 High strength axial radial retainer Anti seize Copper paste Lubrication of cylinder rod gland threads inside barrel Thread locking compound Occurring types T1 medium e g Loctite M243 T2 medium hydraulics e g Loc tite 638 T3 hard e g Loctite 278 Grease gun gun for a...

Page 31: ...Hydraulic diagrams 12 12 Hydraulic diagrams 27 ...

Page 32: ...Endoc AB www husqvarnacp com 115 62 70 26 English 2014 06 ...

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