Bosch Rexroth Hagglunds DUc LS2 Installation & Maintenance Manual Download Page 3

Page: 3 / 88

RE 15326-WA, Version 06.2020, Bosch Rexroth AB

Hägglunds DUc Drive unit 3/88

Contents

This documentation ................................................................................... 5

1.1  Validity of the documentation ........................................................................5
1.2  Required and additional documentations ......................................................5
1.3  Presentation of information ...........................................................................5

Safety instructions .................................................................................... 7

2.1  About this chapter .........................................................................................7
2.2  Intended use..................................................................................................7
2.3  Improper use .................................................................................................8

2.4 Personnel qualifications

................................................................................8

2.5 General safety instructions ............................................................................9

2.6 Product-specific safety instructions

.............................................................10

2.7 Personal protective equipment ....................................................................12

General notes regarding property damages and product damages ........... 13

Scope of delivery ..................................................................................... 15

About this product ................................................................................... 15

5.1 Product description .....................................................................................15

5.2 Product identification

..................................................................................15

5.3 Main components ........................................................................................16

5.4 Hydraulic fluids

...........................................................................................22

5.5 Requirements for hydraulic fluid cleanliness

...............................................23

5.6 Cooling water .............................................................................................24
5.7 Drive Unit monitoring ..................................................................................25

Transport and storage .............................................................................. 26

6.1 Storage of the packed Drive Unit

...............................................................26

6.2 Lifting the packed Drive Unit .......................................................................27

7 Installation .............................................................................................. 28

8 Commissioning ........................................................................................ 55

8.1 Before commissioning .................................................................................55

8.2 Filling up the system with hydraulic fluid

....................................................55

8.3  Flushing before start up ..............................................................................58
8.4  Initial start up procedure .............................................................................59
8.5  Pump settings and adjustments ...................................................................61

Summary of Contents for Rexroth Hagglunds DUc LS2

Page 1: ...RE 15326 WA Version 06 2020 Replaces 09 2019 EN Installation Maintenance manual Hägglunds DUc Drive unit ...

Page 2: ...formation set forth in it are the exclusive property of Bosch Rexroth AG It may not be reproduced or given to third parties without its consent Changes in the equipment may occur We therefore reserve the right to introduce amendments in the manual as we deem necessary without notice or obligations This Installation and maintenance manual is valid for Drive Units manufactured after 01 03 2019 For o...

Page 3: ...ydraulic fluids 22 5 5 Requirements for hydraulic fluid cleanliness 23 5 6 Cooling water 24 5 7 Drive Unit monitoring 25 6 Transport and storage 26 6 1 Storage of the packed Drive Unit 26 6 2 Lifting the packed Drive Unit 27 7 Installation 28 7 1 Installation directives 28 7 2 Lifting methods 28 7 3 Positioning the Drive Unit 31 7 4 Mounting of the cabinet feet 33 7 5 Mounting of main electric mot...

Page 4: ...spection of hydraulic fluid 69 9 5 Air filter breather change 70 9 6 Electric motor 71 9 7 Cooler 73 9 8 Drive Unit out of service 75 9 9 Repair 76 9 10 Spare parts 77 10 Removal and replacement 78 10 1 Common 78 11 Disposal 79 11 1 Environmental protection 79 12 Extension and conversion 79 13 Troubleshooting 80 14 Technical data 84 14 1 Weights 84 15 Declaration of Incorporation 86 ...

Page 5: ... have received and fully understood the documentations identified by the book symbol and observe the instructions included in these documentations Table 1 Necessary and supplementary documentation Title Document no Document type Order confirmation Order specific Order confirmation Order documentation Order specific E g hydraulic and electric diagrams bill of material specifications Hägglunds Spide...

Page 6: ... Risk categories to ANSI Z535 6 2006 Warning sign signal word Meaning DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury WARNING Indicates a hazardous situation which if not avoided could result in death or serious injury CAUTION Indicates a hazardous situation which if not avoided could result in minor or moderate injury NOTICE Indicates potential p...

Page 7: ... EC A partly completed machinery is exclusively intended to form an incomplete or a complete machine together with other components or partly completed machineries The Drive Unit may only be commissioned after it has been installed in the machine system for which it is intended and the safety of the entire system has been established in accordance with the machine directive Intended use includes h...

Page 8: ...sic mechanical electrical and hydraulic knowledge as well as knowledge of the associated technical terms For transporting and handling the product additional knowledge is necessary with regard to working with a lifting device and the corresponding attachment equipment In order to ensure safe use these activities may therefore only be carried out by appropriate qualified personnel or an instructed ...

Page 9: ...ely accessories and spare parts explicitly approved by the manufacturer to avoid accidents due to improper accessories and spare parts Strictly observe the technical data and ambient conditions specified in the product documentation Inadequate products installed or used for safety relevant applications may produce unintended operating behavior and result in product or property damage For this reas...

Page 10: ...rotective goggles safety gloves suitable working clothes safety shoes Use suitable lifting device for transport and storage installation and for removal and repair Make sure the electric motor is well mounted or anchored when the lifting device is disconnected Observe the prescribed position of the lifting strap Observe the national laws and regulations on work and health protection and transporta...

Page 11: ...ations and domestic laws for work on heavy current equipment The operation maintenance and or repair of such equipment is reserved to skilled personnel qualified to work on or with electrical equipment Prior to switching the equipment on always check the protective earth conductor for reliable connection to all electrical equipment according to the connection diagram Exclusively run the component ...

Page 12: ... observe the safety instructions provided by the lubricant manufacturer Use your personal protective equipment e g protective goggles safety gloves suitable working clothes safety shoes If hydraulic fluid should nevertheless come into contact with your eyes or bloodstream or is swallowed consult a doctor immediately Escaping hydraulic fluid due to machine system leakage Risk of burns and risk of i...

Page 13: ...lectro welding on the Hägglunds Drive Unit Damage to equipment due to improper lubrication Product can be damaged or destroyed Never operate the Hägglunds Drive Unit with insufficient hydraulic fluid When commissioning a machine system make sure that the case interior and the service lines of the Hägglunds motor are filled with hydraulic fluid and remain filled during operation Mixing of hydraulic...

Page 14: ...ing Product can be damaged Plug all openings with the appropriate protective equipment in order to prevent detergents from entering the hydraulic system Never use solvents or aggressive detergents Use only water and if necessary a mild detergent to clean the Hägglunds Drive Unit Never use a high pressure washing system to clean inside the Drive Unit For outside washing do not point the power washe...

Page 15: ... The standard control system to the Drive Unit is Hägglunds Spider a small compact and configurable control system It can health monitor the Drive Unit and can control the pumps with a high variation of pre programmed functions The Drive Unit is a very flexible product with a wide option range This makes it possible to select a standard Drive Unit to fulfil the features needed in many different ap...

Page 16: ...2 LT2 8 Oil heater optional not shown Fig 7 9 Oil cooler Fig 6 10 Oil tank Fig 7 11 Flushing or and brake circuits optional not shown 12 Filter 13 Charge filter optional not shown 14 Accumualator optional 15 Light optional not shown 16 Pressure sensors 17 Hoses internal not shown 5 3 Main components Note Changes from the picture and the components may occur Fig 2 Main components DUc MS2 LS2 1 2 6 ...

Page 17: ...h AB Scope of delivery Hägglunds DUc Drive unit 17 88 Fig 3 Main components DUc MT2 LT2 1 2 7 3 14 4 12 10 9 Product identification Oil filling point DD00098769 6 16 Accumulator filling point Thread size 305 32 UNS male Drain tap 1 BSP Female ...

Page 18: ...rol panel at front panel door on DUc LT3 8 Oil heater optional not shown Fig 7 9 Oil cooler Fig 6 10 Oil tank Fig 7 11 Flushing or and brake circuits optional not shown 12 Filter 13 Charge filter optional not shown 14 Accumualator optional 15 Light optional not shown 16 Pressure sensors 17 Hoses internal not shown Fig 4 Main components DUc LS3 1 6 7 3 14 16 4 10 9 Product identification Oil fillin...

Page 19: ...oth AB Scope of delivery Hägglunds DUc Drive unit 19 88 Fig 5 Main components DUc LT3 1 2 6 3 14 4 10 9 Product identification Oil filling point DD00103963 7 16 12 Accumulator filling point Thread size 305 32 UNS male Drain tap 1 BSP Female ...

Page 20: ...unds DUc Drive unit Scope of delivery Bosch Rexroth AB Version 06 2020 RE 15326 WA Fig 6 Oil cooler alternatives Item Description 1 Air oil cooler 2 Water oil plate cooler 3 Water oil tube cooler 1 2 3 DD00098770 ...

Page 21: ... unit 21 88 Item Description 1 Oil level gauge 2 Oil drain valve 3 Level and temperature sensor 4 Air filter breather for tank bladder optional 5 Air filter breather 6 Suction valve 7 Oil heater optional 8 Tank bladder optional 3 2 1 5 4 6 DD00098772 Fig 7 Detailed view tank DUc 7 8 ...

Page 22: ...ousing is within optimum operation range see Fig 8 General recommendation is to have a system temperature of 50 C see dotted line in Fig 8 A VG 68 fluid will render just above 40 cSt at this point Optimum viscosity range is 40 to 150 cSt Running above 150 cSt or below 40 cSt results in reduced efficiency Running above 400 cSt results in substantial efficiency loss For pumps the maximum start up vi...

Page 23: ... it is important to fill through the dedicated oil filling connection see 8 2 Filling up the system with hydraulic fluid For industrial applications the contamination level should not exceed ISO 4406 1999 18 16 13 Have a water content of 200 ppm 0 02 Always use filter elements recommended and supplied by Bosch Rexroth The hydraulic fluid should be analysed according to the maximum intervals on the...

Page 24: ...en the stainless steel connections and water piping If the Drive Unit is equipped with rubber feets flexible hoses are recommended between water connections and water piping It is important to Maintain the water filter if any in a correct way to get the required flow of water through the water oil cooler Check the temperature in the hydraulic system regulary Clean the cooling system if the tempera...

Page 25: ...ing indication is to give an indication about a problem in the Drive Unit that does not need an immediate action The alarm indicates a need for stopping the pump The stop sequence is to first stop the hydraulic motor by setting the pump swash angle to zero without ramp to allow the hydraulic drive to stop and after a short delay switch off the electric motor The low charge pressure indicator must ...

Page 26: ...st be opened to access the plastic hood Open the plastic hood gently to avoid damage Exchange the desiccant bags Original used type Propadry A311 absorption capacity 750 g dessicant bag Table 6 Required quantity of original desiccant bags MS2 LS2 5 pcs MT2 LT2 6 pcs LS3 8 pcs LT3 10pcs For separately delivered parts stored more than 18 months from delivery date the VCI protection can be extended O...

Page 27: ...eleration deceleration and turns while moving the goods Position the forks according to the instructions in 6 2 Lifting the packed Drive Unit section Lifting with fork lift Lifting with fork lift The lifting of drive units must be done according to Table 8 The centre of gravity has to be between the forks Table 8 Minimum required fork length Cabinet size Fork length mm in DUc MS2 MT2 long side 115...

Page 28: ...lic connections from the Drive Unit must always be fitted to the piping with hoses If air oil cooler is mounted at a location other than on the Drive Unit it must be considered that the cooler will start without notice and has sharp edges 7 2 Lifting methods Lifting with fork lift See 6 2 Lifting the packed Drive Unit section lifting with fork lift Lifting with ropes chains The Drive Unit shall be...

Page 29: ...e 4 Example 2 Weight Drive unit LT3 SP500 500 3600 kg weight without cooler and main electric motors 3600 3 assume that main load is on three of the four lifting hooks 1200 kg lifting hook A rope angle of 45 gives a safety factor above 4 Fig 13 Lifting the DUc MS2 with rope angle 60 Table 9 Max load for each lifting hook DUc Rope angle kg lb Safety factor 4 45 3 100 6 834 60 3 800 8 378 90 4 500 9...

Page 30: ...8 Hägglunds DUc Drive unit Installation Bosch Rexroth AB Version 06 2020 RE 15326 WA Fig 15 Lifting the DUc MT2 LT2 with rope angle 45 DD00099011 Fig 16 Lifting the DUc LS3 LT3 with rope angle 45 DD00103961 ...

Page 31: ...ll demand more working space It is important that all pipes both for water and hydraulics are arranged to provide sufficient working space for maintenance WARNING Unstable movement or turning over of the Drive Unit at installation of Drive Units in outdoor environment with heavy wind at inclined surfaces or in areas with risk for earthquakes Risk of injury or serious injuries The Drive Unit has to...

Page 32: ...pace around DUc Minimum space mm in A1 700 28 A2 700 28 B1 700 28 B2 1000 40 C1 600 24 D1 900 36 D2 900 36 H1 150 6 Use A2 instead of A1 when there is external flushing or brake mounted Fig 18 Recommended minimum space around DUc single pumps DD00102066 Fig 19 Recommended minimum space around DUc tandem pumps DD00097371 ...

Page 33: ...ns in 7 2 Lifting methods Use support to provent drop The cabinet feet option minimizes the vibrations and makes it easy to level the Drive Unit They are delivered separately within the cabinet and have to be mounted according to the following instructions 1 Mount the cabinet feet before filling hydraulic fluid in the tank 2 Mount the cabinet feet before the electric motor s if they are delivered ...

Page 34: ...1 Unpack the electric motor Unpack the electric motor Check the electric motor for external damage and that all rating plate data are the same as in the attached technical documentation 2 Check the shaft coupling Check that the axial shaft coupling for external damage and that the locking screw is tightened 3 Lift the electric motor Two separate lifting equipments are needed to lift the electric m...

Page 35: ...ve Unit Lift the electric motor on to the Drive Unit It is important that the electric motor is hanging vertically Fit the shaft coupling through inspection hole Fig 22 into the ring gear coupling without causing any damage Lower the motor to a position approximately 5 mm 0 2 in above the bellhousing Place screws in the holes and tighten by hand Lower the motor to the bellhousing ...

Page 36: ...8 R55 4 0 0 157 R75 5 0 0 197 R90 5 5 0 216 R100 6 0 0 236 R110 6 5 0 256 Table 12 Tightening torques of bellhousing M8 M10 M12 M16 M20 M24 Nm lb ft Nm lb ft Nm lb ft Nm lb ft Nm lb ft Nm lb ft Aluminium 12 9 23 17 40 29 100 74 190 140 Cast iron 23 17 46 34 79 58 195 144 395 291 680 502 Steel 34 25 67 49 115 85 290 214 560 413 970 715 5 Tighten screws to the bellhousing Inspect that there is an ax...

Page 37: ...ficient working space to allow maintenance of the Drive Unit Always use hoses to connect with piping All measures in the hydraulic system must be performed by professional service personnel with knowledge of risks involved Be especially accurate when connecting the A and B connections high pressure DANGER Pressurized oil leakage Danger to life or risk of injury Do not open any connections if the h...

Page 38: ...oler RF1 ISO 8434 1 22L Male ISO 8434 1 22L Male ISO 8434 1 22L Male Oil OUT flushing motor s external pump RF2 ISO 8434 1 28L Male 1 ISO 8434 1 28L Male 1 ISO 8434 1 28L Male 1 Oil OUT flushing with check valve RB1 RB2 ISO 8434 1 12L Male ISO 8434 1 12L Male ISO 8434 1 12L Male Oil OUT to brake 1 Oil OUT to brake 2 D ISO 8434 1 28L Male 1 ISO 8434 1 35L Male 1 ISO 8434 1 35L Male 1 Drain from hyd...

Page 39: ...d in delivery Torque acc to SAE J518 2 with class 10 9 or grade 8 screws Medium frame Large frame 2 comp Large frame 3 comp Function C1 ISO 8434 2 1 JIC Male ISO 8434 2 1 JIC Male ISO 8434 2 1 JIC Male Oil OUT to cooler C2 ISO 8434 2 1 JIC Male ISO 8434 2 1 JIC Male ISO 8434 2 1 JIC Male Oil IN from cooler C3 ISO 8434 2 1 JIC Male Oil OUT to cooler C4 ISO 8434 2 1 JIC Male Oil IN from cooler RF1 I...

Page 40: ... DUc Drive unit Installation Bosch Rexroth AB Version 06 2020 RE 15326 WA Fig 27 Dimensions external connection points example DUc MS2 Fig 28 Dimensions external connection points example DUc MT2 DD00098768 DD00098774 ...

Page 41: ...sion 06 2020 Bosch Rexroth AB Installation Hägglunds DUc Drive unit 41 88 Fig 29 Dimensions external connection points example DUc LS2 Fig 30 Dimensions external connection points example DUc LT2 DD00098776 DD00098777 ...

Page 42: ... DUc Drive unit Installation Bosch Rexroth AB Version 06 2020 RE 15326 WA Fig 31 Dimensions external connection points example DUc LS3 Fig 32 Dimensions external connection points example DUc LT3 DD00103956 DD00103957 ...

Page 43: ...ric connections as well as pipe work and hoses see respective section WARNING The air oil cooler coming loose from it s attachment Risk of injury or serious injury The air oil cooler has to be properly tightened to the bracket CAUTION The air oil cooler starts without warning Particles may go together with the outgoing air flow Risk of injury Disconnect electric power to the air oil cooler electri...

Page 44: ...lift the air oil cooler with lift eyes on the electric motor Mount the air oil cooler on the brackets with screws washers and nuts included in the delivery Check that all screws and nuts are properly tightened See Fig 33 x 4 C1 Fig 35 Mounting of air oil cooler step 2 Connect hydraulic hoses included in the delivery C2 Air flow HDC and BOL 16 30 DD00098789 Air flow BOL 725 2000 ...

Page 45: ...height of the cooling element dimension A since only in this way a proper air supply is ensured See Fig 36 Table 17 Recommended minimum space around air oil cooler Cooler size A mm in HDC 050 772 30 4 HDC 060 815 32 1 HDC 080 1035 40 7 HDC 085 1046 41 2 HDC 090 1356 53 4 HDC 100 1356 53 4 HDC 200 1512 59 5 BOL 16 413 16 2 BOL 30 526 20 7 BOL 400 504 19 8 BOL 725 619 24 4 BOL 950 732 28 8 BOL 1200 ...

Page 46: ... order specific Hägglunds DUc documen tation Mount the preassembled by pass kit including connectors check valve and hose according to Fig 37 Note The check valve must always be mounted at the top connection point and notice the flow direction on the check valve DD00107574 Fig 37 Mounting of air oil cooler HDC 200 with by pass ...

Page 47: ...nd cable contact 7 9 Water connection It is important that all piping to the Drive Unit is installed to provide sufficient working space for maintenance The water pipes and the cooler may need to be insulated to prevent from condensing water and from freezing in winter condition 7 10 Mounting of water oil plate cooler Dimensions and placement of water oil plate cooler see order specific Hägglunds ...

Page 48: ...l tube cooler see order specific Hägglunds DUc documentation Lift cooler assembly only in bracket frame x 4 Fig 40 Mounting of water oil tube cooler step 1 Mount cooler assembly with existing screws nuts and washers Fig 41 Mounting of water oil tube cooler step 2 Mount hoses check that all screws and nuts are properly tightened DD00098792 DD00098793 WA1 WA2 C1 C2 ...

Page 49: ...ter valve Fig 42 Mounting of water valve for tube cooler DUc LS2 LS3 step 3 Mount water valve Check that all screws and nuts are properly tightened Fig 43 Mounting of water valve for tube cooler DUc MT2 LT2 LT3 step 3 Mount water valve and strap the cable to cooler bracket Check that all screws and nuts are properly tightened ...

Page 50: ...ee from cracks and that it is saturated with oil The dirt protections on the fittings must be kept on until final assembly Flange fittings The flange screws must be tightened crosswise Tube fittings 24o cone soft seal DIN 3861 ISO 8434 4 European version Tighten the union nut with a wrench until there is a noticeable force increase Then tighten a further 30 final assembly route Use correct size of...

Page 51: ...t has to be installed and used by qualified personnel who are familiar with relevant safety requirements and domestic laws Personal protective equipment necessary for the prevention of accidents at the mounting and operating site shall be provided in accordance with the regulations prevailing in the local country Grounding shall be carried out according to local regulations before the electric equ...

Page 52: ...ation see air stream arrow in Fig 45 Air flow HDC and BOL 16 30 Star connection 3 phase 400 VAC Connection 1 phase 230 VAC L3 PE L1 L2 O PE L1 7 13 3 Water valve connection plate cooler Connect the preassembled cable connector to the water valve on the top of the drive unit only for DUc LT2 and LT3 See Fig 39 For MS2 MT2 LS2 and LS3 the plate cooler is already mounted on the drive unit within deli...

Page 53: ...on supply voltage in accordance to Fig 49 from MCC Motor Control Center Electric motor must be separatly grounded Y connection D connection Standard voltage D Standard voltage Y 380 V 50Hz 660 V 50Hz 400 V 50Hz 690 V 50Hz 415 V 50Hz 440 V 60Hz 460 V 60Hz 480 V 60Hz Fig 47 Example Siemens marking plate Fig 48 Example WEG marking plate Fig 49 D and Y connections Main voltage and connection DD0007364...

Page 54: ...nection The Hägglunds drive unit must be connected to external ground for voltage equalization The connection point of the Hägglunds drive unit is on the side of the frame to a M8 bolt Minimum required cable area for equalization connection is 10 mm2 0 016 in2 Fig 50 Connection point DD00098796 Fig 51 Connection point DD00103967 ...

Page 55: ...ressure reducing valve Cleanliness The external hydraulic system must be thoroughly cleaned on the inside Pipe work The couplings has to be securely tightened The pipe work must be properly cleaned The pipe work has to be mounted free of stress The lines has to be in accordance with installation drawing piping plan Electrical Check that electric motor s control system and other electrical componen...

Page 56: ...ig 5 Always pump the fluid in through the female quick connection included in delivery The fluid filled into the system will be filtered through the drain filter See Fig 52 The tank must be filled with oil to the nominal level before starting for the first time according to Table 19 Check the function of the level sensor and indication on the level gauge during filling up of the tank Fig 52 Oil fi...

Page 57: ...44 1 73 19 5 700 700 184 9 83 3 27 18 8 715 188 9 60 2 36 19 3 900 900 237 8 83 3 27 18 8 915 241 7 60 2 36 19 3 Warning level Alarm Stop level Volume Distance from top Signal Volume Distance from top Signal Tank model litre US gallon mm in mA litre US gallon mm in mA 130 110 29 0 175 6 89 11 7 90 23 7 266 10 47 6 5 220 175 46 2 299 11 77 9 5 160 42 2 637 25 08 6 8 300 245 64 7 230 9 06 12 2 223 5...

Page 58: ...o the drain line of the motor to enable cleaning of the flushing line Fig 54 Hydraulic circuit flushing CAUTION Wrong direction of rotation of the pump Pump will be damaged System contaminated Make sure that the pump has the correct direction of rotation The correct direction of rotation is marked with a sign placed under the electric motor see Fig 55 Direction of rotation Rotating parts Risk of i...

Page 59: ...the pump as well as any valves on drain lines are open Check that cooling water is connected and turned on if a water oil cooler is used For adjustments and settings on the control system if any see special instruction in attached order specific Hägglunds DUc documentation STEP 2 Start with unloaded pump at short intervals Starting of the Drive Unit shall be carried out with a completely unloaded ...

Page 60: ...DUc documentation These pressure levels are preset at the factory and normally not needed to readjust Check for leakage points Stop the electric motor and correct if any faults discovered on the points above Check all connections screws etc and tighten if necessary Restart when finished STEP 4 Loaded hydraulic system The hydraulic system can be loaded when the hydraulic system functions works sati...

Page 61: ...stem additional flushing is necessary in order to prevent premature failure of system components Check all connections screws etc and tighten if necessary 8 5 Pump settings and adjustments 8 5 1 Variable displacement SP pump Charge pressure level control pressure level high pressure relief valves and pressure compensator are set from factory and there is normally no need for readjustment Check alw...

Page 62: ...or pressures setting To adjust the high pressure relief valves A B ports have to be blocked and the compensator pressure level have to be adjusted down to minimum Swivel the pump to 50 stroke in A side and adjust the compensator pressure up to the requested high pressure level high pressure relief valves setting Adjust the high pressure relief valve A side down to the same level as to the recently...

Page 63: ...ve B Compensator pressure setting View A View B Fig 56 Pump SP40 SP71 Compensator pressure setting A View A Compensator pressure setting High pressure relief valve A Control pressure relief valve High pressure relief valve B Charge pressure relief valve Fig 57 Pump SP125 SP180 Fig 58 Pump SP250 SP750 SP250 SP355 SP500 SP750 DD00073836 DD00073834 DD00073838 DD00073838 DD00073842 DD00073844 DD000738...

Page 64: ...earing in mind the consequences of a breakdown To optimise the maintenance intervals economically a Life Cycle Cost LCC analysis is recommended Follow the 2 Safety instructions during the checks The panels covering the Drive Unit can be dismounted by opening the lever latches or removing the M8 nuts to simplify the access to the components inside the unit CAUTION Drop of panels Risk of injury Be t...

Page 65: ...e at specific time intervals including the following checks and actions All points under frequent checks Check all pressure levels Check for stable temperature levels around the system Drain water and sludge from the tank at the drain tap Check the electric motor Check the function of monitoring equipment switches etc Cleaning NOTICE High pressure washing Damage on equipment Never use a high press...

Page 66: ...0 working hours R Once every 3 months I Once every 6 months I I I Once every 12 months R R I Inspection R Replacement If the contamination indicator is tripped out the filter must be changed immediately and the oil examined For shock load applications i e shredders crushers etc CAUTION Rotating parts Risk of injury Do not touch rotating parts inside the inspection hole see Fig 55 Direction of rota...

Page 67: ...ng and the backup ring for damage Change parts if necessary 5 Mount the filter bowl Tighten by hand to stop and back off 1 8 th of a turn 6 Tighten the lock nut WARNING High temperature oil componets Risk of injury Do not open filters that are in operation Use suitable personal protective equipment Weight of filter bowl Risk of injury Be careful when dismounting the bowl Pressurized machine system...

Page 68: ...When empty tighten the drain plug 5 Open the lock ring for the filter bowl Unscrew the bowl from the filter housing counter clockwise and remove the bowl 6 Change filter cartridge It is very important during the mounting not to expose the cartridge to any dirt i e keep it in the plastic cover as long as possible 7 Check the O ring and the backup ring for damage Change parts if necessary 8 Mount th...

Page 69: ... analysis can indicate when an oil change is required point out shortcomings in maintenance and keep repair cost to a minimum Using oil analysis can create a window of opportunity allowing the user to schedule overhaul maintenance or repairs thus saving money on equipment repairs and downtime The most used method is to take samples in a special bottle and send it to a fluid laboratory for a analys...

Page 70: ...direction of the oil beam Let minimum 2 l 0 53 gal of oil flush into a bucket before you fill the bottle Remove the cap of the bottle as late as possible and avoid any contamination to be in touch with the cap bottle or mini mess hose when the sample is taken To get a reliable result the system must run without moving any valves and the mini mess hose should not touch the bottle Only of the bottle...

Page 71: ...ws 1 Clean the grease nipples at the drive end and non drive end 2 Press in the specified grease and amount of grease according to the data stamped on the lubrication plate Please observe the information on the rating and lubricant plates Regreasing should be carried out when the motor is running max 3600 rpm Specified lubrication intervals are valid for 40o C 104o F ambient temperature In case of...

Page 72: ...on the electric motor not are clogged by dirt and that air can pass easily 9 6 3 Draining The condensate drain holes must be opened at regular intervals depending on climatic conditions NOTICE Reduction of the degree of protection Material damage to the motor After the condensation has been drained all of the drain holes must be closed again ...

Page 73: ...fterwards flush with the fluid medium which is used later Water oil cooler plate type Back flushing with water will remove most soft deposit If fouling appears in the form of hard deposits circulate a weak acid through the cooler in reverse direction to the normal waterflow Use 5 phosphoric acid or for frequent cleaning 5 oxalic acid or similar weak organic acid Afterwards rinse with a large quant...

Page 74: ...he tube Flush the tubes with fresh water Reassembling in reverse order Be sure that the o rings are in correct position and mount the end covers in correct position End cover O ring Fig 61 Exploded view tube cooler DD00073883 Water oil cooler tube type American version The cleaning procedure shall be carried out without removing the tube stack from the body Drain the water from the cooler using th...

Page 75: ...of shut down 2 Topping up system oil If necessary system oil shall be filled before the system is shut down for the off season stop Doing so means that the oil is well cleaned trough filters before shut down and reservoir bottom silt is avoided Note When system oil is filled always use the power unit filling connection to ensure the oil to be filtered before entering the tank 3 Air bleeding To avo...

Page 76: ...nk None of these filters are cleanable and has to be changed see 9 3 and 9 5 In conjunction with changing drain line filter inspection of the same can be used to monitor status on pumps and motors If the filter surface shows high quantity of wear debris the reason for this shall be located and corrected If the debris appears grey the hydraulic motor wears extensively Yellow or bronze debris indica...

Page 77: ...ct can not be assured and you lose your warranty entitlement Recommended spare parts typical example For exact spares and order numbers see order specific documentation Commisioning startup spares Filter insert drain oil Filter insert return oil Ring gear motor pump coupling Air filter tank Air filter tank bladder Operational essential spares Proportional solenoid pump Position switch pump suction...

Page 78: ...vent dirt entering the system Disassembly shall only be done by professional service personnel Disassembly Label the parts Protect easily damaged parts and machined surfaces Inspect all parts during disassembly for wear or damage If hydraulic fluid will be drained and reused make sure that drain containers are clean and covered when not in use Clean all metal parts with a suitable solvent and set ...

Page 79: ... environment Observe the following points when disposing of the Hägglunds DUc 1 Completely empty tank and system 2 Dispose the hydraulic fluid according to the national regulations of your country Also observe the applicable safety data sheet for the hydraulic fluid 3 Remove the DUc into its individual parts and properly recycle these parts separate according to material type Dispose material in a...

Page 80: ... above fluid level 6 Return filter blocked Insufficient power and torque at the hydraulic motor pressure too low 1 Power transmission defective 2 V belt or Toothed belt slipping 3 Direction of rotation wrong 4 Motor defective 5 Key sheared at pump or motor 1 Internal leakages due to wear 2 Unsuitable type 3 Pump defective 4 End of control pressure set too low or control element defective 1 Leakage...

Page 81: ...maged valve seat 4 Broken spring 5 Unsuitable type setting too low 1 Pressure losses excessive 2 False setting 3 Valve defective 4 Unsuitable type 1 Wrong switched position eg pressureless 2 Solenoid defective 3 Internal leakage due to wear 4 Excessive fluid velocity 5 Spool jams 1 Viscosity too low causing excessive leakage 2 Viscosity too high causing excessive flow resistance 3 Fluid foams 1 In...

Page 82: ...ion line is sized wrong 5 Fluid level too low 1 Internal leakage due to wear 2 Pump defective 3 Inlet and return lines wrongly connected 1 Leakages 2 Excessive line resistance 3 Pressure filter blocked 1 Excessive line resistance 2 Filter blocked Excessive operating temperature 1 Reduction in efficiency due to wear 2 With variable pumps the pump control system is defective 3 Rotational speed and o...

Page 83: ...low is too high 2 Undersized valve 3 Pressure setting too high 4 Response time too long 1 Flow rate set too low excessive pump delivery through pressure relief valve 2 Valve defective 1 Leakage losses too high 2 Pressure less oil circulation if used fails to switch on 3 Spool sticking 1 Viscosity too low causing excessive leakage 2 Viscosity too high causing excessive flow resistance 3 Fluid foams...

Page 84: ... 66 5 43 95 7 5 64 141 10 75 165 11 83 183 15 114 251 15 100 220 20 132 291 18 5 165 364 25 176 388 22 170 375 30 198 437 30 240 529 40 223 492 37 285 628 50 243 536 45 320 705 60 394 869 55 420 926 75 507 1 118 75 570 1 257 100 517 1 140 90 670 1 477 125 721 1 590 110 760 1 676 150 760 1 675 132 960 2 116 200 950 2 094 160 990 2 183 250 950 2 094 200 1 190 2 623 300 1 080 2 381 250 1 326 2 923 35...

Page 85: ... air oil cooler Air oil cooler type Weight kg Ib HDC 050 4 38 84 HDC 060 4 60 132 HDC 080 4 101 223 HDC 085 6 131 289 HDC 090 6 173 381 HDC 100 4 222 489 HDC 100 6 196 432 HDC 200 4 429 946 HDC 200 6 357 787 BOL 16 25 55 BOL 30 57 125 BOL 725 77 170 BOL 950 136 300 BOL 1200 195 430 BOL 1600 234 515 BOL 2000 264 582 Table 25 Weight water oil cooler Plate cooler type Weight Tube cooler type Weight k...

Page 86: ...6 88 Hägglunds DUc Drive unit Declaration of Incorporation Bosch Rexroth AB Version 06 2020 RE 15326 WA 15 Declaration of Incorporation Declaration of Incorporation is only available for European version ...

Page 87: ...RE 15326 WA Version 06 2020 Bosch Rexroth AB Declaration of Incorporation Hägglunds DUc Drive unit 87 88 NOTES ...

Page 88: ... 895 80 Mellansel Sweden Tel 46 0 660 870 00 Fax 46 0 660 871 60 hagglunds boschrexroth com We reserve the right to make changes Printed in Sweden Your local contact can be found at www boschrexroth com hagglundscontacts ...

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