Hägglunds Compact CA Installation And Maintenance Manual Download Page 6 | Manualshive

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Installation and Maintenance Manual, Compact CA

1 General

1.1 Safety precautions

It is of high importance that the Safety precautions are always followed, if you
are unsure about something, please do not hesitate to contact your nearest Häg-
glunds office for advice.

Warning signs

In this manual you will find the following signs which indicate a potential hazard, which can or will
cause personal injury or substantial property damage. Depending on the probability of the hazard,
and how serious the injury or property damage could be, there are three levels of classification.

General

WARNING

is used to indicate the presence of a hazard

which can cause severe personal injury, death, or substantial
property damage if the warning is ignored.

DANGER

is used to indicate the presence of a hazard

which will cause severe personal injury, death, or substantial
property damage if the warning is ignored.

CAUTION

is used to indicate the presence of a hazard

which will or can cause minor personal injury or property
damage if the warning is ignored.

Application area

All new and rebuild applications, should always be approved and supervised by Hägglunds per-
sonnel.

Mounting

Carefully follow the instructions and be aware of the high weights and forces during lifting.

Before starting up

Before starting up new, rebuild or just worked on applications, all accessories and safety arrange-
ments functions, should be controlled/tested.

Periodic maintenance

Notice the intervals in maintenance chart (4.4) and keep a record.

Dismounting

Carefully follow the instructions and be aware of the high weights and forces during lifting.

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Summary of Contents for Compact CA

Page 1: ...Installation and Maintenance Manual Compact CA Motors ...

Page 2: ......

Page 3: ...Installation and Maintenance Manual Compact CA EN411 18h 2011 ...

Page 4: ... our own sales and representation offices in some 40 different countries Our high quality Drive Systems are based upon our unique hydraulic piston motors developed through a wealth of experience accumulated over 40 years in marine and industrial areas Today this ongoing development work has re sulted in the powerful COMPACT industrial motor New as well as established technical solutions contribute...

Page 5: ... 3 1 5 Removing the motor from the driven shaft 27 3 1 6 Mounting the reaction point 28 3 1 7 Brake MDA 29 3 1 8 Control of braking torque 29 3 1 9 Installation of MDA hydraulics 30 3 1 10 Brake MDA 5 7 10 31 3 1 11 Mounting MDA 5 7 10 32 3 1 11 Reduction of brake torque 32 Disassembly of MDA 5 7 10 33 3 1 13 Brake MDA 14 21 34 3 1 14 Mounting MDA 14 21 35 Flange mounted brakes 35 Torque arm mount...

Page 6: ...ty damage if the warning is ignored DANGER is used to indicate the presence of a hazard which will cause severe personal injury death or substantial property damage if the warning is ignored CAUTION is used to indicate the presence of a hazard which will or can cause minor personal injury or property damage if the warning is ignored Application area All new and rebuild applications should always b...

Page 7: ...ce ment Specific torque Rated speed Max speed Displace ment Specific torque Rated speed Max speed Ratio Vi cm3 rev Ts Nm bar n rpm n rpm p bar Vi cm3 rev Ts Nm bar n rpm n rpm CA 50 20 1256 20 400 400 350 Not recommended to be used in reduced displacement CA 50 25 1570 25 350 400 350 CA 50 32 2010 32 280 400 350 CA 50 40 2512 40 230 350 350 CA 50 3140 50 200 280 350 1570 25 200 280 1 2 CA 70 40 25...

Page 8: ...Oil main lines are connected to ports A and C in the connection block and drain lines to ports D1 D2 or D3 in the motor housing The motor is connected to the shaft of the driven machine through the hollow shaft of the cylinder block The torque is transmitted by using a mechanical shaft coupling or alterna tively by splines The symmetrical design of the motor has made it possible to design it as a ...

Page 9: ...of max 5 seconds up to 8 bar 116 psi is allowed Max permitted case pressure at stand still is 8 bar 116 psi Technical data 2 Technical data 2 1 Recommended charge pressure The hydraulic system must be such that the motor will receive sufficient charge pressure at the low pressure port This applies to all types of installations In hanging load applications charge pressure at motors connection must ...

Page 10: ...dation or casing This may well be the most important factor to consider since many structures may give rise to resonance resulting in severe noise problems Remarks Background noise The background noise can not normally be influenced but is usually known or easy to measure Pump unit The pump unit is a known noise level Pipe noise The pipe noise is probably the source of the majority of mistakes in ...

Page 11: ...we recommend synthetic oils Fire resistant fluids OPERATING WITH FIRE RESISTANT FLUIDS The following fluids are tested for Hägglunds motors ISO DP 6071 Low viscosity gives reduced service life for the motors Max permitted viscosity is 10000 cSt 48000 SSU IMPORTANT Down rating of pressure data and service life must be considered when using fire re sistant fluid The Hägglunds company or its authoris...

Page 12: ...e service life for the drive as mineral oil The fluid shall have less than 10g 100g according to ASTMD 1958 97 DIN 53241 Technical data Filtration The oil in a hydraulic system must always be filtered and also the oil from your supplier has to be filtered when adding it to the system The grade of filtration in a hydraulic system is a question of service life v s money spent on filtration In order ...

Page 13: ...eloaded check valve must be connected in the drain line to ensure that the motor is filled with oil see 3 2 2 Draining and venting the motor The drain line must be dimensioned so that maximum 3 bar 43 5 psi motor housing pres sure is not exceeded The maximum housing pressure is 3 bar 43 5 psi Brief peaks during operation up to 8 bar 116 psi are permissible The permitted hous ing pressure when the ...

Page 14: ... there is no radial or axial force on the shaft the shaft can be oiled only For production of the shaft see 278 2230 278 2231 278 2232 278 2233 278 2234 278 2235 278 2236 278 2238 and 278 2239 For control of spline see table 3 3 To make it easier to mount the motor on the driven shaft end or to remove the motor from the shaft it is recommended that a hole table 3 4 should be drilled and tapped in ...

Page 15: ... where the centre of gravity is before any lifting Never stand below a hanging mo tor or torque arm 1 Fig 3 4d CA 210 Steel eye with bolt Steel eye bolts 3 x M12 Figure 3 4c Note The end cover and screws must be removed before mounting the steel eye bolts After the lift refit the end cover and screws with torque 81 Nm 59 lbf ft Note Motor lifted without coupling fitted danger of slipping off 1 Max...

Page 16: ... CA50 SA0N 205 2972 240 429 944 456 1003 CA70 XB0NH TA7 CA70 SA0N 175 2538 462 1016 489 1076 CA100 XB0NH TA5 CA50 SA0N 325 4712 270 489 1076 534 1175 49000 36100 CA100 XB0NH TA7 CA70 SA0N 290 4205 522 1148 567 1247 CA100 XB0NH TA10 CA100 SA0N 245 3552 638 1404 683 1503 CA140 XB0NH TA5 CA50 SA0N 260 3770 220 529 1164 571 1256 CA140 XB0NH TA7 CA70 SA0N 235 3408 562 1236 604 1329 CA140 XB0NH TA10 CA1...

Page 17: ...n the end face of the hollow shaft when the coupling is fitted since this may cause damage to the coupling When in storage the motor must always be placed on the end face to the hollow shaft It is also advisable to provide supports at the mounting surface of the motor see figure 3 7 Support Support Motor Motor with shaft coupling Motor with splines kg lb kg lb CA 50 203 447 175 385 CA 70 232 510 2...

Page 18: ...of the coupling screws the following must be observed Keep tension in your lifting wires to avoid a skew setting of the motor on the shaft dur ing the tightening of the screws Wobbling caused by a skew setting of the motor gives extra forces on the main bearings In order to avoid the misalignment of the two clamping rings during the screw tightening the gap between the rings must be measured in se...

Page 19: ...material and dimension on the driven shaft The conical surface between the coupling ring and the clamping rings the bolts shall be coated with MoS2 Molykote see figure 3 8 This is done from the factory at delivery When a motor has been in for overhaul or service and shall be reassembled it may be necessary to lubricate those surfaces with Molykote again but remember only the specified surfaces Rem...

Page 20: ...e right direction when the motor is mounted in place on the machine To achieve the highest possible oil level in the motor housing the motor must be turned until the drain outlets are positioned according to figure 3 12 Line up the torque arm on the motor by using the screws with washers Mount screws and washers according to fig ure 3 9 and screws according to figure 3 9a Tighten the screws to the...

Page 21: ...on the right hand viewed from the motors main connection side Cylinders oil connection A B and C must point in the direction to the motor Mount the hoses The hose mounted to the high pres sure connection C has to be mounted to the hydraulic cylinders connection B and the hose from connection A has to be mounted to the cylinders connection A This is valid with the cylinder on the right side hand si...

Page 22: ...re 3 11 3 11a and the table 3 8 Mounting the motor with a mounting tool figure 3 10 Remove the End cover together with screws and washers Align the motor with the driven shaft Locate the existing plastic washer between the nut on the mounting tool and the bearing retainer Pass the mounting tool through the centre of the motor and screw it into the driven shaft to stated depth by using the key hand...

Page 23: ...motor with a mounting tool Align the motor with the driven shaft using an overhead crane or lifting truck and press it carefully onto the shaft so that the length stated in the table beside is obtained see figure 3 11 To achieve the highest possible oil level in the motor housing the motor must be turned until the drain outlets are positioned according to figure 3 12 B 5 0 B 0 2 0 Figure 3 12 B 5 ...

Page 24: ...ing torque value is critical Use calibrated torque wrench 1 12 11 10 9 8 2 3 4 5 6 7 Figure 3 14 Figure 3 14a Clean the driven shaft and the inside of the motor hollow shaft 9 1 5 Figure 3 13 Installation Table 3 9 Motor type No of screws Screw dim Strength class Tightening torque Type of head Nm lbf ft CA 50 70 8 M16 x 55 10 9 250 185 Hexagon CA 100 140 12 M16 x 65 10 9 250 185 Hexagon CA 210 15 ...

Page 25: ... to the G1 plug Torque the G1 plug MV 125 Nm 90 lbf ft Mount the cover MV 81 Nm 59 lbf ft Oil to be filled before tightening bolt M20 L 100 mm Mounting kit 478 3629 801 Torque arm mounted motors Motors that carry radial load must have the splines oiled The motor can be used for horizontal mount ing and mounting with motor shaft pointing down wards Mount torque arm to motor with bolts supplied Alig...

Page 26: ... Torque the bolt MV 385 Nm 280 lbf ft Mount the brake according to 3 1 9 O ring Installation Torque arm mounted motors with brake Motors with brake BICA must have the screwed centre cover disassembled See Installation and Maintenance Manual for BICA Mount torque arm to motor with bolts supplied Align with oil connection ports as required Lubricate and install O ring at leading edge of motor bore C...

Page 27: ... tool Finally refit the removed Bearing retainer torque 136 Nm 100 lbf ft and End cover torque 81 Nm 59 lbf ft as before Before dismounting the motor from the driven shaft the oil in the motor housing must be drained through the lower draining hole The motor can be removed from the shaft with or without the mounting tool The operation is easier if the tool is used Figure 3 19 Removal of Compact 50...

Page 28: ...Mounting of pivoted attachment x 2 mm 0 079 misalignment in installation x 15 mm 0 59 movement when in use Bearing fitted with Loctite 601 Installation Figure 3 22 Alternative position Steel EN 10113S355N DIN St E39 BS 4360 Grade 50 C DANGER ZONE In case of failure of torque arm installation Note The toggle bearing must be dismounted during welding Protected against corrosion after welding ...

Page 29: ...brake Oils Conventional petroleum based hydraulic oils Be aware of high water content in oil levels above 2 are not allowed due to use of water based glue in disc set Minimum viscosity limit 20 cSt Torque levels in tech data is based on above mentioned oil Other type of oils can give different torques due to different friction coefficient different additives in oil 3 1 8 Control of braking torque ...

Page 30: ...hen designing systems and where multi disc brake MDA will be used Please see figure 3 24 Opening pressure To secure correct opening pressure Use hydraulic scheduling according to figure 3 23 when using external pressure system pressure as control pressure to open and close the brake Pressure reduce valve set at 20 bar and pressure relief valve set at 25 bar in line Air in the brake results in slow...

Page 31: ...ment max Weight Oil volume Nm lbf ft bar psi bar psi bar psi cm3 in3 kg lbs l US gal MDA 5 16 13600 400 10000 295 16 232 19 276 20 25 290 363 155 9 5 100 220 1 7 0 45 MDA 5 26 22600 700 16700 520 MDA 7 34 30400 900 22400 660 16 232 19 276 20 25 290 363 195 11 9 100 220 1 7 0 45 MDA 10 48 41500 2000 30600 1480 16 232 19 276 20 25 290 363 256 15 6 100 220 1 7 0 45 Connection Description Port connec ...

Page 32: ... 21 75 psi The diagram shows that the actual brake torque Mact corresponds to only 90 of Mmax Motors with SPECIAL brakes may have differ ent working operation Please make sure that you check the Ordering code on your brake Diagram 3 1 Installation Back pressure in brake cylinder drainage line MDA5 has 6 outer discs and 5 inner discs MDA7 has 8 outer discs and 7 inner discs MDA10 has 11 outer discs...

Page 33: ...tre hole and lifted off by using the screw Figure 3 28 Installation Note The M12 screw can not be used to hold the brake cover 314 while removing the screws 40 There is a risk that the threaded part in the brake piston 313 can fail due to big forces when removing the screws 3 Inner and outer discs 318 320 can be removed and the screws 43 holding the spacer 3xx in place can be removed 4 Loosen the ...

Page 34: ...0 15 220 20 290 20 25 275 350 318 19 14 230 510 2 0 0 53 MDA 14 38 32700 1800 24100 1330 MDA 14 67 57000 3000 42000 2200 MDA 21 95 81800 4300 60300 3170 15 220 20 290 20 25 275 350 318 19 14 230 510 2 0 0 53 11 7 6 32 5 69 W150x5x30x28x8f DIN 5480 136 296 2x 144 5 160 5 Ø152 0 100 H9 0 Splines B3 5 9882 5 9843 27 B2 B1 1 06 261 10 28 5 35 Connection Description Port connec tion B1 Brake connection...

Page 35: ...nted brakes Disassemble the brakes according to page 38 Note Remove cover pos 312 Mount torque arm on the brake with M20 screws Lubricate and install o ring at leading edge of brakes shaft Check shaft splines for burrs and lubricate shaft splines with Texaco Multifak EP2 Mount the brake on the shaft Mount the mounting kit 078 1700 801 bolt and cover Torque the bolt MV 385 Nm 280 lbf ft Assemble th...

Page 36: ...Lifting the MDA 14 21 brake Steel eye x2 with bolt Steel eye bolts x3 Figure 3 33 Figure 3 32c CA motor type B and tandem kit 278 2339 606 must be used Fill splines and shaft with hydraulic oil Tandem mounting of motor CA and brake MDA 14 Installation ...

Page 37: ...stallation Spline Unidirectional drives Bidirectional drives Steel with yield strength Relmm 450 N mm2 Steel with yield strength Relmm 700 N mm2 The splines shall be grease with Texaco Multifak EP2 or equivalent This is with exception for tandem mounted MDA14 where spline shall be lubricated with hydraulic oil To avoid wear in the splines the installation must be within the specified tolerances in...

Page 38: ...ion carefully before starting the disassembly 320 318 43 25 313 314 315 308 40 6 Mount spacer for MDA 14 308 Mount first one outer disc then inner disc outer disc until all discs are mounted Note Matched disc set MDA 14 has 8 outer discs and 7 inner discs MDA 21 has 11 outer discs and 10 inner discs 7 Grease the seals with Texaco Multifak or equivalent grease without solid additives and mount the ...

Page 39: ... clockwise and L motor counter clockwise viewed from the motor shaft side If the motor is working in half displacement and in not pre ferred direction of rotation allowed pressure is maximum 210 bar 3000 psi Installation Remove the protective cover from motor mounting surface place the O rings included in delivery in their proper position on the valve mounting surface Use grease to keep O ring fix...

Page 40: ...tions for 2 speed valve See figure 3 37b Connection Description Remarks C1 C2 Main connection If C is used as the inlet the motor shaft rotates clockwise viewed from the motor shaft side A1 A2 Main connection If A is used as the inlet the motor shaft rotates counter clockwise viewed from the motor shaft side D1 Drain outlet Normally plugged at delivery D2 D3 Alternative drain outlets Normally plug...

Page 41: ...Manual Compact CA Main connection A C Table 3 18 BSP 1 4 15 0 59 a b c Drain connection D1 D2 Test connection T Installation Motor a mm in b c mm in CA 50 210 31 1 22 1 2 UNC 25 0 98 BSP 3 4 50 2 0 Figure 3 40 Figure 3 39 Figure 3 38 ...

Page 42: ...ted on the motor and the oil supply connected to P give a counter clockwise rotation direction on a motor sign marked L as shown at figure 3 42 and figure 3 42b If the motor sign is marked R the motor rotation direction is clockwise see figure 3 40a The motor sign has to show R or L the spe cific motor rotation direction Example of motor sign with two speed motor C A 5 0 C A L N C Displacement shi...

Page 43: ...r the motor shaft is pointing upwards or downwards Motor shaft pointing downwards The motor must be connected to the drain connection in D1 or D2 and F3 or F4 See figure 3 44 Motor shaft pointing upwards The motor must be connected to the drain line connection on the shaft end housing see figure 3 45 The flushing connection F on the shaft end housing should be connected to the low pressure con nec...

Page 44: ...ive The flushing oil shall be drained in the normal drain line See 3 2 2 Connect the input line for flushing in the lowest flushing F3 or F4 see figure 3 46 For shaft pointing downwards input line shall be D3 see figure 3 43 When there is risk for pressure spikes in motor case input line D3 or D2 is recommended Flushing of motor case To avoid high temperature in the motor case the heat must be rem...

Page 45: ... to the charge pressure curve see 2 1 Recommended charge pressure Check that all hydraulic couplings and plugs are properly tightened to prevent leakage Make sure that the torque arm is sufficiently fastened see 3 1 3 Maintenance 4 3 Commissioning During initial starting and the period immedi ately after it any hydraulic installation must be regularly and carefully checked at frequent intervals Th...

Page 46: ...nsp Inspection Ctrl Control of braking torque Maintenance chart In operation Oil filters Oil Braking equipment Torque arm After the first 100 hours Rpl Insp Insp After 3 months or 500 hours Rpl Insp Once every 6 months Rpl Insp Insp Insp Once every 12 months Ctrl 4 4 1 Cleaning and care Damage to the surface caused by sol vents and aggressive detergents Aggressive detergents may damage the seals o...

Page 47: ...onths or 4000 working hours 4 4 4 Oil Se also 2 3 Analysis It is recommended that the oil should be analysed every 6 months The analysis should cover viscosity oxidation water content addi tives and contamination Most oil suppliers are equipped to analyse the state of the oil and to recommend appropriate action The oil must be replaced immediately if the analysis shows that it is exhausted Viscosi...

Page 48: ...is and from the laboratory you get a report which follow a specific international standard You have to select what analysis the laboratory shouldtake butthemostusedanalysisareparticle count water content oxidation and viscosity Another method is to install an inline particle counter direct in your hydraulic system which give you the contamination level according to the international rules the disa...

Page 49: ...een bottle and cap Do not remove the foil prick the end of your mini mess hose through the foil into the bottle and fill 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 shall be filled because the laboratory has to shake the sample to get a mixed fluid when they analyse it Minimum 200 ml are needed for a g...

Page 50: ... of the motor The D connection Motor rotates in wrong direction Oil supply connections to motor incorrectly connected Connect the oil supply correctly Motor runs jerkily Pressure or flow fluctuations in the hydraulic system Find the cause in the system or in the driven unit Noise in the motor The motor is being operated with the charge pressure too low Internal faults in the motor Adjust the charg...

Page 51: ...der under 3 3 10 13 Draining of brake cylinder Control of braking torque accord ing to 3 1 14 Dismantle the brake and replace the worn discs The brake does not open Insufficient brake opening pres sure Seals or piston damage For the required opening pressure see the section dealing with brake MDA under 3 1 7 Brake MDA Replace seals Replace the piston IMPORTANT The spring in the brake cylinder is t...

Page 52: ...ion documents are implemented by the product user The requirements of Appendix I to Machinery Directive 2006 42 EC not mentioned here are not applied and have no relevance for the product The individual below is authorized to compile the relevant technical files Name Björn Leidelöf Address Hägglunds Drives AB S 890 42 Mellansel Mellansel 2009 12 29 General principle no 1 1 1 3 1 1 5 1 3 1 1 3 2 1 ...

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Page 56: ...unds com Our drive is your performance EN411 18h Repro Öviks Repro Printer Ågrens Tryckeri 2011 Hägglunds Drives AB SE 890 42 Mellansel Sweden Tel 46 0 660 870 00 Fax 46 0 660 871 60 E mail info se hagglunds com ...

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