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Hägglunds Fusion Drive system

| Troubleshooting

Bosch Rexroth AB, RE 15345-WA Version 11.2022,

Causes Of Trouble And Its Effect In The Hydraulic Installation

Source of trouble,
(effects)

Mechanical Drive

Suction Line

Pump

Pressure Line

Return Line

Power Take-off
either does not
turn at all or
too slowly. (no

delivery flow
or insufficient
delivery flow)

1. Coupling

wrongly aligned.

2. Coupling loose.
3. Coupling
defective.

4. Loose mounting

on pump and/or

motor.
5. Other
transmission
elements loose.
6. Pump or motor

defective.
7. Direction of

rotation wrong.

Suction resistance
is excessive:
1. Suction line

blocked or leaking.

2. Suction line is

sized wrong.
3. 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.

Excessive
operating
temperature

1. Reduction in

efficiency due to

wear.

2. With variable

pumps, the pump
control system is

defective.

3. Rotational speed

and/or delivery

excessive.

1. Pipe bore is

too small, causing

high frictional

resistances.

2. Pressure filter
blocked.

1. Pipe bore is

too small, causing

high frictional

resistances.

Line shocks when
switching takes
place.

1. Line mounts are
missing or loose.
2. Poor
installation.

3. Pipe bore too

small.

4. Installation not
bled.

5. Oil volume in
lines is excessive

1. Lines loose.

The pump
switches on and
off too often.

1. Pump defective.

Содержание Fusion

Страница 1: ...H gglunds Fusion Drive system RE 15345 WA Version 11 2022 Replaces New EN INSTALLATION MAINTENANCE MANUAL...

Страница 2: ...well as the data specifications and other information set forth in it are the exclusive property of Bosch Rexroth AB It may not be reproduced or given to third parties without its consent Changes in t...

Страница 3: ...s 13 4 Scope of delivery 15 5 About this product 15 5 1 Product description 15 5 2 Product identification 15 5 3 Main components 16 5 4 Hydraulic fluids 18 5 5 Requirements for hydraulic fluid cleanli...

Страница 4: ...draulic fluid 55 9 5 Air filter breather change 56 9 6 Electric motor 57 9 7 Cleaning of air oil cooler 58 9 8 Drive system out of service 59 9 9 Repair 60 9 10 Flushing after repair 60 9 11 Spare par...

Страница 5: ...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 Or...

Страница 6: ...e 2 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 hazardou...

Страница 7: ...nery is exclusively intended to form an incomplete or a complete machine together with other components or partly completed machineries The drive system may only be commissioned after it has been inst...

Страница 8: ...ctrical 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...

Страница 9: ...ively 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 spec...

Страница 10: ...nd under or put you hands under suspended loads f Ensure your position is stable during transportation f Use your personal protective equipment e g protective goggles safety gloves suitable working cl...

Страница 11: ...lations and domestic laws for work on heavy current equipment f The operation maintenance and or repair of such equipment is reserved to skilled personnel qualified to work on or with electrical equip...

Страница 12: ...ctly observe the safety instructions provided by the lubricant manufacturer f Use your personal protective equipment e g protective goggles safety gloves suitable working clothes safety shoes f If hyd...

Страница 13: ...ue to improper lubrication Product can be damaged or destroyed f Never operate the H gglunds drive system with insufficient hydraulic fluid f When commissioning a machine system make sure that the cas...

Страница 14: ...roduct can be damaged f Plug all openings with the appropriate protective equipment in order to prevent detergents from entering the hydraulic system f Never use solvents or aggressive detergents Use...

Страница 15: ...variable displacement for closed loop systems The electric motor is totally enclosed TEFC The standard control function is a pump control with system control interface for controlling the pump and gat...

Страница 16: ...on See also figure 1 Hydraulic motor 2 Electric motor 3 Main pump 4 HDC cooler 5 Torque arm 6 Tank 3 7 Oil Filter 8 Pump control and power amplifier 9 Speed sensor 5 3 Main components Fig 2 Main compo...

Страница 17: ...osch Rexroth AB Scope of delivery Drive system H gglunds Fusion 17 72 Item Description 1 Oil drain valve 2 Level and temperature sensor 3 Air filter breather 4 Level gauge 3 Fig 3 Detailed view tank 1...

Страница 18: ...is within optimum operation range see Fig 4 General recommendation is to have a system temperature of 50 C see dotted line in Fig 4 A VG 68 fluid will render just above 40 cSt at this point Optimum vi...

Страница 19: ...ng 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 Alway...

Страница 20: ...t 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 allo...

Страница 21: ...or indoor storage up to 12 months from delivery date If storage time exceeds 12 months the crate must be opened to access the plastic hood Open the plastic hood gently to avoid damage Exchange the des...

Страница 22: ...ger to life or risk of injury damage to equipment f See label on the crate for center of gravity f Avoid rapid acceleration deceleration and turns while moving the goods f Position the forks according...

Страница 23: ...for the electric motor and the air oil cooler NOTICE Frame feet bolted to foundation Damage on equipment due to frame not designed to handle external forces f Do not bolt frame feet to foundation 7 2...

Страница 24: ...g with a spanner is sufficient Bolt supporting area must sit proper on bolt on surface Fig 6 Lifting Fusion Table 6 Max load for each lifting hook Working Load Limit WLL kg lb Safety factor 4 3500 771...

Страница 25: ...ee ventilation distance AA and BA and to provide sufficient working space for maintenance distance B and C Heavier maintenance such as change of motor pump will demand more working space Fig 7 Recomme...

Страница 26: ...embly tool can be used The assembly tool is passed through the motor and screwed into a pre made thread in the driven shaft The motor is pulled onto the shaft by turning the nut on the assembly tool M...

Страница 27: ...rry out any similar work on the drive system without Bosch Rexroth approval 7 5 2 Mounting the motor on to the driven shaft Section 7 2 Installation condition in respectively Installation Maintenance...

Страница 28: ...CB 560 520 20 M20 x 100 10 9 490 362 Hexagon CB 840 520 20 M20 x 100 10 9 490 362 Hexagon Splines NOTICE Incorrect installation Damage of motor and customer shaft f See section section 7 4 5 Mounting...

Страница 29: ...em is depressurized f The product is painted with thermosetting plastic paint containing an isocyanate component When a thermosetting plastic paint is heated to over 150 175 C gases are emitted that c...

Страница 30: ...15345 WA Version 11 2022 Load calculations Fig 11 External forces Fr Fb for torque arm 3 o clock position T Torque direction on driven shaft Pushing Fig 12 External forces Fr Fb for torque arm 3 o cl...

Страница 31: ...18000 107 24075 CB 560 560 S 30 kW 113 25425 134 30150 75 kW 113 25425 140 31500 CB 840 840 S 37 kW 169 38025 193 43425 75 kW 169 38025 199 44775 CA 50 50 C 15 kW 10 2250 21 4725 75 kW 10 2250 28 6300...

Страница 32: ...r ring 2 The bearing shall be mounted with the slot in the outer ring perpendicular towards the load direction See Fig 13 3 Lock the bearings with the circlips 5 4 Assemble the rest of the components...

Страница 33: ...is tightened 3 Lift the electric motor Lift the electric motor horizontally Do not use the motor shaft as lifting point One or more lifting strap can be exchanged with chain block s or similar to faci...

Страница 34: ...60 413 970 715 Fig 14 Mounting of electric motor Electrical motor Bellhousing Pump Motor plate Ring gear Inspection hole S DD00070842 Shaft coupling For information about coupling type see order speci...

Страница 35: ...t warning Particles may go together with the outgoing air flow Risk of injury f Disconnect electric power to the air oil cooler electric motor if working in the area of the airflow NOTICE Dirt in the...

Страница 36: ...ng to Fig 16 Note The check valve must always be mounted at the top connection point and notice the flow direction on the check valve 7 5 7 Air breather When the drive system is delivered oil filled 1...

Страница 37: ...ing to local regulations before the electric equipment is connected to the main voltage Grounding point is on the side of the frame see Fig 20 f All electrical supply levels must be within the limits...

Страница 38: ...are marked on the electric motor marking plate see Fig 18 Y or D Connection is done depending on supply voltage in accordance to Fig 19 from MCC Motor Control Center Electric motor must be separatly g...

Страница 39: ...n connection is 10 mm2 0 016 in2 Fig 20 Grounding point 42637 7 6 5 Cabinet heater optional Heating capacity1 Operation voltage Max current Setting range2 1200 W AC 230 V 50 60Hz 13 0 A 0 to 60 C 32 t...

Страница 40: ...ed The accumulator when required has to be filled with dry nitrogen to a pressure level in accordance with the attached order specific H gglunds Fusion documentation the accumulator is normally precha...

Страница 41: ...uid used in the system Fill the motor case with hydraulic fluid via a filter into the drain outlet D2 for minimum oil volumes needed see Table 15 and Table 17 If required fill the pump case with hydra...

Страница 42: ...Signal Inclination litre US gal mm in mA litre US gal mm in mA 0 55 14 5 73 2 87 17 3 60 15 8 44 1 73 18 9 14 55 14 5 73 22 2 87 0 86 17 3 58 15 3 56 5 2 20 0 20 18 3 14 55 14 5 73 125 2 87 4 92 17 3...

Страница 43: ...arning level Alarm stop level Inclination litre US gal litre US gal litre US gal litre US gal 0 55 14 5 60 15 8 50 13 2 44 11 6 14 642 16 9 673 17 7 59 15 6 53 14 0 14 46 12 2 49 12 9 41 10 8 35 9 2 1...

Страница 44: ...nlet side of 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...

Страница 45: ...on 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 a...

Страница 46: ...prevent premature failure of system components Check all connections screws etc and tighten if necessary 8 4 Pump settings and adjustments 8 4 1 Variable displacement pump Charge pressure level high p...

Страница 47: ...orque of 2 Nm in the depressurized conditon until the end stop is reached Forces larger than 2 Nm bend the spring and spring plate The pressure cut off setting can then no longer be guaranteed Swivel...

Страница 48: ...ith blocked main port or blocked actuator Stroke the pump to about 50 of max flow Set the compensator pressure to a value according to the order specific H gglunds Fusion documentation 4 Manual contro...

Страница 49: ...4VG125 42656 42658 42660 High pressure relief valve B Pressure cut off Charge pressure valve High pressure relief valve A High pressure relief valve B Pressure cut off Charge pressure valve High press...

Страница 50: ...on the nature of the equipment the environment it is working in and the duty cycle bearing in mind the consequences of a breakdown To optimize the maintenance intervals economically a Life Cycle Cost...

Страница 51: ...ce 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 an...

Страница 52: ...After 3 months or 500 working hours R Once every 3 months Once every 6 months I I I Once every 12 months R R I I Inspection R Replacement If the contamination indicator is tripped out the filter must...

Страница 53: ...Change parts if necessary 4 Mount the filter bowl Tighten by hand to stop and back off 1 4 th of a turn WARNING High temperature oil components Risk of injury f Do not open filters that are in operat...

Страница 54: ...mpletely at the switched off filter side in order to reduce the pressure 4 If filter is equipped with drain plug loosen the drain plug under the filter bowl to empty from hydraulic fluid Drain the oil...

Страница 55: ...l 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 t...

Страница 56: ...ection 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 t...

Страница 57: ...ease 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...

Страница 58: ...pecified limits due to low cooling capacity Before cleaning Stop the drive system Disconnect the cooler from the main power supply NOTICE Improper handling Environmental risk f Follow the safety preca...

Страница 59: ...uted by adding vapour active anti corrosion agent in to the oil before the planned shutdown Introduction of such additive shall be done a couple of weeks in advance to the stop Quantities to be added...

Страница 60: ...n drive unit when its delivered new from the manufacturer 9 10 1 Cleaning of system after break down If something has happened in the system during operation that may have produced some kind of contam...

Страница 61: ...em particle content has to be verified with oil sample test inline cleanliness measurement or corresponding High cleanliness is important for long lifetime of the hydraulic system In the event of ques...

Страница 62: ...he H gglunds product otherwise the functional reliability of the H gglunds product can not be assured and you lose your warranty entitlement Recommended spare parts typical example For exact spares an...

Страница 63: ...mblies and components Take all precautions necessary to prevent dirt entering the system Disassembly shall only be done by professional service personnel DANGER Danger from suspended loads Danger to l...

Страница 64: ...se an oil binding agent if hydraulic fluid is spilled f Observe the information in the safety data sheet for the hydraulic fluid and the specifications provided by the system manufacturer Disassembly...

Страница 65: ...pletely drain the system from fluid 2 Dispose of the packaging material in accordance with the national regulations in your country 3 Dispose the hydraulic fluid according to the national regulations...

Страница 66: ...t power and torque at the hydraulic motor pressure too low 1 Power transmission defective 3 Direction of rotation wrong 4 Motor defective 5 Key sheared at pump or motor 1 Internal leakages due to wear...

Страница 67: ...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 defec...

Страница 68: ...king 2 Suction line is sized wrong 3 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 fi...

Страница 69: ...tches are defective wrongly set or not connected 1 Constant delivery flow is too high 2 Undersized valve 3 Pressure setting too high 4 Response time too long 1 Flow rate set too low excessive pump del...

Страница 70: ...t Splines Shrink disc coupling kg lb kg lb CA 50 175 437 203 447 CA 70 205 450 232 512 CA 100 265 584 310 683 CA 140 305 672 347 765 CA 210 395 870 456 1005 CB 280 705 1555 800 1760 CB 400 1060 2335 1...

Страница 71: ...1477 Table 24 Weight air oil cooler Air oil cooler type Weight kg Ib HDC 030 4 24 53 HDC 050 4 38 84 HDC 060 4 60 132 HDC 080 4 101 223 Table 25 Weight panels Panels Weight kg Ib Front panel 12 26 To...

Страница 72: ...46 0 660 870 00 www hagglunds com H gglunds is a brand of Rexroth a leading global supplier of drive and control technologies H gglunds solutions enrich a comprehensive Rexroth portfolio We reserve th...

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