Radial-Piston-Motor-Bosch-Rexroth-Hagglunds-CB-1422820525.pdf

Hägglunds CBRadial piston hydarulic motor Installation and maintenance Supersedes: manual EN 683-6H/2011 EN 683-6BR/2011 English The data specified above only serve to describe the product. No statements concerning a certain condition or suitability for a certain application can be derived from our information. The information given does not release the user from the obligation of own judgment and verification. It must be remembered that our products are subject to a natural process of wear and aging. © This document, as well as the data, specifications and other information 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 motors manufactured after 02-01.01. For older motors please contact your Bosch Rexroth representative. The cover shows an example configuration. The product supplied may therefore differ from the figure shown. The original operating instructions were prepared in English. Contents 3/48 Contents 1 General 4 1.1 Safety precautions 4 1.2 Motor data 5 1.3 Functional description 7 2 Technical data 8 2.1 Recommended charge pressure 8 2.2 Sound from a complete installation 10 2.3 Choice of hydraulic fluid 10 3 Installation 13 3.1 13 Mounting instructions 3.1.1 Lifting methods 18 3.1.2 Mounting the coupling onto the motor shaft 21 3.1.3 Fitting the torque arm to the motor 22 3.1.4 Mounting the motor onto the driven shaft – shaft coupling 24 3.1.5 Removing the motor from the driven shaft 30 3.1.6 Mounting the reaction point 31 3.2 33 Oil connections 3.2.1 Direction of rotation of motor shaft 36 3.2.2 Draining and venting the motor 36 3.2.3 Flushing 38 4 Operating instructions 38 4.1 Storage 38 4.2 Before commissioning 38 4.3 Commissioning 40 4.4 Periodic maintenance 40 4.4.1 Cleaning and care 41 4.4.2 Motor 41 4.4.3 Filters 42 4.4.4 Oil (Se also 2.3) 42 4.5 Oil inspection 43 5 Fault finding 45 6 Declaration of incorporation 46 Hägglunds CB, EN 683-6BR/2011, Installation and maintenance manual, Bosch Rexroth Mellansel AB 4/48 General 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 Hägglunds 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. Warning sign, signal word Meaning DANGER Indicates a dangerous situation which may cause death or severe personal injuries if not avoided. WARNING Indicates a dangerous situation which may cause death or severe personal injuries if not avoided. CAUTION NOTICE Indicates a dangerous situation which may cause minor or medium personal injuries if not avoided. Damage to property: The product or the environment could be damaged. •• Application area. All new and rebuild applications, should always be approved and supervised by Hägglunds personnel. •• 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 arrangements 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. Bosch Rexroth Mellansel AB, Installation and maintenance manual, Hägglunds CB, EN 683-6br/2011 1 Max.98. Test pressure 420 bar. cooling and choice of hydraulic system for speed above rated. ** T  he motors are designed according to DNV-rules. (Special considerations regarding charge pressure. Bosch Rexroth Mellansel AB . 1) Special considerations regarding charge pressure. Hägglunds CB. speed cm3 rev Nm Ts bar n rpm n rpm p bar kNm kW CB 280-240 15 100 240 53 68 350 79 530 CB 280 17 600 280 44 58 350 92 530 CB 400-240 15 100 240 94 125 350 79 970 CB 400-280 17 600 280 73 105 350 92 950 CB 400-320 20 100 320 71 94 350 110 970 CB 400-360 22 600 360 59 82 350 120 960 CB 400-440 27 600 440 49 65 320 131 820 CB 400-480 30 200 480 48 62 290 129 660 CB 400-520 32 700 520 41 57 270 130 670 CB 400-560 35 200 560 40 53 250 129 630 CB 400 25 100 400 58 75 350 130 970 CB 560-440 27 600 440 49 65 350 140 930 CB 560-480 30 200 580 48 62 350 160 970 CB 560-520 32 700 520 41 57 350 170 960 CB 560 35 200 560 40 53 350 180 970 CB 840-600 37 700 600 30 45 350 200 880 CB 840-640 40 200 640 28 41 350 210 850 CB 840-680 42 700 680 27 40 350 220 890 CB 840-720 45 200 720 25 37 350 240 870 CB 840-760 47 800 760 23 34 350 250 840 CB 840-800 50 300 800 23 34 350 260 890 CB 840 52 800 840 21 32 350 280 870 CB 1120-880 55 300 880 25 34 350 290 970 CB 1120-920 57 800 920 24 33 350 300 980 CB 1120-960 60 300 960 24 32 350 315 990 CB 1120-1000 62 800 1000 22 31 350 330 1000 CB 1120-1040 65 300 1040 21 29 350 340 980 CB 1120-1080 67 900 1080 20 28 350 355 980 CB 1120 70 400 1120 20 27 350 370 980 Metric Vi Max. pressure torque 2) Displacement Specific torque Rated* speed 1) Max. Installation and maintenance manual.** Max. allowed to occur 10000 times. 2) Calculated as: Metric= Ts·(350-15)·0. EN 683-6br/2011. 4 ports must be used for higher speed). power 3) intermittenly *R  elated to a required pressure of 12 bar for motors in braking mode.2 Motor data Table 1. Peak/transient pressure 420 bar maximum. cooling and choice of hydraulic system for speeds above rated. General 5/48 1. 3) Valid for minimum permissible oil viscosity 20 cSt in the motor case. 6/48 General Table 1. Peak/transient pressure 6000 psi maximum. EN 683-6br/2011 . speed n rpm n rpm p psi lbf-ft hp Max. pressure torque 2) Rated* speed 1) Max. 1) Special considerations regarding charge pressure. (Special considerations regarding charge pressure. 2) Calculated as: US= Ts·(5000-218)·0. ** T  he motors are designed according to DNV-rules. Hägglunds CB. Test pressure 6000 psi. 3) Valid for minimum permissible oil viscosity 20 cSt in the motor case.2 US Displacement Vi CB 280-240 in3 rev Specific torque Ts ft/1000 psi lbf-ft 1000 psi Max. Bosch Rexroth Mellansel AB. allowed to occur 10000 times. 4 ports must be used for higher speed). power 3) intermittenly 920 12 200 53 68 5 000 57 00 710 1 070 14 200 44 58 5 000 67 00 710 CB 400-240 920 12 200 94 125 5 000 57 000 1 300 CB 400-280 1 070 14 200 73 105 5 000 67 000 1 300 CB 400-320 1 230 16 300 71 94 5 000 76 000 1 300 CB 400-360 1 380 18 300 59 82 5 000 86 000 1 300 CB 400-440 1 690 22 400 49 65 4 600 97 000 1 100 CB 400-480 1 840 24 400 48 62 4 200 95 000 890 CB 400-520 1 990 26 400 41 57 3 900 96 000 900 CB 400-560 2 150 28 500 40 53 3 600 95 000 840 CB 400 1 530 20 300 58 75 5 000 95 000 1 300 CB 560-440 1 690 22 400 49 65 5 000 100 000 1 300 CB 280 CB 560-480 1 840 24 400 48 62 5 000 110 000 1 300 CB 560-520 1 990 26 400 41 57 5 000 120 000 1 300 CB 560 2 150 28 500 40 53 5 000 130 000 1 300 CB 840-600 2 300 30 500 30 45 5 000 140 000 1 200 CB 840-640 2 450 32 500 28 41 5 000 150 000 1 100 1 200 CB 840-680 2 610 34 600 27 40 5 000 160 000 CB 840-720 2 760 36 600 25 37 5 000 170 000 1 100 CB 840-760 2 910 38 700 23 34 5 000 180 000 1 100 CB 840-800 3 070 40 700 23 34 5 000 190 000 1 200 CB 840 3 220 42 700 21 32 5 000 200 000 1 200 CB 1120-880 3 370 44 700 25 34 5 000 210 000 1 300 CB 1120-920 3 520 46 700 24 33 5 000 220 000 1 300 CB 1120-960 3 680 48 800 24 32 5 000 230 000 1 300 CB 1120-1000 3 830 50 800 22 31 5 000 240 000 1 300 CB 1120-1040 3 980 52 800 21 29 5 000 250 000 1 300 CB 1120-1080 4 140 54 900 20 28 5 000 260 000 1 300 CB 1120 4 290 56 900 20 27 5 000 270 000 1 300 *R  elated to a required pressure of 175 psi for motors in braking mode.98.** Max. cooling and choice of hydraulic system for speeds above rated. Installation and maintenance manual. cooling and choice of hydraulic system for speed above rated. the cam rollers are pushed against the slope on the cam ring that is rigidly connected to the housing. Shaft coupling 5. Cam roller A. EN 29001 and BS 5750. EP DE 69211238. Oil main lines are connected to ports A and C in the connection block and drain lines to ports D1. Cylinder block / spline 5 6 3. Cam ring 2. Cylindrical roller bearing 11 9. D3 or D4 in the motor housing.3 Functional description The hydraulic industrial motor Hägglunds CB is of the radial-piston type with a rotating cylinder block/hollow shaft and a stationary housing. Connection block 9 10 11. and the torque available is proportional to the pressure in the system. The torque is transmitted by using a mechanical shaft coupling or alternatively by splines. certified to standard ISO 9001. US 005979295A. Piston 7. Bosch Rexroth Mellansel AB . When the hydraulic pressure is acting on the pistons. Valid patents US 4522110.3. General 7/48 1. and the valve plate directs the incoming and outgoing oil to and from the working pistons. Part 1. Rotation therefore occurs. Each piston is working against a cam roller. Cylinder block/hollow shaft 6. EP 0102915. Axial bearing 10. Quality To assure our quality we maintain a Quality Assurance system. Installation and maintenance manual. Valve plate A = Inlet or outlet port »A« C = Inlet or outlet port »C« D = Drain port Fig 1: The Hägglunds CB Motor Hägglunds CB. D2. SE 910 1950-5. GB 1524437. An even number of pistons are radially located in bores inside the cylinder block. The cam rollers transfer the reaction force to the piston which are guided in the rotating cylinder block. EN 683-6br/2011. 1 2 3 D 4 1. The cylinder block is mounted in fixed roller bearings in the housing. C 8 7 4. JP 83162704. thereby producing a torque. Front end cover 8. The motor is connected to the shaft of the driven machine through the hollow shaft of the cylinder block. charge pressure at motors connection must be according to graph below under all conditions. CB 400-320/CB 400-280 CB 280-240 CB 400/CB 400-360 CB 280 CB 560-480/CB 560-440 CB 400-440/CB 400-480 CB 560/CB 560-520 CB 400-520/CB 400-560 CB 840-600 20 CB 840-680/CB 840-640 CB 1120-1040/CB 1120-1080 CB 840 CB 1120-1000 CB 840-800/CB 840-760 CB 1120/CB 1120-880/ CB 1120-920/1120-960 CB 840-720 Table 2. Required charge pressure at the inlet port is according to diagram below. Case 2: The motor works in driving mode only. Installation and maintenance manual. WARNING In hanging load applications.1a: Charge pressure Recommended charge pressure – Hägglunds CB motors Single port connection (2 ports) oil viscosity 40 cSt / 187 SSU 18 14 200 12 150 10 CB 400-240 8 100 6 4 50 2 0 0 0 10 20 30 40 50 60 Speed [rpm] Bosch Rexroth Mellansel AB.1 Recommended charge pressure The hydraulic system must be such that the motor will recieve sufficient charge pressure at the low-pressure port. Hägglunds CB. Required back pressure at the outlet port corresponds to 30% of value given in diagram below. but may not be lower than 2 bar (29 psi). There are two distinct cases: Case 1: The motor works in braking mode.8/48 Technical data 2 Technical data 2. EN 683-6br/2011 70 80 Recommended charge pressure [psi] Recommended charge pressure [bar] 250 16 . This applies to all types of installations. pressure peaks of max 5 seconds upto 8 bar (116 psi) are allowed). CB 400-320/CB 400-280 CB 400/CB 400-360 CB 280-240 CB 560-480/CB 560-440 CB 400-440/CB 400-480 CB 280 CB 560/CB 560-520 CB 400-520/CB 400-560 CB 840-600 CB 840-680/CB 840-640 20 CB 1120-1000 CB 840-800/CB 840-760 CB 1120-880/CB 1120-920/CB 1120-960 CB 840-720 CB 1120/CB 1120-1040/CB 1120-1080 CB 840 Table 2. The graph is valid when 4 ports are used. EN 683-6br/2011. Max permitted case pressure at stand-still is 8 bar (116 psi). Max casing pressure is 3 bar (43. Technical data 9/48 Notice! The diagram is valid for 1 bar (15 psi) case pressure.1b: Charge pressure Recommended charge pressure – Hägglunds CB motors double port connection (4 ports) oil viscosity 40 cSt / 187 SSU 18 14 200 12 CB 400-240 150 10 8 100 6 4 50 Recommended charge pressure [psi] Recommended charge pressure [bar] 250 16 2 0 0 0 10 20 30 40 50 60 70 80 90 100 Speed [rpm] Hägglunds CB. Installation and maintenance manual. With increasing case pressure the charge pressure must be increased accordingly.5 psi)(for 1% of the operation time evenly divided. Bosch Rexroth Mellansel AB . since many structures may give rise to resonance.3 Choice of hydraulic fluid The Hägglunds hydraulic motors are primarily designed to operate on conventional petroleum based hydraulic oils. This may well be the most important factor to consider. (Tables of sound data .10/48 Technical data 2. The final choice of oil must depend on the operating temperature that can be expected or that has been Bosch Rexroth Mellansel AB. 2. bearing the following requirements in mind: General The oil shall have FZG (90) fail stage minimum 11 described in IP 334 (DIN 51354).see subsection 4. Hydraulic motor The hydraulic motor is a known noise level. The hydraulic oil can be chosen in consultation with the oil supplier of your local sales office. Hägglunds CB. Securing to non-rigid metal structures or structures is likely to give resonance and should be avoided. it is highly important to study the construction of the foundation or casing. Driven unit The driven unit is an unknown sound source (for us) but can through certain information probably be obtained from the supplier. The viscosity of mineral oil is highly dependent of the temperature. Pump unit The pump unit is a known noise level. resulting in severe noise problems.9 in the Engineering Manual). EN 683-6br/2011 . Installation and maintenance manual.2 Sound from a complete installation Background noise Pump motor Pipe noise Hydraulic motor Noise from driven unit Foundation and construction noise Remarks: Background noise The background noise can not normally be influenced but is usually known or easy to measure. Pipe noise The pipe noise is probably the source of the majority of mistakes in installations: all pipe clamps should be of vibration insulating type secured to concrete ceiling. When securing the torque arm of a hydraulic motor to the foundation or casing of a driven machine. The oil must also contain inhibitors to prevent oxidation. corrosion and foaming. wall or floor. Bosch Rexroth Mellansel AB . Fire resistant fluids Operating with fire resistant fluids The following fluids are tested for Hägglunds motors: (ISO/DP 6071) Fluid Approved Seals Internal paint HFA: Oil (3-5%) in water emulsion No – – HFB: Inverted emulsion 40-45% water in oil Yes Nitrile (std motor) Not painted* HFC: Water-glycol Yes Nitrile (std motor) Not painted* Yes Viton Not painted* HFD synthetic fluids HFD:R – Phosphate esters HFD:S – Chlorinated hydrocarbons Yes Viton Not painted* HFD:T – Mixture of the above Yes Viton Not painted* HFD:U – Other compositions Yes Viton Not painted* * Must be specified in the order. however many hydraulic fluids are subject to temporary and permanent reductions of the viscosity. as well as resulting in low viscosity. For heavy-duty applications we recommend synthetic oils. Hägglunds CB. Viscosity index = 150 can be used for operation with large temperature difference. Temperature limits Normal operating temperature should be less than +50 °C (122 °F) Nitrile seals (std motor) Viton seals -35 °C to +70 °C -20 °C to +100 °C Nitrile seals (std motor) Viton seals -31 °F to +158 °F -4 °F to +212 °F Minimum viscosity limits at operating temperature in motor case Standard motors with uncoated pistons and uncoated cam rollers 20 cSt/98 SSU* Motors type C (coated pistons and coated cam rollers) for speed below 3 rpm or when charge pressure exceeds 50 bar (725 psi) at speed above 50 rpm 10 cSt/59 SSU* * Low viscosity gives reduced service life for the motors.05%. coated piston or high viscosity shall be used. Technical data 11/48 established in the system and not in the hydraulic tank.1%. Viscosity index = 100 is recommended. In industrial applications with high demands for service life. which in turn provides poor lubrication. Installation and maintenance manual. Content of water shall be less than 0. Hägglunds recommendation is always to use the base oil viscosity when calculating the rated life and max allowed power. For speed below 3 rpm. the content of water shall be less than 0. EN 683-6br/2011. Max permitted viscosity is 10000 cSt/48000 SSU. High temperatures in the system greatly reduce the service life of oil and rubber seals. Recommended viscosity in motor case at operating temperature 40-150 cSt/187-720 SSU. For that reason we recommend a filter with an indicator that gives a signal when it is time to change the filter cartridge.6%). 2. The Hägglunds company or its authorised representative must always be contacted for approval in the case of these types of fluids. ** Environmental acceptable fluid gives the same service life for the drive. class 7). When filling the tank and motor case. we recommend the use of a filter with the grade of filtration β10=75. •• =75 means the grade of filtration of above mentioned size of particle. The grade of filtration in a hydraulic system is a question of service life v. The grade of filtration is defined as number of particles in the oil before filtration in relation to number of particles in the oil after filtration. Filtering recommendations Before start-up. Environmentally acceptable fluids Approved Seals Internal paint Vegetable */** Fluid HTG Fluid Yes Nitrile (std motor) – Synthetic **/*** Esters HE Yes Nitrile (std motor) – * Vegetable fluids give good lubrication and small change of viscosity with different temperature. Vegetable fluids must be controlled every 3 months and temperature shall be less than +45 °C (113 °F) to give good service life for the fluid. check that the system is thoroughly cleaned. When choosing the filter it is important to consider the amount of dirt particles that the filter can absorb and still operate satisfactory. Explanation of “GRADE OF FILTRATION” Grade of filtration ß10=75 indicates the following: •• ß10 means the size of particle ≥10 µm that will be removed by filtration. In order to obtain stated service life it is important to follow our recommendations concerning contamination level. 1. •• Ex. 75 •• This means that N N = 74·N number of particles have been filtered (=98.12/48 Technical data IMPORTANT! Down rating of pressure data and service life must be considered when using fire resistant fluid.s. 75 75 Bosch Rexroth Mellansel AB. money spent on filtration. For industrial applications the contamination level should not exceed ISO 4406:1999 18/16/13 (NAS 1638. *** The fluid shall have less than 10g/100g according to ASTMD 1958-97/DIN 53241 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. Installation and maintenance manual. Grade of filtration is ß10=75. as mineral oil. •• Before the filtration the oil contains N number of particles ≥10 µm and after passing the filter once the oil contains N number of particles ≥10 µm. Hägglunds CB. EN 683-6br/2011 . 0866 -0.061 -0.85 194 7. see 3.17 117 4.4.00067 -0.015 7. Installation 13/48 3 Installation 3. Table 3. 3 bar (43.2.1 Mounting instructions If the motor is to work properly it must be installed with the greatest possible precision.00055 -0. Hägglunds CB. see 2. the drain ports must be positioned vertically.014 -0. 3.1 and tables 3. Normally the motor must be completely filled with oil. The motor must always be connected in such a way as to give a sufficient boost.1 and 3.5 psi). EN 683-6br/2011.00272 10. Brief peaks during operation up to 8 bar (116 psi) are permissible. The higher of the four ports must be used: see fig. it is recommended that the driven shaft should have a stress relieving groove.2362 B mm in 106 4. 3.00213 CB 400 180 -0.1a: Valid for couplings Dim A mm in CB 280 -0.2 “Draining and venting the motor”.1 “Recommended charge pressure”. for example on changes in the direction of rotation. see fig.61 153 6. This is particularly important at high speeds and with rapid reversing.00240 200 7. make-up flow at the low pressure connection. Bosch Rexroth Mellansel AB . The permitted housing pressure when the motor is stationary is 8 bar (116 psi).069 -0.64 254 10 Notice! The dimensions are valid for +20 °C (68 °F) Design of driven shaft end on heavily-loaded shaft Where the driven shaft is heavily loaded and is subject to high stresses.054 -0.02 C mm in 174 6. Every item connected to the motor that does not meet the requirements of the following instructions may result in stresses that adversely affect the service life of the motor. When the motor is mounted with the shaft in the vertical plane.8740 CB 560/840 -0.017 260 -0.00059 0. The max housing pressure is 3 bar (43. Installation and maintenance manual. The drain line must be dimensioned so that max.5 psi) motor housing pressure is not exceeded. When the motor is installed with the shaft in the horizontal plane.25. for example for changes in the direction of rotation and/or load. 3.2 and tables 3. it is recommended that the driven shaft should have a stress relieving groove. EN 683-6br/2011 . 3. Hägglunds CB.02) B±0.24±0.5 (B±0. Installation and maintenance manual.5 (0.5.2a Table 3. R a 3.02) R 50 (R 1.2 30° 6±0. Where the driven shaft is heavily loaded and is subject to high stresses.14/48 Installation G F C E D A Max.24±0.1 and 3. Bosch Rexroth Mellansel AB. the shaft can be plain.02) Fig. G F E D A Max. see fig.97) Fig. 3.5 (0. see figures below.1a Normally-loaded shaft In drives with only one direction of rotation where the stresses in the shaft are moderate.2 30° 6±0.2a Unidirectional drives Steel with yield strength Rel = 300 N/mm Bidirectional drives Steel with yield strength Rel = 450 N/mm Dimensions CB1120 Design of driven shaft end on heavily loaded shaft. Ra 3. 02) R 50 (R 1. the shaft can be plain.2 30° 6±0. EN 683-6br/2011. Installation and maintenance manual.1b Dim A mm in CB 1120 -0.025 -0.15 -0.1b Normally loaded shaft In drives with only one direction of rotation and/or load where the stresses in the shaft are moderate. 3.46 C mm in 334 13.02) Fig. Ra 3.00098 340 13. Bosch Rexroth Mellansel AB .5 (0.97) B±0.025 -0.2 30° 6±0.5 (0. R a 3.02) Fig.2b Table 3.3858 B mm in 215 8. Installation 15/48 A C Max.24±0.00098 Notice! The dimensions are valid for +20 °C (68 °F) Hägglunds CB. A Max.5 (B±0. see figure and below. 3.24±0. 3. EN 683-6br/2011 . with hydraulic oil or filled with transmission oil from the connected gearbox. For control of spline see table below. To avoid wear in the splines.3 Unidirectional drives 2 Steel with yield strength Relmin = 450 N/mm Bidirectional drives 2 Steel with yield strength Relmin = 700 N/mm Bosch Rexroth Mellansel AB. 278 5024. Installation and maintenance manual. Hägglunds CB. Table 3. see 278 5023.2b: Recommended material in the shaft Unidirectional drives Steel with yield strength Rel = 300 N/mm Bidirectional drives Steel with yield strength Rel = 450 N/mm 215 [8.24] Fig. the installation must be within the specified tolerances in figure below.16/48 Installation Table 3. For production of the shaft.46] 6x15° [0.3 Spline The splines shall be lubricated. 278 5025 and 278 5026. If there is no radial or axial force on the shaft. the shaft can be oiled only. 3.201 Ø 188 0 -1.15 A (0. Table 3. EN 683-6br/2011. The tool has both a UNC thread and a metric thread.1.87) G 50 (1.181 270.2) CB 280-840 D M20 UNC 5/8" E >17 (0.088 -0.320 Ø 259 Measure over measuring pins -0.015) Fig.006) 0.18) ł ł A 0.1.201 Ø 248 Major diameter 0 -0.4 Motor CB 280/400 CB 560/840/1120 DIN 5480 DIN 5480 Tooth profile and bottom form Tolerance Guide Pressure angle Module Number of teeth Pitch diameter 8f 8f Back Back 30° 30° 5 5 38 50 Ø 190 Ø 250 Minor diameter 0 -1. Installation 17/48 Table 3.103 -0.307 Diameter of measuring pins Ø 10 Ø 10 Addendum modification X M +2. 3. Installation and maintenance manual.5) should be drilled and tapped in the centre of the shaft for a mounting tool.98) 22 (0. see 3. Bosch Rexroth Mellansel AB .5 “Removing the motor from the driven shaft”.158 -0.3 Hägglunds CB.1 and 3.157 210.4 A (0.4 “Mounting the motor onto the driven shaft”.25 +2.5 (0. so that the hole can be drilled and tapped to conform to one of the two alternatives given in table below.25 Thread for mounting tool 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 3.53) F 25 (0.5: Alternative thread (fig.67) >13. and 3.97) 30 (1.290 Ø199 0 -0. 1. Hägglunds CB. 3. Fig. 3.1 Lifting methods Always make sure where the centre of gravity is before any lifting. 3. Installation and maintenance manual.4b Fig.4a Fig.18/48 Installation 3. EN 683-6br/2011 .4c Bosch Rexroth Mellansel AB. Hägglunds CB.7: Torque arm Weight Weight kg lb TCA 40 128 282 TCA 84 224 493 TCA 112 310 683 WARNING Lifting straps must be chosen with reliable saftey margin over the total weight of the lifted object. EN 683-6br/2011.5 DANGER Always make sure where the centre of gravity is before any lifting. Table 3. 3. Bosch Rexroth Mellansel AB . Installation and maintenance manual. Installation 19/48 Fig. Never stand below a hanging motor or torque arm.6: Motor Motor with shaft coupling Motor with splines kg lb kg lb CB 280 800 1 760 705 1 555 CB 400 1 160 2 555 1 060 2 335 CB 560 1 290 2 840 1 115 2 450 CB 840 1 620 3 570 1 445 3 185 CB 1120 2 340* 5 160* 1 770 3 900 Notice! *CB1120 with shaft coupling set Table 3. 9 and 3. Bosch Rexroth Mellansel AB. 3.10).20/48 Installation Standing the motor on a flat surface When the motor is placed on a flat surface such as a floor. 3. When in storage. the motor must always be placed on the end face to the hollow shaft. since this may cause damage to the coupling. it must stand either on its outer diameter or on the suitably protected end face of the hollow shaft (see fig. Hägglunds CB.6 Support Fig. It is also advisable to provide supports at the mounting surface of the motor. 3.10. EN 683-6br/2011 . 3.7 Notice! The motor must not be placed on the end face of the hollow shaft when the coupling is fitted. Support Fig. see fig. Installation and maintenance manual. (Dimensional check). see fig. Use a screwdriver to open the coupling ring for easier mounting. (Use torque wrench).4. •• Right torque on the bolts. 3. (With or without using the mounting tool). •• Alignment of the motor on the shaft. 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 relubricate those surfaces with Molykote again but remember only the specified surfaces! •• Absolutely no Molykote on the surfaces between shaft-motor.11.and inside of the Hägglunds CB motor hollow shaft. •• Minimum variation in the gap between the clamping rings. Installation and maintenance manual. see fig. This lubricants shall remain on those surfaces but: CAUTION Molykote must under no circumstances be trans-fered to the surfaces between the driven shaft and the motor. •• Mount the motor onto the driven shaft by following the instruction in the section 3.1. Clean the driven shaft and the inside of the motor hollow shaft. CAUTION Never tighten the coupling screws until the motor has been mounted onto the driven shaft. Remember •• The conical surface between the coupling ring and the clamping rings + the bolts shall be coated with MoS2 (Molykote). EN 683-6br/2011. •• Mount the coupling on the hollow shaft of the motor. The coupling must be pushed right up to the stop of the shaft. Bosch Rexroth Mellansel AB . If those conditions are fulfilled you may start the mounting. 3.2 Mounting the coupling onto the motor shaft Before the motor is mounted there are some preconditions which must be fulfilled: •• You should note that the couplings are from the factory lubricated with MoS2 (Molykote) on the conical surfaces and the bolts. It is therefore important that you clean your hands free from Molykote.11. •• Remove the spacers between the two clamping rings of the coupling. (Dimensional check).1. Hägglunds CB. Installation 21/48 3. •• Clean the driven shaft and the out. drill. Bosch Rexroth Mellansel AB. Installation and maintenance manual. •• Make sure that the torque arm will be pointing in the right direction when the motor is mounted in place on the machine.= Coated surface Cleaned surface Centre of motor Fig. CAUTION Do not weld. •• Oil the screws..3 Fitting the torque arm to the motor The torque arm is fitted to the motor before the motor is mounted on the driven shaft. Hägglunds CB...22/48 Installation CAUTION Before starting the motor. Clamping rings Coupling ring Seal Washer Motor hollow shaft . 3.. the motor must be turned until the drain outlets are positioned according to fig 3. •• Tighten the screws to the torque stated in the table below. grind or carry out any similar work on the torque arm without Hägglunds approval.12. EN 683-6br/2011 . check that the rotating coupling can not cause damage. •• Line up the torque arm on the motor by using the screws with washers. •• Clean the spigot surface on the torque arm and motor.1.8 3. To achieve the highest possible oil level in the motor housing. 9a CB 560/840/1120 Table 3.10b.8 Motor Tightening torque Screw dimension Number of screws Nm lbf·ft CB 280/400 M20 Strength class 10.1.9 41 900 660 Notice! Use torque wrench and oiled screws! 3. Bosch Rexroth Mellansel AB .3b Fitting the double ended torque arm The torque arm is fitted to the motor before the motor is mounted on to the driven shaft. Hägglunds CB. Alt. Installation 23/48 Fig. Mount the rod to the torque arm. 3. use the shaft (pos 2) and lock them with circlips. EN 683-6br/2011. 1: Check and adjust the rod end (pos 1) according to the drawing. Tighten the 4 pcs of screw (pos 3) on the rod end with torque according to table 3.1. 3. See 3.9 CB 280/400 Fig.9 34 540 400 CB 560/840/1120 M24 Strength class 10. Installation and maintenance manual.3a “Fitting the torque arm to the motor”. 7b Cylinder Screw dimension Tightening torque Nm lbf·ft 63/45 M10x30 49 36 63/50 M10x30 49 36 70/45 M10x30 49 36 80/50 M10x30 49 36 80/56 M10x30 49 36 80/63 M10x30 49 36 Remark! Start the system and run it for some minutes. 3. Vent the cylinder from air. EN 683-6br/2011 . Table 3. and on the right hand viewed from the motors main connection side. C2) has to be mounted to the cylinders connection B. The piston rod has to be mounted upwards. It is important to arrive at the correct clamping length between the driven shaft and the hollow shaft of the shaft adapter. Use the vent screws on the cylinder (pos 4). Bosch Rexroth Mellansel AB. Cylinders oil connection A.1. Installation and maintenance manual.9b 3.4 Mounting the motor onto the driven shaft – shaft coupling The motor can be mounted onto the driven shaft with or without a mounting tool. A2) has to be mounted to the hydraulic cylinders connection A. and the hose from (C1.24/48 Installation Mount the hydraulic cylinder. 1 A2 C1 C2 1 A B C 3 2 A A2 4 C C2 Fig. The hose mounted to connection (A1. Mount the hoses. but the use of a mounting tool is recommended since it makes the work easier. This is valid with the cylinder on the right side hand-side of the the motor. Hägglunds CB. B and C must point in the direction to the motor. and a single speed motor. •• Refit the end cover and tighten the screws together with washers. Bearing retainer Plastic washer Mounting tool Nut Fig.9. and screw it into the driven shaft to stated depth by using the key handle in the end of the tool.10. 3. •• Pass the mounting tool through the centre of the motor. This is of particular importance if the duty is so severe that a stress relieving groove has been made on the driven shaft. •• Refit the plug.. measuring and marking the driven shaft. CAUTION Clean the driven shaft and the inside of the motor hollow shaft.12) •• Remove the end cover together with screws and washers. Mounting the motor with a mounting tool (fig. 3. 3. Installation and maintenance manual. 3.11.13a and table 3. •• Remove the mounting tool.11a and the table 3.. •• Align the motor with the driven shaft. 3. Bosch Rexroth Mellansel AB . •• Pull the motor onto the shaft by turning the nut on the mounting tool until the length B is obtained. 3. See fig.13. Torque 80 Nm (59 lbf·ft). •• Tightening the shaft coupling see table 3. Push and pull the end of the torque arm for easier mounting.10 Mounting the CB 280. see fig.840 Hägglunds CB. EN 683-6br/2011. •• Locate the existing plastic washer between the nut on the mounting tool and the bearing retainer. Installation 25/48 Ensure that the full clamping length is used by.10. for example. 3.02 Bosch Rexroth Mellansel AB.02 CB 840 153 6.9 Motor Length CB 280 Length B mm B in 106 4.11 Without stress relieving groove B+50 ( B+0.2 0 ) Fig. Installation and maintenance manual.17 CB 400 117 4. 3.61 CB 560 153 6.26/48 Installation B+50 ( B+0.11a With stress relieving groove Table 3. Hägglunds CB.2 0 ) Fig. EN 683-6br/2011 . However. 3.13. In order to avoid the misalignment of the two clamping rings during the screw tightening. Hägglunds CB. 3. Pre-set the coupling screws in opposite pairs (12-6-3-9 o’clock) until you reach max.10. The difference between the measured gaps must never vary more than 1 mm (0. see the sign on the coupling. remove the end cover as described in “Mounting the motor with a mounting tool”. Wobbling caused by a skew setting of the motor gives extra forces on the main bearings. To achieve the highest possible oil level in the motor housing. though this is more difficult and takes longer time. 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. 50% of the torque specified for the screws. Set the torque wrench for the specified maximum torque. Tightening torque of the coupling screws. EN 683-6br/2011. or table 3. it is easier to mount the motor if during mounting the compressed air trapped within the hollow shaft is evacuated. the gap between the rings must be measured in several places during the process. Now start tightening the screws in sequence shown in fig. 3. To do this. Installation and maintenance manual. Tightening of shaft coupling However for the tightening 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 during the tightening of the screws.14. 3.14.04”) during any stage of the tightening process. It is very important that when you reach this stage the misalignment is controlled as described above. see fig. see fig. Installation 27/48 D1 D2 Fig.12 Mounting the motor without a mounting tool The motor can be mounted onto the driven shaft without using a mounting tool. Mark the screw heads at 12 o’clock with a pen or paint so that you can follow the turning sequence of the screws.14a. the motor must be turned until the drain outlets are positioned according to fig 3. Bosch Rexroth Mellansel AB . Table 3. 3.9 490 362 Hexagon CB 560 20 M20 x 100 10. Keep checking the alignment of the coupling. EN 683-6br/2011 . There is a metallic sign on every coupling with a tightening torque stamped on it. Use calibrated torque wrench.14a Bosch Rexroth Mellansel AB. 3. Several passes are required before the screws are tightened to specified torque. When the specified torque is reached it is important that all screws are tightened with specified torque and that no further movement can be observed.10 Motor type No of screws Screw dim Strength class Tightening torque Nm Type of head lbf·ft CB 280 12 M20 x 80 10. Installation and maintenance manual. Hägglunds CB.9 490 362 Hexagon CB 1120 Note Note Note Note 1 2 3 4 Uncoated screws greased with MoS2. (15-20 passes may be necessary).9 490 362 Hexagon CB 400 15 M20 x 90 10.28/48 Installation Keep on doing this until you have reached the stated torque. CB 1120 with shaft coupling set Fig.14 1 12 2 11 3 4 10 5 9 6 7 8 Fig.9 490 362 Hexagon 32 M20 x 130 10. Tightening torque value is critical. This torque is always to be used.9 490 362 Hexagon CB 840 20 M20 x 100 10. Installation 29/48 3. •• Mount the cover. •• Mount the motor on to the shaft. •• Mark spline tooth location on outside of motor bore to assist alignment during installation. MV=81 Nm/59 lbt*ft. Then take away the o-ring. •• Fill up hydraulic oil to the G1 plug. •• Fill up hydraulic oil to the G1 plug. Torquearm mounted motors Motors that carry radial load. Installation and maintenance manual. EN 683-6br/2011.2) Oil to be filled before If oil here. •• Mount torque arm to motor with bolts supplied. MV=125 Nm/90 lbf*ft. Hägglunds CB. •• Mark spline tooth location on outside of motor bore to assist alignment during installation. With no radial load. If the motor is subject to radial load. •• Lubricate and install O-ring at leading edge of motor bore. the spline shall normally not be subject to radial load. The motor can be used for horizontal mounting and mounting with motor shaft pointing downwards. Bosch Rexroth Mellansel AB .1. •• Mount the motor using the installation tool. •• Align with oil connection ports as required.4b Mounting the motor onto the driven shaft – splines Flange mounted motors For flange mounted motors. •• Mount special designed bolt. must have the splines oiled. •• Torque the bolt. it can tightening G1 plug be used for the spline. MV=385 Nm/280 lbf*ft. o-ring Axial clearance min 5 (0. •• Bolt the motor to the flange. •• Lubricate and install O-ring at leading edge of motor bore. •• Check shaft/splines for burrs and lubricate shaft/splines. the spline shaft can be oiled before mounting the motor. •• Check shaft/splines for burrs and lubricate shaft/ •• splines. MV=81 Nm/59 lbf*ft. •• Torque the G1 plug. •• Mount the cover. the splines shall be filled up with oil. DANGER Never stay below the motor during disassembly. EN 683-6br/2011 . The motor can be removed from the shaft with or without the mounting tool.15 Removal of Hägglunds CB 280. The operation is easier if the tool is used.30/48 Installation o-ring 10 (0. 3.4) during filling of oil Spacer Oil to be filled before tightening bolt M20 L=100 mm 3.. Installation and maintenance manual. Bearing retainer Plastic washer Mounting tool Nut Fig.. WARNING Always make sure that the lifting equipment is strong enough to handle the weight of the motor.840 Bosch Rexroth Mellansel AB.5 Removing the motor from the driven shaft Before dismounting the motor from the driven shaft the oil in the motor housing must be drained through the lower draining hole.1. Hägglunds CB. Bosch Rexroth Mellansel AB . •• Screw in the nut of the tool until the bearing retainer can be refitted. Installation 31/48 Removal by using the mounting tool •• Slacken the shaft coupling screws gradually. after welding. EN 683-6br/2011. ±25° Notice! The toggle bearing must be dismounted during welding. Alternative position x 10 Steel: EN 10113S355N DIN St E39 BS 4360 Grade 50 C Protected against corrosion. refit the removed components as before. see “Mounting the motor without a mounting tool“. Removing the motor without using the mounting tool •• Slacken the screws of the shaft coupling. 3. Each screw should be slackened only about a quarter of a turn each time. see fig. and screw it into the driven shaft to stated depth. see above “Removal of motors by using the mounting tool”. •• Remove end cover and plug to allow air to enter the space in the hollow shaft of the motor.59 inch) movement when in use.6 Mounting the reaction point x = ±2 mm (0. Thus tilting and jamming of the collars or thread stretching will be avoided. torque 136 Nm (100 lbf·ft) and end cover. After removal of the motor. •• Carefully pull the motor off the driven shaft supported by an overhead crane or a lifting truck. Then pass the tool through the centre shaft. x ≤ ±15 mm (0. Fig. Installation and maintenance manual. torque 80 Nm (59 lbf·ft) as before.16 •• Locate the existing plastic washer outside the mounting tool nut. •• Remove the end cover and bearing retainer together with screws and washers. The screws must be slackened until the coupling ring is fully released.1. refit the removed bearing retainer. Finally. •• Remove the bearing retainer and mounting tool.14 and 3. 3.079 inch) misalignment in installation. 3. see fig. 3.16 Mounting of pivoted attachment Hägglunds CB. torque 136 Nm (100 lbf·ft) •• Remove the motor from the driven shaft by unscrewing the nut of the mounting tool.14a. Bosch Rexroth Mellansel AB.18 DANGER Make sure that the foundation can withstand the forces from the torque arm. EN 683-6br/2011 .17 The bearing shall be mounted so that the slot in the outer race is perpendicular towards the load direction. The bearing shall be mounted with a mounting sleeve or tube applied on the bearing outer ring. Danger zone! In case of failure of torque arm installation Fig.32/48 Installation Fig. Installation and maintenance manual. Hägglunds CB. 3. 3. T1 T2 C1 A1 D1 D4 F2 F3 Y D2 T3 A2 C2 X T4 Fig. EN 683-6br/2011. The length of the hoses should be kept fairly short. 3. Bosch Rexroth Mellansel AB . Installation and maintenance manual. Installation 33/48 3.25 C1 A1 Fig.25a Hägglunds CB. it is recommended to fit flexible hoses between the motor and piping to avoid damage due to vibration and to simplify installation of the motor.2 Oil connections When using (heavy wall) piping and in frequent reversal drives. 3. 11 Connection Description Remarks C1. T2.25b Table 3. T2 T3 T4 y mm y in x mm y in 1 1/4" 1 1/2" 1 1/4" 1 1/2" G 1 1/4" G 1" G 1/4" G 1/2" G 1/4" M16 G 1/4" G 1/2" 223 223 8. D2. F2 Flushing connection For flushing of radial lip seal. D2.12 Motor CB 280.1120 A* C* D1. A1. T1 Test connection Used to measure pressure and/or temperature at the main connections. F2 F3 T1. Installation and maintenance manual.38) Bosch Rexroth Mellansel AB. code 62. 414 bar (6000 psi).98 *SAE coupling J 518 C.22) UNC 1/2" UNC 5/8" 27 (1. the motor shaft rotates clockwise.78 8. T4 Pressure connection Connection for double ended torque arm. D4 D3 F1.34/48 Installation Table 3. c Main connection A. D1 Drain outlet Normally plugged at delivery.90 3. Hägglunds CB.1120 Connection a mm (in) b c mm (in) 1 1/4" 1 1/2" 31 (1. EN 683-6br/2011 .13 Motor CB 280 . 3. Normally plugged. viewed from the motor shaft side. F1. T3 Test connection Used to measure pressure and/or temperature in drain oil. 1 1/4” or 1 1/2” can be used. A2 Main connection If A is used as the inlet. D4 Alternative drain outlets Normally plugged at delivery. D3. C2 Main connection If C is used as the inlet. Table 3. viewed from the motor shaft side.78 99 101 3. the motor shaft rotates counterclockwise.06) 35 (1. C b a Fig. F3 Flushing connection For flushing of axial bearing and motor case... Installation and maintenance manual. 3.25d Hägglunds CB.0) BSP 3/4" Drain connection D1. Bosch Rexroth Mellansel AB .25c BSP 1/4" 15 (0. D4 Fig. D2. Installation 35/48  50 (2. EN 683-6br/2011.59) Test connection T Fig. 3. This gives flushing of the radial lip seal. Drain line must be connected direct to the tank with a minimum of restrictions. the highest of the four drain outlets D1. D3 or D4 must be used. EN 683-6br/2011 . With bidirectional drives. Vertical mounting When the motor is mounted vertically. It is advisable to fit the nipple and the hose to the motor before fitting the torque arm.28. anti-clockwise viewed from the motor shaft side. 3. see figure 3. Bosch Rexroth Mellansel AB. Installation and maintenance manual.36/48 Installation 3. D2. D2. see fig.1 Direction of rotation of motor shaft With the inlet pressure supply connected to A port. the motor shaft rotates in the direction shown by the arrow. The flushing connection F2 shall be connected to low pressure connection. D3 or D4 must always be used. C1 A1 Fig. use the connection with lowest average pressure. With the inlet pressure supply connected to C port. (Connection to high pressure will increase the motor drain flow). Orifice must be installed. Hägglunds CB.29. Motor shaft pointing downwards The motor must be connected to one of the drain connections in the connection block. 3.30. see figure 3.2. the highest of the four drain outlets D1. Flushing of radial seal from low pressure is necessary.26 3.2.2 Draining and venting the motor Horizontal mounting When the motor is installed with the shaft in the horizontal plane. the motor shaft rotates clockwise viewed from the motor shaft side. to ensure that the maximum housing pressure is not exceeded. The flushing connection F1 on the shaft end housing should be connected to the low pressure connection. Motor shaft pointing upwards The motor must be connected to the drain line connection on the shaft end housing. 0 (0. Flushing connection F2 Orifice Ø1.28 G 1/4". 3.30 Hägglunds CB. Installation 37/48 Drain line connection Fig. 3.04) Low pressure Drain line connection Fig. Flushing connection F1 Drain line connection Orifice Ø1.04) Low pressure Fig.29 G 1/4". 3. EN 683-6br/2011. Bosch Rexroth Mellansel AB . Installation and maintenance manual.0 (0. C1. Seal connections A and C with the cover plate fitted to the connection surface at delivery. Check that the O-rings or rubber seals are in position in the cover plate. Notice! the anti-rust protection must be touched-up after transport and handling. A1. Take extreme care to ensure that no contamination enters the motor. D1. This provides sufficient protection for indoor storage in normal temperatures for about 12 months.e. the table below states the amount of oil needed to fill the various types of motors.2 “Oil connections” and 3. D2. •• The motor case must be flushed when the output power exceeds the values shown beside. Bosch Rexroth Mellansel AB. Connect the input line for flushing in the lowest flushing F3.7.2. D3 or D4. Place the motor as shown in fig 4. 3. before starting the first time: Make sure that all fluids been removed from the motor to prevent accidental mixing with the hydraulic fluid used in the system. 4 Operating instructions 4.1. “Filtration” and table 4.1 Storage The motor is delivered with internal protection in the form of an oil film and external protection in the form of an anti-rust film.2. See 2.2 Before commissioning Check the following points before commissioning the motor. If the motor is stored for more than 3 months in uncontrolled environment or more than 12 months in controlled environment. it must be filled with oil and positioned as shown in fig. D3 and D4. •• Check that the motor is connected to give the correct direction of rotation (see 3. i.2. because high temperature gives lower viscosity and that gives reduction in basic rating life/ service life.38/48 Operating instructions 3. please contact your Hägglunds representative. The flushing oil shall be drained in the normal drainline.3. See 3.1. Fit the plug to D1.1 “Direction of rotation of motor shaft”). Maximum power without flushing CB 280 120 kW (160 hp) CB 400/560/840/1120 170 kW (227 hp) For calculation of required flushing. Installation and maintenance manual. D2. fill the motor with filtered oil in the following order: D1.3 Flushing Flushing of motor case To avoid high temperature in the motor case the heat must be removed. 4. Hägglunds CB. EN 683-6br/2011 . In F3 the max allowed flushing is 40 l/min (11 gpm).2. •• Check that the charge pressure conforms to the charge pressure curve (see 2.0 CB 840 25 6. see 3. see 3. A1 D4 C1 D1 D2 Fig.1 “Recommended charge pressure”).1 Motor Oil volume approx. •• Make sure that the torque arm is sufficiently fastened. D2 or the vent hole (depending on how the motor is mounted).1 “Mounting instructions” and 3.1 Table 4.6.1. •• Check the drain line to ensure that excessive pressure does not build up in the motor housing.3 and 3.6 CB 560 19 5.2 “Motor data”).5 Hägglunds CB.2.1.3 “Choice of hydraulic fluid”).2. •• Check that all hydraulic couplings and plugs are properly tightened to prevent leakage.6 CB 1120 32 8. Bosch Rexroth Mellansel AB . •• Fill the motor housing with hydraulic fluid via a filter into the drain outlets D1.0 CB 400 21 5. “Draining and venting the motor”. Operating instructions 39/48 •• Select the hydraulic fluid in accordance with the recommendations (see 2. see table 4. 4. Litres US gallon CB 280 15 4. •• Check that the motor is protected from overloads (see 1.1. EN 683-6br/2011. Installation and maintenance manual. Insp. and clean if necessary. •• Check all lines. Hägglunds CB. Installation and maintenance manual. Adjust valves etc. inspect tank. replace all filter cartridges for which a filter clogged indication has been given. see 4. – – – Once every 12 months Rpl = Replacement Insp = Inspection Bosch Rexroth Mellansel AB. dirt particles in the system are removed by the filters. 4.4 Periodic maintenance When a hydraulic system has been in service for some time. •• Check the pressure and temperature of the hydraulic fluid and carry out routine operations. •• Inspect and clean all air. Tighten the screws. thus leakage and faults will be detected earlier. •• We recommend that a running log be kept and that planned inspections are carried out at set intervals. After 3 months or 500 hours Rpl.5 psi). The filter cartridges have to be changed after the first 100 working hours and after that according to the maintenance chart. etc. Check that the outside of the hydraulic motor in an installation is kept free of dirt. – Insp. see the section headed “Oil”. •• Check that no dirt or other contaminations enter the system during inspection. EN 683-6br/2011 .40/48 Operating instructions 4. oil and magnetic filters. it must undergo periodic maintenance and servicing at intervals which depend on the equipment and the type of duty. •• The working pressure and charge pressure must be checked to ensure that they correspond to the contracted values.4 note to check the “filter clogged” indicators. filters etc. •• Check the hydraulic fluid. •• During the start up period. •• Check other possible leakage points and replace faulty parts. correct the fault and carry out new measurements. This pressure limit is important for the life of the motor seals. A not run-in motor in combination with dirt particles in the oil can badly affect the sliding surfaces in the motor. This periodic maintenance must include the following operations: •• Check the hydraulic system for leakage. replace faulty seals and keep the drive clean. and correct if necessary. •• The pressure in the drain line measured at the motor must be less than 3 bar (43. This is valid during the first 100 working hours. any hydraulic installation must be regularly and carefully checked at frequent intervals. •• Maintenance checks and operations are as follows: Maintenance chart In operation After the first 100 hours Oil filters Oil Torque arm Rpl. Insp. screws. – – Once every 6 months Rpl. Notice: It is important that the pressure is limited to 250 bar (3626 psi) when starting up the motor. if necessary. pump.3 Commissioning •• During initial starting and the period immediately after it. •• If leakage occurs. connections. •• Do not point the high-pressure cleaner at sensitive components. Hägglunds CB.1 Cleaning and care CAUTION Damage to the surface caused by solvents and aggressive detergents! Aggressive detergents may damage the seals on the hydraulic motor and cause them to age faster. 4. g. the motor must be regularly turned a few revolutions. Mix anti-rust additive with the hydraulic fluid of the system. electrical connections and speed encoder. •• Use only water and. 4. after which time the motor must be turned a few revolutions. If no additives are used. plug all connections.4. such as sensors and valve blocks clean. This can be done as follows: 1. EN 683-6br/2011. This additive gives rust protection for up to about 1 year. Use 2% of Shell VSI 8235. if necessary. •• Remove coarse dirt from the outside of the machine and keep sensitive and important components. •• Check whether all plugs and plug seals are securely seated to ensure that no moisture can penetrate into the hydraulic motor during cleaning. e. shaft seal. open drain outlet D1 or D2 on the port end housing (or if the motor is mounted vertically. it must be protected from internal rust. check the compatibility of the detergent with the seal type (Nitrile or Viton) specified in the hydraulic motor. (See fig. •• If in doubt. 4. flushing connection F1 on the shaft end housing) and fill the motor with hydraulic fluid. •• Never use solvents or aggressive detergents. a mild detergent to clean the hydraulic motor. observe the following: •• Plug all openings with suitable protective caps/devices. 3. seals in general. 2.3a).3 and fig. If it is not possible to turn the motor. Bosch Rexroth Mellansel AB . CAUTION Damage to the hydraulic system and the seals! Using a high-pressure cleaner could damage the speed encoder and the seals of the hydraulic motor. For cleaning and care of the hydraulic motor.2 Motor If the motor is to be stored stationary for a longer period than about one month. Operating instructions 41/48 4. Installation and maintenance manual.4. Hägglunds CB.4. oxidation.3 Fig. Bosch Rexroth Mellansel AB. and this means poorer lubrication. 4.3a 4.42/48 Operating instructions D1 D2 Fig. Viscosity Many hydraulic oils become thinner with increasing use. The viscosity of the oil in service must never fall below the minimum recommended viscosity. The oil must be replaced immediately if the analysis shows that it is exhausted. They must then be changed at regular intervals of 6 months or 4000 working hours.3 Filters Filters must be changed after the first 100 working hours and the second change is to be carried out after 3 months or 500 working hours whichever is earlier.4. Most oil suppliers are equipped to analyse the state of the oil and to recommend appropriate action. The analysis should cover viscosity. EN 683-6br/2011 .3) Analysis It is recommended that the oil should be analysed every 6 months. additives and contamination. Installation and maintenance manual. water content.4 Oil (Se also 2. 4. 4. Installation and maintenance manual. which then collects at the bottom of the tank. 4. Most hydraulic oils repel the water. 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 an analysis and from the laboratory you get a report. oxidation and viscosity. and the oil should then be checked more often. the acidity is stated in terms of the “neutralisation number”. With scheduled oil analysis. point out shortcomings in maintenance and keep repair cost to a minimum. Obtain the advice of your oil supplier in such cases. wear products can be identified and corrective action can be taken before failure occurs. this can be detected by coatings on filter cartridges or a change in the colour of the oil. which follow a specific international standard. The cause of the contamination must be immediately investigated and remedied. but the most used analysis are particle count. This is indicated by changes in colour and smell. EN 683-6br/2011. allowing the user to schedule re-fittings or overhauls. Degree of contamination Heavy contamination of the oil causes increased wear of the hydraulic system components. The oxidation process increases the acidity of the fluid. Water content Contamination of the oil by water can be detected by sampling from the bottom of the tank. Oil analysis can indicate when an oil change is required. Typical oxidation is slow initially and increases rapidly later.Another method is to install an inline particle counter direct in your hydraulic system which give you the Hägglunds CB. CAUTION All hydraulic fluids are affected differently. You have to select what analysis the laboratory should take. A sharp increase (by a factor of 2 and 3) in the neutralisation number between inspections is a signal that the oil has oxidized too much and should be replaced immediately. Obtain the advice of your oil supplier or by Hägglunds representative. This water must be drained off at regular intervals. Operating instructions 43/48 Oxidation Hydraulic oil oxidizes with time of use and temperature.5 Oil inspection Purpose The purpose to take an oil sample is to check the condition of the oil. The rate of oxidation increases rapidly at surface temperatures above 60 °C (140 °F). increased acidity or the formation of sludge in the tank. Certain types of transmission oils and engine oils emulsify the water. water content. maintenance or repairs. Bosch Rexroth Mellansel AB . Using oil analysis can create a “window of opportunity”. Inline measure The sample shall be taken at the mini-mess coupling on the charge pressure side of the motor in of the closed loop system. Bosch Rexroth Mellansel AB. bottle or the mini-mess hose when the sample is taken.44/48 Operating instructions contamination level according to the international rules. •• Only ¾ of the bottle shall be filled because the laboratory has to shake the sample to get a mixed fluid when they analyse it. General •• The intention is to verify the condition of the oil during operation. •• The cleanliness is extremely important during sampling. •• Be careful when connecting the mini-mess hose because the oil beam can be dangerous and should never point against any person or other sensible object. •• To get a reliable result the system must run without moving any valves and the mini-mess hose should not touch the bottle. the disadvantage with this method is that you only get the contamination level in the oil. •• Remove the cap of the bottle as late as possible and don’t let any contamination be in touch with the cap. Never out of the tank using the ball valves. use a soft plastic foil (normal as protection in laboratory bottles between bottle and cap). •• Check and be aware of the pressure you may have on the connection before you connect. The motors should be running at normal operation while the sample is taken. •• Connect the mini-mess hose to the coupling but be careful and be aware of the direction of the oil beam. EN 683-6br/2011 . •• Clean the coupling and the hose carefully. •• Always clean the connections carefully before you connect the mini-mess hose to the coupling. To get a true value the contamination readings have to be stable about 10 min before you stop to measure. •• When the bottled is filled close the cap as soon as possible to prevent contamination from the air that might enter the bottle and give you a wrong result.6 gallon US) of oil flush into a bucket before you fill the bottle. •• Always use bottles adapted to oil samples. How to do Bottle samples •• The sample shall be taken at the mini-mess coupling on the charge pressure side of the motor in the closed loop system. Hägglunds CB. •• Do not remove the foil. Minimum 200 ml are needed for a good analysis. •• Never try to clean your own bottle if you want a true value of the result. Installation and maintenance manual. •• Let minimum 2 litres (0. prick the end of your mini-mess hose through the foil into the bottle and fill. •• The sample should be taken by using a mini-mess hose connected to a mini-mess coupling. Clean the coupling and the hose carefully. Connect the hoses according to the particle counters manual. •• In dirty air area. they can be ordered from any fluid analysis laboratory. Connect the oil supply correctly. Check the hydraulic system. Fault finding 45/48 5 Fault finding Fault Action Mechanical stop in the drive. Insufficient or no oil being supplied to motor. Investigate the pressure level in the system and correct the setting of the pressure limiting valve if necessary. Investigate the drain oil. The motor does not deliver enough torque because the pressure difference across the motor is not great enough for the load. Adjust the charge pressure to the correct level. If the pressure has risen to the relief valve setting. remove the load from the drive. Steel particles indicate damage. Noise in the motor. External oil leakage on the motor. Put a magnetic plug in the oil flow and check the material that sticks to the magnet. Note that fine material from the castings may be deposited and does not mean internal damage in the motor. The motor does not run. Replace the radial lip seal. Motor runs jerkily. Motor rotates in wrong direction. Find the cause in the system or in the driven unit. if necessary. Check the external leakage of the motor. Bosch Rexroth Mellansel AB . Probable cause Hägglunds CB.1 „Recommended charge pressures“. The radial lip seal is worn. Internal faults in the motor. Installation and maintenance manual. The motor is being operated with the charge pressure too low. See 2. Pressure or flow fluctuations in the hydraulic system. EN 683-6br/2011. (The D connection). Oil supply connections to motor incorrectly connected. Check system pressure. Translations into other languages are also available.3.3.5.3 1.5 1.46/48 Declaration of incorporation 6 Declaration of incorporation Example of the Declaration of Incorporation given by Hägglunds Drives AB Declaration of Incorporation of partly completed machinery As defined by the EC Machinery Directive 2006/42/EC. These are transferred on request to the market surveillance body in paper-based/electronic format.6 1.8 1. The individual below is authorized to compile the relevant technical files: Name: Address: Björn Leidelöf Hägglunds Drives AB. is available on request for deliveries from Hägglunds Drives AB. EN 683-6BR/2011 . 1.1.6.4 1.5.3.7 1. Installation and maintenance manual.13 1.3 1. Conformity with the provisions of further EU Directives.1.3. project management and configuration documents) are implemented by the product user.2 1. Hägglunds CB. Bosch Rexroth Mellansel AB.7.5.3 1.1 1. It is also declared that the special technical documents for this partly completed machinery have been compiled in accordance with Appendix VII.6 1.3 1.5. Current issue on request. operating instructions.3 1.6.1 1. Standards or Specifications: SS-EN 982 SS-EN ISO 12100-1 SS-EN ISO 12100-2 The partly completed machinery may only be put into operation when it has been established that the machine into which the partly completed machinery is to be incorporated conforms to the provisions of EC Machinery Directive 2006/42/EC. Part B.4 The requirements are fulfilled provided that the data in the product documentation (fitting instructions. S-890 42 Mellansel Mellansel.5. The requirements of Appendix I to Machinery Directive 2006/42/EC not mentioned here are not applied and have no relevance for the product.4 1. 1.3.5. where relevant according to this directive. The declaration of incorporation above.3. 2009-12-29 We reserve the right to make changes to the content of the Declaration of Incorporation.5 1. Appendix II B The manufacturer Hägglunds Drives AB hereby declares that the partly completed machinery Name: Function: Model: Type: Trade name: Compact CB Hydraulic motor Compact CB Compact CB satisfies the following essential requirements of Machinery Directive 2006/42/EC in accordance with the chapter numbers in Appendix I: General principle no.7. Bosch Rexroth Mellansel AB . Installation and maintenance manual. EN 683-6BR/2011. Declaration of incorporation 47/48 NOTES Hägglunds CB. mll@boschrexroth. +46 (0) 660 870 00 Fax +46 (0) 660 871 60 documentation.com/hagglunds Your local contact can be found at: www.boschrexroth.boschrexroth.Bosch Rexroth Mellansel AB SE-895 80 Mellansel Sweden Tel.com/adresses We reserve the right to make changes Printed in Sweden EN 683-6BR/2011 .se www.