Bosch Rexroth Hagglunds DOb Handbuch

Installation and maintenance

manual

RE 15327-WA/05.2017

Supersedes

12.2016

English

Hägglunds DOb

Drive unit

The data specied above only serve to describe

the product. No statements concerning a

certain condition or suitability for a certain

application can be derived from our informa-

tion. The information given does not release

the user from the obligation of own judgment

and verication. It must be remembered that

our products are subject to a natural process of

wear and aging.

tions 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 there-

fore reserve the right to introduce amendments

in the manual as we deem necessary without

notice or obligations.

The cover shows an example conguration. The

product supplied may therefore dier from the

gure shown.

The original operating instructions were pre-

pared in English.

Hägglunds DOb, RE 15327-WA/05.2017, Installation and maintenance manual, Bosch Rexroth AB

3/80 Contents

Contents

1 This documentation 5

1.1 Scope of documentation 5

1.2 Required and additional documentation 5

1.3 Display of information 5

2 Safety instructions 7

2.1 About this chapter 7

2.2 Intended use 7

2.3 Improper use 7

2.4 Personnel qualications 8

2.5 General safety instructions 9

2.6 Product-specic safety instructions 10

2.7 Personal protection equipment 12

3 General instructions on material damage and product damage 13

4 Delivery contents 15

5 About this product 15

5.1 Product description 15

5.2 Product identication 15

5.3 Main components 16

5.4 Hydraulic uids 17

5.5 Requirements for hydraulic uid cleanliness 18

5.6 Control cabinet function 19

5.7 Control cabinet interface 20

6 Transport and storage 21

6.1 Storage of the packed drive unit 21

6.2 Lifting the packed drive unit 22

7 Installation 23

7.1 Installation directives 23

7.2 Lifting methods 23

7.3 Positioning the drive unit 24

7.4 Hydraulic connections 26

7.5 Pipe work, internal 28

7.6 Electric connections 30

8 Commissioning 33

8.1 Before commissioning 33

8.2 Filling up the system with hydraulic uid 33

8.3 Flushing before start up 36

8.4 Initial start up procedure 37

8.5 Pressure settings and adjustments 39

8.6 Temperature settings for cooling 39

4/80

Bosch Rexroth AB, Installation and maintenance manual, Hägglunds DOb, RE 15327-WA/05.2017

9 VFD (Variable frequency drive) 40

9.1 PC based commissioning of VFD 40

9.2 Front panel based commissioning of VFD 45

9.3 Functions and Parameters 48

10 Maintenance and repair 62

10.1 Maintenance log 62

10.2 Preventive maintenance 62

10.3 Filter change 64

10.4 Inspection of hydraulic uid 64

10.5 Electric motor 66

10.6 Cooler 68

10.7 Drive unit out of service 68

10.8 Repair 69

10.9 Spare parts 69

11 Removal and replacement 70

11.1 Common 70

12 Disposal 71

12.1 Environmental protection 71

13 Extension and conversion 71

14 Troubleshooting 72

15 Technical data 76

15.1 Weights 76

16 Declaration of Incorporation 77

This documentation 5/80

Hägglunds DOb, RE 15327-WA/05.2017, Installation and maintenance manual, Bosch Rexroth AB

1 This documentation

1.1 Scope of documentation

This documentation applies to the drive unit Hägglunds DOb and is intended for

machine/system manufactures, tters and service engineers.

This documentation contains important information required to transport, install,

commission, operate, use, service, dismantle the product safely and professionally.

▶Read this documentation completely, before using the Hägglunds DOb.

1.2 Required and additional documentation

Do not start using the product until you have familiarised yourself with the

documentation marked with the book symbol and followed it.

Table 1: Necessary and supplementary documentation.

Title Document no Document type

Order conrmation Contains the order-related

technical data for your

Hägglunds DOb.

Order conrmation

Order documentation Order specic E.g. hydraulic and electric

diagrams, bill of material,

specications

Hydraulic uid quick

reference

RE 15414 Data sheet

Float switch, Type ABZMS-41 RE 50222-B Operation manual

1.3 Display of information

Standardized safety instructions, symbols, terms and abbreviations are used so that

you can use this documentation to work quickly and safely with your product. To give

you a better understanding they are explained in the sections below.

1.3.1 Safety instructions

This documentation includes safety instructions in chapter 2.6: Product-specific

safety instructions and in chapter 3: General instructions on material damage and

product damage and before a sequence of actions or an

instruction for action involving a risk of personal injury or damage to equipment.

The described danger prevention measures must be observed.

Safety instructions are formatted as follows:

6/80 This documentation

Bosch Rexroth AB, Installation and maintenance manual, Hägglunds DOb, RE 15327-WA/05.2017

SIGNAL WORD

Type of risk

Consequences of non-observance

▶Safety precautions

•Warning sign: Draws your attention to the hazard

•Signal word: Indicates the degree of hazard

•Type of risk!: Species the type and source of the hazard

•Consequences: Describes the consequences of non-compliance

•Precaution: Species how the hazard can be prevented

Table 2: Risk categories to ANZI Z535.6-2006

Warning signs, signal word Meaning

DANGER Indicates a dangerous situation which will result in death or

serious physical injury unless averted.

WARNING Indicates a dangerous situation which could result in death

or serious physical injury unless averted.

CAUTION Indicates a dangerous situation which could result in minor

to moderate physical injury unless it is averted.

NOTice Material damage: the product or its environment could be

damaged.

1.3.2 Symbols

The symbols below indicate instructions which are not safety-relevant but help to

make the documentation easier to understand.

Table 3: Key to symbols

Symbol Meaning

You will be unable to use or operate the product optimally unless this

information is observed.

▶

•

Individual self-contained action (alternatives)

Numbered operating instruction:

The numbers indicate the actions follow one another in sequence

Center of gravity

Markings on packaging to indicate where the center of gravitiy are.

Safety instructions 7/80

Hägglunds DOb, RE 15327-WA/05.2017, Installation and maintenance manual, Bosch Rexroth AB

2 Safety instructions

2.1 About this chapter

This product was made in accordance with the generally accepted rules of the art

but there is a risk of personal injury and damage to property unless you follow this

chapter and the safety instructions in this documentation.

▶Read this documentation carefully through in full before using product.

▶Keep this documentation so it is accessible to all users at all times.

▶Always give products to third parties with the documentation required.

2.2 Intended use

The Hägglunds DOb is a hydraulic power unit

In the application the Hägglunds DOb drive unit is classied as a partly completed

machinery in the sense of the EU machine directive 2006/42/EC. A partly completed

machinery is exclusively intended to form an incomplete or a complete machine

together with other components or partly completed machineries. The DOb drive

unit may only be commissioned after it has been installed in the machine/system

for which it is intended and the safety of the entire system has been established in

accordance with the machine directive.

Intended use includes having read and understood the complete documentation,

especially the chapter 2: Safety instructions.

The product is intended for the following use:

• Create hydraulic ow in a open loop hydraulic system.

Standard drive units are not allowed to be used outside an ambient temperature of

0 °C to 40 °C (32 °F to 104 °F) or in areas with potentially explosive atmospheres.

2.3 Improper use

Any use other than that described as intended use shall be considered as improper

and is therefore impermissible.

Bosch Rexroth shall accept no liability whatsoever for damage resulting from

improper use. The user shall bear all risks arising from improper use.

Similarly, the following foreseeable faulty usages are also considered to be improper:

• Using outside the operating parameters approved in the product-specic data

sheet or in the order conrmation (unless customer-specic approval has been

granted)

• Use of uids outside of the standards as specied in RE15414 Hydraulic fluid quick

reference.

• Modication of factory settings by non-authorized persons

• Use of add/on parts (e.g. mountable lter, control unit, valves) that are not

specied by Bosch Rexroth has to be approved by contact at Bosch Rexroth.

8/80 Safety instructions

Bosch Rexroth AB, Installation and maintenance manual, Hägglunds DOb, RE 15327-WA/05.2017

• Extension or conversion is not permissible and has to be approved by contact at

Bosch Rexroth.

• Using the Drive unit in explosive environments unless the component or machine/

system has been certied as compliant with the ATEX directive.

• Using the Drive unit in an aggressive atmosphere without necessary additional

measures.

2.4 Personnel qualications

The activities described in this documentation require basic mechanical, electrical

and hydraulic knowledge, as well as knowledge of the associated technical terms.

For transporting and handling the product, additional knowledge is necessary with

regard to working with a lifting device and the corresponding attachment equipment.

In order to ensure safe use, these activities may therefore only be carried out by

appropriate qualied personnel or an instructed person under the direction and

supervision of qualied personnel.

Qualied personnel are those who can recognize possible hazards and institute

the appropriate safety measures due to their professional training, knowledge, and

experience, as well as their understanding of the relevant regulations pertaining

to the work to be done. Qualied personnel must observe the rules relevant to the

subject area and have the necessary hydraulic, electric and automation knowledge.

Hydraulic knowledge means, for instance:

• reading and fully understanding hydraulic diagram,

• fully understanding in particular the interrelationships regarding safety devices and

having knowledge on the function and assembly of hydraulic components.

Electric knowledge means, for instance:

• Reading and fully understanding of electrical diagrams

• Certication for work with electrical equipment

Automation knowledge means, for instance:

• Reading and fully understanding of logic diagrams

Knowledge of programmable equipment (PLC, VFD etc)

Bosch Rexroth oers training support for special elds. For more information about

training, please contact your Bosch Rexroth representative.

Safety instructions 9/80

Hägglunds DOb, RE 15327-WA/05.2017, Installation and maintenance manual, Bosch Rexroth AB

2.5 General safety instructions

• Follow current accident prevention and environmental protection rules.

• Observe the safety rules and regulations of the country in which the product is

used.

• Do not use Bosch Rexroth products unless they are in perfect working order.

• Follow all the instructions on the product.

• Before starting up new, rebuild or just worked on installations, all accessories and

safety arrangement functions must be controlled/tested.

• Persons who install, operate, remove or maintain Bosch Rexroth products must

not consume any alcohol, drugs or pharmaceuticals that may aect their ability to

respond.

• Use only Bosch Bosch Rexroth spare parts to avoid the risk of personal injury

through using unsuitable parts.

• Comply with the technical data and ambient conditions stated in the product

documentation.

• If unsuitable products are tted or used in safety-critical applications, unintended

operating conditions may arise which could cause personal injury and damage to

property. So do not use a product for safety-critical applications unless that use is

specically stated and allowed in the product documentation, e.g. in explosion risk

areas or in safety-critical controls (operating safety).

• You may only commission the product if it has been determined that the end

product (e.g. machinery or a system) into which the Bosch Rexroth products are

installed complies with the country-specic provisions, safety regulations and

standards of the application.

• Use safety equipment like helmet, protective goggles, safety shoes and hearing

protection.

• In emergency situations, use only re-extinguisher adapted for use both to oil

products and electric equipment.

• Follow the general installation and safety regulations when working on power

installations

• Do not remove or plug in connectors when the unit is powered

10/80 Safety instructions

Bosch Rexroth AB, Installation and maintenance manual, Hägglunds DOb, RE 15327-WA/05.2017

2.6 Product-specic safety instructions

The safety instructions below apply to chapters 6: Transport and storage to 15:

Technical data

DANGER

Danger from suspended loads!

Danger to life or risk of injury, damage to equipment!

Improper transportation may cause the Hägglunds drive unit to fall down lead to

injuries e.g. crushing or broken bones or damage to the product.

▶Make certain that the forklift truck or lifting device has adequate lifting capacity.

▶Never stand under or put your hands under suspended loads.

▶Ensure your position is stable during transportation.

▶Use your personal protective equipment (e.g. safety glasses, safety gloves,

suitable working clothes, safety shoes).

▶Use suitable lifting device for transport and storage. For removal and repair,

make sure the electric motor is well mounted or anchored when the lifting

device is disconnected.

▶Observe the prescribed position of the lifting strap.

▶Observe the national laws and regulations on work and health protection and

transportation.

Pressurized machine/system!

Danger to life or risk of injury, serious injuries when working on machines/systems

not shutdown! Damage to equipment!

▶Do not disconnect any line connections, ports and components when the

machine/system is pressurized.

▶Always ensure that no energy is accumulated before any measures.

▶Ensure that no pressure will enter the hydraulic system in the drive unit via the

hydraulic motor e.g. loads on the shaft or winch drum.

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