Related Manuals for Bosch Rexroth Hägglunds DOb
Summary of Contents for Bosch Rexroth Hägglunds DOb
- Page 1 Hägglunds DOb Drive unit Installation and maintenance Supersedes manual 12.2016 RE 15327-WA/05.2017 English...
- Page 2 © This document, as well as the data, specifica- 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.
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Page 3: Table Of Contents
Pipe work, internal Electric connections Commissioning Before commissioning Filling up the system with hydraulic fluid Flushing before start up Initial start up procedure Pressure settings and adjustments Temperature settings for cooling Hägglunds DOb, RE 15327-WA/05.2017, Installation and maintenance manual, Bosch Rexroth AB... - Page 4 10.7 Drive unit out of service 10.8 Repair 10.9 Spare parts Removal and replacement 11.1 Common Disposal 12.1 Environmental protection Extension and conversion Troubleshooting Technical data 15.1 Weights Declaration of Incorporation Bosch Rexroth AB, Installation and maintenance manual, Hägglunds DOb, RE 15327-WA/05.2017...
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Page 5: This Documentation
The described danger prevention measures must be observed. Safety instructions are formatted as follows: Hägglunds DOb, RE 15327-WA/05.2017, Installation and maintenance manual, Bosch Rexroth AB... - Page 6 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. Bosch Rexroth AB, Installation and maintenance manual, Hägglunds DOb, RE 15327-WA/05.2017...
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Page 7: Safety Instructions
• Modification of factory settings by non-authorized persons • Use of add/on parts (e.g. mountable filter, control unit, valves) that are not specified by Bosch Rexroth has to be approved by contact at Bosch Rexroth. Hägglunds DOb, RE 15327-WA/05.2017, Installation and maintenance manual, Bosch Rexroth AB... -
Page 8: Personnel Qualifications
• Reading and fully understanding of logic diagrams Knowledge of programmable equipment (PLC, VFD etc) Bosch Rexroth offers training support for special fields. For more information about training, please contact your Bosch Rexroth representative. Bosch Rexroth AB, Installation and maintenance manual, Hägglunds DOb, RE 15327-WA/05.2017... -
Page 9: General Safety Instructions
• 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. -
Page 10: Product-Specific Safety Instructions
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. Bosch Rexroth AB, Installation and maintenance manual, Hägglunds DOb, RE 15327-WA/05.2017... - Page 11 Risk of personal injury or property damage. ▶ Follow instructions for delivered equipment. Rotating parts! Risk of injury or serious injuries. ▶ Do not touch rotating parts or in the zone of rotating parts. Hägglunds DOb, RE 15327-WA/05.2017, Installation and maintenance manual, Bosch Rexroth AB...
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Page 12: Personal Protection Equipment
The personal protective equipment is the responsibility of the user of the Hägglunds drive unit. Observe the safety regulations and provisions of your country. All components of the personal protective equipment must be intact. Bosch Rexroth AB, Installation and maintenance manual, Hägglunds DOb, RE 15327-WA/05.2017... -
Page 13: General Instructions On Material Damage And Product Damage
Electrical motor damage! ▶ All electrical supply levels shall be within the limits that the equipment is constructed for, see Hägglunds DOb custom documentation and product identification. Hägglunds DOb, RE 15327-WA/05.2017, Installation and maintenance manual, Bosch Rexroth AB... - Page 14 The warranty applies only to the delivered configuration. The entitlement to warranty cover will be rendered void if the product is incorrectly installed, commissioned or operated, or if it is used or handled improperly. Bosch Rexroth AB, Installation and maintenance manual, Hägglunds DOb, RE 15327-WA/05.2017...
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Page 15: Delivery Contents
This installation and maintenance manual is intended to cover default setup of the system. 5.2 Product identification 1 Type code 2 Serial number 3 Weight 4 Manufacturer 5 Max pressure DD00057560 Fig. 1: Product identification Hägglunds DOb, RE 15327-WA/05.2017, Installation and maintenance manual, Bosch Rexroth AB... -
Page 16: Main Components
Oil tank Fig. 19 Filter Pressure sensor Oil level/temperature sensor Fig. 19 Air breather Fig. 19 Oil-drain valve Fig. 19 Main power switch Fig. 5 Emergency stop actuator Fig. 5 Bosch Rexroth AB, Installation and maintenance manual, Hägglunds DOb, RE 15327-WA/05.2017... -
Page 17: Hydraulic Fluids
• For pumps, the maximum start-up viscosity is 1600 cSt. • Running below 30cSt may impact the system service life. • Running below 20 cSt may render instant system seizure. Hägglunds DOb, RE 15327-WA/05.2017, Installation and maintenance manual, Bosch Rexroth AB... -
Page 18: Requirements For Hydraulic Fluid Cleanliness
4406:1999 18/16/13. • Have a water content of <200 ppm (0,02%). • Always use filter elements recommended and supplied by Bosch Rexroth. • The hydraulic fluid should be analysed according to the special maintenance intervals for your specific drive unit or the maximum intervals on the maintenance chart (see Table 11: Maintenace chart). -
Page 19: Control Cabinet Function
Clogged return oil filter will be indicated on the front panel DD00081610 Fig. 4: Monitoring logic diagram Hägglunds DOb, RE 15327-WA/05.2017, Installation and maintenance manual, Bosch Rexroth AB... -
Page 20: Control Cabinet Interface
System running Alarm oil temperature Alarm oil level Control panel frequency converter Actual pressure Actual speed Warning cooler Warning filter Regulator on/off Command local/remote Main power switch Warning sign electricity Bosch Rexroth AB, Installation and maintenance manual, Hägglunds DOb, RE 15327-WA/05.2017... -
Page 21: Transport And Storage
If storage time exceed limits, the drive unit must be operated so that the hydraulic system is lubricated with new fluid (see 10.7: Drive unit out of service). Hägglunds DOb, RE 15327-WA/05.2017, Installation and maintenance manual, Bosch Rexroth AB... -
Page 22: Lifting The Packed Drive Unit
See Fig. 6 for maximum total width of the forks. Position forks about the centre of gravity at lifting. DD00083913 Fig. 6: Maximum width of forks lifting packed drive unit Bosch Rexroth AB, Installation and maintenance manual, Hägglunds DOb, RE 15327-WA/05.2017... -
Page 23: Installation
7.2 lifting methods lifting with fork lift See 6.2: Lifting the packed drive unit section lifing with fork lift. DD00083914 Fig. 7: Maximum width of forks lifting drive unit Hägglunds DOb, RE 15327-WA/05.2017, Installation and maintenance manual, Bosch Rexroth AB... -
Page 24: Positioning The Drive Unit
Risk of injury or serious injuries ▶ The drive unit has to be fixed to the ground with fixing screws or similar. Bosch Rexroth AB, Installation and maintenance manual, Hägglunds DOb, RE 15327-WA/05.2017... - Page 25 Fig. 10. Max inclination of drive unit is 14°. DD00083915 Fig. 10: Anchoring Dob Hägglunds DOb, RE 15327-WA/05.2017, Installation and maintenance manual, Bosch Rexroth AB...
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Page 26: Hydraulic Connections
Fig. 11: Hydraulic connections at the drive unit Table 6: Hydraulic connections "1"" SAE J518C Flange A-Port pump 3/4" G Male Drain from hydraulic motor 1" G Male Return from hydraulic motor Bosch Rexroth AB, Installation and maintenance manual, Hägglunds DOb, RE 15327-WA/05.2017... - Page 27 *) Torque acc. to SAE J518-2 with class 10.9 or grade 8 screws. DD00082671 Fig. 12: High pressure connection DD00082672 DD00081611 125 mm 4.92 in 190 mm 7.48 in 355 mm 13.98 in Fig. 13: Dimensions external connections points Hägglunds DOb, RE 15327-WA/05.2017, Installation and maintenance manual, Bosch Rexroth AB...
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Page 28: Pipe Work, Internal
1/4 to 1/2 turn after the nut has been tightened so that the hose can not be turned. 4. Check that the hose doesn’t get twisted when the nut is tightened. Bosch Rexroth AB, Installation and maintenance manual, Hägglunds DOb, RE 15327-WA/05.2017... - Page 29 Ensure that hoses not are stressed or twisted on installation, to avoid premature failure. Bend radius should conform to manufacturers recommendations. Right Wrong Right Wrong Right Wrong Right Wrong Wrong Right DD00073548 Fig. 14: Mounting of hoses Hägglunds DOb, RE 15327-WA/05.2017, Installation and maintenance manual, Bosch Rexroth AB...
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Page 30: Electric Connections
Hägglunds DOb documentation and rating plate. DD00083859 Grounding point Fig. 15: Grounding point 7.6.2 Electrical connection Connect the cables to the terminals inside the control cabinet Bosch Rexroth AB, Installation and maintenance manual, Hägglunds DOb, RE 15327-WA/05.2017... - Page 31 Installation 31/80 DD00081605 Fig. 16: External connections DD00081624 Fig. 17: Simplified terminals view inside cabinet Hägglunds DOb, RE 15327-WA/05.2017, Installation and maintenance manual, Bosch Rexroth AB...
- Page 32 Speed signal (JUMPER IF NOT USED) +4-20 mA out (0-2.7 rpm) 4-20 mA return Power off input (JUMPER IF NOT USED) +24 V Signal must be isolated in external system Bosch Rexroth AB, Installation and maintenance manual, Hägglunds DOb, RE 15327-WA/05.2017...
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Page 33: Commissioning
Use a fluid filling pump unit with a filter rating of β10 ≥ 75. Cleanliness in barrels with new oil is not clean enough for the system and has to be filtrated before filling up in to the system to avoid problems. Hägglunds DOb, RE 15327-WA/05.2017, Installation and maintenance manual, Bosch Rexroth AB... - Page 34 LED 1 will switch off. See Table 9: Volumes for threshold levels, for corresponding values. • Fill the tank until the oil level reaches the nominal value. See Table 9: Volumes for threshold levels for corresponding values. Bosch Rexroth AB, Installation and maintenance manual, Hägglunds DOb, RE 15327-WA/05.2017...
- Page 35 Distance Volume Volume Volume from top from top from top inch inch inch 0.98 4.25 6.61 DD00082938 Fig. 19: Tank with level sensor DD00082676 Fig. 20: Point of measure Hägglunds DOb, RE 15327-WA/05.2017, Installation and maintenance manual, Bosch Rexroth AB...
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Page 36: Flushing Before Start Up
High cleanliness is important for long lifetime of the hydraulic system. DD00082677 Hoses connected together Flow direction Flushing filter Check valve drive unit Fig. 21: Hydraulic circuit flushing Bosch Rexroth AB, Installation and maintenance manual, Hägglunds DOb, RE 15327-WA/05.2017... -
Page 37: Initial Start Up Procedure
Start the unit in local mode and set minimum speed of the electric motor. The machine should have no load, which gives as low pressure as possible in the system. CAUTIoN Rotating parts! Risk of injury. ▶ Do not touch rotating parts Hägglunds DOb, RE 15327-WA/05.2017, Installation and maintenance manual, Bosch Rexroth AB... - Page 38 10.3: Filter change to avoid dirt into the system. If there still is dirt in the system, additional flushing is necessary in order to prevent premature failure of system components. • Check all connections, screws etc. and tighten if necessary. Bosch Rexroth AB, Installation and maintenance manual, Hägglunds DOb, RE 15327-WA/05.2017...
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Page 39: Pressure Settings And Adjustments
Assignment of the upper limit). The alarm (stop) level for the oil temperature in the tank is set to 63 °C [145 °F] and should normally not be changed. Contact your Bosch Rexroth representative if you need to change this value. -
Page 40: Vfd (Variable Frequency Drive)
9.1.1 How to start transmission • Click on Tools→ Connect/Switch Online When the device is connected properly with the PC, the grey color PC to converter connector symbol will be coloured . Bosch Rexroth AB, Installation and maintenance manual, Hägglunds DOb, RE 15327-WA/05.2017... - Page 41 9.1.3 How to load a new parameter file using ConverterWorks software In order to load a parameter file, the device must be online. • Click on Parameterization → Load. • Choose a parameter file. • Click on Load. Hägglunds DOb, RE 15327-WA/05.2017, Installation and maintenance manual, Bosch Rexroth AB...
- Page 42 • Change the parameter value. • Press enter to save the parameter value. • Close the parameter box It is possible to compare two parameter files with the option Compare Bosch Rexroth AB, Installation and maintenance manual, Hägglunds DOb, RE 15327-WA/05.2017...
- Page 43 Firmware version is older than 03Vxx (new version). If updated all the parameters will be set to default values’. • Confirm with Ok. All configured parameters must be updated. Hägglunds DOb, RE 15327-WA/05.2017, Installation and maintenance manual, Bosch Rexroth AB...
- Page 44 • The module loading message appears three times. The device will boot automatically, after the update has been finished. ‘Firmware updated successfully’ is displayed and the update window can be closed. • The device has to be rebooted after update. Bosch Rexroth AB, Installation and maintenance manual, Hägglunds DOb, RE 15327-WA/05.2017...
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Page 45: Front Panel Based Commissioning Of Vfd
Green (Short dark long red) Blinks in Red Warning at stop Green/Off Off/ Green (Short dark long red) Blinks in Red Error Green/Off Off/ Green (Short red long dark) Hägglunds DOb, RE 15327-WA/05.2017, Installation and maintenance manual, Bosch Rexroth AB... - Page 46 Change the necessary parameter value by pressing <▲> or <▼>. The new parameter value can be saved by pressing <Set>. It is possible to go back to previous step, by pressing <Func> button. Fig. 25: operating Example Bosch Rexroth AB, Installation and maintenance manual, Hägglunds DOb, RE 15327-WA/05.2017...
- Page 47 'E0.08' displayed. The digit shifting function is only available for parameters with values and unavailable for parameter with options. Hägglunds DOb, RE 15327-WA/05.2017, Installation and maintenance manual, Bosch Rexroth AB...
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Page 48: Functions And Parameters
Low speed running mode output frequency lower than Output frequency low limit (E0.10) E0.17 Direction control 1: Forward only E0.26 Acceleration time Ramp rise time E0.27 Deceleration time Ramp fall time Bosch Rexroth AB, Installation and maintenance manual, Hägglunds DOb, RE 15327-WA/05.2017... - Page 49 E4.00 PID reference channel AI 2 analog input E4.01 PID feedback channel AI 1 input U1:Panel parameters U1.00 Run monitoring display Actual speed U1.10 Stop monitoring display Setting speed Hägglunds DOb, RE 15327-WA/05.2017, Installation and maintenance manual, Bosch Rexroth AB...
- Page 50 – Read: Parameter setting is read-only and cannot be modified. • DOM: Depends on model • [bx.xx], [Cx.xx], [Ex.xx], [Hx.xx], [Ux.xx], [dx.xx]: Function / parameter values • Value: The value we chosen for the frequency controller Bosch Rexroth AB, Installation and maintenance manual, Hägglunds DOb, RE 15327-WA/05.2017...
- Page 51 Change the duty mode to 'Normal duty' by modifying the parameter setting from '1' to '0' according to the actual application. • 1: HD (Heavy duty). This mode is set by default. Hägglunds DOb, RE 15327-WA/05.2017, Installation and maintenance manual, Bosch Rexroth AB...
- Page 52 When the output frequency is higher than [C1.75] 'Low speed derating frequency', the allowed continuous current is [C1.07] 'Motor rated current'. • When the output frequency is lower than [C1.75], the allowed continuous current is reduced to [C1.76] (‘C1.76’=Zero speed load). Bosch Rexroth AB, Installation and maintenance manual, Hägglunds DOb, RE 15327-WA/05.2017...
- Page 53 • The actual slip compensation is 2.50 Hz x 100 % = 2.50 Hz. • 101...200 %: Over slip compensation • Example: [C1.12] = 2.50 Hz, [C2.07] = 200 % • The actual slip compensation is 2.50 Hz x 200 % = 5.00 Hz. Hägglunds DOb, RE 15327-WA/05.2017, Installation and maintenance manual, Bosch Rexroth AB...
- Page 54 AI2 input (PID control reference) as second frequency setting source. The frequency converter for controlling the cooler uses AI1 analog input (Frequency setting signal from temperature sensor) as first frequency setting source. Bosch Rexroth AB, Installation and maintenance manual, Hägglunds DOb, RE 15327-WA/05.2017...
- Page 55 The frequency is calculated as f=n/30 n: The speed of motor in rpm f: frequency in Hz Hägglunds DOb, RE 15327-WA/05.2017, Installation and maintenance manual, Bosch Rexroth AB...
- Page 56 • When stopping command is active, the motor freewheels to stop as [E0.50] = 1. • When direction command is changed during running, the motor decelerates to stop according to the defined deceleration time as [E0.50] = 0. Bosch Rexroth AB, Installation and maintenance manual, Hägglunds DOb, RE 15327-WA/05.2017...
- Page 57 : For the main pump drive, X3 starts the forward running : For the cooler drive, the signal from the main pump drive to X1 starts the cooler. • 36: Reverse running (REV) • 41: PID deactivation via X4. Hägglunds DOb, RE 15327-WA/05.2017, Installation and maintenance manual, Bosch Rexroth AB...
- Page 58 The output is active when the frequency converter is running and has frequency output including 0.00 Hz. Used as start signal for cooler drive from the main pump drive Bosch Rexroth AB, Installation and maintenance manual, Hägglunds DOb, RE 15327-WA/05.2017...
- Page 59 • [E4.00] = 9: Speed reference E4.04 The reference value is set by parameter E4.04. Frequency converter for pump drive uses AI 2 analog input (E4.00=4) as the PID reference channel. Hägglunds DOb, RE 15327-WA/05.2017, Installation and maintenance manual, Bosch Rexroth AB...
- Page 60 33: I/O card EAI input 35: AO1 output 37: I/O card EAO output 40: Digital input 1 43: I/O card digital input 45: DO1 output 47: I/O card EDO output Bosch Rexroth AB, Installation and maintenance manual, Hägglunds DOb, RE 15327-WA/05.2017...
- Page 61 This function can detect the input missing possibly due to the Analog input cable disconnection. Solution is to check wiring of AI1, AI2 and EAI Once the broken wire is detected, the frequency converter can stop with error indication (Error code: AibE). Hägglunds DOb, RE 15327-WA/05.2017, Installation and maintenance manual, Bosch Rexroth AB...
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Page 62: Maintenance And Repair
… The air flow paths not are blocked … Pressure levels normal - stable … Operating temperature … The drive is running smoothly … Contamination indicators on the filters … Check and clean the oil pan Bosch Rexroth AB, Installation and maintenance manual, Hägglunds DOb, RE 15327-WA/05.2017... - Page 63 Once every 6 months Once every 12 months I = Inspection R = Replacement *If the contamination indicator is tripped out, the filter must be changed immediately and the oil examined. Hägglunds DOb, RE 15327-WA/05.2017, Installation and maintenance manual, Bosch Rexroth AB...
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Page 64: Filter Change
Danger associated to Hydraulic fluid. Risk of environmental damage ▶ Store up used hydraulic fluid and contamined filter elements for destruction. Different hydraulic fluids are affected differently - consult the manufacturer. Bosch Rexroth AB, Installation and maintenance manual, Hägglunds DOb, RE 15327-WA/05.2017... - Page 65 The disadvantage with this method is that you only get the contamination level in the oil. If inline measurement has to be done, please contact your Bosch Rexroth representative for advice.
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Page 66: Electric Motor
The electric motor is used with D-connection. Electric motor must be properly grounded. DD00073030 DD00062668 Main voltage and connection Fig. 26: Example Hoyer marking plate Fig. 27: D connections Bosch Rexroth AB, Installation and maintenance manual, Hägglunds DOb, RE 15327-WA/05.2017... - Page 67 Check the rotation direction of the new electric motor. Correct direction is clockwise viewed from fan side of the motor. (See Fig. 28) DD00083916 Fig. 28: Electric motor rotation direction Hägglunds DOb, RE 15327-WA/05.2017, Installation and maintenance manual, Bosch Rexroth AB...
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Page 68: Cooler
Before the plant is re-started after a long stop period, a check must be done to verify the system function. Meassures to be done: • Remove preservative fluid and any signs of contamination. • Follow the procedure in 8.4: Initial start up procedure. Bosch Rexroth AB, Installation and maintenance manual, Hägglunds DOb, RE 15327-WA/05.2017... -
Page 69: Repair
Maintenance and repair 69/80 10.8 Repair Bosch Rexroth offers a comprehensive range of services for the repair of Hägglunds products. Repairs on the Hägglunds products may only be performed by service centers certified by Bosch Rexroth. ▶ Use exclusively original spare parts from Bosch Rexroth to repair the Hägglunds product, otherwise the functional reliability of the product can not be assured and you lose your warranty entitlement. -
Page 70: Removal And Replacement
• Replace all seals, gaskets and o-rings with new items of the correct size and lubricate with system hydraulic fluid before assembly. • Refill hydraulic fluid according to section 8.2: Filling up the system with hydraulic fluid Bosch Rexroth AB, Installation and maintenance manual, Hägglunds DOb, RE 15327-WA/05.2017... -
Page 71: Disposal
RE 15327 Hägglunds DOb . 13 Extension and conversion Do not modify Hägglunds products. Please contact your Bosch Rexroth representative for extension or conversion. Hägglunds DOb, RE 15327-WA/05.2017, Installation and maintenance manual, Bosch Rexroth AB... -
Page 72: Troubleshooting
6.Pump or motor defective Foaming of the 1. Suction line leaks 1. Shaft seals on hydraulic fluid 2. Fluid level too the suction side are low. defective. Bosch Rexroth AB, Installation and maintenance manual, Hägglunds DOb, RE 15327-WA/05.2017... - Page 73 4.Pilot pressure 4.Unsuitable remote- variations control valve 5. Adjustable damping on valves, has not been set 6.Check the electrical controls. 1. Unsuitable fluid for the duty. Hägglunds DOb, RE 15327-WA/05.2017, Installation and maintenance manual, Bosch Rexroth AB...
- Page 74 1. Line mounts are Lines loose. switching takes missing or loose. place. 2. Poor installation. 3. Pipe bore too small. 4. Installation not bled. 5. Oil volume in lines is excessive Bosch Rexroth AB, Installation and maintenance manual, Hägglunds DOb, RE 15327-WA/05.2017...
- Page 75 2. No damping. valves have not been orifices are damaged type of valve (the fitted in front of the or missing. openingcross- switching valves. sectional area changes too quickly). Hägglunds DOb, RE 15327-WA/05.2017, Installation and maintenance manual, Bosch Rexroth AB...
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Page 76: Technical Data
Fig. 29 DD00082691 Fig. 29: Placement of product identification plate Table 12: weights Part weight Electric motor 7,5 kW Pump 8,1 cc 14.1 10,6 cc 14.1 Air cooler Bosch Rexroth AB, Installation and maintenance manual, Hägglunds DOb, RE 15327-WA/05.2017... -
Page 77: Declaration Of Incorporation
XXX XXX, DC-IA/EHD DC-IA/PRM8 XXX XXX, DC-IA/TE8 We reserve the right to make changes to the content of the Declaration of Incorporation. Current issue on request. Page 1 / 1 Hägglunds DOb, RE 15327-WA/05.2017, Installation and maintenance manual, Bosch Rexroth AB... - Page 78 78/80 Declaration of Incorporation NoTES Bosch Rexroth AB, Installation and maintenance manual, Hägglunds DOb, RE 15327-WA/05.2017...
- Page 79 Declaration of Incorporation 79/80 NoTES Hägglunds DOb, RE 15327-WA/05.2017, Installation and maintenance manual, Bosch Rexroth AB...
- Page 80 Bosch Rexroth AB SE-895 80 Mellansel Sweden Tel. +46 (0) 660 870 00 Fax +46 (0) 660 871 60 documentation.mll@boschrexroth.se www.boschrexroth.com/hagglunds Your local contact can be found at: www.boschrexroth.com/adresses We reserve the right to make changes Printed in Sweden RE 15327-WA /05.2017...