Hägglunds Fusion Installation & Maintenance Manual

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INSTALLATION & MAINTENANCE MANUAL

Hägglunds Fusion

Drive system

RE 15345-WA, Version: 11.2022, Replaces: New, EN

Table of Contents

Summary of Contents for Hägglunds Fusion

Page 1 INSTALLATION & MAINTENANCE MANUAL Hägglunds Fusion Drive system RE 15345-WA, Version: 11.2022, Replaces: New, EN...
Page 2 The data specified only serve to describe the product. No statements concerning a certain condition or suitability for a certain application can be derived from our information. Catalog specifications do not constitute assured characteristics. The information given does not release the user from the obligation of own judgment and verification.
Page 3: Table Of Contents
Contents | Hägglunds Fusion Drive system 3/72 Contents This documentation ................... 5 Validity of the documentation ................5 Required and additional documentations ............5 Presentation of information ................5 Safety instructions ..................7 About this chapter ..................7 Intended use....................7 Improper use ....................8 Personnel qualifications ................8 General safety instructions ................9...
Page 4 4/72 Hägglunds Fusion Drive system | Contents Maintenance and repair ................50 Maintenance log ..................50 Preventive maintenance ................50 Filter change ....................53 Inspection of hydraulic fluid ................55 Air filter breather change ................56 Electric motor ....................57 Cleaning of air oil cooler ................58 Drive system out of service ................59...
Page 5: This Documentation
American version, and is intended for machine/system manufactures, fitters and service engineers. Hägglunds Fusion is a flexible product with a wide option range, this installation and maintenance manual is intended to cover all these options. Some options might not be included in the delivered drive system, see order specific documentation for the exact content.
Page 6 6/72 Hägglunds Fusion Drive system | This documentation 1.3.1 Safety messages This documentation includes safety messages placed before sequential operating procedures that may involve the risk of personal or property damage. The described precautionary measures must be observed. Safety messages are structured as shown below:...
Page 7: Safety Instructions
2.2 Intended use The Hägglunds Fusion is a hydraulic drive system. In the application the Hägglunds Fusion drive system is classified as a partly completed machinery in the sense of the EU machine directive 2006/42/EC, Appendix IIB. A partly completed machinery is exclusively intended to form an incomplete or a complete machine together with other components or partly completed machineries.
Page 8: Improper Use
8/72 Hägglunds Fusion Drive system | Safety instructions 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.
Page 9: General Safety Instructions
Safety instructions | Drive system Hägglunds Fusion 9/72 2.5 General safety instructions • Observe the regulations for accident prevention and environmental protection. • Comply with the local safety provisions and regulations of the country in which the product is used.
Page 10: Product-Specific Safety Instructions
10/72 Hägglunds Fusion Drive system | Safety instructions 2.6 Product-specific safety instructions The safety instructions below apply to chapters 6: Transport and storage to 14: Technical data DANGER Danger from excessively high pressure Danger to life or risk of injury, damage to equipment.
Page 11 Safety instructions | Drive system Hägglunds Fusion 11/72 WARNING Escaping oil mist Risk of explosion, fire, health hazard, environmental pollution. f Depressurize the machine/system and repair the leak. f Keep open flames and ignition sources away from the Hägglunds drive system.
Page 12: Personal Protective Equipment
12/72 Hägglunds Fusion Drive system | Safety instructions CAUTION High noise development in operation Danger of hearing damage, deafness. The noise emission of Hägglunds drive system depends on speed, operating pressure and installation conditions. f Always wear hearing protection when in the vicinity of the operating drive system.
Page 13: General Notes Regarding Property Damages And Product Damages
General notes regarding property damages and product damages | Drive system Hägglunds Fusion 13/72 3 General notes regarding property damages and product damages NOTICE Danger from improper handling Product can be damaged. f Do not expose the product to an impermissible mechanical load.
Page 14 14/72 Hägglunds Fusion Drive system | General notes regarding property damages and product damages NOTICE Contamination of the hydraulic fluid The cleanliness of the hydraulic fluid has a considerable impact on the cleanliness and service life of the hydraulic system. Contamination of the hydraulic fluid could cause premature wear and malfunctions.
Page 15: Scope Of Delivery
5 About this product 5.1 Product description Hägglunds Fusion is a closed loop hydraulic system that converts electric energy to mechanical rotation of a shaft. All included parts are assembled in a compact cabinet. The drive system has one pump driven by one electric motor to provide the hydraulic motor with the required flow of oil and pressure at the right time.
Page 16: Main Components
16/72 Hägglunds Fusion Drive system | Scope of delivery About this produkt 5.3 Main components 42629 Product identification Drain tap 1˝ BSP Female Oil filling point Fig. 2: Main components Hägglunds Fusion Main components Item Description See also figure Hydraulic motor –...
Page 17 About this produkt Scope of delivery | Drive system Hägglunds Fusion 17/72 42466 Fig. 3: Detailed view, tank Item Description Oil-drain valve Level and temperature sensor Air filter breather Level gauge RE 15345-WA, Version 11.2022, Bosch Rexroth AB...
Page 18: Hydraulic Fluids
About this produkt 18/72 Hägglunds Fusion Drive system | Scope of delivery 5.4 Hydraulic fluids The Hägglunds hydraulic system is primarily designed for operation with hydraulic fluids according to ISO 11158 HM. Fluids by the standards given in Table 4 are suggested. Before the start of project...
Page 19: Requirements For Hydraulic Fluid Cleanliness
About this produkt Scope of delivery | Drive system Hägglunds Fusion 19/72 5.5 Requirements for hydraulic fluid cleanliness The drive systems are equipped with a filter in the charge line. In order to obtain stated service life it is important to follow recommendations concerning cleanliness levels and maintenance.
Page 20: Drive System Monitoring
The low (charge) pressure indicator must be interlocked during stop and startup of the electric motor to avoid alarm and give the pump time to build up the charge pressure after start. Note! For Fusion with pump control alarm and warning be handled by must customer control system.
Page 21: Transport And Storage
Transport and storage | Drive system Hägglunds Fusion 21/72 6 Transport and storage 6.1 Storage of the packed drive system At delivery the drive system is protected by a wooden crate covering a sealed plastic hood and internally protected with desiccant bags to absorb moisture. Do...
Page 22: Lifting The Packed Drive System
22/72 Hägglunds Fusion Drive system | Transport and storage 6.2 Lifting the packed drive system The packed drive system is marked with center of gravity and weight. The drive system package is designed for forklift handling. WARNING Packed drive system can tip over Danger to life or risk of injury, damage to equipment f See label on the crate for center of gravity.
Page 23: Installation
Installation | Drive system Hägglunds Fusion 23/72 7 Installation 7.1 Installation directives If the drive system is to work properly it must be installed in accordance with these instructions. The conditions the system will operate in must be taken into consideration.
Page 24 = number of load bearing leg n x cos ß ß = angle or inclination of the chain to the vertical G = Weight of Hägglunds Fusion. See 14.1: Weights n = 2 (due to asymmetrical load) ß = 0 - 45° 42633 Fig.
Page 25: Positioning The Drive System
Installation | Drive system Hägglunds Fusion 25/72 7.3 Positioning the drive system The following space must be left free around the drive system, to allow free ventilation (distance A and B ) and to provide sufficient working space for maintenance (distance B and C). Heavier maintenance such as change of motor/ pump will demand more working space.
Page 26: Required Tools
26/72 Hägglunds Fusion Drive system | Installation 7.4 Required tools Assembly tool for CA and CB motor For easier and faster mounting of the motor on driven shaft, a special assembly tool can be used. The assembly tool is passed through the motor and screwed into a pre made thread in the driven shaft.
Page 27: Drive System Mounting
7.5 Drive system mounting 7.5.1 Before mounting the Fusion drive system Instruction to follow when mounting the Hägglunds Fusion on a driven shaft. Before it is mounted there are some preconditions which must be fulfilled: f The shaft material for the driven shaft must be of a quality which meets the minimum requirements specified by Bosch Rexroth.
Page 28 28/72 Hägglunds Fusion Drive system | Installation DD00058188 Fig. 9: Tightening order Table 9: Screws and tightening torque, for standard shrink discs Motor type Shrink Number of Screw Strength Tightening Type of disc size screws dim. head Ib·ft CA 50/CA 70 ⌀...
Page 29 Installation | Drive system Hägglunds Fusion 29/72 7.5.3 Mounting the reaction point (articulated connection) DANGER Articulated connection rotates with the motor! 42635 Risk to life and risk of injury or serious injuries and risk of damage to equipment! f Make sure the foundation...
Page 30 30/72 Hägglunds Fusion Drive system | Installation Load calculations 42476 T= Torque direction on driven shaft Fig. 11: External forces Fr, Fb for torque arm (3 o'clock position) 42478 T= Torque direction on driven shaft Fig. 12: External forces Fr, Fb for torque arm (3 o'clock position)
Page 31 37 kW 38025 43875 75 kW 38025 45225 The Force Fr is calculated including the total weight of the Fusion unit. The option BICA brake is not considered in the calculation of external forces. RE 15345-WA, Version 11.2022, Bosch Rexroth AB...
Page 32 32/72 Hägglunds Fusion Drive system | Installation Articulated connection 1. The bearing (6) shall be mounted by using a mounting sleeve or tube applied on the bearing outer ring. 2. The bearing shall be mounted with the slot in the outer ring perpendicular towards the load direction.
Page 33 Installation | Drive system Hägglunds Fusion 33/72 7.5.4 Mounting of main electric motor In some cases the electric motor is delivered separately. The following instructions are applicable for these cases only. WARNING Unsecured motor can fall Risk to life or serious injury or material damage.
Page 34 Inspection hole Ring gear Bellhousing Pump DD00070842 Fig. 14: Mounting of electric motor Shaft coupling For information about coupling type, see order specific Hägglunds Fusion documentation Table 13: Axial shaft coupling clearance Axial clearance, S Coupling types 0.118 0.118 0.138 0.157...
Page 35 Installation | Drive system Hägglunds Fusion 35/72 7.5.6 Mounting of air-oil cooler The air-oil cooler is normally mounted on the drive system. In some cases is the cooler separately mounted. For dimensions and placement of air-oil cooler see order specific Hägglunds Fusion documentation.
Page 36 42669 Fig. 16: Mounting of air-oil cooler HDC 080 with by-pass If by-pass on the cooler is needed (see order specific Hägglunds Fusion documen- tation). Mount the preassembled by-pass kit (including connectors, check valve and hose) according to Fig. 16...
Page 37: Electric Connections
Grounding point is on the side of the frame see Fig. 20. f All electrical supply levels must be within the limits that the equipment is constructed for, see order specific Hägglunds Fusion documentation and rating plates. 7.6.1 Control system All external electrical connections must be connected according to the electrical drawings in the order specific Hägglunds Fusion documentation.
Page 38 38/72 Hägglunds Fusion Drive system | Installation 7.6.3 Electric motor The main voltage and connection are marked on the electric motor marking plate, see Fig. 18. Y or D Connection is done depending on supply voltage in accordance to Fig. 19 from MCC (Motor Control Center).
Page 39 Installation | Drive system Hägglunds Fusion 39/72 7.6.4 Voltage equalization External grounding The Hägglunds drive system must be connected to external grounding for voltage equalization. The grounding point of the Hägglunds drive system is on the side of the frame to a M8 bolt.
Page 40: Commissioning
• The accumulator (when required) has to be filled with dry nitrogen to a pressure level in accordance with the attached order specific Hägglunds Fusion documentation (the accumulator is normally precharged to approx. 2 bar (29 psi) at delivery due to transportation safety reason).
Page 41: Filling Up The System With Hydraulic Fluid
Commissioning | Drive system Hägglunds Fusion 41/72 8.2 Filling up the system with hydraulic fluid If the Hägglunds system is delivered oil filled from manufacturer, this chapter can be disregarded during commisioning if the oil level is ok. • Do not mix different types of hydraulic fluid.
Page 42 42/72 Hägglunds Fusion Drive system | Commissioning 42639 Fig. 21: Oil filling WARNING Leakage of hydraulic oil Risk of personal injury f Check the caution sign on the hydraulic fluid container and the warnings in section 2. f Avoid long contact between skin and hydraulic fluid.
Page 43 Commissioning | Drive system Hägglunds Fusion 43/72 Table 16: Volumes for oil gauge levels readings Nominal level Max level Warning level Alarm (stop) level Inclination litre US gal litre US gal litre US gal litre US gal 0° 14.5 15.8 13.2...
Page 44: Initial Start Up Procedure
• Check that cooling water is connected and turned on if a water-oil cooler is used. • For adjustments and settings on the control system (if any) see special instruction in attached order specific Hägglunds Fusion documentation. STEP 2 Start with unloaded pump at short intervals Starting of the drive system shall be carried out with a completely unloaded pump in short intervals.
Page 45 • Check that the specified pressure levels for charge pressure at the drive system are maintained in accordance with the values stated on the hydraulic diagram in the order specific Hägglunds Fusion documentation. These pressure levels are preset at the factory and normally not needed to readjust.
Page 46: Pump Settings And Adjustments
Charge pressure level, high pressure relief valves and pressure compensator are set from factory and there is normally no need for readjustment. Always check the pressure levels in the attached order specific Hägglunds Fusion documentation. Setting of pressures on the pump must be performed by skilled service personnel familiar with the functions and risks involved with the pump.
Page 47 47/72 2. High pressure relief valves (HD valves) setting A and B side For setting levels see the order specific Hägglunds Fusion documentation. The high pressure relief valve setting should be 40 bar [580 psi] > compensator pressure setting. Carry out checking and adjustment at operating temperature.
Page 48 Stroke the pump to about 50% of max flow. Set the compensator pressure to a value according to the order specific Hägglunds Fusion documentation. 4. Manual control of flow on A4VG pump The A4VG pump flow can be controlled manually with a button on each side of the pump controller.
Page 49 Commissioning | Drive system Hägglunds Fusion 49/72 High pressure relief valve A Charge pressure valve High pressure relief valve A Pressure cut-off 42656 Fig. 27: Pump A4VG28 High pressure relief valve A Charge pressure valve High pressure relief valve B...
Page 50: Hägglunds Bica Brake
50/72 Hägglunds Fusion Drive system | Maintenance and repair 8.5 Hägglunds BICA Brake Its important to bleed the brake before start up. For more infomation see 643. 9 Maintenance and repair 9.1 Maintenance log We recommend that a maintenance log is kept to record service/maintenance/ repair, addition and alteration of the equipment.
Page 51 Maintenance and repair | Drive system Hägglunds Fusion 51/72 Frequent checks … Unusual vibrations or noises … Fluid leaks … Fluid level in the tank … The unit is clean … The air flow paths are not blocked ...
Page 52 Do not touch rotating parts inside the inspection hole see Fig. 24. or in the zone of rotating parts. … Check the cooling water flow … Check that the cover of the Fusion not are damaged Table 18: Maintenace chart Absolute max. intervals for major...
Page 53: Filter Change
Maintenance and repair | Drive system Hägglunds Fusion 53/72 9.3 Filter change WARNING High temperature oil /components Risk of injury f Do not open filters that are in operation f Use suitable personal protective equipment Weight of filter bowl Risk of injury...
Page 54 54/72 Hägglunds Fusion Drive system | Maintenance and repair When removing a filter element take some time to inspect and look for unusual contamination within the pleats. Contact your Bosch Rexroth representative for advice. Duplex filter 1. Establish which filter side is inoperation – look at pictogram on the filter 2.
Page 55: Inspection Of Hydraulic Fluid
Maintenance and repair | Drive system Hägglunds Fusion 55/72 9.4 Inspection of hydraulic fluid CAUTION Hot hydraulic fluid. Risk of injury f Use personal protective equipment NOTICE Danger associated to hydraulic fluid. Risk of environmental damage f Store used hydraulic fluid and contamined filter elements for disposal.
Page 56: Air Filter Breather Change
56/72 Hägglunds Fusion Drive system | Maintenance and repair General The intention is to verify the condition of the oil during operation. The motors should be running at normal operation while the sample is taken. The cleanliness is extremely important during sampling.
Page 57: Electric Motor
Maintenance and repair | Drive system Hägglunds Fusion 57/72 9.6 Electric motor 9.6.1 Lubrication For electric motors with regreasing system, relubrication intervals, grease quantity and grease grade are provided on the lubricant plate. Additional data can be taken from the electric motors rating plate see Fig. 18.
Page 58: Cleaning Of Air Oil Cooler
58/72 Hägglunds Fusion Drive system | Maintenance and repair 9.6.2 Air inlet Check that the air inlets on the electric motor are not clogged by dirt and that air can pass easily. 9.6.3 Draining The condensate drain holes must be opened at regular intervals, depending on climatic conditions.
Page 59: Drive System Out Of Service
Maintenance and repair | Drive system Hägglunds Fusion 59/72 9.8 Drive system out of service Periods out of service 1. Check system for leaks. All system pipe joints and rotating seals are to be checked to find if any leaks exists. Leaking pipe joint shall be immediately corrected, if possible by tightening.
Page 60: Repair
In the event of questions regarding repairs, contact your Bosch Rexroth representative. 9.10 Flushing after repair There is no need for flushing of a Fusion drive unit when its delivered new from the manufacturer! 9.10.1 Cleaning of system after break down If something has happened in the system during operation, that may have produced some kind of contamination.
Page 61 Maintenance and repair | Drive system Hägglunds Fusion 61/72 CAUTION Wrong direction of rotation of the pump Pump will be damaged. System contaminated f Make sure that the pump has the correct direction of rotation. The correct direction of rotation is marked with a sign placed between the electric motor and motor plate see Fig.
Page 62: Spare Parts
62/72 Hägglunds Fusion Drive system | Maintenance and repair 9.11 Spare parts Address all questions regarding spare parts to your responsible Bosch Rexroth Service partner or the service department of the manufacturer‘s plant for the Hägglunds products. Details can be found on the name plate of the Hägglunds product.
Page 63: Removal And Replacement
Removal and replacement | Drive system Hägglunds Fusion 63/72 10 Removal and replacement 10.1 Required tools In addition to standard tools the following are also needed, for example: • Lifting tool/device • Lifting eyes • Assembly tool • Waste oil collector 10.2 Common...
Page 64 64/72 Hägglunds Fusion Drive system | Removal and replacement CAUTION Contact with hydraulic fluid! Hazard to health/health impairment e.g. eye injuries, skin damage, toxication during inhalation! f Avoid contact with hydraulic fluids. f When working with hydraulic fluids, strictly observe the safety instructions provided by the lubricant manufacturer.
Page 65: Disposal
3. Dispose the hydraulic fluid according to the national regulations of your country. Also observe the applicable safety data sheet for the hydraulic fluid. 4. Remove the Fusion into its individual parts and properly recycle these parts separate according to material type, for instance:...
Page 66: Troubleshooting
66/72 Hägglunds Fusion Drive system | Troubleshooting 13 Troubleshooting Please, contact your nearest Bosch Rexroth representative. Causes Of Trouble And Its Effect In The Hydraulic Installation Source of trouble, Mechanical Drive Suction Line Pump Pressure Line Return Line (effects) Excessive noises 1.
Page 67 Troubleshooting | Drive system Hägglunds Fusion 67/72 Causes Of Trouble And Its Effect In The Hydraulic Installation Flow Control Directional Pressure Valves Fluid Motor Others Valves Control Valves 1. Valve chatter 1. The valve 1. Valve chatters 1. Cavitation 1. Wear of running...
Page 68 68/72 Hägglunds Fusion Drive system | Troubleshooting Causes Of Trouble And Its Effect In The Hydraulic Installation Source of trouble, Mechanical Drive Suction Line Pump Pressure Line Return Line (effects) Power Take-off 1. Coupling Suction resistance 1. Internal leakage 1. Leakages.
Page 69 Troubleshooting | Drive system Hägglunds Fusion 69/72 Causes Of Trouble And Its Effect In The Hydraulic Installation Pressure Valves Flow Control Directional Fluid Motor Others Valves Control Valves 1. Operating 1. Flow rate set 1. Wrong switched 1. Viscosity too 1.
Page 70: Technical Data
70/72 Hägglunds Fusion Drive system | Technical data 14 Technical data 14.1 Weights Total weight of the drive system The total weight of the drive system, is marked on the product identification located on the cabinet frame, see Fig. 2.
Page 71 Technical data | Drive system Hägglunds Fusion 71/72 Table 23: Weight electric motor Electric motor Weight 18.5 1477 Table 24: Weight air-oil cooler Air-oil cooler Weight type HDC 030-4 HDC 050-4 HDC 060-4 HDC 080-4 Table 25: Weight panels Panels...
Page 72 HÄGGLUNDS Bosch Rexroth AB SE-895 80 Mellansel tel: +46 (0)660 870 00 www.hagglunds.com Hägglunds is a brand of Rexroth, a leading global supplier of drive and control technologies. Hägglunds solutions enrich a comprehensive Rexroth portfolio. We reserve the right to make changes, these could pertain to this document and/or the product RE 15345-WA, Version: 11.2022...