Bosch Rexroth Hagglunds DOb Manual

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.
© This document, as well as the data, specica-
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

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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

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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:

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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)
1.
2.
3.
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.

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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.

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• 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.

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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

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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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WARNING
Escaping oil mist!
Risk of explosion, re, health hazard, environmental pollution!
▶Depressurize the machine/system and repair the leak.
▶Keep open ames and ignition sources away from the Hägglunds drive unit.
High voltage!
Danger to life or personal injury hazard through electrical shock!
▶Prior to accessing electrical parts with a voltage higher than 50 volts always
disconnect the device from the mains or power unit. Secure the electrical
equipment against being switched on again by accident.
▶Observe the general deployment regulations and the safety regulations for work
on heavy-current equipment.
▶The operation, maintenance and/or repair of such equipment is reserved to
skilled personnel qualied to work on or with electrical equipment.
▶Prior to switching the equipment on always check the protective earth conductor
for reliable connection to all electrical equipment according to the connection
diagram.
▶Exclusively run the component/device - even for short-time measurements or
tests - with the protective earth conductor reliably connected to the dedicated
connection points.
▶Always wait 5 minutes after switching o power to allow live capacitors to
discharge before accessing an electric component. Measure the electrical
voltage of live parts before beginning to work to make sue that the equipment is
safe to touch.
▶Never touch electrical connection points of the components while power is
turned on.
Danger due to incorrect mounting and setting of electrical, hydraulic and
mechanical functions as well as controls
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.

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CAUTION
High noise development in operation!
Danger of hearing damage, deafness!
The noise emission of Hägglunds drive unit depends on speed, operating pressure
and installation conditions.
▶Always wear hearing protection when in the vicinity of the operating drive unit.
Hot surfaces on the drive unit!
Risk of burns!
▶Allow the Hägglunds drive unit to cool down suciently before touching it.
▶Wear heat-resistant protective clothing, e.g. gloves.
Improper routing of cables and lines!
Tripping hazard and damage to equipment!
▶Lay cables and lines so that they can not be damaged and nobody can trip over
them.
Contact with hydraulic uid!
Hazard to health/health impairment e.g. eye injuries, skin damage, toxication during
inhalation!
▶Avoid contact with hydraulic uids.
▶When working with hydraulic uids, strictly observe the safety instructions
provided by the lubricant manufacturer.
▶Use your personal protective equipment (e.g. safety glasses, safety gloves,
suitable working clothes, safety shoes).
▶If hydraulic uid should, nevertheless, come into contact with your eyes or
bloodstream or is swallowed, consult a doctor immediately.
Escaping hydraulic uid due to machine/system leakage!
Risk of burns and risk of injury due to escaping oil jet!
▶Depressurize the machine/system and repair the leak.
▶Never attempt to block or seal the leak or oil jet with a cloth.
Operator error
Risk of personal injury or damage to the product!
▶Check both the general and the custom technical documentation to identify the
features of your unique drive unit
No brake
Risk of personal injury or damage to the product!
▶Take care of at power failure or when system is switched o, the system has no
load holding function!
2.7 Personal protection equipment
Use safety equipment like helmet, protective goggles, safety shoes and hearing
protection.
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.

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3 General instructions on material damage
and product damage
NOTe
Danger from improper handling!
Product can be damaged!
▶Do not expose the product to an impermissible mechanical load.
▶Never use the product as a handle or step.
▶Do not place/lay any objects on the product.
▶Do not strike the Hägglunds drive unit or any part of it or its accessories.
▶Do not strike ttings (e.g. sensors or valves).
▶Do not strike sealing surfaces (e.g. service line ports).
▶Leave the protective cover on the Hägglunds drive unit until shortly before the
lines are connected.
▶The protections on all parts must be kept on until nal assembly to avoid dirt in
the system
▶Do not perform electro-welding on the Hägglunds drive unit.
Damage to equipment due to improper lubrication!
Product can be damaged or destroyed!
▶Never operate the Hägglunds drive unit with insucient hydraulic uid.
▶When commissioning a machine/system, make sure that the case interior and
the service lines of the Hägglunds motor are lled with hydraulic uid and
remain lled during operation.
Mixing of hydraulic uids!
Product can be damaged!
▶Before installation, remove all uids from the Hägglunds motor to prevent mixing
with the hydraulic uid used in the machine/system.
▶Any mixing of hydraulic uids of dierent manufacturers or dierent types of the
same manufacturer is not permissible in general.
Wrong voltage!
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
identication.

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NOTe
Contamination of the hydraulic uid!
The cleanliness of the hydraulic uid has a considerable impact on the cleanliness
and service life of the hydraulic system. Contamination of the hydraulic uid could
cause premature wear and malfunctions!
▶Make sure that the working environment at the installation site is fully free of
dust and foreign substances in order to prevent contaminants, such as welding
beads or metal cuttings, from getting into the hydraulic lines and causing
product wear or malfunctions. The Hägglunds drive unit must be installed in a
clean condition.
▶Use only clean connections, hydraulic lines and attachments (e.g. measuring
equipment).
▶No contaminants may enter the connections when they are plugged.
▶Before commissioning, make sure that all hydraulic connections are tight and
that all of the connection seals and plugs are installed correctly to ensure that
they are leakproof and uids and contaminants are prevented from penetrating
the product.
▶Use a suitable lter system to lter hydraulic uid during lling to minimize solid
impurities and water in the hydraulic system.
Improper cleaning!
Product can be damaged!
▶Plug all openings with the appropriate protective equipment in order to prevent
detergents from entering the hydraulic system.
▶Never use solvents or aggressive detergents. Use only water and, if necessary, a
mild detergent to clean the Hägglunds drive unit.
▶Never use a high pressure washing system to clean inside the drive unit
▶Do not point the power washer at sensitive components, e.g. shaft seal,
electrical connections and components.
▶Use lint-free cloths for cleaning.
Environmental pollution due to incorrect disposal!
Careless disposal of the Hägglunds drive unit and its ttings, the hydraulic uid and
the packaging material could lead to pollution of the environment!
▶Dispose of the Hägglunds drive unit, hydraulic uid and packaging in accordance
with the national regulations in your country.
▶Dispose of the hydraulic uid in accordance with the applicable safety data
sheet for the hydraulic uid.
Escaping or spilling hydraulic uid!
Environmental pollution and contamination of the ground water!
▶Use an oil binding agent if hydraulic uid is spilled.
▶Observe the information in the safety data sheet for the hydraulic uid and the
specications provided by the system manufacturer.
The warranty applies only to the delivered conguration.
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.

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4 Delivery contents
Included in the delivery contents are:
• Hägglunds DOb as per order conrmation
5 About this product
5.1 Product description
The DOb unit provides a hydraulic motor with required hydraulic oil ow and power
together with system control functionality and is assembled in a compact cabinet.
The DOb unit has an open loop hydraulic system and gives possibility to get control
functionality of torque (pressure) or speed of the hydraulic motor shaft. The unit has
a xed hydraulic pump and a speed controlled electrical motor to drive the pump.
DOb is equipped with an air cooler for the hydraulic oil, the fan of the cooler is
speed controlled to minimize the sound level.
The unit has a maximum power of 7.5 kW, maximum ow of 30 lpm and maximum
working pressure of 315 bar. (The max ow and max pressure cannot be achieved
simultaneous)
The control cabinet contains two VFD units (Variable Frequency Drive) for speed
control of main pump and cooler electric motors, health monitoring of the drive unit
system and system status indication. The ow from the unit can be controlled locally
from the cabinet front or via remote connections to terminals inside the cabinet.
This installation and maintenance manual is intended to cover default setup of the
system.
5.2 Product identication
4
2
1
3
5
1 Type code
2 Serial number
3 Weight
4 Manufacturer
5 Max pressure
Fig. 1: Product identication
DD00057560

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5.3 Main components
.
Fig. 2: Main components DOb
DD00081619
Main components
Item Description See also gure
1Main electrical motor
2 Hydraulic pump
3Pump safety block Fig. 22
4 Shaft coupling/bellhousing –
5 Frame (not shown) –
6 Panels (not shown) –
7 Control cabinet Fig. 5
8Air oil cooler
9 Cooler fan motor
10 Oil tank Fig. 19
11 Filter
12 Pressure sensor
13 Oil level/temperature sensor Fig. 19
14 Air breather Fig. 19
15 Oil-drain valve Fig. 19
16 Main power switch Fig. 5
17 Emergency stop actuator Fig. 5
8
1
22
4
5
7
9
10
11
11
3
12
13
15
14
16
17

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5.4 Hydraulic uids
The Hägglunds hydraulic system is primarily designed for operation with hydraulic
uids according to ISO 11158 HM.
Fluids by the standards given in Table 4: Suggested fluid types are suggested.
Before the start of project planning, see data sheet RE 15414, Hydraulic uid
quick reference, for detailed information on hydraulic uids and specic additional
demands
Table 4: Suggested uid types
SO 11158 ISO 15380 ISO 12922
HM HEES HFB
HV HEPG HFC
HEPR HFDU
Details regarding the selection of hydraulic uid
The hydraulic uid should be selected such that the operating viscosity in the
temperature range, as measured in the motor housing, is within optimum operation
range, see Fig. 3: Selection diagram for viscosity ranges with straight fluids, i.e.
viscosity index 100. General recommendation is to have a system temperature of
50°C, see dotted line in Fig. 3: Selection diagram for viscosity ranges with straight
fluids, i.e. viscosity index 100. A VG 68 uid will render just above 40 cSt at this
point.
• Optimum viscosity range is 40 to 150 cSt.
• Running above 150 cSt or below 40 cSt results in reduced efficiency.
• Running above 400 cSt results in substantial efficiency loss.
• 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.

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?
n
Fig. 3: Selection diagram for viscosity ranges with straight uids, i.e. viscosity index 100
5.5 Requirements for hydraulic uid cleanliness
The drive units are equipped with lters on the drain line and return line. In order
to obtain stated service life it is important to follow recommendations concerning
cleanliness levels and maintenance.
Cleanliness level recommendations
• The system must be ushed before start up (see section 8.3: Flushing before start
upWhen lling the tank with hydraulic uid it is important to ll through the special
oil ller connection (see 8.2: Filling up the system with hydraulic fluid).
• For industrial applications the contamination level should not exceed ISO
4406:1999 18/16/13.
• Have a water content of <200 ppm (0,02%).
• Always use lter elements recommended and supplied by Bosch Rexroth.
• The hydraulic uid should be analysed according to the special maintenance
intervals for your specic drive unit or the maximum intervals on the maintenance
chart (see Table 11: Maintenace chart). Be particularly vigilant when removing
equipment for repairs or maintenance, dirt must not be allowed to enter the
system, clean prior to opening and plug open connections.
NOTice
Dirt in oil
Damage on equipment
▶Do not re-use hydraulic uid which has leaked out.
DD00082885

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5.6 Control cabinet function
The control cabinet main components are two VFD’s.
The first VFD controls the speed of the electrical motor driving the hydraulic pump.
This VFD also contains a configurable function for start/stop logic, speed or torque
(pressure) control and start cooling command. Speed/torque control can be
activated with a switch on the front panel.
Start/stop of the hydraulic flow is via front panel buttons in local drive mode or via a
dry contact connected to terminals for start/stop in remote mode.
The command for setting of speed or pressure is via a front panel potentiometer in
local mode and via terminals for a 4-20mA signal in remote mode. Selection of local
or remote mode is done with a front panel switch.
Indicators of speed and pressure are available on the front panel.
The second VFD controls the speed of the electrical motor driving the air-oil cooler
fan. The speed of the fan is controlled by the oil temperature in the hydraulic tank.
Minimum oil level and maximum oil temp in the tank are monitored with indication
on the front panel and will stop the drive at critical level. Clogged return oil filter will
be indicated on the front panel
Fig. 4: Monitoring logic diagram
DD00081610

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5.7 Control cabinet interface
1
2
3
4
5
6
13
12
11
10
9
8
7
Pos. Description
1Emergency stop
2 System alarm
3System running
4 Alarm oil temperature
5 Alarm oil level
6 Control panel frequency converter
7 Actual pressure
8Actual speed
9 Warning cooler
10 Warning lter
11 Regulator on/o
12 Command local/remote
13 Main power switch
14 Warning sign electricity
Fig. 5: Front control cabinet
DD00082773
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