Bosch Rexroth Hagglunds CA Series Manual

Installation and maintenance
manual
RE 15354-WA / 04.2015
Supersedes:
New
English
Hägglunds CA 10 to CA 40
Radial piston hydraulic motor

Bosch Rexroth Mellansel AB, Installation and maintenance manual, Hägglunds CA 10 - CA 40, RE 15354-WA/04.2015
3/52Contents
Contents
1 This documentation 6
1.1 Scope of documentation 6
1.2 Required and additional documentation 6
1.3 Display of information 6
1.3.1 Safety instructions 6
1.3.2 Symbols 7
2 Safety instructions 8
2.1 About this chapter 8
2.2 Intended use 8
2.3 Improper use 8
2.4 Personnel qualications 9
2.5 General safety instructions 9
2.6 Product-specic safety instructions 10
2.7 Personal protection equipment 11
3 General instructions on material damage and product damage 12
4 Delivery contents 14
5 About this product 14
5.1 Performance description 14
5.2 Product description 14
5.3 Product identication 15
6 Transport and storage 16
6.1 Product transport 16
6.1.1 Lifting methods 16
6.1.2 Lifting CA 10 - CA 40 motor 17
6.2 Product storage 18
6.2.1 Standing the motor on a at surface 18
6.2.2 Storing for extended periods or in uncontrolled environment 19
6.2.3 Storing during maintenance 20
7 Installation 20
7.1 Unpacking 20
7.2 Installation conditions 21
7.2.1 Dimensions shaft end with spline 21
7.3 Product installation 22
7.3.1 Mounting the motor onto the driven shaft - splines 22
7.3.2 Lubrication of spline 24
7.3.3 Draining and venting the motor 25
7.3.4 Flushing 27
7.3.5 Hydraulic ports 29
7.3.6 Direction of rotation of motor shaft 31
8 Commissioning 33
8.1 Commissioning 33
8.1.1 Oil lling 33
8.1.2 Start of the hydraulic supply 34
8.2 Re-commisioning after standstill 34
9 Operation 34
10 Maintenance and repair 35

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10.1 Cleaning and care 35
10.2 Maintenance plan 35
10.2.1 Filter maintenance 36
10.2.2 Oil maintenance 36
10.3 Repair 37
10.4 Spare parts 37
11 Removal and replacement 38
11.1 Required tools 38
11.2 Preparing for removal 38
11.3 Removing Hägglunds CA 10 - CA 40 38
11.4 Preparing the components for storage or further use 38
12 Disposal 39
12.1 Environmental protection 39
13 Extension and conversion 39
14 Troubleshooting 40
15 Technical data 41
15.1 Technical data, Hägglunds CA 10 - CA 40 41
15.1.1 Motor data 41
15.1.2 Recommended charge pressure 43
15.1.3 Dimensions and weights, motor 45
15.1.4 Hydraulic uids 49

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6/52 This documentation
RE 15354-WA/04.2015, Installation and maintenance manual, Hägglunds CA 10 - CA 40, Bosch Rexroth Mellansel AB
1 This documentation
1.1 Scope of documentation
This documentation applies to the radial piston hydraulic motor Hägglunds CA
10 - CA 40 and is intended for machine/system manufactures, tters and service
engineers.
This documentation contains important information required to transport,
installation, commission, operate, use, service, dismantle the product safely and
professionally.
▶Read this documentation completely, before using the Hägglunds CA 10 - CA 40.
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 CA 10 - CA
40.
Order conrmation
Hägglunds CAB RE 15354 Data sheet
Hydraulic uid quick reference RE 15414 Data sheet
Sound an vibrations RE 15411 Data sheet
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.

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Safety instructions are formatted as follows:
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 the 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 CA 10 - CA 40 motor is a radial piston hydraulic motor.
In the application the Hägglunds CA 10 - CA 40 motor is classied as a component in
terms of the CETOP Position Paper PP07. Radial piston motors are not ready-to-use
machines for the purpose of the EU machinery directive. The product/component
is exclusively intended for being integrated in a machine or system or for being
assembled with other components to form a machine or system. The CA 10 - CA 40
motor 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:
• Radial piston motor in open or closed circuit: The radial piston motor is only
approved to be used in motor mode or pump mode for hydrostatic drives.
Observe the technical data, application and operating conditions and performance
limits as specied in the product-specic data sheet and in the order conrmation.
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 Data sheet RE 15414 Hydraulic
fluid quick reference.
• Modication of factory settings by non-authorized persons

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• 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.
•Extension or conversion is not permissible and has to be approved by contact at
Bosch Rexroth.
•Using the Radial piston motor under water without necessary additional measures.
•Using the Radial piston motor when the exterior pressure is greater than the
interior pressure (case pressure).
•Using the Radial piston motor in explosive environments unless the component or
machine/system has been certied as compliant with the ATEX directive 94/9/EC.
•Using the Radial piston motor 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 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.
Bosch Rexroth oers training support for special elds. For more information about
training, please contact your Bosch Rexroth representative.
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.
•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 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

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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.
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 excessively high pressure!
Danger to life or risk of injury, damage to equipment!
Operating the motor above the permissible maximum pressure can cause
components to burst and hydraulic uid to escape under high pressure.
▶Operate the motor only within permissible maximum pressure.
Danger from suspended loads!
Danger to life or risk of injury, damage to equipment!
Improper transportation may cause the Hägglunds motors 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 you 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, installation and for removal
and repair. Make sure the 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!
▶Protect the complete system against being energized.
▶Make sure that the machine/system is depressurized. Please follow the machine/
system manufacturer’s instructions.
▶Do not disconnect any line connections, ports and components when the
machine/system is pressurized.
▶Switch o all power-transmitting components and connections
(electric, pneumatic, hydraulic, mechanical) in accordance with the
manufacturer‘sinstruction and secure them against being switched back on.

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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 motors.
▶If Hägglunds motors are to be situated in the vicinity of ignition sources or
powerful thermal radiators, a shield must be erected to ensure that any escaped
hydraulic uid can not ignite, and to protect hose lines from premature aging.
CAUTION
High noise development in operation!
Danger of hearing damage, deafness!
The noise emission of Hägglunds motors depends on speed, operating pressure and
installation conditions.
▶Always wear hearing protection when in the vicinity of the operating radial
piston motor.
Hot surfaces on the radial piston motor!
Risk of burns!
▶Allow the Hägglunds motors 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.
2.7 Personal protection equipment
The personal protective equipment is the responsibility of the user of the Hägglunds
motors. Observe the safety regulations and provisions of your country. All
components of the personal protective equipment must be intact.

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RE 15354-WA/04.2015, Installation and maintenance manual, Hägglunds CA 10 - CA 40, Bosch Rexroth Mellansel AB
3 General instructions on material damage
and product damage
NOTice
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 motor or any part of it or its accessories.
▶Do not set/place the Hägglunds motor on the drive shaft or ttings.
▶Do not strike ttings (e.g. sensors or valves).
▶Do not strike sealing surfaces (e.g. service line ports).
▶Leave the protective covers on the Hägglunds motor until shortly before the
lines are connected.
▶Do not perform electro-welding on the Hägglunds motor.
▶Make sure that the electronics are not electro-statically charged (e.g. for
painting operations).
Damage to equipment due to improper lubrication!
Product can be damaged or destroyed!
▶Never operate the Hägglunds motor 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.
▶Check the hydraulic uid level in the case interior regularly; if necessary,
recommission. With above-reservoir installation, the case interior may drain via
the reservoir line after longer standstill periods (air enters via the shaft seal) or
via the service line (gap leakage). The bearings are thus insuciently lubricated
at switch on.
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.

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NOTice
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 motor 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 motor.
▶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 motor and its ttings, the hydraulic uid and the
packaging material could lead to pollution of the environment!
▶Dispose of the Hägglunds motor, 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!
▶Always place a drip tray under the Hägglunds motor when lling and draining the
hydraulic uid.
▶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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RE 15354-WA/04.2015, Installation and maintenance manual, Hägglunds CA 10 - CA 40, Bosch Rexroth Mellansel AB
4 Delivery contents
Included in the delivery contents are:
• Hägglunds CA 10 - CA 40 as per order conrmation
5 About this product
5.1 Performance description
Hägglunds CA 10 - CA 40 is a radial piston hydraulic motor that converts hydraulic
ow into mechanical rotation. Refer to product-specic data sheet (RE 15354
Hägglunds CAB) and the order conrmation for technical data, operating conditions
and operating limits of the specic Hägglunds CA 10 - CA 40.
5.2 Product description
Bosch Rexroth‘s hydraulic industrial motor Hägglunds CA is of the radial-piston type
with a rotating cylinder block/ hollow shaft and a stationary housing. The cylinder
block is mounted in xed roller bearings in the housing. An even number of pistons
are radially located in bores inside the cylinder block, and the distributor directs the
incoming and outgoing oil to and from the working pistons. Each piston is working
against a cam roller.
When the hydraulic pressure is acting on the pistons, the cam rollers are pushed
against the slope on the cam ring that is rigidly connected to the housing, thereby
producing a torque. The cam rollers transfer the reaction force to the pistons which
are guided in the cylinder block. Rotation therefore occurs, and the torque available
is proportional to the pressure in the system.
Oil main lines are connected to ports A and C in the connection block and drain lines
to ports D1 or D2 in the motor housing.
The motor is connected to the shaft of the driven machine through the hollow shaft
of the cylinder block. The torque is transmitted by splines.
Quality
To assure our quality we maintain a Quality Assurance System, certied to standard
ISO 9001.

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a
Fig. 1: The Hägglunds CA 10 - CA 40 radial piston motor
4
1
2
7
6
3
5
8
Connection side
of the motor
Shaft side
of the motor
1 Cam ring
2 Cam roller
3 Piston
4 Cylinder block, spline
5 Housning cover
6 Cylindrical roller bearing
7 Distributor
8 Connection housning
5.3 Product identication
4
2
1
Fig. 2: Plate on motor
3
5
DD00057560
DD00069421
1 Ordering code
2 Serial number
3 Weight
4 Manufacturer
5 Max pressure
DD00070605

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6 Transport and storage
6.1 Product transport
6.1.1 Lifting methods
DANGER
Danger while transporting or lifting Hägglunds motors due to heavy weight!
Danger to life, risk of injury or serious injuries and risk of damage to equipment!
▶Make sure that lifting device is correctly installed.
▶Do not stand under suspended load.
Danger if using wrong lifting eyes!
Danger to life, risk of injury or serious injuries and risk of damage to equipment!
▶Make sure the correct lifting eye is used and tightened close to the mating
surface, see Fig. 4: Lifting eyes at motor:
Center of gravity
Fig. 3: Center of gravity
Table 4: Center of gravity
Motor type Measure A (mm)
CA 10 99
CA 20 118
CA 30 137
CA 40 164
DD00070605
Fig. 4: Lifting eyes at motor
DD00070606
Lifting eyes
Lifting eyes
A

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6.1.2 Lifting CA 10 - CA 40 motor
Fig. 5: Lifting motor with shaft in vertical plane
Fig. 6: Lifting motor with shaft in horizontal plane, see Table 4: Center of gravity
DD00070818
A
B) CA 30, CA 40
A
A) CA 10, CA 20
DD00071346 DD00070609

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6.2 Product storage
The motor is delivered with internal protection in the form of an oil lm with vapor
state corrosion inhibitors (Shell VSI 8235), and external protection in the form of
an anti-rust lm. This provides sucient protection for indoor storage in normal
temperatures for about 12 months.
6.2.1 Standing the motor on a at surface
Fig. 7: Hägglunds CA 10 - CA 40 standing on a at surface
When the motor is placed on a at surface such as a oor, it must stand either on
its outer diameter or on the suitably protected end face of the hollow shaft. It is also
advisable to provide supports shown in Fig. 7: Hägglunds CA 10 - CA 40 standing on a
flat surface.
Support
NOTice
Incorrect placement of the motor!
Risk of damage to equipment.
▶When in storage with shaft vertical, the motor must always be placed with the
hollow shaft facing down.
▶It is also advisable to provide supports att the mounting surface of the motor,
see Fig. 7: Hägglunds CA 10 - CA 40 standing on a flat surface alt.B) Standing
with shaft vertical .
A) Standing with
shaft horizontal
B) Standing with
shaft vertical
DANGER
Unsecured motor can fall!
Danger to life or risk of injury, damage to equipment!
▶When in storage or during oil lling, the motor must always be secured from
falling.
DD00070624

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Table 5: Oil volume
Motor Oil volume approx.
Litres US gal.
CA 10 0.7 0.19
CA 20 1.0 0.26
CA 30 1.1 0.29
CA 40 1.2 0.32
Fig. 8: Filling the motor with oil
6.2.2 Storing for extended periods or in uncontrolled environment
NOTice
Insucient cleanliness!
Risk of damage to equipment.
▶Take extreme care to ensure that no contamination enters the motor.
If the motor is stored for more than 3 months in an uncontrolled environment or
more than 12 months in a controlled environment, it must be lled with oil.
1 Place the motor as shown in Fig. 7: Hägglunds CA 10 - CA 40 standing on a flat
surface, alt.A) Standing with shaft horizontal.
2 Fill the motor with ltered oil in the following order: D1, A1, C1.
NOTE! See Table 5: Oil volume.
3 Seal connections A1 and C1 with the plugs tted to the connection surface at
delivery. Check that the O-rings or rubber seals are in position on the plugs.
4 Fit the plug to D1.
5 Position the motor as shown in Fig. 7: Hägglunds CA 10 - CA 40 standing on a flat
surface, alt. A) Standing with shaft horizontal. or B) Standing with shaft vertical.
DD00070796