Bosch Rexroth Hagglunds CA Series User manual

ATEX Appendix
Installation and maintenance
manual
RE 15440-X-B2/11.2016
Supersedes
RE 15440-X-B2/
10.2015
English
Hägglunds motors
Radial piston hydraulic motors,
in accordance with ATEX Directive 2014/34/EU
Explosion-proof

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 picture on the front page shows the
The original operating instructions were pre-
pared in English.

RE 15440-X-B2/11.2016, Product specic Intallation and maintenance manual Hägglunds motors, Bosch Rexroth Mellansel AB
3/20 Contents
Contents
1 This documentation 4
1.1 Display of information 4
1.1.1 Safety instructions 4
1.1.2 Symbols 5
2 Safety instructions 6
2.1 About this chapter 6
2.2 Intended use 6
2.3 Improper use 6
2.4 Personnel qualications 7
2.5 General safety instructions 7
2.6 Product-specic safety instructions 8
2.7 Personal protection equipment 10
3 General instructions on material damage and product damage 11
4 Productidentication 13
5 Motor 14
6 Sensors 18
6.1 Temp Sensor 18
6.2 Speed sensors 18
6.2.1 SPDB2 18
6.2.2 Inductive encoder 19

4/20 This documentation
Bosch Rexroth Mellansel AB, Product specic Intallation and maintenance manual, Hägglunds motors RE 15440-X-B2/11.2016
1 This documentation
1.1 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.
1.1.1 Safety instructions
This documentation includes safety instructions in 2.6: Product-specific safety
instructions, 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:
SIGNAL WORD
Type of risk
Consequences of non-observance
▶Safety precautions
▶<List>
•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 1: 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.

This documentation 5/20
RE 15440-X-B2/11.2016, Product specic Intallation and maintenance manual Hägglunds motors, Bosch Rexroth Mellansel AB
1.1.2 Symbols
The symbols below indicate instructions which are not safety-relevant but help to
make the documentation easier to understand.
Table 2: 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.

6/20 Safety instructions
Bosch Rexroth Mellansel AB, Product specic Intallation and maintenance manual, Hägglunds motors RE 15440-X-B2/11.2016
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 motor is a radial piston hydraulic motor.
The motor fullls the requirements in accordance with ATEX Directive 2014/34/EU.
In the application the Hägglunds motor is classied as a component 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 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
uid quick reference.
• Modication of factory settings by non-authorized persons

Safety instructions 7/20
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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 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 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.

8/20 Safety instructions
Bosch Rexroth Mellansel AB, Product specic Intallation and maintenance manual, Hägglunds motors RE 15440-X-B2/11.2016
• 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 wrong
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
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.
Static discharge
Cleaning the motor with a dry rug may lead to explosions through electrostatic
discharge that may cause severe injuries and even death.
▶Do not use a dry rug for cleaning!
Lack of grounding
Risk of explosion that may cause severe injuries and even death.
▶Remember the lock washer on grounding point when remounting details.

10/20 Safety instructions
Bosch Rexroth Mellansel AB, Product specic Intallation and maintenance manual, Hägglunds motors RE 15440-X-B2/11.2016
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.

General instructions on material damage and product damage 11/20
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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.
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.

12/20 General instructions on material damage and product damage
Bosch Rexroth Mellansel AB, Product specic Intallation and maintenance manual, Hägglunds motors RE 15440-X-B2/11.2016
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.

Product identication 13/20
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4
2
1
3
5
1 Type code
2 Serial number
3 Weight
4 Manufacturer
5 Max pressure
6 ATEX classication
7 Additional
information
8 Year of
manufacturing
9 CE marking acc. to
ATEX directive
Fig. 1: Productidendication
Fig. 2: ATEXidendication
4 Product identication
7
6
8
9
4
DD00057560
DD00071649

14/20 Motor
Bosch Rexroth Mellansel AB, Product specic Intallation and maintenance manual, Hägglunds motors RE 15440-X-B2/11.2016
5 Motor
Pressure limitation
If there is a risk for pressure peeks over 350 bar in the hydraulic system, a cross-over
valve must be installed to limit the pressure level.
Voltage equalization
The Hägglunds hydraulic motor must be connected to external ground for voltage
equalization. The grounding point of the Hägglunds hydraulic motor is on one of
the screws for port connection as per Fig. 3. Minimum required cable area for
equalization connection is 10 mm2.
Fig. 3: Grounding of motor
DD00075144
Table 3: Grounding assembly details
Pos Qty Mat.nr. Description
1 1 R939062517 Washer M12-M6-EN1.4401
2 1 R939062518 Washer M16-M6-EN1.4401
3 1 R939062519 Washer M20-M6-EN1.4401
41R939062520 Washer 5/8-M6-EN1.4401
52R913018264 Washer ISO7092-12-200HV-A4
61R913049653 Washer ISO8738-16-160HV-A4
71R913049655 Washer ISO8738-20-160HV-A4
81R913015066 Hexagon screw ASME B18.2.1-5/8 UNC X1 1/2-GRADE5-A3K
Tightening torque 140 Nm (103 lbf ft)
91R913049670 Pan-head screw ISO14583-M6X16-A4-70
Tightening torque 6.3 Nm (4.6 lbf ft)
10 1 R911373380 Terminal lug KR-M6/0,75-10,0NN11,0-11,5
11 1 R913015031 Serrated lock washer M6 DIN6798-A6,4-A4
12 1 R913049671 Hexagon Nut M6 ISO7042-M6-A4-70
13 1 R913015261 Hexagon screw ISO4017-M10X14-8.8-A3K
The parts for grounding (washers, screws and terminal lug) are delivered in a small
bag attached to the motor. The bag contains parts to fit all motor types so all parts
will not be used. Cable is not included in the delivery.
It is important to follow the grounding point examples for each motor type. Flange for
connection can be selected to best fit the installation.

Motor 15/20
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9
10
11
1
12
5
5
Existing flange screw
6
12
2
11
10
9
Existing flange screw
Fig. 4: Grounding point example, Hägglunds CA
Fig. 5: Grounding point example, Hägglunds CB
DD00075859
DD00075860

16/20 Motor
Bosch Rexroth Mellansel AB, Product specic Intallation and maintenance manual, Hägglunds motors RE 15440-X-B2/11.2016
Existing flange screw
Fig. 6: Grounding point example, Hägglunds CBP
Fig. 7: Grounding point example, Hägglunds CBM
DD00075865
DD00075866

Motor 17/20
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9
10
11
4
12
8
9
10
11
3
7
12
Existing flange screw
Fig. 8: Grounding point example, Hägglunds Viking 44/64
Fig. 9: Grounding point example, Hägglunds Viking 84
DD00075877
DD00075876

18/20 Sensors
Bosch Rexroth Mellansel AB, Product specic Intallation and maintenance manual, Hägglunds motors RE 15440-X-B2/11.2016
6 Sensors
Sensors are optional and their explosive area classication will limit the area
classication for the complete motor.
6.1 Temp Sensor
The house temp sensor is of standard PT100 type used as “simple apparatus” (will
not add any energy in the electric circuit)
Electrical connection
The temp sensor must be operated via an intrinsically safe amplier to limit the
energy to the explosive zone.
Table 4: Electrical connections, temp sensor
Connector M12 DIN 60751
Connection Pin 1 or 2 Pin 2 + signal
Pin 3 or 4 Pin 1 or 3 - signal
6.2 Speed sensors
6.2.1 SPDB2
The SPDB2 speed encoder is a ame proof incremental quad pulse encoder
certied Ex d IIC T5 for gas and Ex tD A21 IP65 T95°C for dust.
Electrical connection
Electrical connection is done to screw terminals inside the Exd enclosure under the
back cover and fed through the housing via a M20 opening where an Exd IIC certied
cable gland and lled cable is required. Maximum allowed supply voltage 30 VDC
A prepared connection set with Exd cable gland, 5 m cable and Exe connection box
can be ordered separately to simplify installation, part number R939003770.
Table 5: Electrical connections, SPDB2
Terminal
1+9-30 VDC
20 V
3signal 0
4 signal 0 inv.
5 signal 1
6 signal 1 inv.
7 signal 2
8 signal 2 inv.

Sensors 19/20
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Maintenance and repair
If the back cover has to be opened in Ex environment, wait minimum 15 minutes
after power has been switched o before opening to allow internal components to
cool down to safe temperature. The encoder is not reparable by the user.
6.2.2 Inductive encoder
The inductive speed encoder is an Namur intrinsic safe incremental single pulse
encoder with 40ppr, certied II 2G Ex ia IIC T6 Ga for gas area.
Electrical connection
The inductive speed encoder must be operated via an intrinsically safe switching
amplier to limit the energy to the explosive zone.
Table 6: Electrical connections, inductive encoder
Connector M12
Connection Pin1 + signal
Pin3 - signal
Self inductance 2mH
Self capacitance 250nF
Grounding point
Fig. 10: Grounding of SPDB2
DD00073914
Voltage equalization
An external ground connection is required to the grounding point on the housing.
Minimum required cable area for equalization is 1,5 mm2.

Bosch Rexroth AB
SE-895 80 Mellansel
Sweden
Tel. [phone]
Fax [phone]
[e-mail]
www.boschrexroth.com/hagglunds
We reserve the right to make changes
Printed in Sweden
RE 15440-X-B2/11.2016
Your local contact can be found at:
www.boschrexroth.com/adresses