Bosch Rexroth Hagglunds DUc MS2 Instruction Manual

RE 15326-WA, Version: 06.2020, Replaces: 09.2019, EN
Installation & Maintenance
manual
Hägglunds DUc
Drive unit

The data in this document only serve to describe
the product. No statements concerning a certain
condition or suitability for a certain application can
be derived from our information. The information
given does not release the user from the obliga-
tion 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 therefore
reserve the right to introduce amendments in the
manual as we deem necessary without notice or
obligations.
This Installation and maintenance manual is valid
for Drive Units manufactured after 01.03.2019.
For older Drive Units please contact your nearest
Bosch Rexroth representative.
The cover shows an example conguration. The
product supplied may therefore differ from the
gure shown.
The original operating instructions were prepared
in English.

RE 15326-WA, Version 06.2020, Bosch Rexroth AB
| Hägglunds DUc Drive unit 3/88
Contents
1 This documentation ................................................................................... 5
1.1 Validity of the documentation........................................................................5
1.2 Required and additional documentations ......................................................5
1.3 Presentation of information ...........................................................................5
2 Safety instructions .................................................................................... 7
2.1 About this chapter .........................................................................................7
2.2 Intended use..................................................................................................7
2.3 Improper use .................................................................................................8
2.4 Personnel qualications ................................................................................8
2.5 General safety instructions............................................................................9
2.6 Product-specic safety instructions .............................................................10
2.7 Personal protective equipment ....................................................................12
3 General notes regarding property damages and product damages........... 13
4 Scope of delivery..................................................................................... 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 ...........................................................................................22
5.5 Requirements for hydraulic uid cleanliness ...............................................23
5.6 Cooling water .............................................................................................24
5.7 Drive Unit monitoring ..................................................................................25
6 Transport and storage.............................................................................. 26
6.1 Storage of the packed Drive Unit ...............................................................26
6.2 Lifting the packed Drive Unit .......................................................................27
7 Installation.............................................................................................. 28
7.1 Installation directives ..................................................................................28
7.2 Lifting methods ..........................................................................................28
7.3 Positioning the Drive Unit ...........................................................................31
7.4 Mounting of the cabinet feet........................................................................33
7.5 Mounting of main electric motor..................................................................34
7.6 Hydraulic connections .................................................................................37
7.7 Control system ............................................................................................43
7.8 Mounting of air-oil cooler.............................................................................43
7.9 Water connection.........................................................................................47
7.10 Mounting of water-oil plate cooler...............................................................47
7.11 Mounting of water-oil tube cooler ...............................................................48
7.12 Pipe work, internal ......................................................................................50
7.13 Electric connections ....................................................................................51
8 Commissioning ........................................................................................ 55
8.1 Before commissioning .................................................................................55
8.2 Filling up the system with hydraulic uid ....................................................55
8.3 Flushing before start up ..............................................................................58
8.4 Initial start up procedure.............................................................................59
8.5 Pump settings and adjustments...................................................................61

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Bosch Rexroth AB, Version 06.2020, RE 15326-WA
9 Maintenance and repair ........................................................................... 64
9.1 Maintenance log ..........................................................................................64
9.2 Preventive maintenance ..............................................................................64
9.3 Filter change................................................................................................67
9.4 Inspection of hydraulic uid ........................................................................69
9.5 Air lter breather change .............................................................................70
9.6 Electric motor..............................................................................................71
9.7 Cooler .........................................................................................................73
9.8 Drive Unit out of service ..............................................................................75
9.9 Repair..........................................................................................................76
9.10 Spare parts..................................................................................................77
10 Removal and replacement ....................................................................... 78
10.1 Common......................................................................................................78
11 Disposal .................................................................................................. 79
11.1 Environmental protection ............................................................................79
12 Extension and conversion ........................................................................ 79
13 Troubleshooting ...................................................................................... 80
14 Technical data ......................................................................................... 84
14.1 Weights ......................................................................................................84
15 Declaration of Incorporation ................................................................... 86

RE 15326-WA, Version 06.2020, Bosch Rexroth AB
This documentation | Hägglunds DUc Drive unit 5/88
1 This documentation
1.1 Validity of the documentation
This documentation applies to the Drive Unit Hägglunds DUc, European and
American version, and is intended for machine/system manufactures, tters and
service engineers.
This documentation contains important information required to transport,
install, commission, operate, use, service and dismantle the product safely and
professionaly.
▶Read this documentation completely before using the Hägglunds DUc
1.2 Required and additional documentations
▶Before commissioning the product, make sure to have received and fully
understood the documentations identied by the book symbol and observe
the instructions included in these documentations.
Table 1: Necessary and supplementary documentation.
Title Document no Document type
Order conrmation Order specic Order conrmation
Order documentation Order specic E.g. hydraulic and electric
diagrams, bill of material,
specications
Hägglunds Spider 2 RE 15330-WA User manual
Pump control Hägglunds ICp RE 15422 Data sheet
Hydraulic uid quick
reference
Hägglunds products
RE 15414 Data sheet
1.3 Presentation of information
Consistent safety instructions, symbols, terms and abbreviations are used in the
present documentation to facilitate orientation for the reader and to ensure safe
product handling. The explanations in the following sections will provide for easy
understanding.

6/88 Hägglunds DUc Drive unit | This documentation
Bosch Rexroth AB, Version 06.2020, RE 15326-WA
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:
SIGNAL WORD
Type and source of risk
▶Consequences if disregarded
▶Precautionary measures
▶<listing>
• Warning sign: draws attention to the risk
• Signal word: identies the hazard level
• Type and source of risk: identies the type and source of the hazard
• Consequences: describes what occurs when the safety messages are of non
compliance type
• Precautions: indicates how the hazard can be avoided
Table 2: Risk categories to ANSI Z535.6-2006
Warning sign, signal word Meaning
DANGER Indicates a hazardous situation which, if not avoided, will
result in death or serious injury.
WARNING Indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION Indicates a hazardous situation which, if not avoided, could
result in minor or moderate injury.
NOTICE Indicates potential property damage: the product or the
environment may be damaged.
1.3.2 Symbols
The following symbols identify notices that are not safety-relevant, but enhance
the comprehensibility of the documentation.
Table 3: Meaning of the symbols
Symbol Meaning
When this information is not observed, optimum use or operation of the product
cannot be ensured.
▶Single, independent step
1.
2.
3.
Numbered instructions:
The number indicates that the different steps are to be performed successively.
Center of gravity
Markings on packaging to indicate where the center of gravitiy are.

RE 15326-WA, Version 06.2020, Bosch Rexroth AB
Safety instructions | Hägglunds DUc Drive unit 7/88
2 Safety instructions
2.1 About this chapter
This product has been manufactured in strict compliance with the generally
accepted rules of technology. However, this does not exclude the risk of damage
to persons or property if this chapter and the safety instructions included in the
present documentation are not observed.
▶Read the entire documentation carefully before starting to use the product.
▶Keep this documentation in a location where it is accessible to all users at any
time.
▶When passing over the product to third parties, make sure to include the
necessary documentation.
2.2 Intended use
The Hägglunds DUc drive unit is a hydraulic power unit.
In the application the Hägglunds DUc Drive Unit is classied as a partly completed
machinery. The European version 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 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 closed loop hydraulic system.
Special Drive Units
Standard Drive Units are not allowed to be used beside an ambient temperature of
-20 °C to 40 °C (-4 °F to 104 °F), or in areas with potentially explosive
atmospheres.
Drive Units intended for use in ambient temperature below 0 °C (32 °F), will be
tted with special optional equipment for preheating the hydraulic system before
start.
Observe the technical data, application and operating conditions and performance
limits as specied in the product-specic documentation and in the order
conrmation.

8/88 Hägglunds DUc Drive unit | Safety instructions
Bosch Rexroth AB, Version 06.2020, RE 15326-WA
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 uid
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.
• 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 local regulations.
• 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 offers training support for special elds. For more information
about training, please contact your Bosch Rexroth representative.

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Safety instructions | Hägglunds DUc Drive unit 9/88
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.
• Make sure to use Rexroth products in perfect working order.
• Strictly observe all instructions on the product.
• Persons, who assemble, operate, disassemble or maintain Rexroth products
must not consume any alcohol, drugs or pharmaceuticals that may affect their
ability to respond.
• Use exclusively accessories and spare parts explicitly approved by the
manufacturer to avoid accidents due to improper accessories and spare parts.
• Strictly observe the technical data and ambient conditions specied in the
product documentation.
• Inadequate products installed or used for safety-relevant applications may
produce unintended operating behavior and result in product or property
damage. For this reason, use a product in safety-relevant applications only on
condition that such use is specied and allowed in the corresponding product
documentation.
• Prior to commissioning the product, make sure that the end product (e. g. a
machine or line), into which Rexroth products are integrated, perfectly complies
with the country-specic provisions, safety regulations and standards applicable
to its use.

10/88 Hägglunds DUc Drive unit | Safety instructions
Bosch Rexroth AB, Version 06.2020, RE 15326-WA
2.6 Product-specic safety instructions
The safety instructions below apply to chapters 6: Transport and storage to 14:
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 you hands under suspended loads.
▶Ensure your position is stable during transportation.
▶Use your personal protective equipment (e.g. protective goggles, safety gloves,
suitable working clothes, safety shoes).
▶Use suitable lifting device for transport and storage, installation and 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.
▶Always lockout-tagout electric motors before maintenance.
▶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, safety regulations and domestic
laws 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.
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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Bosch Rexroth AB, Version 06.2020, RE 15326-WA
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 suf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. protective goggles, 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
2.7 Personal protective equipment
Use personal protective 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 in perfect condition.

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General notes regarding property damages and product damages | Hägglunds DUc Drive unit 13/88
3 General notes regarding property
damages and product damages
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 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 covers on the Hägglunds Drive Unit until shortly before
the lines are connected.
▶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 insuf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 different manufacturers or different 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 order specic Hägglunds DUc documentation and product
identication.

14/88 Hägglunds DUc Drive unit | General notes regarding property damages and product damages
Bosch Rexroth AB, Version 06.2020, RE 15326-WA
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 Drive Unit must be installed in a
clean condition.
▶Use only clean connections, hydraulic lines and attachments (e.g. measuring
equipment).
▶Keep the connections plugged as long as possible.
▶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
▶For outside washing, do not point the power washer at sensitive components,
e.g. 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.

RE 15326-WA, Version 06.2020, Bosch Rexroth AB
Scope of delivery | Hägglunds DUc Drive unit 15/88
4 Scope of delivery
Included in the delivery contents are:
• Hägglunds DUc as per order conrmation
5 About this product
5.1 Product description
The intention with the Drive Unit is to provide the hydraulic motor(s) with
the required ow of oil and pressure at the right time. All included parts are
assembled in a compact cabinet. The Drive Unit has one to four pumps driven by
one or two electric motors. The main pump is an axial piston pump with variable
displacement for closed loop systems. The electric motor is totally enclosed
(TEFC).
The standard control system to the Drive Unit is Hägglunds Spider, a small,
compact and congurable control system. It can health monitor the Drive Unit and
can control the pumps with a high variation of pre-programmed functions.
The Drive Unit is a very exible product with a wide option range. This makes
it possible to select a standard Drive Unit to full the features needed in many
different applications.
This installation and maintenance manual is intended to cover all standard options.
It may not cover all details on customized Drive Units and other control systems
than Hägglunds Spider, that differs from the standard Hägglunds DUc concept.
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: Example of product identication from DUc European version
DD00057560

16/88 Hägglunds DUc Drive unit | Scope of delivery
Bosch Rexroth AB, Version 06.2020, RE 15326-WA
Main components
Item Description See also gure
1 Electrical motor –
2 Hydraulic pump –
3 Shaft coupling/bellhousing –
4 Frame –
5 Panels (not shown) –
6 Control system, Hägglunds Spider (at backside on DUc MT2, LT2) –
7 Control panel (at front side panel door on DUc MT2, LT2) –
8 Oil heater (optional, not shown) Fig. 7
9 Oil cooler Fig. 6
10 Oil tank Fig. 7
11 Flushing or /and brake circuits (optional, not shown) –
12 Filter –
13 Charge lter (optional, not shown) –
14 Accumualator (optional) –
15 Light (optional, not shown) –
16 Pressure sensors –
17 Hoses, internal (not shown) –
5.3 Main components
Note! Changes from the picture and the components may occur.
Fig. 2: Main components DUc MS2, LS2
1
2
6, 7
3
14
16
4
12
10
9
Product
identication
Oil lling
point
Accumulator
lling point.
Thread size
.305-32 UNS
male
DD00072757
Drain tap
1˝ BSP Female

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Fig. 3: Main components DUc MT2, LT2
1
2
7
3
14
4
12
10
9
Product
identication
Oil lling
point
DD00098769
6
16
Accumulator lling
point.
Thread size .305-32
UNS male
Drain tap
1˝ BSP Female

18/88 Hägglunds DUc Drive unit | Scope of delivery
Bosch Rexroth AB, Version 06.2020, RE 15326-WA
Main components
Item Description See also gure
1 Electrical motor –
2 Hydraulic pump –
3 Shaft coupling/bellhousing –
4 Frame –
5 Panels (not shown) –
6 Control system, Hägglunds Spider (at backside on DUc LT3) –
7 Control panel (at front panel door on DUc LT3) –
8 Oil heater (optional, not shown) Fig. 7
9 Oil cooler Fig. 6
10 Oil tank Fig. 7
11 Flushing or /and brake circuits (optional, not shown) –
12 Filter –
13 Charge lter (optional, not shown) –
14 Accumualator (optional) –
15 Light (optional, not shown) –
16 Pressure sensors –
17 Hoses, internal (not shown) –
Fig. 4: Main components DUc LS3
1
6, 7
3
14
16
4
10
9
Product
identication
Oil
lling point
DD00103962
2
12
Accumulator lling
point.
Thread size .305-32
UNS male
Drain tap
1˝ BSP Female

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Scope of delivery | Hägglunds DUc Drive unit 19/88
Fig. 5: Main components DUc LT3
1
2
6
3
14
4
10
9
Product
identication
Oil lling
point
DD00103963
7
16
12
Accumulator
lling point.
Thread size
.305-32 UNS
male
Drain tap
1˝ BSP Female

20/88 Hägglunds DUc Drive unit | Scope of delivery
Bosch Rexroth AB, Version 06.2020, RE 15326-WA
Fig. 6: Oil cooler alternatives
Item Description
1 Air-oil cooler
2 Water-oil plate cooler
3 Water-oil tube cooler
1
2
3
DD00098770