Hägglunds Fusion Instruction Manual

Hägglunds Fusion
Drive system
RE 15345-WA, Version: 11.2022, Replaces: New, EN
INSTALLATION & MAINTENANCE MANUAL

The data specied only serve to describe
the product. No statements concerning
a certain condition or suitability for a
certain application can be derived from
our information. Catalog specications do
not constitute assured characteristics. 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cations and other information set forth
in it, are the exclusive property of Bosch
Rexroth AB. 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 systems manufactured
after 01.01.2022. For older drive systems
please contact your nearest Bosch Rexroth
representative.
The cover shows an example application. The
product delivered may differ from the image
on the cover.
Original instruction manual

RE 15345-WA, Version 11.2022, Bosch Rexroth AB
Contents | Hägglunds Fusion Drive system 3/72
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 ...........................................................................................18
5.5 Requirements for hydraulic uid cleanliness ...............................................19
5.6 Drive system monitoring ..............................................................................20
6 Transport and storage.............................................................................. 21
6.1 Storage of the packed drive system ...........................................................21
6.2 Lifting the packed drive system ...................................................................22
7 Installation.............................................................................................. 23
7.1 Installation directives ..................................................................................23
7.2 Lifting methods ..........................................................................................23
7.3 Positioning the drive system .......................................................................25
7.4 Required tools .............................................................................................26
7.5 Drive system mounting ................................................................................27
7.6 Electric connections ....................................................................................37
8 Commissioning ........................................................................................ 40
8.1 Before commissioning .................................................................................40
8.2 Filling up the system with hydraulic uid ....................................................41
8.3 Initial start up procedure.............................................................................44
8.4 Pump settings and adjustments...................................................................46
8.5 Hägglunds BICA Brake .................................................................................50

4/72 Hägglunds Fusion Drive system | Contents
Bosch Rexroth AB, Version 11.2022, RE 15345-WA
9 Maintenance and repair ........................................................................... 50
9.1 Maintenance log ..........................................................................................50
9.2 Preventive maintenance ..............................................................................50
9.3 Filter change................................................................................................53
9.4 Inspection of hydraulic uid ........................................................................55
9.5 Air lter breather change .............................................................................56
9.6 Electric motor..............................................................................................57
9.7 Cleaning of air oil cooler .............................................................................58
9.8 Drive system out of service..........................................................................59
9.9 Repair..........................................................................................................60
9.10 Flushing after repair ....................................................................................60
9.11 Spare parts..................................................................................................62
10 Removal and replacement ....................................................................... 63
10.1 Required tools .............................................................................................63
10.2 Common......................................................................................................63
11 Disposal .................................................................................................. 65
11.1 Environmental protection ............................................................................65
12 Extension and conversion ........................................................................ 65
13 Troubleshooting ...................................................................................... 66
14 Technical data ......................................................................................... 70
14.1 Weights ......................................................................................................70

RE 15345-WA, Version 11.2022, Bosch Rexroth AB
This documentation | Drive system Hägglunds Fusion 5/72
1 This documentation
1.1 Validity of the documentation
This documentation applies to the Drive System, Hägglunds Fusion, European and
American version, and is intended for machine/system manufactures, tters and
service engineers.
Hägglunds Fusion is a exible product with a wide option range, this installation
and maintenance manual is intended to cover all these options. Some options
might not be included in the delivered drive system, see order specic
documentation for the exact content.
This documentation contains important information required to transport,
install, commission, operate, use, service and dismantle the product safely and
professionaly.
fRead this documentation completely before using the Hägglunds Fusion
1.2 Required and additional documentations
fBefore 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 CA* RE 15305-WA Installation & maintenance manual
Hägglunds CB* RE 15302-WA Installation & maintenance manual
Hägglunds BICA brake** EN 643 Installation & maintenance manual
Hägglunds Spider 2** RE 15330-WA User manual
HJägglunds Fusion RE 15345 Data sheet
Hägglunds Torque arms RE 15355 Data sheet
Hägglunds SPDC RE 15350 Data sheet
Hydraulic uid quick reference
Hägglunds products
RE 15414 Data sheet
Axial piston variable pump
A4VG series 32 Europe
92003-01-B Instruction manual
*Depending on the hydraulic motor type in the drive system
** Required if included in scope
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.

6/72 Hägglunds Fusion Drive system | This documentation
Bosch Rexroth AB, RE 15345-WA Version 11.2022,
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
fPrecautionary measures
f<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.
fSingle, 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 15345-WA, Version 11.2022, Bosch Rexroth AB
Safety instructions | Drive system Hägglunds Fusion 7/72
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.
fRead this documentation carefully before starting to use the product.
fKeep this documentation in a location where it is accessible to all users at any
time.
fWhen providing the product to third parties, make sure to include the
necessary documentation.
2.2 Intended use
The Hägglunds Fusion is a hydraulic drive system.
In the application the Hägglunds Fusion drive system is classied as a partly
completed machinery in the sense of the EU machine directive 2006/42/EC,
Appendix IIB. A partly completed machinery is exclusively intended to form an
incomplete or a complete machine together with other components or partly
completed machineries. The drive system 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:
• Closed loop hydraulic system to convert electric energy to mechanical rotation of
a shaft.
Special drive systems
Standard drive systems are not allowed to be used outside an ambient
temperature range of -20 °C to 40 °C (-4 °F to 104 °F), or in areas with potentially
explosive atmospheres.
Drive systems intended for use in ambient temperature below 0 °C (32 °F), can 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.

8/72 Hägglunds Fusion Drive system | Safety instructions
Bosch Rexroth AB, RE 15345-WA Version 11.2022,
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 specic documention.
• 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 system in explosive environments unless the component or
machine/system has been certied as compliant with the local regulations.
• Using the drive system 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.

RE 15345-WA, Version 11.2022, Bosch Rexroth AB
Safety instructions | Drive system Hägglunds Fusion 9/72
2.5 General safety instructions
• Observe the regulations for accident prevention and environmental protection.
• Comply with the local safety provisions and regulations of the country in which
the product is used.
• 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.

10/72 Hägglunds Fusion Drive system | Safety instructions
Bosch Rexroth AB, RE 15345-WA Version 11.2022,
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 excessively high pressure
Danger to life or risk of injury, damage to equipment.
Operating the components above the permissible maximum pressure can cause
components to burst and hydraulic uid to escape under high pressure.
fOperate the components 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 drive system to fall down lead
to injuries e.g. crushing or broken bones or damage to the product.
fMake certain that the forklift truck or lifting device has adequate lifting
capacity.
fNever stand under or put you hands under suspended loads.
fEnsure your position is stable during transportation.
fUse your personal protective equipment (e.g. protective goggles, safety gloves,
suitable working clothes, safety shoes).
fUse 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.
fObserve the prescribed position of the lifting strap.
fObserve 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.
fAlways lockout-tagout electric motors before maintenance.
fDo not disconnect any line connections, ports and components when the
machine/system is pressurized.
fAlways ensure that no energy is accumulated before any measures.
fEnsure that no pressure will enter the hydraulic system in the drive system via
the hydraulic motor e.g. loads on the shaft or winch drum.