Hägglunds Compact CA Series Manual

Installation and Maintenance Manual
Compact CA
EN411-13h 2006

2
Installation and Maintenance Manual, Compact CA
Preface
Preface
Hägglunds Drives is one of the worlds leading manufacturers of large hydraulic
Drive Systems. A leading position, made possible by unbeatable service spirit
and of continuing development of both products and markets all over the world.
Our drives are to be found in most industrial and marine segments, where
there are extremely high demands for efficiency and reliability. Our main office
and production plant is in Mellansel, Sweden and we have our own sales- and
representation offices in some 40 different countries.
Our high quality Drive Systems, are based upon our unique hydraulic piston
motors, developed through a wealth of experience accumulated over 30
years in marine and industrial areas.Today this ongoing development work
has resulted in the powerful COMPACT CA industrial motor. New, as well as
established technical solutions, contribute to the creation of this product. The
most desirable features and operating reliability have been designed in this
hydraulic motor.
This manual provides necessary information for installation and maintenance
of the motor. In order to find particular information, just search for the wanted
section as listed in the table of contents. However, 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 motors manufactured after 2003-06-01.
For older motors please contact your nearest
Hägglunds Drives representative.
Original EN411-13h, 2006

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Installation and Maintenance Manual, Compact CA
Contents
1. GENERAL ..............................................................................................................................4
1.1 Safety precautions .. ...............................................................................................................4
1.2 Motor data...............................................................................................................................5
1.3 Functional description.............................................................................................................6
2. TECHNICAL DATA.................................................................................................................7
2.1 Recommended charge pressure.............................................................................................7
2.2 Sound from a complete installation.........................................................................................8
2.3 Choice of hydraulic fluid..........................................................................................................9
Environmentally acceptable fluids.........................................................................................10
3. INSTALLATION ....................................................................................................................11
3.1 Mounting instructions............................................................................................................11
Thread for mounting tool.......................................................................................................12
Spline ...................................................................................................................................12
3.1.1 Lifting methods......................................................................................................................13
Standing the motor on a flat surface .....................................................................................15
3.1.2 Mounting the coupling onto the motor shaft..........................................................................16
Instruction to follow when mounting the COMPACT CA motor on a driven shaft..................16
3.1.3a Fitting the torque arm to the motor .......................................................................................18
3.1.3b Fitting the double ended torque arm.....................................................................................19
3.1.4a Mounting the motor onto the driven shaft - shaft coupling....................................................20
3.1.4b Mounting the motor onto the driven shaft - splines...............................................................22
3.1.5 Removing the motor from the driven shaft............................................................................24
3.1.6 Mounting the reaction point ..................................................................................................25
3.1.7 Brake MDA............................................................................................................................26
3.1.8 Brake MDA 5, 7 & 10 ............................................................................................................26
3.1.9 Mounting MDA 5, 7 & 10.......................................................................................................27
3.1.10 Draining of brake cylinder ....................................................................................................27
Disassembly of MDA 5, 7 &10 .............................................................................................28
3.1.11 Brake MDA 14 & 21 ..............................................................................................................29
3.1.12 Mounting MDA 14 & 21 ........................................................................................................30
3.1.13 Draining of brake cylinder . ...................................................................................................30
Disassembly and assembly of MDA 14 & 21 . ......................................................................31
3.1.14 Control of braking torque ......................................................................................................31
3.1.15 Motors with 2-speed valve ....................................................................................................32
Mounting of 2-speed valve on CA 50 - 210 ..........................................................................32
3.2 Oil connections .....................................................................................................................33
3.2.1 Direction of rotation of motor shaft........................................................................................35
Motor with displacement shift valve .....................................................................................35
3.2.2 Draining and venting the motor.............................................................................................36
3.2.3 Flushing ................................................................................................................................37
4. OPERATING INSTRUCTIONS.............................................................................................37
4.1 Storage .................................................................................................................................37
4.2 Before commissioning...........................................................................................................37
4.3 Commissioning .....................................................................................................................38
4.4 Periodic maintenance ...........................................................................................................38
Maintenance chart ................................................................................................................38
Axial thrust bearing . .............................................................................................................39
Motor.....................................................................................................................................39
Filters ....................................................................................................................................40
Oil..........................................................................................................................................40
4.5 Oil inspection ........................................................................................................................40
5. FAULT FINDING ...................................................................................................................42
DECLARATION OF CONFORMITY.....................................................................................44
Contents

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Installation and Maintenance Manual, Compact CA
1.1 Safety precautions
1. GENERAL
General
It is of high importence that the Safety precautions are always followed, if you are
unsure about something, please don´t hesitate to contact your nearest HD-office
for advice.
WARNING is used to indicate the presence of a hazard
which can cause severe personal injury, death, or
substantial property damage if the warning is ignored.
DANGER is used to indicate the presence of a hazard
which will cause severe personal injury, death, or
substantial property damage if the warning is ignored.
CAUTION is used to indicate the presence of a hazard
which will or can cause minor personal injury or property
damage if the warning is ignored.
In this manual you will find the following signs which indicate a potential hazard, which can or will
cause personal enjury or substantial property damage. Depending on the probability of the hazard,
and how serious the injury or property damage could be, there are three levels of classification.
Warning signs
Application area
Mounting
Before starting up
All new and rebuild applications, should always be approved and supervised by Hägglunds
personel.
Before starting up new, rebuild or just worked on applications, all accessories and safety
arrangements functions, should be controlled/tested.
Carefully follow the instructions and be aware of the high weights and forces during lifting.
Periodic maintenance
Notice the intervals in maintenance chart (4.4) and keep a record.
Dismounting
Carefully follow the instructions and be aware of the high weights and forces during lifting.

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Installation and Maintenance Manual, Compact CA
Motor type FULL DISPLACEMENT Max. **
pressure
DISPLACEMENT SHIFT
Displace-
ment
Specific
torque
Rated
speed
Max. ***
speed
Displace-
ment
Specific
torque
Rated
speed
Max.
speed
Ratio
psi
CA 50 20 76,6 1017 400 400 5000
CA 50 25 95,8 1271 350 400 5000
CA 50 32 122,6 1627 280 400 5000
CA 50 40 153,3 2034 230 350 5000
CA 50 191,6 2543 200 280 5000 95,8 1271 200 280 1:2
CA 70 40 153,3 2034 270 400 5000
CA 70 50 191,6 2543 225 320 5000 95,8 1271 225 320 1:2
CA 70 60 230,1 3051 195 275 5000 115,1 1526 195 275 1:2
CA 70 268,5 3560 180 240 5000 134,3 1780 180 240 1:2
CA 100 40 153,3 2034 390 400 5000
CA 100 50 191,6 2543 320 400 5000
CA 100 64 245,3 3254 260 390 5000
CA 100 80 306,6 4068 220 310 5000 153,3 2034 220 310 1:2
CA 100 383,2 5085 190 270 5000 191,6 2543 190 270 1:2
CA 140 80 306,6 4068 245 340 5000
CA 140 100 383,2 5085 205 275 5000 191,6 2543 205 275 1:2
CA 140 120 460,3 6102 180 245 5000 230,1 3050 180 245 1:2
CA 140 537 7119 170 220 5000 268,5 3560 170 220 1:2
CA 210 160 613,2 8136 105 150 5000 306,7 4068 105 150 1:2
CA 210 180 690,4 9154 100 135 5000 345,2 4577 100 135 1:2
CA210 805,5 10678 85 115 5000 402,8 5339 85 115 1:2
Motor type FULL DISPLACEMENT Max. **
pressure
DISPLACEMENT SHIFT
Displace-
ment
Specific
torque
Rated
speed
Max.***
speed
Displace-
ment
Specific
torque
Rated
speed
Max.
speed
Ratio
bar
CA 50 20 1256 20 400 400 350
CA 50 25 1570 25 350 400 350
CA 50 32 2010 32 280 400 350
CA 50 40 2512 40 230 350 350
CA 50 3140 50 200 280 350 1570 25 200 280 1:2
CA 70 40 2512 40 270 400 350
CA 70 50 3140 50 225 320 350 1570 25 225 320 1:2
CA 70 60 3771 60 195 275 350 1886 30 195 275 1:2
CA 70 4400 70 180 240 350 2200 35 180 240 1:2
CA 100 40 2512 40 390 400 350
CA 100 50 3140 50 320 400 350
CA 100 64 4020 64 260 390 350
CA 100 80 5024 80 220 310 350 2512 40 220 310 1:2
CA 100 6280 100 190 270 350 3140 50 190 270 1:2
CA 140 80 5024 80 245 340 350
CA 140 100 6280 100 205 275 350 3140 50 205 275 1:2
CA 140 120 7543 120 180 245 350 3771 60 180 245 1:2
CA 140 8800 140 170 220 350 4400 70 170 220 1:2
CA 210 160 10051 160 105 150 350 5026 80 105 150 1:2
CA 210 180 11314 180 100 135 350 5657 90 100 135 1:2
CA 210 13200 210 85 115 350 6600 105 85 115 1:2
ViTs n n p ViTs n n
cm3 Nm rev rev cm3 Nm rev rev
rev bar min min rev bar min min
US
General
Table 1.1
Metric
1.2 Motor data
Not recommended to be used in
reduced displacement
Not recommended to be used in
reduced displacement
* Related to a required charge pressure of 12 bar/175 psi for motors in braking mode. (Special considerations
regarding charge pressure, cooling and choice of hydraulic system for speeds above rated, 4 ports must be used).
** The motors are designed according to DNV-rules. Test pressure 420 bar/6000 psi.
Peak/transient pressure 420 bar/6000 psi maximum, allowed to occur 10000 times.
*** Speed above 280 rpm requires viton seals. Max permitted continues case pressure is 2 bar.
ViTs n n p ViTs n n
in3 lbf·ft rev rev in3 lbf·ft rev rev
rev 1000 psi min min rev 1000 psi min min

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Installation and Maintenance Manual, Compact CA
1.3 Functional description
1
2
3
4
5
6
7
D
8
A, C
Fig. 1 The COMPACT CA motor
10
9
11
Hägglunds hydraulic industrial motor COM-
PACT CA is of the radial-piston type with a
rotating cylinder block/hollow shaft and a sta-
tionary housing.The cylinder block is mounted
in fixed roller bearings in the housing. An even
number of pistons are radially located in bores
inside the cylinder block, and the valve plate
directs the incoming and outgoing oil to and
from the working pistons. Each piston is wor-
king 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
piston which are guided in the rotating 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, D2 or D3 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
using a mechanical shaft coupling, or alterna-
tively by splines.
The symmetrical design of the motor has made
it possible to design it as a two displacement
motor. This means that two different speeds
can be obtained for a given flow. The simplest
way of performing displacement change is by
connecting a special valve, direct to the flange
face on the connection block.
Valid patents
US 4522110, US 005979295A, SE 456517,
EP 0102915, JP 83162704, GB 1385693,
EP No 0524437.
Quality
To assure our quality we maintain a Quality
Assurance system, certified to standard ISO
9001, EN 29001 and BS 5750; Part 1.
General
1. Cam ring
2. Cam roller
3. Piston
4. Shaft coupling
5. Cylinder block /
hollow shaft
6. Cylinder block / spline
7. Front end cover
8. Cylindrical roller
bearing
9. Connection block
10. Valve plate
11. Axial bearing
A = inlet or outlet port »A«
C = inlet or outlet port »C«
D = drain port
F4 = Flushing
F4

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Installation and Maintenance Manual, Compact CA
There are three distinct cases:
Case 1:
The motor works in braking mode. Required
charge pressure at the inlet port is according
to diagram below.
Case 2:
The motor works in driving mode only. Required
back pressure at the outlet port corresponds to
30% of value given in diagram below, but may
not be lower than 2 bar (29 psi).
Case 3:
The motor is used with 2-speed valve.Required
charge pressure at inlet port for valve is
according to AC-3.1 Accessories.
The hydraulic system must be such that the
motor will recieve sufficient charge pres-
sure at the low-pressure port. This app-
lies to all types of installations.
Note:
The diagram is valid for 1 bar (15 psi) case pressure. With increasing case pressure the charge
pressure must be increased accordingly. The graph is valid when 4 ports are used. Max casing
pressure is 3 bar (43,5 psi)(for 1% of the operation time evenly divided, pressure peaks of max 5
seconds upto 8 bar (116 psi) is allowed). Max permitted case pressure at stand-still is 8 bar (116
psi).
Technical data
2. TECHNICAL DATA
2.1 Recommended charge
pressure
In hanging load applications, charge
pressure at motors connection must
be according to graph below under
all conditions.
Table 2.1 Charge pressure
RECOMMENDED CHARGE PRESSURE - COMPACT CA MOTORS
Double port connection (4 ports) oil viscolisty 40 cSt / 187 SSU
Compact motors Double port connection (4 ports)
0
2
4
6
8
10
12
14
16
18
20
0 50 100 150 200 250 300 350 400
Speed (rpm)
Recommended charge pressure (bar)
0
50
100
150
200
250
Recommended charge pressure (psi)
CA 210
CA 210-180
CA 210-160
CA 140 CA 70, CA 100, CA 140-120 CA 50, CA 70-60
CA 100-80, CA 140-100
CA 140-80
CA 70-50, CA 50-40
CA 100-64
CA 50-32
CA 70-40
CA 100-50
CA 50-32
CA 100-40
CA 50-20

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Installation and Maintenance Manual, Compact CA
2.2 Sound from a complete installation
Technical data
Hydraulic motor
The hydraulic motor is a known noise level.
(Tables of sound data - see subsection 4.9 in
the Engineering Manual).
Driven unit
The driven unit is an unknown sound source
(for us) but can through certain information
probably be obtained from the supplier. When
securing the torque arm of a hydraulic motor to
the foundation or casing of a driven machine,
it is highly important to study the construction
of the foundation or casing. This may well be
the most important factor to consider, since
many structures may give rise to resonance,
resulting in severe noise problems.
Remarks:
Background noise
The background noise can not normally be
influenced but is usually known or easy to
measure.
Pump unit
The pump unit is a known noise level.
Pipe noise
The pipe noise is probably the source of the
majority of mistakes in installations: all pipe
clamps should be of vibration insulating type
secured to concrete ceiling, wall or floor.
Securing to non-rigid metal structures or
structures is likely to give resonance and
should be avoided.
Background noise
Pump
motor
Pipe
noise
Hydraulic
motor
Noise from
driven unit
Foundation and construction noise

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Installation and Maintenance Manual, Compact CA Technical data
2.3 Choice of hydraulic fluid
The Hägglunds hydraulic motors are primarily designed to operate on conventional petroleum
based hydraulic oils. The hydraulic oil can be chosen in consultation with the oil supplier of your
local sales office, bearing the following requirements in mind:
GENERAL
The oil shall have FZG (90) fail stage minimum 11 described in IP 334 (DIN 51354).The oil must also
contain inhibitors to prevent oxidation, corrosion and foaming. The viscosity of mineral oil is highly
dependent of the temperature. The final choice of oil must depend on the operating temperature
that can be expected or that has been established in the system and not in the hydraulic tank.
Fire resistant fluids
OPERATING WITH FIRE RESISTANT FLUIDS
The following fluids are tested for Hägglunds motors: (ISO/DP 6071)
* Many hydraulic fluids with VI-improvers are subject to temporary and permanent reductions of the viscosity.
** Low viscosity gives reduced service life for the motors and
reduction of max. allowed power for "COMPACT CA".
IMPORTANT!
Down rating of pressure data and service life must be considered when using fire
resistant fluid.The Hägglunds company or its authorised representative must always
be contacted for approval in the case of these types of fluids.
RECOMMENDED VISCOSITY AT
OPERATING TEMPERATURE
40-150 cSt/187-720 SSU.
FOR SPEED BELOW 5 RPM, COATED
PISTONS OR HIGH VISCOSITY SHALL
BE USED.
High temperatures in the system greatly reduce
the service life of oil and rubber seals, as well
as resulting in low viscosity, which in turn
provides poor lubrication.
Content of water shall be less than 0,1%.
In Industrial applications with high demands
for service life, the content of water shall be
less than 0,05%.
* Must be specified in the order.
**The motor must have synthetic oil for the axial bearing.
Viscosity limits
Viscosity index = 100 recommended
= 150* for operation
with large temperature
difference
Min. permitted in continuous duty
Min. permitted in intermittent duty
Max. permitted
40 cSt/187 SSU
20 cSt/98 SSU**
10000 cSt/48000 SSU
Temperature limits
Normal operating temperature should be less
than +50°C (122°F)
Nitrile seals (std motor)
Viton seals
-35°C to +70°C
-20°C to +100°C
Nitrile seals (std motor)
Vition seals
-31°F to +158°F
-4°F to +212°F
Fluid Approved Seals Internal paint
HFA: Oil (3-5%) in water emulsion No - -
HFB: Inverted emulsion 40-45% water in oil Yes Nitrile (std motor) Not painted*
HFC: Water-glycol Yes Nitrile (std motor)** Not painted*
HFD synthetic fluids
HFD:R - Phosphate esters Yes Viton Not painted*
HFD:S - Chlorinated hydrocarbons Yes Viton Not painted*
HFD:T - Mixture of the above Yes Viton Not painted*
HFD:U - Other compositions Yes Viton Not painted*

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Installation and Maintenance Manual, Compact CA
Environmentally acceptable fluids
Explanation of
"GRADE OF FILTRATION"
Grade of filtration β10=75 indicates the fol-
lowing:
β10 means the size of particle ≥10µm that will
be removed by filtration.
=75 means the grade of filtration of above
mentioned size of particle. The grade of
filtration is defined as number of particles in
the oil before filtration in relation to number of
particles in the oil after filtration.
Ex. Grade of filtration is β10=75.
Before the filtration the oil contains Nnumber
of particles ≥10µm and after passing the filter
once the oil contains number of particles
≥10µm.
This means that number of
particles have been filtered (=98,6%).
* Vegetable fluids give good lubrication and small change of viscosity with different temperature. Vegetable fluids
must be controlled every 3 months and temperature shall be less than +45° (113°F) C to give good service life for
the fluid.
** Environmental acceptabel fluid gives the same servicelife for the drive, as mineral oil.
Technical data
Filtration
The oil in a hydraulic system must always be
filtered and also the oil from your supplier has
to be filtered when adding it to the system.
The grade of filtration in a hydraulic system is
a question of service life v.s. money spent on
filtration.
In order to obtain stated service life it is im-
portant to follow our recommendations con-
cerning contamination level.
When choosing the filter it is important to
consider the amount of dirt particles that the
filter can absorb and still operate satisfactory.
For that reason we recommend a filter with an
indicator that gives a signal when it is time to
change the filter cartridge.
Filtering recommendations
Before start-up, check that the system is
thoroughly cleaned.
1. In general the contamination level in our
motors should not exceed ISO 4406 19/15.
(NAS 10)
2. For heavy-duty industrial applications the
contamination level should not exceed ISO
4406 16/13. (NAS 7)
3. When filling the tank and motor housing, we
recommend the use of a filter with the grade
of filtration β10=75.
Fluid Approved Seals Internal paint
Vegetable */** Fluid
HTG Yes Nitrile (std motor) -
Synthetic ** Esters HE Yes Nitrile (std motor) -