A21 - W912P824R0040 Attachments2.pdf

RA15322-WA/05.2018, Operations and Maintenance Manual, Bosch Rexroth Corporation

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Contents

1 This documentation

1.1 Scope of documentation

1.2 Required and additional documentation

1.3 Display of information

2 Safety instructions

2.1 About this chapter

2.2 Intended use

2.3 Improper use

2.4 Personnel qualifications

2.5 General safety instructions

2.6 Product-specific safety instructions

2.7 Personal protection equipment

3 General instructions on material damage and product damage

4 Delivery contents

5 About this product

5.1 Product description

5.2 Product identification

5.3 Main components

5.4 Hydraulic fluids

5.5 Requirements for hydraulic fluid cleanliness

5.6 Cooling water

5.7 Drive unit monitoring

6 Transport and storage

6.1 Storage of the packed drive unit

6.2 Lifting the packed drive unit

7 Installation

7.1 Installation directives

7.2 Lifting methods

7.3 Positioning the drive unit

7.4 Mounting of the cabinet feet

7.5 Mounting of main electric motor

7.6 Mounting of top cover

7.7 Hydraulic connections

7.8 Mounting of air oil cooler

7.9 Water connection

7.10 Mounting of water-oil plate cooler

7.11 Mounting of water-oil tube cooler

7.12 Mounting of sound protection

7.13 Mounting of rain protection

7.14 Pipe work, internal

7.15 Electric connections

FOR REFERENCE ONLY

Bosch Rexroth Corporation, Operations and Maintenance Manual, RA15322-WA/05.2018

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8 Commissioning

8.1 Before commissioning

8.2 Filling up the system with hydraulic fluid

8.3 Flushing before start up

8.4 Initial start up procedure

8.5 Pump settings and adjustments

9 Maintenance and repair

9.1 Maintenance log

9.2 Preventive maintenance

9.3 Filter change

9.4 Inspection of hydraulic fluid

9.5 Air filter breather change

9.6 Electric motor

9.7 Cooler

9.8 Drive unit out of service

9.9 Repair

9.10 Spare parts

10 Removal and replacement

10.1 Common

11 Disposal

11.1 Environmental protection

12 Extension and conversion

13 Troubleshooting

14 Technical data

14.1 Weights

This documentation 5/72

1 This documentation

1.1 Scope of documentation

This documentation applies to the drive unit Hägglunds PAC/PBC and is intended for machine/system manufacturers, fitters and service engineers.

This documentation contains important information required to transport, install, commission, operate, use, service, dismantle the product safely and professionally.

▶ Read this documentation completely, before using the Hägglunds PAC/PBC.

1.2 Required and additional documentation

Do not start using the product until you have familiarised yourself with the documentation marked with the book symbol and followed it.

Table 1: Necessary and supplementary documentation.

Title Document no Document type Order confirmation Contains the order-related technical data for your Hägglunds PAC/PBC.

Order confirmation

Order documentation Order specific E.g. hydraulic and electric diagrams, bill of material, specifications

Hydraulic fluid quick reference

RE 15414 Data sheet

1.3 Display of information

Standardized safety instructions, symbols, terms and abbreviations are used so that you can use this documentation to work quickly and safely with your product. To give you a better understanding they are explained in the sections below.

1.3.1 Safety instructions

This documentation includes safety instructions in chapter 2.6: Product-specific safety instructions and in chapter 3: General instructions on material damage and product damage and before a sequence of actions or an instruction for action involving a risk of personal injury or damage to equipment.

The described danger prevention measures must be observed.

Safety instructions are formatted as follows:

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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!: Specifies the type and source of the hazard

• Consequences: Describes the consequences of non-compliance

• Precaution: Specifies how the hazard can be prevented

Table 2: Risk categories to ANZI Z535.6-2006 Warning signs, signal word Meaning

DANGER Indicates a dangerous situation which will result in death or serious physical injury unless averted.

WARNING Indicates a dangerous situation which could result in death or serious physical injury unless averted.

CAUTION Indicates a dangerous situation which could result in minor to moderate physical injury unless it is averted.

NOTICE Material damage: the product or its environment could be damaged.

1.3.2 Symbols

The symbols below indicate instructions which are not safety-relevant but help to make the documentation easier to understand.

Table 3: Key to symbols Symbol Meaning

You will be unable to use or operate the product optimally unless this information is observed.

Individual self-contained action (alternatives)

1.

2.

3.

Numbered operating instruction:

The numbers indicate the actions follow one another in sequence

Center of gravity Markings on packaging to indicate where the center of gravitiy are.

Safety instructions 7/72

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 PAC/PBC is a hydraulic drive unit

In the application the Hägglunds PAC/PBC drive unit is classified as a partly completed machinery. A partly completed machinery is exclusively intended to form an incomplete or a complete machine together with other components or partly completed machineries. The PAC/PBC 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 flow in a closed loop hydraulic system.

Special drive units Standard drive units are not allowed to be used outside the ambient temperature range of –40 °F to 105 °F, or in areas with potentially explosive atmospheres.

Drive units intended for use in ambient temperature below 20 °F, will be fitted with special optional equipment for preheating the hydraulic system before start.

Drive units intended for use in areas with potentially explosive atmospheres will be fitted with suitable components for use in such areas and manufactured in accordance with valid rules and standards complying with NEC-directives. Observe the technical data, application and operating conditions, and performance limits as specified in the product-specific documentation and in the order confirmation.

2.3 Improper use

Any use other than that described as intended use shall be considered as improper and is therefore impermissible.

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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-specific data sheet or in the order confirmation (unless customer-specific approval has been granted)

• Use of fluids outside of the standards as specified in RE15414 Hydraulic fluid quick reference.

• Modification of factory settings by non-authorized persons

• Use of add/on parts (e.g. mountable filter, control unit, valves) that are not specified 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 certified as compliant with the NEC directive.

• Using the Drive unit in an aggressive atmosphere without necessary additional measures.

2.4 Personnel qualifications

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 qualified personnel or an instructed person under the direction and supervision of qualified personnel.

Qualified 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. Qualified 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 offers training support for special fields. For more information about training, please contact your Bosch Rexroth representative.

Safety instructions 9/72

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.

• Before starting up new, rebuild or just worked on installations, all accessories and safety arrangement functions must be controlled/tested.

• Persons who install, operate, remove or maintain Bosch Rexroth products must not consume any alcohol, drugs or pharmaceuticals that may affect 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.

• If unsuitable products are fitted 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 specifically stated and allowed in the product documentation, e.g. in explosion risk areas or in safety-critical controls (operating safety).

• You may only commission the product if it has been determined that the end product (e.g. machinery or a system) into which the Bosch Rexroth products are installed complies with the country-specific provisions, safety regulations and standards of the application.

• Use safety equipment like helmet, protective goggles, safety shoes and hearing protection.

• In emergency situations, use only fire-extinguisher adapted for use both to oil products and electric equipment.

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2.6 Product-specific 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. 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 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!

▶ 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.

Safety instructions 11/72

WARNING

Escaping oil mist!

Risk of explosion, fire, health hazard, environmental pollution!

▶ Depressurize the machine/system and repair the leak.

▶ Keep open flames 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 and the safety regulations for work on heavy-current equipment.

▶ The operation, maintenance and/or repair of such equipment is reserved to skilled personnel qualified 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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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 sufficiently 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 fluid!

Hazard to health/health impairment e.g. eye injuries, skin damage, toxication during inhalation!

▶ Avoid contact with hydraulic fluids.

▶ When working with hydraulic fluids, 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 fluid should, nevertheless, come into contact with your eyes or bloodstream or is swallowed, consult a doctor immediately.

Escaping hydraulic fluid 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 protection equipment

Use safety 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 intact.

General instructions on material damage and product damage 13/72

3 General instructions on material damage and product damage

NOTE

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 fittings (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 insufficient hydraulic fluid.

▶ When commissioning a machine/system, make sure that the case interior and the service lines of the Hägglunds motor are filled with hydraulic fluid and remain filled during operation.

Mixing of hydraulic fluids!

Product can be damaged!

▶ Before installation, remove all fluids from the Hägglunds motor to prevent mixing with the hydraulic fluid used in the machine/system.

▶ Any mixing of hydraulic fluids 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 Hägglunds PAC/PBC custom documentation and product identification.

14/72 General instructions on material damage and product damage

NOTE

Contamination of the hydraulic fluid!

The cleanliness of the hydraulic fluid has a considerable impact on the cleanliness and service life of the hydraulic system. Contamination of the hydraulic fluid 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).

▶ 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 fluids and contaminants are prevented from penetrating the product.

▶ Use a suitable filter system to filter hydraulic fluid during filling 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 ▶ 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 drive unit and its fittings, the hydraulic fluid and the packaging material could lead to pollution of the environment!

▶ Dispose of the Hägglunds drive unit, hydraulic fluid and packaging in accordance with the national regulations in your country.

▶ Dispose of the hydraulic fluid in accordance with the applicable safety data sheet for the hydraulic fluid.

Escaping or spilling hydraulic fluid!

Environmental pollution and contamination of the ground water!

▶ Use an oil binding agent if hydraulic fluid is spilled.

▶ Observe the information in the safety data sheet for the hydraulic fluid and the specifications provided by the system manufacturer.

The warranty applies only to the delivered configuration.

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.

Delivery contents 15/72

4 Delivery contents Included in the delivery contents are:

• Hägglunds PAC/PBC as per order confirmation

5 About this product

5.1 Product description

The intention with the drive unit is to provide the hydraulic motor(s) with the required flow of oil and pressure at the right time. All included parts are assembled in a compact cabinet. The drive unit has one or more pumps driven by one or more 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 the Hägglunds Spider, a small, compact and configurable control system. It can health monitor the drive unit and can control up to four pumps with a high variation of pre-programmed functions.

The drive unit is a very flexible product with a wide option range. This makes it possible to select a standard drive unit to fulfil 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 PAC/PBC concept.

5.2 Product identification

1 Model number 2 Weight 3 Serial number 4 Tank volume 5 Flow capacity 6 Max pressure 7 Manufacturer 8 Date of manufacture 9 Job/order number 10 Electric motor power 11 Electric motor voltage 12 Electric motor frequency 13 Electric motor rpm

Fig. 1: Product identification

16/72 About this product

5.3 Main components

Notice! Changes from the picture and the components may occur.

Fig. 2: Main components PAC S, M, L, and XL

About this product 17/72

Main components

Item Description See also figure

1 Electrical motor –

2 Hydraulic pump –

3 Shaft coupling/bellhousing –

4 Frame –

5 Panels (PAC only) –

6 Top cover (PAC only) –

7 Control system, Hägglunds spider –

8 Oil heater (optional) –

9 Oil cooler (not shown) —

10 Oil tank Fig. 4

11 Filter –

12 Hoses, internal All

Fig. 3: Main components PBC S, M, L, and XL

18/72 About this product

Fig. 4: Detailed view, tank PAC/PBC S, M, L, and XL

Item Description

1 Oil-level gauge

2 Oil-drain valve

3 Level and temperature sensor

4 Air filter breather

5 Suction ports / valves

6 Oil heater

About this product 19/72

5.4 Hydraulic fluids

The Hägglunds hydraulic system is primarily designed for operation with hydraulic fluids according to ISO 11158 HM.

Fluids by the standards given in Table 4: Suggested fluid types are suggested. Before the start of project planning, see data sheet RE 15414, Hydraulic fluid quick reference, for detailed information on hydraulic fluids and specific additional demands

Table 4: Suggested fluid types

SO 11158 ISO 15380 ISO 12922

HM HEES HFB

HV HEPG HFC

HEPR HFDU

Details regarding the selection of hydraulic fluid The hydraulic fluid should be selected such that the operating viscosity in the temperature range, as measured in the motor housing, is within optimum operation range, see Fig. 5: Selection diagram for viscosity ranges with straight fluids, i.e. viscosity index 100. General recommendation is to have a system temperature of 122 °F, see dotted line in Fig. 5: Selection diagram for viscosity ranges with straight fluids, i.e.

viscosity index 100. A VG 68 fluid will render just above 40 cSt at this point.

• Optimum viscosity range is 40 to 150 cSt.

• Running above 150 cSt or below 40 cSt results in reduced efficiency.

• Running above 400 cSt results in substantial efficiency loss.

• For pumps, the maximum start-up viscosity is 1000 cSt.

• For motors, starting at above 10000 cSt imparts unnecessary strain on parts.

• Running below 30cSt may impact the service life.

• Running below 20 cSt may render instant seizure.

20/72 About this product

20000

10000

M ax im um v is co si ty a t co ld s ta rt

Viscosity, ν [cSt]

M in im um v is co si ty fo r sh or t-te rm o pe ra tio n

–40 (–40)

–30 (–22)

–20 (–4)

–10 (14)

(32)

(50)

(68)

(86)

(104)

(122)

(140)

(158)

(176)

(194)

(230)

(212)

Temperature, t [°C (°F)]

C on tin uo us o pe ra tio n

O pt im al o pe ra tio n

5.5 Requirements for hydraulic fluid cleanliness

The drive units are equipped with filters on the drain line and return line. In order to obtain stated service life it is important to follow recommendations concerning cleanliness levels and maintenance.

Cleanliness level recommendations

• The system must be flushed before start up (see section 8.3 Flushing before start up).

• When filling the tank with hydraulic fluid it is important to fill through the special oil filler connection (see 8.2: Filling up the system with hydraulic fluid).

• For industrial applications the contamination level should not exceed NAS 16389 Class 9 (ISO 4406:1999 18/16/13).

• Have a water content of <200 ppm (0,02%).

• Always use filter elements recommended and supplied by Bosch Rexroth.

• The hydraulic fluid should be analyzed according to the special maintenance intervals for your specific drive unit or the maximum intervals on the maintenance chart (see Table 15: Maintenance chart). Be particularly vigilant when removing equipment for repairs or maintenance, dirt must not be allowed to enter the system, clean prior to opening and plug open connections.

NOTICE

Dirt in oil Damage on equipment

▶ Do not re-use hydraulic fluid which has leaked out.

Fig. 5: Selection diagram for viscosity ranges with straight fluids, i.e. viscosity index 100

About this product 21/72

5.6 Cooling water

The cooling water must be filtered to 44 µm.

It is important to:

• Maintain the water filter (if any) in a correct way to get the required flow of water through the Water-oil cooler.

• Check the temperature in the hydraulic system, according to the special maintenance intervals for your specific drive unit.

• Clean the cooling system if the temperature in the hydraulic system is above the specified limits on account of too low cooling capacity.

• Clean and empty the cooling system (water side) before periods of rest (especially if the cooling water is not totally clean).

NOTICE

Cooling capacity too low The service life of hydraulic motor, the main components in drive unit and the hydraulic fluid will be reduced.

▶ Have the required flow, pressure and temperature of the cooling water (see Hägglunds PAC/PBC order specific documentation).

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5.7 Drive unit monitoring

If the monitoring function is not included in a control system supplied with the drive unit, the following function must be fulfilled in the system.

The monitoring of the drive unit switches and sensors are grouped in two levels according to the logic diagram.

The warning indication is to give an indication about a problem in the drive unit but does not need an immediate action. The alarm indicates a need for stopping the pump.

The stop sequence is to first stop the hydraulic motor by setting the pump swash angle to zero without ramp and after a short delay to allow the hydraulic drive to stop, switch off the electric motor.

The low (charge) pressure indicator must be interlocked during stop and startup of the electric motor to avoid alarm and give the pump time to build up the charge pressure after start.

>150 psi

>158°F

>158°F

>140°F

>140°F

>105°F

<65°F

>131°F

>131°F

>131°F

>138°F

<32°F

Fig. 6: Monitoring logic diagram

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6 Transport and storage

6.1 Storage of the packed drive unit

At delivery the drive unit is protected by a plastic hood with a label showing the center of gravity. Do not remove the plastic hood until installation!

At delivery, the hydraulic components are protected internally with desiccant bags to absorb moisture. This provides sufficient corrosion protection for indoor storage in air conditioned premises for about 12 months.

The drive unit and belonging parts (including parts delivered separately) should be stored indoors, in dry, vibration free and dust free conditions. It should not be stored for more than three months in non-air conditioned premises. The drive unit must be placed where not exposed to strong sunlight or severe cooling to avoid condensation.

If storage time exceed limits, the drive unit must be operated so that the hydraulic system is lubricated with new fluid (see 9.8: Drive unit out of service).

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6.2 Lifting the packed drive unit

The packed drive unit is among other things marked with center of gravity and weight.

Normally the drive unit package is designed for forklift truck handling.

WARNING

Packed unit can tip Danger to life or risk of injury, damage to equipment

▶ Center of gravity is high, see label on the crate.

▶ Avoid rapid acceleration, deceleration and turns while moving the goods.

▶ Position the forks according to the instructions in : If storage time exceed limits, the drive unit must be operated so that the hydraulic system is lubricated with new fluid (see 9.8: Drive unit out of service)., section Lifting with fork lift

Lifting with fork lift The lifting of drive units can is done by lifting from the long side.

The absolute minimum requi red fork length, see Table 5: Minimum fork length

The minimum distance between the forks is 31.5 in – 43.25 in depending of the drive unit size.

Position forks about the centre of gravity at lifting from long side. At lifting from short side the lifting shall be done from the side closest to the center of gravity.

Parts that are delivered separately

• The package is always marked with the weight.

• Packages are only designed for forklift truck handling.

Table 5: Minimum fork length

Cabinet size

Fork length

PAC/PBC

in

PAC/PBC S2 48

PAC/PBC S3 48

PAC/PBC M2 65

PAC/PBC M3 65

PAC/PBC L3 72

PAC/PBC XL3 84

Installation 25/72

7 Installation

7.1 Installation directives

If the drive unit is to work properly it must be installed in accordance with these instructions. The conditions the unit will operate in must be taken into consideration.

Improper installation, not following the instructions in this manual and in the attached technical documentation, may affect the function and/or the service life of the drive unit. It is important that the safety precautions in this manual always are followed.

Position the drive unit:

• on a firm level foundation to avoid vibrations.

• to ease maintenance and service (see 7.3: Positioning the drive unit).

• protected from weather, airborne sprays, heavy contaminations and radiated heat.

• to ensure free ventilation for cooling purposes for the electric motor and the air-oil cooler.

• to minimize pipe runs.

Clamp each pipe in the pipe run separately and attach it to a firm foundation to avoid vibration. The hydraulic connections from the drive unit must always be fitted to the piping with hoses. If air-oil cooler is mounted at a location other than on the drive unit, it must be considered that the cooler will start without notice and has sharp edges.

7.2 Lifting methods

Lifting with fork lift See 6.2: Lifting the packed drive unit section lifting with fork lift.

Lifting with ropes/chains Lift the drive unit without top cover, maximum lifting angle 90°.

Fig. 7: Lifting the PAC/PBC S, M, L, AND XL

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DANGER

Danger while transporting or lifting Hägglunds drive unit due to heavy weight!

Danger to life, risk of injury or serious injuries and risk of damage to equipment

▶ Do not stand under hanging load.

▶ Use only lifting equipment adapted to the weight of the drive unit (check rating plate inside the cabinet).

▶ Centre of gravity is high, see label on plastic cover of cabinet.

▶ Do not lift the drive unit with hydraulic fluid in the tank, or with the front bar disassembled.

▶ Do not lift the drive unit with main electric motors installed unless the motors are pre-assembled at delivery.

▶ Always use a minimum of four lifting points when lifting the drive unit.

7.3 Positioning the drive unit

The following minimum space must be left around the drive unit, to ensure free ventilation and provide sufficient working space for easier maintenance. Heavier maintenance e.g. change of motor/pump will demand more working space. The drive units may not be installed side by side without facing side walls removed. It is important that all pipes (both for water and hydraulics) are mounted to give sufficient working space for maintenance.

WARNING

Unstable movement or turning over of the drive unit at installation of drive units in outdoor environment with heavy wind, at inclined surfaces or in areas with risk for earthquakes.

Risk of injury or serious injuries

▶ The drive unit has to be fixed to the ground with fixing screws or similar.

Installation 27/72

A B

A

D

C

A B

A

D

C

Fig. 8: Recommended minimum space around drive unit, PAC Fig. 9: Recommended minimum space around drive unit, PBC

Table 6: Recommended space around PAC/PBC

Minimum space PAC (in.) PBC (in.)

A 32 32 B 48 32 C 32 32 D 24 24

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Side by side positioning When drive units are installed side by side, side panels must be removed to make it possible to perform service on the drive unit. Distance between units should be 5 mm to allow assembly of sealing strip. Use sealing strip from Bosch Rexroth!

• No side walls

• Sealing strip

Fig. 10: Drive unit installation side by side

Installation 29/72

7.4 Mounting of the cabinet feet

CAUTION

Unplanned drop of the unit Risk of crushing hands.

▶ Follow the safety precautions in 7.2: Lifting methods ▶ Use support to prevent drop.

The cabinet feet (option) minimizes the vibrations and makes it easy to level the drive unit. They are delivered separately within the cabinet and have to be mounted according to the following instructions:

1. Mount the cabinet feet before filling hydraulic fluid in the tank.

2. Mount the cabinet feet before the electric motor(s), if they are delivered separately or supplied by the customer.

3. Lift the drive unit according to 7.2: Lifting methods. Notice especially the safety precautions.

4. Mount the cabinet feet according to Fig. 11: Adjusting cabinet feet and Table 7:

Adjusting cabinet feet. Level the drive unit by the adjusting screws.

Fig. 11: Adjusting cabinet feet

Table 7: Adjusting cabinet feet

Cabinet size Adj. height A

Adj. screw head size in mm

PAC/PBCS2

1.56–2.56 22

PAC/PBCS3

PAC/PBCM2

PAC/PBCM3

PAC/PBCL3

PAC/PBCXL3

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7.5 Mounting of main electric motor

In many cases the electric motor(s) are delivered separately. The following instructions are applicable for these cases only.

WARNING

Unsecured motor can fall Risk to life or serious injury or material damage.

▶ Do not stand under hanging load.

▶ Use all lifting ears when the electric motor is hanging free.

▶ Earbolts must be screwed in right up to their supporting surface and tightly fastened ▶ Use only lifting equipment adapted to the weight on the rating plate.

▶ No hands between electric motor and bellhousing during assembly.

▶ If necessary, use suitable, sufficiently-sized transport equipment such as lifting straps (EN1492-1)

1. Unpack the electric motor Unpack the electric motor. Check the electric motor for external damage and that all rating plate data are the same as in the attached technical documentation.

2. Check the shaft coupling Check that the axial shaft coupling for external damage and that the locking screw is tightened.

3. Lift the electric motor Two separate lifting equipments are needed to lift the electric motor.

– Lift the electric motor horizontally with both lifting equipments.

Do not use the motor shaft as lifting point!

– When at a reasonable height, lower one of the lifting equipment until the motor is hanging vertically.

– If needed, lower the motor to a stable frame or similar resting on the electric motor flange.

– If needed reconnect one lifting equipment for vertical lifting of the electric motor.

The straps must be separated to avoid force from the straps to the fan cover (Fig.

12). Never let the electric motor stand on the shaft coupling!

Dismount the front beam of the PAC/PBC to simplify the assembly of the electric motor!

Installation 31/72

Fig. 12: Lifting electrical motor vertically

4. Mount the electric motor in the drive unit Lift the electric motor in to the drive unit. It is important that the electric motor is hanging vertically. Fit the shaft coupling through inspection hole (Fig. 13: Mounting of electrical motor) into the ring gear coupling without causing any damage. The connection box on the electric motor must be positioned as shown on the order specific dimension drawing. Lower the motor to a position approximately 0.25 in above the bellhousing. Place screws in the holes and tighten by hand. Lower the motor to the bellhousing.

5. Tighten screws to the bellhousing Inspect that there is an axial clearance (Fig. 13: Mounting of electrical motor) through the inspection hole in the bellhousing. Tighten the attached screws to the bellhousing with torque according to Table 8: Tightening torques of bellhousing.

6. Mount unit top cover Assemble top cover according to 7.6: Mounting of top cover and mount on the PAC/PBC.

Table 8: Tightening torques of bellhousing

Bolt Size 1/2-13 5/8-11 3/4-10

Tightening torque (ft lbs) 94 187 323

32/72 Installation

Fig. 13: Mounting of electrical motor

Shaft coupling

For information about coupling type, see order specific PAC/PBC documentation

Table 9: Axial shaft coupling clearance

Keyed Coupling Spline Coupling Coupling Type

A B C D Screw Size

Torque (ft lbs)

Screw Size

Torque (ft lbs)

38/45 3.160 4.500 0.981 0.156 5/16-18 14 3/8-16 49 42/55 3.740 5.000 1.031 0.156 3/8-16 23 7/16-14 76 55/70 4.130 6.300 1.173 0.156 1/2-13 50 7/16-14 76 75/90 6.300 8.270 1.534 0.219 1/2-13 50 5/8-11 230 90/100 7.880 9.650 1.746 0.266 3/4-10 167 5/8-11 230

Installation 33/72

7.6 Mounting of top cover

If the drive unit is placed outdoors, the top cover should be sealed with sealing strip.

Do not glue the top cover! The air intake shall be turned away if possible, from dusty environment.

Fig. 14: Parts for assembling of top cover

Fig. 15: Panels

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Fig. 16: Air outlet (only for top cover > 1000 mm)

Fig. 17: Lifting top cover (when built on floor)

If the top cover is assembled on the floor, screws must be loose to allow the top cover construction to align with the frame after positioning. Tighten all screws properly when all is in position.

Installation 35/72

7.7 Hydraulic connections

During mounting of the hydraulic connections the following points must be followed.

• Do not remove coupling protections until final assembly.

• Mount all external pipes to give sufficient working space to allow maintenance of the drive unit.

• Always use hoses to connect with piping.

• All measures in the hydraulic system must be performed by professional service personnel with knowledge of risks involved. Be especially accurate when connecting the A- and B- connections (high pressure).

DANGER

Pressurized oil leakage Danger to life or risk of injury.

▶ Do not open any connections if the hydraulic system is pressurized.

F

D

Win & Wout

C₁ & C₂

Fig. 18: Connections PAC

Table 10: Connections PAC

Function C1 C2

Oil OUT to cooler Oil IN from cooler

F Oil OUT flushing motor(s) D Drain from hydraulic motor(s) Win Wout

Water in oil cooler Water out oil cooler

36/72 Installation

Table 11: Dimensions pump connections

Pump type Dimensions main connection A&B

Thread Depth of threaded holes

Thickness std flange connections

Torque*) in in ft lbs

+10% -0

SP40 3/4" SAE 3/8-16" UNC 0.8 0.7 44

SP71 1" SAE 7/16" UNC 0.6 0.9 68

SP125 1 1/4" SAE 1/2" UNC 1.0 1.0 111

SP180 1 1/4" SAE 1/2" UNC 1.0 1.0 111

SP250 1 1/2" SAE J5118C flange code 62-6000psi

5/8-11 UNC 1.1 1.1 218

SP355

SP500 2" SAE J5118C flange code 62-6000psi

3/4-10 UNC 1.6 1.5 332

SP750

HD6-HD7 1 1/2" SAE J5118C flange code 62-6000psi 5/8-11 UNC 1.3 1.1 218

HD11-HD14

HD24-HD30 2" SAE J5118C flange code 62-6000psi

3/4-10 UNC 1.5 1.5 332

*) Torque acc. to SAE J518-2 with class 10.9 or grade 8 screws.

Table 12: Dimensions external connections points PAC Small, Medium, Large and X Large

Cabinet Size A B C D E F G

PAC/PBC S2 8.625 13.75 3 6.063 11.875 59.188 14.375

PAC/PBC S3 8.625 13.75 3 33.563 11.875 59.188 14.375

PAC/PBC M2 10.625 17.875 3 6.063 11.875 65.188 14.375

PAC/PBC M3 10.625 19.375 3 41.813 11.875 65.188 14.375

PAC/PBC L3 10.625 20.125 3 45.313 11.875 77.188 14.375

PAC/PBC XL3 10.625 23 3 61.563 20.875 78.156 15.188

Fig. 19: Dimensions external connections points example PAC Small, Medium, Large and X Large

Installation 37/72

7.8 Pipe work, internal

General The drive unit should be placed as close to the hydraulic motor as possible, taking other circumstances (e.g. space, environmental conditions ) into consideration. The main connections of the main pump and the hydraulic motor must always be fitted to the piping with hoses. We recommend to use shut off valves for the main lines A and B. The protections on all ports must be kept on until final assembly to avoid dirt in the system.

Storage of included components The included components shall be stored according to 6.1: Storage of the packed drive unit.

Handling of fittings General Inspect the sealing surfaces on the couplings visually before mounting. It must be free from any damages. Handle the couplings with care. Check that the sealing (if any) is in its right position, free from cracks and that it is saturated with oil . The dirt protections on the fittings must be kept on until final assembly.

Flange fittings The flange screws must be tightened crosswise.

JIC type, tube fittings, 37o flare (SAE J514, ISO8434-2)

• Tighten the fitting nut with wrench until it stops. Tighten additional 1/4 turn to 1/2 turn.

• Use correct size of tool, to avoid fitting to be damaged and difficult to remove.

Cleaning The pipes and hoses should be pre cleaned, inspected and sealed by the supplier. If the pipes are field bent and installed the overall system must be carefully oil flushed to reach the required cleanliness level.

Mounting of hoses Ensure that hoses not are stressed or twisted on installation, to avoid premature failure. Bend radius should conform to manufacturers recommendations.

38/72 Installation

Right

Right Wrong

Right Wrong

Right Wrong

Right Wrong

Fig. 20: Mounting of hoses

7.9 Electric connections

7.9.1 Safety precautions

Installation of electrical equipment must in most countries be installed by licensed electricians (ref. to domestic laws).

• All electric equipment has to be installed and used by qualified personnel who are familiar with relevant safety requirements.

• Safety equipment necessary for the prevention of accidents at the mounting and operating site shall be provided in accordance with the regulations prevailing in the local country.

• Grounding shall be carried out according to local regulations before the electric equipment is connected to the main voltage. Grounding point on the back side of the frame.

• All electrical supply levels must be within the limits that the equipment is con-structed for, see order specific Hägglunds PAC/PBC documentation and rating plate.

Installation 39/72

7.9.2 Control system box and additional box

Connect the cables to the terminals inside the control system box. For some features, there is an additional junction box next to the control system box. All external electrical connections must be connected according to the electrical drawings in the Hägglunds PAC/PBC order specific documentation.

7.9.3 Air-oil cooler

The main voltage and connection are marked on the electric motor marking plate. Y or D Connection is done depending on supply voltage in accordance to Fig. 23: D and Y connections from MCC (Motor Control Center). The start and stop signal to control the MCC shall be connected according to the order specific documentation. Check direction of rotation, see air stream arrow in Fig. 21: Air-oil cooler

Air stream

BOL 8–30

Air stream

BOL 400–2000

Fig. 21: Air-oil cooler

7.9.4 Water-oil plate cooler

Connect the water-oil cooler to the pre-assembled cable connector on the backside of the drive unit.

7.9.5 Water-oil tube cooler

Cable is pre-assembled to the water valve for the cooler.

7.9.6 Oil heater

Connect the cables on the screw terminals inside the terminal box as shown in Fig. 22: Connections terminal box, oil heater. For power and voltage see attached Hägglunds PAC/PBC order-specific documentation and rating on the oil heater.

The start and stop signal to control the heater shall be connected according to the Hägglunds PAC/PBC order-specific documentation.

Star connection 3-phase 400 VAC

Connection 1-phase 230 VAC

Fig. 22: Connections terminal box, oil heater

40/72 Installation

7.9.7 Electric motor

The main voltage and connection are marked on the electric motor marking plate, Y or D Connection is done depending on supply voltage in accordance to Fig. 23: D and Y connections from MCC (Motor Control Center). Electric motor must be separately grounded.

Y -connectionD -connection

Fig. 23: D and Y connections

Table 13: Standard voltage

Standard voltage D Standard voltage Y

380 V /50Hz 660 V /50Hz

400 V /50Hz 690 V /50Hz

415 V /50Hz

440 V /60Hz

460 V /60Hz

480 V /60Hz

Commissioning 41/72

8 Commissioning

8.1 Before commissioning

General

• Read and understand this complete manual and the other attached technical documentation.

• Visually check the whole system for: signs of damage, incorrect circuitry, security of foundations.

• Check that the coupling between the electric motor and pump is properly mounted.

• The accumulator has to be filled with dry nitrogen to a pressure level in accordance with the attached order specific Hägglunds PAC/PBC documentation (the accumulator is normally precharged to approximately 130 psi at delivery). For filling point see Fig. 2: Main components PAC S, M, L, and XL and Fig. 3: Main components PBC S, M, L, and XL.

NOTICE

The system will not fullfil the functionality Damage to the customer equipment

▶ The accumulator must be charged with dry nitrogen from a bottle equipped with a pressure reducing valve.

Cleanliness

• The external hydraulic system must be thoroughly cleaned on the inside.

Pipe work

• The couplings has to be securely tightened.

• The pipe work must be properly cleaned.

• The pipe work has to be mounted free of stress.

• The lines has to be in accordance with installation drawing/piping plan.

Electrical

• Check that electric motor(s), control system and other electrical components are connected to the correct voltages.

• Check the function of electrical components and monitoring system manually.

Instruments that cannot be actuated can be checked for correct wiring and possibly operated manually. Level switch and indication should be checked when filling up the tank.

• Check interlock of electric motor.

• Check the stop sequence of the system at alarm.

8.2 Filling up the system with hydraulic fluid

Before filling

• Check that the correct type and quality of hydraulic fluid is used. Do not mix different types of hydraulic fluid without first checking with manufacturers.

• Check that the barrel with hydraulic fluid and tank/hoses not are contaminated with water or other substances.

42/72 Commissioning

Filling Use a fluid filling pump unit with a filter rating of β10 ≥ 75.

Cleanliness in barrels with new oil is not clean enough for the system and has to be filtered before filling up in to the system to avoid problems.

NOTICE

Dirty oil in the system!

Damage on the equipment!

▶ Only use the specific filling point in the drive unit to fill up the hydraulic system, see Fig. 2: Main components PAC S, M, L, and XL and Fig. 3: Main components PBC S, M, L, and XL

Always pump the fluid in through the special quick connection. The quick connection is a completely rust-proof quick release coupling, The fluid filled into the system will be filtered through the drain filter.

The tank must be filled with oil to the nominal level before starting for the first time, according to Table 14: Oil volume in tank. Check the function of the level sensor and indication on the level gauge during filling up of the tank.

Table 14: Oil volume in tank

Reservoir Size Recommended Fill (gallons)

Sight Glass Maximum (gallons)

Max Oil Volume (gallons)

200 52 56 61

400 103 108 116

600 155 162 173

800 217 228 243

1000 265 276 291

1200 324 336 357

1600 445 460 485

NOTE: Recommended oil fill is based on oil level being 2" down from top of sight glass.

WARNING

Leakage of hydraulic oil Risk of personal injury

▶ Check the caution sign on the hydraulic fluid container and the warnings in section 5.4: Hydraulic fluids.

▶ Avoid long contact with the skin and the hydraulic fluid.

▶ Remove any spilled oil from the floor, great risk to slip and fall.

Commissioning 43/72

8.3 Flushing before start up

A pressure filter and check valve has to be connected to the main line at the drive unit.

This filter is connected on the return side of the drive pump. Recommended filtration degree β10 ≥ 75. The size of the flushing filter should be matched to the installed pump, so that the pressure drop across the filter is not excessive and that the max pressure/flow ratings for the filter is not exceeded.

The main lines should be connected together at the motor side enabling the entire system to be flushed, see Fig. 24: Hydraulic circuit flushing. If the system not is fitted with a flushing line to the hydraulic motor, the drain line from the motor has to be plugged.

If the system is fitted with a flushing line to the hydraulic motor, the flushing line shall be connected to the drain line of the motor to enable cleaning of the flushing line.

CAUTION

Wrong direction of rotation of the pump Pump will be damaged. System contaminated

▶ Make sure that the pump has the correct direction of rotation. The correct direction of rotation is marked with a sign placed under the electric motor.

Rotating parts!

Risk of injury.

▶ Do not touch rotating parts inside the inspection hole or in the zone of rotating parts.

The maximum flow from the drive unit should be flushed through the main circuit for at least 2 hours on small installations and considerably longer time on large installations.

Use extreme caution to ensure pump is stroked in sync with free flow direction of check valve.