Assembly Instructions

Hägglunds Compact
CBP 840 DD00074338

This material is strictly for internal use within the Bosch Rexroth Group.

SC-2.75
2015-06-02
 Preface
Bosch Rexroth is the manufacturer of Hägglunds
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 effi-
ciency and reliability. Our main office and produc-
tion plant is in Mellansel, Sweden.
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 HÄGGLUNDS CBP 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
assembly the motor. 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.

The data specified above serve to describe the

product. If there is also information on the use, it
is only to be regarded as application examples
and proposals. Catalog information does not
constitute warranted properties. The information
given does not release the user from the obliga-
tion for own judgement and verification. Our prod-
ucts are subject to a natural process of wear and
aging.

 This document, as well as the data, specifica-

tions and other information set forth in it, are the
exclusive property of Bosch Rexroth Mellansel. It
may not be reproduced or given to third parties
without its consent.

The cover page shows an example configuration.

The product supplied may therefore differ from
the photo shown.

Page 2
 Security instructions............ page 4

Lifting instructions............. page 5-6

Important............................ page 7-8

Tourque................................page 9

Assembly Instructions
Compact CBP 840
A1-A122............................ page 10-40

Exploded view ...................page 41

Notes .................................page 42

Assembly Instructions CBP 840 Page 3 Contents

S. Safety instructions

NOTE
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.
• Follow all the instructions on the product.
• Persons who install, operate, remove or maintain Bosch Rexroth products must not consume any
alcohol, drugs or pharmaceuticals that may affect their ability to respond.
Personal protection
• The personal protective equipment is the responsibility of the user of the Hägglunds motors.
Observe the safety regulations and provisions of your country. All components of the personal pro-
tective equipment must be intact.
• Use your personal protective equipment (e.g. safety glasses, safety gloves, suitable working clo-
thes, safety shoes).
• Avoid contact with hydraulic fluids. Hazard to health/health impairment e.g. eye injuries, skin
damage, toxication during inhalation! If hydraulic fluid should, nevertheless, come into contact
with your eyes or bloodstream or is swallowed, consult a doctor immediately.
Personnel qualifications
• The activities described in this documentation require basic mechanical and hydraulic knowledge.
In order to ensure safe use, these activities may therefore only be carried out by appropriate quali-
fied personnel.
• Bosch Rexroth offers training support for special fields. For more information about training,
please contact your Bosch Rexroth representative.

! CAUTION
Cleaning
• Plug all openings with the appropriate protective equipment in order to prevent detergents from
entering the motor.
• Never use solvents or aggressive detergents. Use only water and, if necessary, a mild detergent to
clean the Hägglunds motor.
• Do not point the power washer at sensitive components, e.g. shaft seal, components.
• Use lint-free cloths for cleaning.
• Take extrem care to ensure that no contamination enters the motor!

! DANGER
Danger from suspended loads!
Danger to life or risk of injury, damage to equipment!
• Make certain that the forklift truck or lifting device has adequate lifting capacity.
• Never stand under or put your hands under suspended loads.
• Use suitable lifting device for transport and handling.
• Make sure the motor is well mounted or anchored when the lifting device is disconnected.
• Make sure the correct lifting eye is used.
• Observe the prescribed position of the lifting strap. Use a protection e.g. cloth for sharp edges.
• Observe the national laws and regulations on work and health protection and transportation.

Assembly Instructions CBP 840 Page 4 For internal use only

A. Lifting and standing methods

DANGER! Always make sure where the centre DANGER! Lifting straps must be chosen with
of gravity is before any lifting. reliable safety margin over the total
Never stand below a hanging motor weight of the lifted object.
or torque arm.

Fig. A1, CBP 140 Fig. A3, CBP 140

Fig. A4, CBP 840

Fig. A2, CBP 280

Fig. A5, Torque arm

Assembly Instructions CBP 840 Page 5 For internal use only

 Fig. A6, Table; Weight motor Fig A7, Table; Weight torque arm

Motor with Motor with Weight

Motor splines shaft coupling Torque arm
kg lb
kg lb kg lb
CBP 140 360 780 410 900 TCA 14 65 143
CBP 280 N/A 1580 3480 TCA 40 128 282
CBP 400 1880 4150 1930 4250 TCA 84 224 493
CBP 560 1900 4180 2000 4400
CBP 840 2170 4780 N/A

Standing the motor on a flat surface
When the motor is placed on a flat surface such as a
floor, it must stand either on its outer diameter or on the
suitably protected end face of the hollow shaft (see Fig.
A8 Standing on the outer diameter and Fig. A9 Standing on
the end face).
CAUTION! When in storage, the motor must
always be placed on the end face to
the hollow shaft. It is also advisable
to provide supports at the mounting
surface of the motor, see fig. A8.

NOTE:
The motor must not be placed on the end face of the
hollow shaft when the coupling is fitted, since this may
cause damage to the coupling.

Fig. A8, Standing on the outer diameter Fig. A9, Standing on the end face

Support

Assembly Instructions CBP 840 Page 6 For internal use only

 Important!
The highest cleanliness of the motor parts and of
the workplace is always the basics to ensure the
smooth functioning of the hydraulic motor!

For a motor with splines a lifting capacity of

2200 kg (4850 lb)
is required to perform this work!

Make a note in the service inspection report: the motor

type and individual number from the sign on the motor.
This is important when you are ordering spare parts.

Special tool needed

R939004273 R913029452 R9390055019

Support Air hammer Assembly tool,
roll pin

R0003017/R0003019 R939055213 R913032748

Assembly tool, Mounting mandrel Lapping film
Radial lip seal

Assembly Instructions CBP 840 Page 7 For internal use only

 Work to be done before
cleaning the motor parts:
It is very important to
clean the cam ring good
before assembling!
Grind the cam ring surface
around the roll pin holes with
a fine grinding stone.
Sliding surface
Grind the spacer ring over
the roll pin holes with a fine
grinding stone on both sides
of the spacer ring. Do not
grind on the sliding surface
for the roller.
Always treat the sliding surfaces with care
Shaft end housing
Assembly Instructions CBP 840
Important preparation
before assembly
The highest cleanliness of the motor parts and of the
workplace are basics to ensure the smooth functio-
ning of the hydraulic motor!
Make sure to minimise that contamination can enter
into the motor during the assembling.
Ensure that you have cleaned all motor parts
thoroughly, especially if you have re-machined, grin-
ded or in some other way worked up the motor parts.
After final cleaning of the motor parts, don’t leave the
parts too long before assembling.
When lubricating
· always use clean filtrated oil, recommended ISO
class 16/13 according to ISO 4406, NAS.7,
· always use clean grease of type Texaco Multifac
EP2 or equivalent.
Rust protection
Use Shell Ensis SX or equivalent rust protection fluid.
Always use new gasket set.
Connection block and valve plate Spacer ring
Page 8 For internal use only
 Torque

Use a Torque machine

Oil
Use a Torque
machine

,Oil
Use a Torque
machine
,Oil
Use a Torque
machine

Assembly Instructions CBP 840 Page 9 For internal use only

A1 A2
Protect the surfaces against Install the balancing sleeves.
rust, use Shell Ensis SX or Turn the track on the piston
equivalent rust protection down, into the connection
fluid. Install the compression block.
springs in the connection block.

A3 A4
Lubricate the O-ring with oil and install it. Install the balancing pistons. Turn the
track on the pistons down, the
spherical end of the balancing piston
must point out from the valve plate.
Note! Always treat the sliding surfaces on the valve
plate with care.

Assembly Instructions CBP 840 Page 10 For internal use only

A5
Grease the pistons so they
stay in position when you
turn the valve plate. Install
the valve plate gently, so no balancing pistons are
falling out when you turn the valve plate.
A6
Always make sure to install a locating bolt with
thread locking. Thread locking can also be made
by use of middlestrong locking (Loctite No. 243).
Allen key 5 mm. Torque 30 Nm (22 lbf·ft).

Position of
the snap ring

Radial
lip seal

A7 A8
The snap ring on the bearing shall be towards Heat up the roller bearing to 110°C (230°F) in an
the middle of the motor. oven. Tap the bearing down with a brass or a plas-
tic rod. The bearing should be turned according to
drawing A7.
Note! To avoid damages on the bearing, only tap
on the inner race of the bearing.

Assembly Instructions CBP 840 Page 11 For internal use only

A9 A10
Install the O-ring for the wear ring on the shaft. Lubricate the O-ring with grease.

A11 A12
Heat up the wear ring to 110°C (230°F). Install it Install the lock ring for the wear ring.
on the shaft. Tap it down with a plastic hammer.

Assembly Instructions CBP 840 Page 12 For internal use only

A13 A14
Gently pull back the wear ring so that the lock ring Secure the center shaft and
no longer is loose. carefully turn the shaft up side
To keep the lock ring permanent, the wear ring down. Install the connection
has to be kept in place against the lock ring, until block on the centre shaft.
it is shrinked.

Note!
The splines are
not aligned! 3

!
A15 A16
Lubricate the surfaces. Note the position of the splines when you are
installing the cylinder blocks. You have to turn the
cylinder block a little bit when you passed the first
row and also when you passed the second row.
Note! Don’t use force - it can cause damages on
the splines.

Assembly Instructions CBP 840 Page 13 For internal use only

 Square
holes
A17 A18
Install the first cylinder block. Protect the surfaces against rust, use Shell Ensis
Note! Install it with the square SX or equivalent.
hole down, so they will correspond
with the square holes on the shaft
end housing.

A19
Install the piston ring. The direction
of the piston ring is important. The marking (4
strokes) on the piston ring shall be turned upwards
against the top of the piston.
A20
Lubricate the piston bores with oil.
Note! Oil cleanliness level important.

Assembly Instructions CBP 840 Page 14 For internal use only

A21 A22  5 5

Install the pistons. Check thoroughly the cam rollers for damages. Place the
lapping film on a flat surface e.g. glass with a 2 - 5 mm
thick rubber plate in between and polish the cam rollers
gently in circles on the lapping film, 5 times clockwise
and 5 times counterclockwise. Important! After polish,
clean the roller thoroughly. Use a washing machine, ex.
Viverk VKT-164 or equivalent. Make sure the cam rollers
are clean and dry afterwards.

Install above the o-ring

A23 A24
Lubricate the piston balancing surfaces with oil. Install the cam rollers into the pistons. Check so
the cam roller slide easily.
Note! Make sure to place the roller on top of the
O-ring to avoid damages to the sliding surface.

Assembly Instructions CBP 840 Page 15 For internal use only

 Cam Ring mark
Motor Sign

Flat part, attachment ring

A25 A26
Push the piston assemblies into the cylinder block. Position of cam ring mark, seal retainer, shaft end
housing and attachment ring.

A27 A28
Always make sure that the surfaces between cam Install the first cam ring. Secure all parts together
ring and spacer/attachment ring are absolutely with 2 cover screws and washers, in order to keep
clean. the parts together while you punsch in the roll
pins.
Note! Before you install the cam ring: make sure
that the surfaces between are absolutely clean.

Assembly Instructions CBP 840 Page 16 For internal use only

 64 mm
(2.5 in)

A29 A30
Lubricate the holes with oil and Drive the roll pins down 64 mm (2.5. in).
install the roll pins. Remove oil that are superfluous.
Turn the slots in tangential
direction.

A31 A32
Lubricate the O-ring with oil and install it on Install the attachment ring.
the attachment ring. Position, see figure A26.

Assembly Instructions CBP 840 Page 17 For internal use only

A33 A34
Lubricate the O-ring with oil and install it on the Lubricate the holes with
spacer ring. grease and install the roll pins.
Turn the slots in tangential direction.
Remove grease that are superflous.

17 mm
(0.7 in)

A35 A36
Drive the roll pins down 17 mm (0.7 in). Protect the surfaces against rust, use Shell Ensis
Use tool R913029452 and R9390055019. SX or equivalent. Install the second cylinder block.
Use two safety lifting eyes.

Assembly Instructions CBP 840 Page 18 For internal use only

A37 A38
Lubricate piston bores with oil. Install the piston.
Note! Oil cleanliness level important.

A39
Check thoroughly the cam rollers for
damages. Place the lapping film on a A40
flat surface e.g. glass with a 2 - 5 mm Lubricate the piston balancing surface with oil.
thick rubber plate in between and
 5 5

polish the cam rollers gently in circles on the lapping

film, 5 times clockwise and 5 times counterclockwise.
Important! After polish, clean the roller thoroughly. Use
a washing machine, ex. Viverk VKT-164 or equivalent.
Make sure the cam rollers are clean and dry afterwards.

Assembly Instructions CBP 840 Page 19 For internal use only

 Inst
all a
bov
e th
eo
-rin
g

A41 A42
Install the cam rollers into the pistons. Check so Push the piston assemblies into the cylinder block.
the cam roller slide easily.
Note! Make sure to place the roller on top of the
O-ring to avoid damages to the sliding surface.

A43
Lubricate the surface with oil.
Note! Oil cleanliness level important.
A44
Install second cam ring. Use two safety lifting eyes
M16. Position, see figure A26.
Note! Before you install the cam ring: make sure
that the surfaces between the cam ring and cover
is absolutely clean.

Assembly Instructions CBP 840 Page 20 For internal use only

 61 mm
(2.4 in)

A45 A46
Lubricate the holes with grease Drive the roll pins down 61 mm (2.4. in).
and install the roll pins.
Turn the slots in tangential direction.
Remove grease that are superfluous.

A47 A48
Lubricate the O-ring with oil and install it Always make sure that the surfaces between cam
on the spacer ring. ring and spacer ring are absolutely clean.

Assembly Instructions CBP 840 Page 21 For internal use only

A49 A50
Make sure that the surfaces between the cam ring Lubricate the O-ring groove with oil.
and spacer ring are absolutely clean, then install
the spacer ring. Position, se figure A26.

A51 A52
Install the O-ring. Lubricate the holes with grease
and install the roll pins.
Turn the slots in tangential direction.
Remove grease that are superfluous.

Assembly Instructions CBP 840 Page 22 For internal use only

 17 mm
(0.7 in)

A53 A54
Drive the roll pins down 17 mm (0.7. in). Install the third cylinder block.
Use tool R913029452 and R9390055019. Note! Install it with the square hole upwards.
Remove grease that are superfluous.

A55 A56
Install the circlip. Lubricate the piston bores with oil.
Note! Oil cleanliness level important.

Assembly Instructions CBP 840 Page 23 For internal use only

A57 A58
Install the piston. Check thoroughly the cam rollers for
damages. Place the lapping film on a
 5 5

flat surface e.g. glass with a 2 - 5 mm thick rubber plate

in between and polish the cam rollers gently in circles on
the lapping film, 5 times clockwise and 5 times coun-
terclockwise. Important! After polish, clean the roller
thoroughly. Use a washing machine, ex. Viverk VKT-164
or equivalent. Make sure the cam rollers are clean and
dry afterwards.

Inst
all a
bov
e th
eo
-rin
g

A59
Lubricate the piston balancing surface with oil.
Note! Oil cleanliness level important.
A60
Lubricate the piston balancing surface with oil. In-
stall the cam rollers into the pistons. Check so the
cam roller slide easily.
Note! Make sure to place the roller on top of the
O-ring to avoid damages to the sliding surface.

Assembly Instructions CBP 840 Page 24 For internal use only

A61 A62
Push the piston assemblies into the cylinder block. Install the third cam ring.
Position, see figure A26.

A63 A64
Lubricate the holes for the roll pins with oil. Install the roll pins. Turn the slots in tangential
direction. Remove grease that are superfluous.

Assembly Instructions CBP 840 Page 25 For internal use only

 61 mm
(2.4 in)

A65 A66
Drive the roll pins down 61 mm (2.4 in). Protect the surfaces against rust, use Shell Ensis
Use tool R913029452 and R9390055019. SX or equivalent.
Remove grease that are superfluous.

A67 A68
Always make sure that the surfaces are absolutely Lubricate the surfaces on the second connection
clean. block.

Assembly Instructions CBP 840 Page 26 For internal use only

A69 A70
Install the compression springs in the connection Protect the surfaces against rust, use Shell Ensis
block. SX or equivalent.

A71 A72
Install the balancing sleeves. Lubricate the O-ring with oil and install it.
Turn the track on the piston down, into the con-
nection block.

Assembly Instructions CBP 840 Page 27 For internal use only

A73
Install the balancing pistons. Turn the track on the
pistons down, the spherical end of the balancing
piston must point out from the valve plate.
Note! Always treat the sliding surfaces on the
valve plate with care.
A75
Install the valve plate gently, so no balancing pis-
tons are falling out when you turn the valve plate.
Assembly Instructions CBP 840 Page 28
A74
Grease the pistons so they stay in position when
you turn the valve plate.
A76
Always make sure to install a locating bolt with
thread locking. Thread locking can also be made
by use of middlestrong locking (Loctite No. 243).
Allen key 5 mm. Torque 30 Nm (22 lbf·ft).
For internal use only
A77 A78
Turn over carefully the connection block and install Install 4 screws, tighten them firmly.
the connection block. The roll pin holes should
correspond to the threaded holes in the shaft end
housing.

A79 A80
Install the radial bearing. Push down the radial bearing with special tool
R939055213

Assembly Instructions CBP 840 Page 29 For internal use only

A81 A82
Remove the tool. Install the O-ring.

A83 A84
Lubricate the O-ring with oil. Heat up the wear ring to 110°C (230°F) in an oven.
Install the wear ring.

Assembly Instructions CBP 840 Page 30 For internal use only

A85 A86
Protect the surface against rust, use Shell Ensis Install the O-ring into the seal retainer.
SX or equivalent.

A87 A88
Protect the surfaces against rust, use Shell Ensis Install the radial lip seal into
SX or equivalent. the seal retainer.
Tool R0003017/R0003019.

Assembly Instructions CBP 840 Page 31 For internal use only

A89 A90
Lubricate the seal with Texaco Multifac EP2 Protect the surface against rust, use Shell Ensis
or equivalent. SX or equivalent.

A91 A92
Install the seal retainer. Tighten the plug. Allen key size 3/8”.
Knock it down with a plastic Torque 30 Nm (22 lbf•ft).
hammer.

Assembly Instructions CBP 840 Page 32 For internal use only

A93 A94
Install the washers and the four screws. Lubricate the O-ring with oil and install it on the
bearing retainer.

A95 A96
Install the G1" plug firmly. Install the bearing retainer.

Assembly Instructions CBP 840 Page 33 For internal use only

A97 A98
Install the washers. Lubricate the threads with oil and install the six
hexagon socket head cap screws.

A99 A100
Tighten the screws in the seal retainer. Tighten the hexagon socket head cap screws
Allen key size 10 mm. Torque 136 Nm (100 lbf·ft). in the bearing retainer. Allen key size 10 mm.
Torque 136 Nm (100 lbf·ft).

Assembly Instructions CBP 840 Page 34 For internal use only

A101 A102
Install two cover screws on the opposite side Lubricate the holes for the roll pins with oil.
to each other.

17 mm
(0.7 in)

A103 A104
Install the roll pins with the slot in tangential Drive the roll pins down 17 mm (0.7 in).
direction. Use tool R913029452 and R9390055019.

Assembly Instructions CBP 840 Page 35 For internal use only

A105 A106
Install the protecting rubber Install the plugs firmly (to avoid that dirt comes
plugs on the roll pins. into the motor). Install the Hexagon socket head
cap screws.

This picture shows a CBP 560

Note! We advise that you use a pneu-

matic or electric torque wrench.
! However if you use an ordinary tor-
que wrench make sure that you have
secured the motor with safety hooks
and with a counter-hold (see picture).
A107 A100
Tightening sequence for for the Hexagon headed Tighten the four M20 hexagon headed screws (with
screws. washers) in the relevant order (see drawing A99)
to the specified maximum torque. Then tighten the
rest of the screws. Spanner size 30 mm. Torque
540 Nm (398 lbf·ft).
Note! Secure the motor so that it will not overturn.

Assembly Instructions CBP 840 Page 36 For internal use only

A109 A110
Install the three test connections. Spanner size 19 Protect the surfaces against rust. Use Shell Ensis
mm. Torque 30 Nm (22 lbf•ft). SX or equivalent rust protection fluid.

A111 A112
Install the flanges for the main connections. Install the three G 1/4" plugs.
Oil the threads. Allen key size 5/8”. Torque 30 Nm (22 lbf·ft).
Torque 380 Nm (280 lbf·ft).

Assembly Instructions CBP 840 Page 37 For internal use only

A113 A114
Install the plugs. Allen key size 6 mm. Tighten the G1” plug.
Torque 30 Nm (22 lbf·ft). Torque 125 Nm (92 lbf·ft).

A115
A116
Install the O-ring into the seal retainer.
Lubricate the support and
install the radial lip seal.

Assembly Instructions CBP 840 Page 38 For internal use only

A117 A118
Turn the motor carefully with three safety hooks in Install and tighten the four hexagon socket head
the load rings. Install the seal retainer. cap screws. Allen key size 10 mm. Torque 136 Nm
(100 lbf·ft).

A119 A120
Install the O-ring. Tighten the hexagon headed screws (30 x M16).
Spanner size 24 mm. Torque 136 Nm (100 lbf·ft).

Assembly Instructions CBP 840 Page 39 For internal use only

A121 A122
Install the O-ring in the end cover. Install the end cover. Spanner size 24 mm.
Torque 136 Nm (100 lbf·ft).

Assembly Instructions CBP 840 Page 40 For internal use only

 086 087

Uncoated piston set Coated piston set

030084
029035 029028
030084A
029028A
030083 030083A

Assembly Instructions CBP 840

Connection unit 039 029029A 030029A
See separate 039
tab of graphics. 018

039
049 055
005 039
068

Page 41
074

013
014 003

015 063

013
Adapter set to convert
902 005
oil connections from 014 073
BSP to JIC, for US market.
015
013 094

014
Seal kit, nitrile 015
Seal kit, viton
See separate Connection unit End cover unit
tab of graphics. See separate See separate
tab of graphics. tab of graphics.

For internal use only

Notes

Assembly Instructions CBP 840 Page 42 For internal use only

Assembly Instructions CBP 840 Page 43 For internal use only
Bosch Rexroth Mellansel AB
SE-895 80 Mellansel
Sweden
Phone +46 (0)660 870 00
Fax +46 (0)660 871 60

www.boschrexroth.com/hagglunds
www.boschrexroth.com/extranet_LHD