Bosch A20V(L)O, Instruction Manual

Page 1: ...Instruction manual RE 93100 01 B 2019 09 10 Replaces English Axial piston variable double pump A20V L O Series 1 ...

Page 2: ...concerning a certain condition or suitability for a certain application can be derived from our information The information given does not release the user from the obligation of own judgment and verification It must be remembered that our products are subject to a natural process of wear and aging The cover shows an example application The product delivered may differ from the image on the cover ...

Page 3: ...duct damage 16 4 Scope of delivery 19 5 About this product 20 5 1 Performance description 20 5 2 Product description 20 5 2 1 Axial piston unit layout 20 5 2 2 Functional description 21 5 3 Product identification 22 6 Transport and storage 23 6 1 Transporting the axial piston unit 23 6 1 1 Transport by hand 23 6 1 2 Transport with lifting devices 24 6 2 Storing the axial piston unit 26 7 Installat...

Page 4: ... 1 3 Performing a functional test 51 8 2 Running in phase 52 8 3 Recommissioning after standstill 52 9 Operation 53 10 Maintenance and repair 54 10 1 Cleaning and care 54 10 2 Inspection 54 10 3 Maintenance 55 10 4 Repair 56 10 5 Spare parts 56 11 Removal and replacement 57 11 1 Required tools 57 11 2 Preparing for removal 57 11 3 Performing the disassembly 57 11 4 Preparing the components for sto...

Page 5: ...umentation marked with the book symbol is available to you and you have understood and observed it Table 1 Required and supplementary documentation Title Document number Document type Order confirmation Contains the order related technical data for your axial piston variable double pump A20V L O Order confirmation Installation drawing Contains the outer dimensions all connections and the hydraulic...

Page 6: ...selecting a hydraulic fluid for your hydraulic system 90223 Bosch Rexroth Fluid Rating List for Rexroth hydraulic components pumps and motors Contains the hydraulic fluids positively evaluated by Bosch Rexroth 90245 Information on the use of hydrostatic drives at low temperatures Contains additional information on the use of Rexroth axial piston units at low temperatures 90300 03 B Manual Storage ...

Page 7: ...ord Meaning DANGER Identifies a dangerous situation that will result in death or serious injury if it is not avoided WARNING Identifies a dangerous situation that may result in death or serious injury if it is not avoided CAUTION Identifies a dangerous situation that may result in minor to moderate injury if it is not avoided NOTICE Property damage The product or surrounding area may be damaged 1 ...

Page 8: ...ications Threaded plug Metal screw pressure resistant Protective plug Made out of plastic not pressure resistant only for transportation As umbrella term for axial piston variable double pump A20V L O the designation axial piston unit will be used in the following 1 3 4 Abbreviations This documentation uses the following abbreviations Table 5 Abbreviations Abbreviation Meaning ATEX EC directive on...

Page 9: ...h the Machinery Directive This product is intended for the following use The axial piston unit is only approved as a pump for hydrostatic drives in an open circuit For combined operation as pump and motor please contact us Adhere to the technical data the application and operating conditions and the performance limits as specified in 93100 and in the order confirmation Information on approved hydr...

Page 10: ...otentially explosive areas unless the component or machine system has been certified as compliant with the ATEX Directive 2014 34 EU Use of the axial piston unit in a corrosive atmosphere Use of the axial piston unit in aircraft or spacecraft 2 4 Personnel qualifications The activities described in this documentation require a basic understanding of mechanics electricity and hydraulics as well as ...

Page 11: ...entation e g in explosion protection areas or in safety related parts of a control system functional safety Only commission the product if it has been determined that the end product e g machinery system in which the Rexroth products are installed complies with the country specific provisions safety regulations and standards for the application Use tools appropriate for the work being performed an...

Page 12: ...injury e g crushing or fracture or damage to the product Make sure that the load bearing capacity of the lifting device is sufficient to safely bear the weight of the axial piston unit Never step or grip under suspended loads Ensure a stable transport position Use your personal protective equipment e g safety goggles safety gloves suitable working clothes safety shoes Use suitable lifting devices ...

Page 13: ...ovements Use the manual override only for functional testing or in the event of technical malfunctions Using the manual override on a permanent basis e g by wedging blocking is not permitted The use of the manual override is only permitted with limited technical data e g 0 25 maximum data Check whether or not your machine requires additional safety measures for your application to avoid unintentio...

Page 14: ...t they are not bend or twisted do not chafe on edges and are not guided through ducts with sharp edges without sufficient protection Contact with hydraulic fluid Danger to health damage to health e g eye injury skin damage toxication in the event of inhalation Avoid any contact with hydraulic fluids When handling hydraulic fluids the safety instructions of the lubricant manufacturer need to be obs...

Page 15: ... O Series 1 Bosch Rexroth AG 2 7 Personal protective equipment Personal protective equipment is the responsibility of the user of the axial piston unit Observe the safety regulations in your country All pieces of personal protective equipment should be intact ...

Page 16: ...ions Risk of property damage due to inadequate lubrication Product can be damaged or destroyed Never operate the axial piston unit with insufficient hydraulic fluid Specifically make sure that the rotary group has sufficient lubrication When commissioning a machine system make sure that the housing area and the working lines of the axial piston unit are filled with hydraulic fluid and remain fille...

Page 17: ...mmissioning ensure that all hydraulic connections are tight and that all seals and plugs of the plug in connection are correctly installed and undamaged to prevent fluids and foreign particles from entering the product Filter the hydraulic fluid when filling the system with a suitable filter system to minimize the solid particle contamination and water in the hydraulic system and to achieve the re...

Page 18: ...ion of the ground water Always place a drip tray under the axial piston unit when adding and draining the hydraulic fluid Use a suitable binding agent if hydraulic fluid is spilled Observe the safety data sheet for the hydraulic fluid and the specifications provided by the system manufacturer Danger due to heat development in components Adjacent products may be damaged Due to a heat development in...

Page 19: ... 1 1 2 3 Fig 1 Axial piston unit example A20VLO size 260 Included in the scope of delivery Axial piston unit as per order confirmation The following parts come assembled on the unit Protective covers 1 Protective plug threaded plugs 2 for version with through drive protective cover incl mounting bolts 3 ...

Page 20: ...mp with two axial piston rotary groups in swashplate design for hydrostatic drives in open circuits Flow is proportional to drive speed and displacement The flow can be continuously adjusted by controlling the swashplates cradles 16 For axial piston units with swashplate design the pistons 12 are arranged axially to the drive shaft 1 In an open circuit the hydraulic fluid flows from the reservoir ...

Page 21: ...e glide surface of the cradle and or the sliding disc 15 by the retaining plate 2 The pitch of the swashplate during a revolution causes each piston to move over the bottom and top dead centers and back to its initial position During this sequence hydraulic fluid is fed in and drained out through the two control slots in the control plate 8 according to displacement On the suction side 5 hydraulic...

Page 22: ... FD Rexroth A20VO520DR 10RVZH26K07 19W03 1 5 2 3 4 9 10 11 12 6 7 8 13 14 Fig 4 Name plate A20VO size 520 1 Word mark 2 Manufacturing date 3 Internal plant designation 4 Direction of rotation viewed on drive shaft here clockwise 5 Bar code 6 Power setting optional 7 Rotational speed optional 8 Flow setting optional 9 Pressure controller setting optional 10 Displacement optional 11 Serial number 12...

Page 23: ...lation drawing request if necessary Height mm Depth mm Weight may vary by equipment 6 1 1 Transport by hand Up to a specific maximum weight axial piston units can be transported by hand for a short distance Observe the national regulations in your country To prevent health damage we recommend renouncing any transport by hand CAUTION Risk of injury due to heavy loads Health hazard from carrying axi...

Page 24: ...same system of units and of the correct size To do this screw an eye bolt completely into the female thread on the drive shaft The thread size is indicated in the installation drawing Make sure that the eye bolt can bear the total weight of the axial piston unit plus 20 You can lift the axial piston unit as shown in Fig 5 with the eye bolt screwed into the drive shaft Fig 5 Mounting the eye bolt i...

Page 25: ...ossible lifting strap Make sure that the axial piston unit is securely fixed with the lifting strap Only guide the axial piston unit by hand for fine positioning and to avoid swinging Never step or grip under suspended loads Place the lifting strap around the axial piston unit in such a way that it does not pass over assembled parts e g valves piping and that the axial piston unit is not suspended...

Page 26: ... maximum permissible storage times for an unpackaged axial piston unit as per data sheet 90312 Table 7 Storage time with factory corrosion protection Storage conditions Standard corrosion protection Long term corrosion protection optional Closed dry room uniform temperature between 5 C and 20 C Undamaged and closed corrosion protection film Maximum 12 months Maximum 24 months The warranty will be ...

Page 27: ... 54 2 Drain the axial piston unit 3 For storage times up to 12 months Moisten the inside of the axial piston unit with mineral oil and fill with approx 100 ml mineral oil For storage times up to 24 months Fill the axial piston unit with VCI 329 corrosion protection 20 ml Filling is done through the drain port L1 L2 L3 or L4 and or T1 or T2 and or R L 1 or R L 2 see chapter 7 4 Installing the axial...

Page 28: ...country 7 2 Installation conditions The installation position and location of the axial piston unit essentially determine how it is installed and commissioned such as when filling and air bleeding the axial piston unit Fasten the axial piston unit so that the expected forces and torque can be transferred without any danger The machine system manufacturer is responsible for sizing the fasteners Obs...

Page 29: ...1 2 1 S Fig 8 Suction pressure 1 Absolute pressure gauge 2 Standard pressure gauge relative The suction conditions improve with below and inside reservoir installation Make sure that the working environment at the installation site is completely free of dust and foreign substances The axial piston unit should be clean when installed Contamination of the hydraulic fluid can considerably affect the ...

Page 30: ... F SB ht min hmin F S L3 L2 L3 L1 L2 L4 L1 L4 4 SB ht min hmin S F L3 L2 L1 L4 3 S SB ht min hmin F L3 L1 L2 L4 Fig 9 Below reservoir installation A20VO size 60 with installation position 1 4 F Filling air bleeding ht min Minimum required immersion depth 200 mm L1 L2 L3 L4 Drain port hmin Minimum required distance to reservoir bottom 100 mm S Suction port SB Baffle baffle plate Table 8 Below reser...

Page 31: ...eed Filling 5 drive shaft horizontal F S T1 6 drive shaft horizontal F S T2 7 8 R L 2 T2 T1 S SB ht min hmin F R L 1 S F T2 T1 SB ht min hmin Fig 11 Below reservoir installation A20VO size 520 with installation position 7 8 F Filling air bleeding ht min Minimum required immersion depth 200 mm R L 1 R L 2 Air bleed port hmin Minimum required distance to reservoir bottom 100 mm T1 T2 Drain port SB B...

Page 32: ...n the axial piston unit is installed in the reservoir below the minimum fluid level The axial piston unit is completely below the hydraulic fluid If the minimum fluid level is equal to or below the upper edge of the pump see chapter 7 3 3 Above reservoir installation on page 34 Axial piston units with electric components e g electric controls sensors must not be installed in a reservoir below the ...

Page 33: ...e port L3 automatically via the open port L3 and S by position below the hydraulic fluid level 11 12 T2 T2 T1 T1 T1 T2 T1 T2 hmin ht min hmin ht min S S SB SB Fig 13 Inside reservoir installation A20VLO e g size 190 with installation position 11 12 T1 T2 Drain port hmin Minimum required distance to reservoir bottom 100 mm S Suction port SB Baffle baffle plate ht min Minimum required immersion dept...

Page 34: ... open port R L 1 and S by position below the hydraulic fluid level 7 3 3 Above reservoir installation Above reservoir installation means that the axial piston unit is installed above the minimum fluid level of the reservoir Observe the maximum permissible suction height hS max 800 mm The permissible suction height hS is derived from the total pressure loss Because complete air bleeding and filling...

Page 35: ...eding hmin Minimum required distance to reservoir bottom 100 mm L1 L2 L3 L4 Drain port hS max Maximum permissible suction height 800 mm S Suction port hES min Minimum height required to prevent axial piston unit from draining 25 mm ht min Minimum required immersion depth 200 mm SB Baffle baffle plate Table 14 Above reservoir installation Installation position Air bleed Filling 14 drive shaft horiz...

Page 36: ... F1 F2 F1 T2 F2 S 7 4 Installing the axial piston unit 7 4 1 Preparation 1 Check the specifications on the name plate to see you have the correct axial piston unit 2 Compare the material number and designation type code with the details in the order confirmation If the material number for the axial piston unit does not match the one in the order confirmation contact your local contact person for c...

Page 37: ... Follow these general instructions when installing the axial piston unit Note that certain installation positions will affect the control system Gravity dead weight and case pressure can cause minor characteristic shifts and changes in response time Torsional vibrations and speed variations may cause leaks in the shaft seal and increased rotary angular acceleration of the rotary group of the axial...

Page 38: ...is equipped with a female thread Use this female thread to pull the coupling element onto the drive shaft The size of the female thread can be seen in the installation drawing 2 Clamp the coupling hub onto the drive shaft or ensure permanent lubrication of the drive shaft This prevents the formation of frictional corrosion and the associated wear 3 Transport the axial piston unit to the installati...

Page 39: ...tely 7 4 6 Installation with cardan shaft The following describes how to connect the axial piston unit to the drive motor with a cardan shaft NOTICE Damage to the axial piston unit and leaks at the shaft seal due to incorrectly installed cardan shaft Improperly installed cardan shafts generate unbalances This results in vibrations and excessive forces on the drive shaft Observe the cardan shaft ma...

Page 40: ...f the plant that manufactured the axial piston unit 1 1 2 3 Fig 18 Removing transport protection e g A20VLO size 260 1 Protective covers 2 Protective plugs threaded plugs 3 For version with through drive protective cover and mounting bolts Ports intended for connecting lines come with protective plugs and or threaded plugs which serve as transport protection All ports required for functional opera...

Page 41: ...ng elements and lines correspond to the specified application conditions pressure flow hydraulic fluid temperature with the necessary safety factors Connect only hydraulic lines that are match the axial piston unit port pressure level size system of units Observe the following information when routing the suction pressure and drain lines Lines and hoses should be installed without pre charge press...

Page 42: ...als are also used The system of units the kind of seal and the size of female thread and stud ends e g threaded plug must all match There is a risk of confusion due to the limited ways of visually telling them apart WARNING Leaky and bursting stud ends For fittings if a stud end that does not match the system of units kind of seal and size of the female thread is pressurized the stud end may loose...

Page 43: ... L4 B2 B1 L4 L2 S L3 X Fig 19 Port overview A20VO size 60 S T1 1 A B T2 2 T1 2 T2 1 R 2 R 1 MA M1A M1B MB GB GA Fig 20 Port overview A20V L O size 95 to 260 B1 B3 K1 K3 MB1 MB3 U2 R L 1 R L 2 T1 T2 S B4 B2 K4 K2 MB4 MB2 U1 MS Pst2 Pst1 Fig 21 Port overview A20VO size 520 Port overview ...

Page 44: ...4 X MB1 MB4 Measuring port working pressure 400 X MS Measuring port suction port 30 X Pst1 Pst2 Pilot pressure port 100 O R L 1 Air bleed port 4 O6 R L 2 Air bleed port 4 X6 T1 Drain port 4 O6 T2 Drain port 4 X6 U1 U2 Flushing port 4 X 1 The measuring system and thread size can be found in the installation drawing 2 Depending on the application momentary pressure peaks can occur Keep this in mind ...

Page 45: ...the customer side If you have opened the threaded plug accidentally please contact your local contact person to ensure safe re closing of the plug You can find the address at www boschrexroth com addresses Table 19 Tightening torques for female threads and threaded plugs Ports Maximum permissible tightening torque of female threads MG max Required tightening torque of threaded plugs MV WAF hexagon...

Page 46: ... pieces couplings or connecting points with hoses or pipes to ensure they are in safe working condition 7 4 9 Electrically connecting the axial piston unit NOTICE Short circuit due to penetrating hydraulic fluid Fluid can penetrate the product and cause a short circuit Do not install axial piston units with electric components e g electric controls sensors in a reservoir below the fluid level insi...

Page 47: ... for size 520 If necessary you can change the position of the connector by turning the solenoid body This is independent of the connector version CAUTION Hot surfaces on the solenoid Risk of burning Allow the solenoid to cool down sufficiently before touching it Protect yourself with heat resistant protective clothing e g gloves To do this proceed as follows 1 Loosen the mounting nut 1 of the sole...

Page 48: ...em Bosch Rexroth recommends a flushing cycle for the entire system prior to initial commissioning To avoid internal contamination do not include the axial piston unit in the flushing cycle Use an additional flushing unit to perform the flushing cycle Follow the instructions of the flushing unit s manufacturer for the exact procedure during the flushing cycle ...

Page 49: ...ies from Bosch Rexroth 8 1 Initial commissioning During all commissioning work on the axial piston unit observe the general safety instructions and intended use detailed in chapter 2 Safety instructions on page 9 Connect the pressure gauge for the working pressure case pressure and suction pressure to the specified measuring points on the axial piston unit or in the hydraulic system to check the t...

Page 50: ...viscosities and admissible temperatures in data sheet 93100 Proceed as follows to fill the axial piston unit 1 Place a drip tray under the axial piston unit to collect any hydraulic fluid that may leak NOTICE Contaminated hydraulic fluid The cleanliness levels of commercial hydraulic fluids are usually insufficient for our components Use a suitable filter system to filter hydraulic fluids during f...

Page 51: ...bubbles 3 Increase the load and check whether the working pressure rises as expected 4 Perform a leak test to ensure the hydraulic system is sealed and can withstand the max pressure 5 Check the suction pressure at port S of the axial piston pump at nominal speed and maximum swivel angle Refer to data sheet 93100 for the permissible value 6 At maximum working pressure check the case pressure at po...

Page 52: ...d mechanical hydraulic efficiency is also greater until the running in phase of about 10 operating hours is concluded To ensure that contamination in the hydraulic system does not damage the axial piston unit Bosch Rexroth recommends the following procedure after the running in phase After the running in phase have a hydraulic fluid sample analyzed for the required cleanliness level Change the hyd...

Page 53: ...o settings or changes during operation For this reason this chapter of the manual does not contain any information on adjustment options Use the product only within the performance range specified in the technical data The machine system manufacturer is responsible for proper project planning of the hydraulic system and its control ...

Page 54: ...l connections and components For cleaning and care of the axial piston unit observe the following Check whether all seals and plug in connections are securely seated to ensure no moisture can penetrate into the axial piston unit during cleaning Use only water and if necessary a mild cleaning agent to clean the axial piston unit Never use solvents or aggressive cleaning agents Remove major external...

Page 55: ...em clean Daily Check axial piston unit for unusual noise development Daily Check mounting elements for tight seating All fasteners have to be checked when the hydraulic system is switched off depressurized and cooled down Monthly 10 3 Maintenance The axial piston unit is low maintenance when used as intended The service life of the axial piston unit is heavily dependent on the quality of the hydra...

Page 56: ... can cause injury and property damage Only use original spare parts from Rexroth to repair the Rexroth axial piston units otherwise the functional reliability of the axial piston unit cannot be guaranteed and the warranty will be voided The spare parts lists for axial piston units are order specific When ordering spare parts specify the material and serial number of the axial piston unit as well a...

Page 57: ...bly Proceed as follows to remove the axial piston unit 1 Make sure you have the appropriate tools and wear personal protective equipment 2 Allow the axial piston unit to cool down until it can be removed without danger 3 For below reservoir installation before removing the axial piston unit from the entire system seal the connection to the reservoir and or drain the reservoir 4 Place a drip tray u...

Page 58: ...ly drain the axial piston unit 2 Dispose of the axial piston unit and packaging material in accordance with the regulations in your country 3 Dispose of the hydraulic fluid in accordance with the regulations of your country Also observe the applicable safety data sheet for the hydraulic fluid 4 Disassemble the axial piston unit into its constituent parts for proper recycling 5 For example separate...

Page 59: ... side should only be made using the product specific setting instructions The warranty from Bosch Rexroth only applies to the product as delivered The warranty will be voided if the unit is modified or extended Adjusting the setting screws will render the warranty void If you need to change the settings please contact your local contact person you can find their contact information at www boschrex...

Page 60: ...r product works in conjunction with the entire system Try to find out whether or not the product was working properly in conjunction with the entire system before the fault occurred Try to determine any changes to the entire system in which the product is installed Have there been any changes to the application conditions or operating range of the product Has maintenance work recently been carried...

Page 61: ...e suction line with hydraulic fluid Remove foreign particles from the suction line Drive speed too high Machine system manufacturer Reduce drive speed Wrong direction of rotation Machine system manufacturer Check correct direction of rotation see chapter 7 4 1 Preparation on page 36 Improper mounting of the axial piston unit Check the mounting of the axial piston unit according to the specificatio...

Page 62: ...ction pressure too low foreign particles in the suction line impermissible filter in the suction line Machine system manufacturer Check the system e g optimize inlet conditions use suitable hydraulic fluid Fill the suction line with hydraulic fluid Remove foreign particles from the suction line Hydraulic fluid not in optimal viscosity range Machine system manufacturer Check temperature range and u...

Page 63: ...vice Malfunction of the control device or controller of the axial piston unit Contact Bosch Rexroth Service Control of the control device defective Check control contact machine system manufacturer or Bosch Rexroth Service Wear or mechanical damage to the axial piston unit Replace axial piston unit Contact Bosch Rexroth Service Output unit defective e g hydraulic motor or cylinder Contact machine ...

Page 64: ...ystem e g malfunction in the cooler insufficient hydraulic fluid in the reservoir Wrong setting and or malfunction of the pressure relief and pressure control valves e g high pressure relief valve pressure controller Optimize the adjustment of the pressure limitation and pressure control valves of the axial piston unit and the pressure safeguarding in the hydraulic system Contact Bosch Rexroth Ser...

Page 65: ...nical data The permissible technical data for your axial piston unit can be found on the data sheet 93100 The data sheet can be found in the online product catalog at www boschrexroth com p A20VO Order related technical data for your axial piston unit can be found in the order confirmation ...

Page 66: ...48 Functional description Control 21 Functional test 51 I Identification 22 Inside reservoir installation 32 Inspection 54 Installation 28 36 Completion 40 General instructions 37 On a gearbox 39 On gearbox 39 Preparation 36 With cardan shaft 39 With coupling 38 Installation conditions 28 Installation position Above reservoir installation 34 Below reservoir installation 30 Inside reservoir install...

Page 67: ...ning in phase 52 S Safety instructions 9 General 11 Product specific 12 Signal word 7 Scope of delivery 19 Slipper pad 21 Solenoid position Changing 47 Spare parts 56 Storage 23 26 Storage time 26 Stroking piston 21 Suction side 21 Symbols 7 T Technical data 65 Tightening torques 45 Tools 57 Transport 23 By hand 23 with eye bolt 24 with lifting strap 25 Transporting 23 Transport protection 40 Trou...

Page 68: ...rexroth de www boschrexroth com Subject to change Printed in Germany RE 93100 01 B 2019 09 10 Your local contact person can be found at www boschrexroth com addresses Bosch Rexroth AG An den Kelterwiesen 14 72160 Horb a N Germany Tel 49 7451 92 0 info ma boschrexroth de www boschrexroth com ...