Bosch Rexroth 11 Series, Instruction Manual

Page 1: ... Replace this illustration area with an illustration of your product Instruction manual RE 92801 01 B 11 2018 Replaces English Axial piston variable pump A15VSO A15VLO Series 11 ...

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: ...5 About this product 18 5 1 Performance description 18 5 2 Product description 18 5 2 1 Axial piston unit layout 18 5 2 2 Functional description 19 5 3 Product identification 20 6 Transport and storage 21 6 1 Transporting the axial piston unit 21 6 1 1 Transport by hand 21 6 1 2 Transport with lifting devices 21 6 2 Storing the axial piston unit 24 7 Installation 26 7 1 Unpacking 26 7 2 Installati...

Page 4: ...45 8 2 Running in phase 46 8 3 Recommissioning after standstill 46 9 Operation 47 10 Maintenance and repair 47 10 1 Cleaning and care 47 10 2 Inspection 48 10 3 Maintenance 48 10 4 Repair 49 10 5 Spare parts 49 11 Removal and replacement 50 11 1 Required tools 50 11 2 Preparing for removal 50 11 3 Performing the disassembly 50 11 4 Preparing the components for storage or further use 50 12 Disposal...

Page 5: ...om your contact at Bosch Rexroth Installation drawing Axial piston variable pump A15VSO A15VLO Contains the permissible technical data ports main dimensions and circuit diagrams 92801 Data sheet Hydraulic fluids based on mineral oils and related hydrocarbons Describes the requirements for hydraulic fluids on mineral oil basis and related hydrocarbons for operation with Rexroth hydraulic components...

Page 6: ... sign draws attention to the danger Signal word identifies the degree of the danger Type and source of danger indicates the type and source of the danger Consequences describes what occurs if safety instructions are disregarded Precautions states how the danger can be avoided Table 2 Hazard classes as defined in ANSI Z535 6 Warning sign signal word Meaning DANGER Identifies a dangerous situation t...

Page 7: ...e plug Made out of plastic not pressure resistant only for transportation As umbrella term for axial piston variable pump A15VSO A15VLO 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 explosion protection Atmosphère explosible DIN Deutsches Institu...

Page 8: ...product is intended for the following use The axial piston unit is only approved as a pump for hydrostatic drives in an open circuit Observe the technical data the application and operating conditions and the performance limits as specified in the data sheet 92801 and in the order confirmation Information about approved hydraulic fluids can be found in data sheet 92801 The axial piston unit is onl...

Page 9: ...l as familiarity with associated technical terms For transporting and handling the product knowledge regarding the use of lifting devices and lifting accessories is required In order to ensure safe use these activities should only be performed by skilled personnel or an instructed person under the direction and supervision of skilled personnel Skilled personnel refers to persons who possess the pr...

Page 10: ...ion protection applications 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 or 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 and wear appro...

Page 11: ...jury 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 fo...

Page 12: ...nexpected machine movements 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 ...

Page 13: ...fficient 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 observed at all times Use your personal protective equipment e g safety goggles safety gloves suitable working cloth...

Page 14: ...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 filled during operation Avoid air inclusions in the forward drive shaft bearing especially with the axial piston unit installed with the drive shaft up Check the hydraulic fluid level in the housing area regularly and recommission...

Page 15: ...nation and water in the hydraulic system Improper cleaning Product can be damaged Close all openings with appropriate protective covers in order to prevent cleaning agents from entering the hydraulic system Never use solvents or aggressive cleaning agents Use only water and if necessary a mild cleaning agent to clean the axial piston unit Do not point a high pressure cleaner at sensitive component...

Page 16: ...r 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 components e g solenoids adjacent products may be damaged during assembly if no sufficient safety distance is complied with When installing the axial piston unit check the safety distances to nearby products to e...

Page 17: ...pe of delivery Axial piston unit as per order confirmation The following parts come assembled on the unit Protective cover incl mounting bolts 1 Threaded plug 2 Protective plug 3 Steel flange covers the flange cover on the suction port provides a secure stand and protection for the Vg max stop 4 for version with through drive protective cover incl mounting bolts 5 ...

Page 18: ...e speed and displacement The flow can be smoothly changed using the control cradle 12 For axial piston units with swashplate design the pistons 10 are arranged axially relative to the drive shaft In an open circuit the hydraulic fluid flows from the reservoir to the hydraulic pump from where it is fed to the consumer e g hydraulic motor From the consumer the hydraulic fluid flows directly back to ...

Page 19: ...tem by the pistons on the high pressure side 3 The swivel angle of the cradle 12 is infinitely variable Controlling the swashplate swivel angle changes the piston stroke and therefore the displacement The swivel angle is controlled hydraulically by means of the stroking piston The cradle is mounted in swivel bearings for smooth operation and it is kept in balance by the opposed piston not illustra...

Page 20: ...xxxx MNR FD Rexroth A15VSO280LRE2A0V 11MRVE4A4EA3S20 0 18W28 1 2 3 4 9 10 11 12 6 7 8 13 14 5 Fig 4 Name plate A15VSO 1 Manufacturer 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 8 Flow setting optional 9 Pressure controller setting optional 10 Displacement 11 Serial number 12 Ma...

Page 21: ...ensions and weights without through drive A15VLO Size 145 175 210 280 Weight kg 92 110 125 148 Width mm Dimensions vary by equipment The values applicable for your axial piston unit can be found in the installation drawing request if necessary Height mm Depth mm Weight may vary by equipment 6 1 1 Transport by hand Axial piston units with a weight of up to 15 kg can be transported by hand for a sho...

Page 22: ... 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 in the drive shaft For all female threads use a stud end from the same system of units and of the correct size Screw an eye bolt fully into the female thread in the housing Make sure that each eye bolt can bear the total ...

Page 23: ...trap 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 from assembled p...

Page 24: ...e max permissible storage times for an unpackaged axial piston unit as per data sheet 90312 Table 8 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 Max 12 months Max 24 months The warranty will be voided if t...

Page 25: ...g and care on page 47 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 The filling is carried out via the drain port T1 T2 or T3 see chapter 7 4 Installing the axial piston unit Fig...

Page 26: ... 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 Install 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 O...

Page 27: ...n pump see Fig 8 See data sheet for other pressure values 0 2 0 8 abs 1 2 3 0 0 1 2 1 2 1 S Fig 8 Suction pressure 1 Absolute pressure gage 2 Standard pressure gage relative The suction conditions improve with installation below and inside the reservoir Make sure that the working environment at the installation site is completely free of dust and foreign substances The axial piston unit should be ...

Page 28: ...min hmin T1 T3 T2 S F F F SB ht min hmin T1 T3 T2 S SB ht min hmin T1 T3 T2 S T1 T2 T3 Highest drain port SB Baffle baffle plate F Filling air bleeding ht min Minimum required immersion depth 200 mm S Suction port hmin Minimum required distance to reservoir bottom 100 mm Port F is part of the external piping and must be provided on the customer side to make filling and air bleeding easier Table 9 ...

Page 29: ... to or below the upper edge of the pump see chapter 7 3 3 Above reservoir installation on page 30 Axial piston units with electric components e g electric controls sensors must not be installed in a reservoir below the fluid level Exception Installation of the axial piston unit with E2 E6 control However only with Hirschmann connector and if mineral hydraulic fluids are used and the fluid temperat...

Page 30: ... position 7 Observe the maximum permissible suction height hS max 800 mm The permissible suction height hS is derived from the total pressure loss 6 7 ht min hmin hS max SB F T1 T2 T3 S hES min SB ht min F hmin hS max T1 T2 T3 S Fig 11 Above reservoir installation A15VSO A15VLO with installation position 6 7 T1 T2 T3 Highest drain port ht min Minimum required immersion depth 200 mm F Filling air b...

Page 31: ... permissible direction of rotation of the axial piston unit on the name plate and make sure that this corresponds to the direction of rotation of the drive motor L R Fig 12 Direction of rotation L Counter clockwise R Clockwise The direction of rotation as indicated on the name plate determines the direction of rotation of the axial piston unit as viewed on the drive shaft see chapter 5 3 Product i...

Page 32: ...hat the respective case pressure in each unit is not exceeded The shared drain line must be dimensioned to ensure that the maximum permissible case pressure of all connected units is not exceeded in any operating conditions particularly at cold start If this is not possible separate drain line must be laid if necessary The type of installation for the axial piston unit depends on the connecting el...

Page 33: ...uired tools and tightening torques for the mounting bolts are available from the machine system manufacturer 11 When using elastic couplings check that the drive does not resonate after completing the installation 7 4 5 Installation on a gearbox The following describes how to install the axial piston unit on a gearbox After installing on a gearbox the axial piston unit is covered and is difficult ...

Page 34: ...ing the axial piston unit to the installation position and fasten it Details of the required tools and tightening torque for the mounting bolts can be obtained from the system manufacturer 7 4 7 Completion of assembly 1 Remove any installed transport screws CAUTION Operation with protective plugs Operating the axial piston unit with protective plugs may result in injury or damage to the axial pist...

Page 35: ... see Table 12 Ports A15VSO A15VLO series 11 on page 39 Failure to do so could lead to malfunctions or damage If a port is not being used it is to be plugged with a threaded plug since the protective plugs are not pressure resistant Important for LRDRS0 controllers Port X is equipped with a protective plug 3 This port must be connected Failure to do so could lead to malfunctions or damage You will ...

Page 36: ...astening threads are designed for the maximum permissible pressures pmax see Table 12 Ports A15VSO A15VLO series 11 on page 39 The machine system manufacturer is required to ensure that the connecting 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...

Page 37: ...ican imperial and the Japanese measuring system JIS Japan Industrial Standard Various kinds of seals 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 or bursting stud ends For fittings if a stud end that does not match the ...

Page 38: ...M T2 A S P T1 MA T3 Fig 14 Port overview A15VLO with E2DR control clockwise rotation M T2 A S P X T1 MA T3 Fig 15 Port overview A15VSO with LRDRS0 control clockwise rotation M T2 A S P X T1 MA T3 Fig 16 Port overview A15VSO with LRDRS0 control counter clockwise rotation Port overview ...

Page 39: ...e found in the installation drawing 2 Depending on the application momentary pressure peaks can occur Keep this in mind when selecting measuring devices and fittings 3 O Must be connected comes plugged X Plugged in normal operation 4 Depending on the installation position T1 T2 or T3 must be connected see chapter 7 3 Installation position on page 28 The following tightening torques apply Fittings ...

Page 40: ...10 Nm and for M12 1 5 to 17 Nm To connect the axial piston unit to the hydraulic system 1 Remove the protective plugs or threaded plugs from the ports where the connections should be made according to the hydraulic circuit diagram 2 Make sure the sealing surfaces of the hydraulic ports and functional surfaces are not damaged 3 Use only clean hydraulic lines or flush them before installation Observ...

Page 41: ...rer is responsible for electric control layout Electrically controlled axial piston units must be connected in accordance with the electrical circuit diagram for the machine system For axial piston units with electrical control and or mounted sensors observe the information in data sheet 92801 e g Permissible voltage range Permissible current Correct pin assignment Recommended electrical control u...

Page 42: ...ig 17 Hirschmann connector 7 5 Performing flushing cycle In order to remove foreign particles from the system 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 un...

Page 43: ... accessories 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 8 Connect the pressure gage 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 che...

Page 44: ...he 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 fluid are usually insufficient for our components Use a suitable filter system to filter hydraulic fluids during filling to minimize solid particle contamination and water in the hydraulic system 2 Fill ...

Page 45: ...tem 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 max swivel angle Refer to data sheet 92801 for the permissible value 6 At max working pressure check the case pressure at port T1 T2 or T3 Refer to data sheet 92801 for the permissible value 8 1 3 Performing a functional test WARNING Improperly connected axial pisto...

Page 46: ...ric and 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 after the running in phase After the running in phase have a hydraulic fluid sample analyzed for the required cleanliness level Change the hydraul...

Page 47: ...rvals described in this manual 10 1 Cleaning and care NOTICE Damage to seals and electrical system due to mechanical effects The jet of a high pressure cleaner may damage the seals and electrical system of the axial piston unit Do not point a high pressure cleaner at sensitive components e g shaft seal electrical connections and components For cleaning and care of the axial piston unit observe the...

Page 48: ...nd faults on the machine system and rectify them This is why Bosch Rexroth recommends always keeping the axial piston unit and system 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 ...

Page 49: ...parts Spare parts that do not meet the technical requirements specified by Bosch Rexroth 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 orderi...

Page 50: ...sembly 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 or drain the reservoir 4 Place a drip tray un...

Page 51: ...nstituent parts for proper recycling 5 For example separate the parts into Castings Steel Aluminum Non ferrous metal Electronic waste Plastic Seals 13 Extension and conversion Do not modify the axial piston unit or its assembled parts This includes also the change of the setting screws or the wiring Changes to settings on the customer side should only be made using the product specific setting ins...

Page 52: ...our 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 carri...

Page 53: ...the 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 31 Improper mounting of the axial piston unit Check the mounting of the axial piston unit according to the specificat...

Page 54: ...uction 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 ...

Page 55: ...rvice 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 56: ...ct system e g malfunction in the cooler insufficient hydraulic fluid in the reservoir Wrong setting 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 57: ...nit can be found on the data sheet 92801 The data sheet can be found on the Internet at www boschrexroth com mediadirectory You can find further information about A15VSO A15VLO series 11 in the online product catalog industrial hydraulics www boschrexroth com ics Order related technical data for your axial piston unit can be found in the order confirmation ...

Page 58: ...22 F Filling 43 Flushing cycle 42 Functional test 45 H High pressure side 18 I Identification 20 Impeller 18 19 Inside reservoir installation 29 Inspection 48 Installation 26 31 Completion 34 general instructions 32 On a gearbox 33 On gearbox 33 Preparation 31 With cardan shaft 34 With coupling 32 Installation conditions 26 Installation position Above reservoir installation 30 Below reservoir inst...

Page 59: ...5 Retaining plate 18 Running in phase 46 S Safety instructions 8 General 10 Product specific 11 Signal word 6 Scope of delivery 17 Slipper pad 18 Spare parts 49 Storage 21 24 Storage time 24 Suction side 18 Symbols 6 T Technical data 57 Tightening torques 39 Tools 50 Transport 21 by hand 21 with eye bolt 22 with lifting strap 23 Transporting 21 Transport protection 35 Troubleshooting 52 U Unpackin...

Page 60: ...terwiesen 14 72160 Horb a N Germany Tel 49 7451 92 0 info ma boschrexroth de www boschrexroth com Subject to change Printed in Germany RE 92801 01 B 11 2018 Your local contact person can be found at www boschrexroth com addresses ...