Bosch Rexroth 40 Series, Operating Instructions Manual

Page 1: ...Operating Instructions RE 79039 01 B 01 2021 Replaces 11 2018 English MOBILEX GFB 8000 Hydrostatic swing drives for mobile applications Series 40 Sizes 8110 8195 ...

Page 2: ...t may not be reproduced or given to third parties without its consent The brand product and company names which are mentioned in this operating instructions are registered trademarks of their respective owners The copying or changing of products with registered trademarks is not permitted without the permission of the respective owner A CE marking of the gearboxes as well as the EC declaration of ...

Page 3: ... 5 About this product 19 5 1 Performance description 19 5 2 Product description 19 5 2 1 Application conditions 19 5 3 Description of the brake 20 5 4 Product overview 21 5 5 Identification of the product 22 5 5 1 Standard name plate 22 6 Transport and storage 23 6 1 Transporting the MOBILEX GFB 8000 23 6 2 Storing the MOBILEX GFB 8000 24 6 2 1 Preservation 25 6 2 2 Maximum storage periods 25 7 As...

Page 4: ... 8 1 3 Before filling the planetary gearbox with lubricating oil 40 8 1 4 Filling the planetary gearbox with lubricating oil 41 8 1 5 Fill lubricating oil through the oil filler opening planetary gearbox without circulating oil lubrication 41 8 1 6 Completing commissioning and run in period 43 8 2 Recommissioning after standstill 43 9 Operation 44 10 Servicing and repair 45 10 1 Cleaning and care ...

Page 5: ...B 01 2021 MOBILEX GFB 8000 series 40 general operating instructions Bosch Rexroth AG 14 Extension and conversion 59 15 Troubleshooting and fault correction 60 15 1 Troubleshooting procedure 60 16 Technical data 62 17 Appendix 62 ...

Page 6: ...he valid configuration of your hydrostatic swing drive MOBILEX GFB 8000 see the chapters Product description Scope of supply and appendix D Technical data Drawings of the material number specific operating instructions Also observe the respective chapters of these general operating instructions For simplification purposes the product is referred to as MOBILEX GFB 8000 planetary gearbox or as plane...

Page 7: ...g used For better understanding these are explained in the following sections 1 3 1 Safety instructions In this documentation safety notes are located in chapter 2 6 Product and technology dependent safety instructions and in chapter 3 General information concerning damage to property and product damages as well as before any sequence of actions or sequence of instructions where there is a danger ...

Page 8: ... it is not avoided CAUTION identifies a dangerous situation where mild to medium personal injury will result if it is not avoided NOTE identifies damage to property The product or the environment can get damaged 1 3 2 Symbols The following symbols identify information which is not relevant for safety however does increase the coherency of the documentation Table 3 Meaning of symbols Symbol Meaning...

Page 9: ...move preservative L XBCHA3 GB 7324 94 FAG Arcanol MULTI3 Klüberplex BE 31 222 Lithium multi purpose grease Screw plug Metallic screw pressure resistant Plug Made of plastic not pressure resistant only for transport 1 3 4 Abbreviations The following abbreviations are used in this documentation Table 5 Abbreviations Abbreviation Meaning RE Rexroth Document in English Language RDE Rexroth Document in...

Page 10: ...hnical data sheet For this refer to the material number specific operating instructions The planetary gearbox is intended only for professional use and not for private use Intended use includes that this documentation especially chapter 2 Safety instructions has been read and understood 2 3 Improper use Any use other than described in intended use is not in accordance with the requirements and the...

Page 11: ...ntal protection Observe all safety instructions and provisions of the country where the planetary gearbox is going to be deployed operated Only use Rexroth products which are in perfect technical condition Observe all instructions on the planetary gearbox Persons who assemble commission operate disassemble or maintain Rexroth products must not consume alcohol drugs or pharmaceuticals that may affe...

Page 12: ...combustible materials please observe the product data sheets and safety data sheets of the respective manufacturer Do not use fire or naked light when working on the planetary gearbox its mounting parts and when handling with combustible materials Do not smoke in the vicinity of combustible materials Always wear the protective equipment which is specified in the safety data sheets of the respectiv...

Page 13: ...es or draining oil When taking the oil sample or draining the lubricating oil carefully open the oil sampling point or oil drain Sharp edges and tensioned tension belts and cable fasteners as well as rebounding parts Risk of injury Carefully remove any attached tension belts and chains When cutting tension belts and detaching chains always wear protective goggles and cut resistant safety gloves Da...

Page 14: ... Never try to stop or seal the leak or oil jet using a cloth 2 7 Personal Safety Equipment PSA The personal safety equipment for users of the planetary gearbox comprises Safety gloves The required characteristics of the safety gloves are determined by the conditions encountered in practice Wear resistant safety gloves of the corresponding classification according to action step for example heat re...

Page 15: ... the crane and the slinging equipment Lack of knowledge when handling a crane or wrong slinging equipment may lead to uncontrolled movements of the planetary gearbox and therefore damage the machine or vehicle Use a crane with sufficient lifting capacity for lifting the planetary gearbox Only use approved transport equipment Use e g straps chains swivel hooks shackles or suitable equipment as slin...

Page 16: ...arbox caused by commissioning with too much lubricating oil When commissioning the planetary gearbox and the static multiple disk parking brake integrated in the planetary gearbox with too much lubricating oil thermal overloads may occur causing damage to the gears seals and bearings as well as failure of the static multiple disk brake When commissioning or recommissioning the machine or a vehicle...

Page 17: ...ce a catch basin with sufficient capacity under the planetary gearbox when replacing draining lubricating oil or working with a pressure medium Bond any passing flow of lubricating oil or spilled lubricating oil or pressure medium with appropriate absorption material such as oil absorbent granule Dispose the lubricating oil or pressure medium in accordance with local country regulations and provis...

Page 18: ...rts Take the planetary gearbox out of service and contact the nearest Rexroth Service point if you find any irregularities during maintenance work or inspections Unpunctual inspection and maintenance work Risk of damage Adhere to the planetary gearbox s maintenance intervals schedule when carrying out mandatory maintenance work 4 Scope of supply Refer to your material number specific operating ins...

Page 19: ... parts Connections Optional equipment Lubrication etc The entire planetary gearbox which is mounted in rolling bearings is equipped with a splash oil lubrication Optionally the planetary gearbox can also be provided with connections for a circulating oil lubrication The externally toothed planet gears are case hardened The bottom bearing of the output shaft in the output shaft housing is grease lu...

Page 20: ...lways replace the disks the springs and the sealing elements after a functional impairment or thermal overload and by any repair work on the multiple disk parking brake Danger of delayed stopping of the static multiple disk parking brake Delayed application of the static multiple disk parking brake can lead to accidental turning of the e g superstructure Please ensure that the brake line of the st...

Page 21: ...entering seat Variant Long with two centering seats 1 Axial piston motor 2 Motor attachment screws 3 Vent 4 Oil filler 5 Oil dipstick 6 Brake release connection 7 MOBILEX GFB 8000 planetary gearbox 8 Oil drain 9 Grease nipple 10 Output shaft output pinion The shown versions of the MOBILEX GFB 8000 planetary gearbox are only examples and may differ from the supplied version ...

Page 22: ...ol system Type of oil level control system oil dipstick Position and type of mounting parts Optional Circulating oil lubrication oil cooling 5 5 Identification of the product A name plate is located on the planetary gearbox enabling you to identify the product 5 5 1 Standard name plate The following information is indicated on the name plate Fig 2 Example of a planetary gearbox name plate 1 Manufa...

Page 23: ...ed personnel with credentials using attachment means and is transported only by said qualified personnel with a crane or forklift In addition observe chapter 2 4 Qualification of Personnel Adjust the lifting means crane or forklift and attachment means chains and shackles or straps or ropes to the weight and the dimensions of the planetary gearbox Design the load carrying capacity of the lifting m...

Page 24: ...earbox from tipping over Use e g a suitable wooden frame When setting down the planetary gearbox horizontally use suitable measures to protect the gearbox from rolling away Use e g wedges or scantlings see adjacent sketches 6 2 Storing the MOBILEX GFB 8000 NOTE Risk of damaging the planetary gearbox A planetary gearbox stored for more than 12 months has to be thoroughly inspected and submitted to ...

Page 25: ... whether the outside preservation is still correct If the preservation is damaged and gearbox parts on the outside have bright spots then preserve these spots again with e g PERIGOL VCI 230 or CUSTOS 10 38 Observe the manufacturer s product data sheets and safety data sheets when using preservative These data sheets are not included within Rexroth s scope of supply Use a brush to apply the preserv...

Page 26: ...covered in shrink wrap To unpack the planetary gearbox 1 Remove the shrink wrap and the oiled paper 2 Remove the clamping bands 3 Check the scope of supply for transport damage and completeness see chapter 4 Scope of supply 4 Compare material number and designation type code with those specified in the order confirmation If the material number of the planetary gearbox does not match the one in the...

Page 27: ...umber and designation type code with those specified in the order confirmation If the material number of the planetary gearbox does not match the one in the order confirmation contact the Rexroth Service for clarification For the address see appendix A Address directory of the material number specific operating instructions 5 Lift the planetary gearbox out of the packing with suitable lifting mean...

Page 28: ...lation position The standard installation position of the planetary gearbox is vertical axial piston motor on top The planetary gearbox installation position approved and recommended by Rexroth is indicated on the drawing in appendix D Technical data Drawings of the material number specific operating instructions NOTE Installation of the planetary gearbox in a non approved Rexroth mounting positio...

Page 29: ... order depends on the machine the vehicle or the chassis or equipment frame design Refer to the instructions in chapter 7 2 Installation conditions In addition observe the assembly instructions of the machine or vehicle manufacturer The dimensioned drawing contains the dimensions of all connections of the MOBILEX GFB 8000 planetary gearbox Also observe the instructions of the manufacturers of the ...

Page 30: ...rer for setting the backlash The machine or vehicle manufacturer is responsible for the correct setting 7 5 3 Installing the planetary gearbox with eccentric optional eccentric NOTE Risk of damaging the planetary gearbox A wrong or incorrectly installed planetary gearbox can lead to planetary gear failure or damage to the live ring Use mounting screws with strength class 8 8 or 10 9 according to E...

Page 31: ...rbox at in the machine or chassis frame 1 For installation strictly observe the corresponding data in the dimensioned drawing of the planetary gearbox in appendix D Technical data Drawings of the material number specific operating instructions 2 Also observe the primary operating instructions of the machine or vehicle and the manufacturer s frame drawing 3 For the planetary gearbox weight refer to...

Page 32: ...the planetary gearbox For this observe the instructions in chapter 7 Assembly 7 5 6 Connecting the planetary gearbox s axial piston motor to the hydraulic system The machine or vehicle manufacturer is responsible for laying the lines The axial piston motor or the static multiple disk parking brake parking brake has to be connected to the hydraulic system according to the machine or vehicle manufac...

Page 33: ...r If the planetary gearbox is delivered without the axial piston motor install as follows Assemble the axial piston motor to the planetary gearbox Then assemble the planetary gearbox with mounted axial piston motor to the machine or chassis frame 1 Remove the dust cap 11 and the thrust cup 12 Installing the axial piston motor to the planetary gearbox CAUTION Failure or damage to the planetary gear...

Page 34: ...ystem 7 5 8 Installing the planetary gearbox with connection for an electric motor electric motor is not included in the scope of supply CAUTION Failure or damage to the planetary gearbox If you install the planetary gearbox in any other installation position than the one permitted by Rexroth the planetary gearbox may be damaged or fail The warranty claim lapses Only install the planetary gearbox ...

Page 35: ...t of the electric motor Installing the electric motor to the planetary gearbox Work on electrical systems or equipment may only be carried out by a qualified electrician or by instructed persons under the direction and supervision of a qualified electrician in accordance with the electronic regulations If Rexroth delivers the hydrostatic swing drive without electric motor the operating instruction...

Page 36: ...tiple disk parking brake Make sure that neither dirt nor foreign substances penetrate in the brake release connection Ensure that the brake release connection is carefully sealed Assemble hydraulic lines and hoses without mechanical stress Use e g copper sealing rings according to DIN 7603 as sealing means Make sure that no dynamic pressure occurs in the brake line Only use pressure fluid based on...

Page 37: ... Performing a flushing cycle Rexroth recommends to flush the planetary gearbox when changing the lubricating oil type or the lubricating oil manufacturer as well as after carrying out a major repair Before commissioning the axial piston motor Rexroth recommends a rinsing run of the entire system Observe the information in the operating instructions of the axial piston motor manufacturer The flushi...

Page 38: ... of the material number specific operating instructions for information on the permissible operating conditions The machine or vehicle manufacturer must ensure that these are complied with 7 10 Completing the assembly Remove all means of attachment such as straps swivel hooks shackles or devices which are still attached Once again check all connecting parts for proper fit and tightness All connect...

Page 39: ...roducts Risk of injury and property damage Improperly installed products may cause injuries or damages to the product Make sure that all electrical or hydraulic connections are connected or sealed Only commission a completely installed product 8 1 Initial commissioning Before commissioning the planetary gearbox following documents must be at hand Dimensioned drawing of the planetary gearbox Techni...

Page 40: ...axial piston motor 8 1 2 Initial commissioning the electric motor connection If the planetary gearbox is supplied with a connection for mounting an electric motor If Rexroth delivers the hydrostatic swing drive without electric motor the operating instructions of the motor are not included in the scope of supply Observe the operating instructions of the electric motor provided by the manufacturer ...

Page 41: ...ause injury Wear appropriate protective clothing Due to the preserving oil already in the planetary gearbox the oil quantity can differ from the oil quantity indicated in the technical data sheet of the material number specific operating instructions when filling the planetary gearbox for the first time The exact oil volume has therefore to be determined on the planetary gearbox Filling the planet...

Page 42: ...free cloth to remove any lubricating oil sticking to the dipstick 19 Move the oil dipstick 5 to the position as shown in the figure above The oil level is correct if it is between the marks Min and Max of the oil dipstick 5 with the planetary gearbox at standstill 20 If the oil level is too low fill in lubricating oil until the oil level is between the marks Min and Max of the oil dipstick 5 There...

Page 43: ...0 hours of full load operation that all mounting screws are tightly secured Proceed as described in chapter 10 2 4 Checking and retightening screw connections For this put the planetary gearbox out of service Proceed as described in the instructions of the machine or the overall vehicle After reaching the operating temperature check that the planetary gearbox does not show any leakage The maximum ...

Page 44: ...ng brake is no longer warranted Switch off hydraulic pressure when the planetary gearbox is blocked Avoid contamination caused by unclean pressure fluids rubbed off parts or residual dirt from system components Ensure proper installation of an emergency stop function so that the consumer driven machine can be brought into a safe situation Always replace the disks the springs and the sealing elemen...

Page 45: ...and repair works Let the planetary gearbox cool down to approx 50 C before touching it 10 1 Cleaning and care NOTE Penetrating dirt and liquids Damage to the planetary gearbox Extreme cleanness is required when working on the planetary gearbox Do not use a high pressure cleaner for the cleaning of the planetary gearbox Seal all openings with suitable protective caps and or protection devices so th...

Page 46: ...etary gearbox to cool down to approx 50 C before touching To protect yourself from burns wear appropriate protective clothing such as heat resistant safety gloves Always wear protective goggles Risk of injury Solid particles such as metal particles or metal abrasion which are in the lubricating oil or on the screw plug can cause injury Wear appropriate protective clothing NOTE Risk of damaging the...

Page 47: ... Observe the information on the planetary gearbox dimensioned drawing in appendix D Technical data Drawings of the material number specific operating instructions Oil filler opening 4 for filling the lubricating oil Oil dipstick 5 for checking the lubricating oil level Oil drain opening 8 for draining the lubricating oil 1 Allow the planetary gearbox cool down to approx 50 C after standstill 2 Tur...

Page 48: ...unning noise 10 2 4 Checking and tightening screw connections Check as specified in the maintenance plan that all screw connections are tightly secured Especially check the gearbox mounting screws the motor fixing screws the screw plug oil filler opening 4 the screw plug oil drain opening 8 Tighten the screws of the planetary gearbox at the torque specified for the corresponding screws in the plan...

Page 49: ...50 motor operating hours Perform the first oil change refer to chapter 10 4 2 Daily Perform noise test refer to chapter 10 2 3 Weekly Perform visual inspection refer to chapter 10 2 1 Perform oil level check refer to chapter 10 2 2 Monthly Check that the planetary gearbox mounting screws are tightly secured If necessary retighten mounting screws Every six months With existing grease nipple Use lit...

Page 50: ...ly cooled down This ensures that solid particles have not yet settled Strictly observe the lubricating oil manufacturer s product data sheets and safety data sheets when handling lubricating oil These data sheets are not included within Rexroth s scope of supply Change the lubricating oil at the intervals specified in the maintenance schedule If existing observe the maintenance schedule in the mat...

Page 51: ... bearing in the output shaft housing is permanently greased the planetary gearbox is not provided with a grease nipple But if the bearing is grease lubricated the planetary gearbox has at least one grease nipple 9 Grease the output shaft bearing at the intervals specified in the maintenance schedule If necessary use lithium multi purpose grease L XBCHA3 GB 7324 94 or FAG Arcanol MULTI3 or Klüberpl...

Page 52: ...the multiple disk parking brake This can lead to damage to the multi disk package and to decreasing brake action or failure of the multiple disk parking brake Always replace the disks the springs and the sealing elements after a functional impairment or thermal overload and by any repair work on the multiple disk parking brake Please contact Rexroth Service in your area in case repairs are require...

Page 53: ...ales Department for the corresponding spare parts kits Place spare parts orders in writing In cases of urgency you can also order by phone if you confirm your order promptly by fax or e mail The parts list of the MOBILEX GFB 8000 planetary gearbox is material number specific Place spare parts orders with the Rexroth Service Please provide the following information from the name plate with your ord...

Page 54: ...1 2021 11 Decommissioning The MOBILEX GFB 8000 planetary gearbox is a subassembly that does not have to be decommissioned For this reason the chapter in this manual contains no information How to disassemble and replace the MOBILEX GFB 8000 planetary gearbox is described in chapter 12 Disassembly and replacement ...

Page 55: ...ns for circulating oil lubrication or oil cooling please observe the disassembly instructions in the following document included in the material number specific operating instructions Chapter G Supplementary connections In addition observe the instructions of the machine or vehicle manufacturer If the material number specific operating instructions includes action steps for Disassembly that deviat...

Page 56: ...hen removing the planetary gearbox may damage the planetary gearbox Avoid strong impacts on the planetary gearbox during disassembly Avoid exerting axial forces and high compression forces on the gearbox housing Make sure that the planetary gearbox is not tilted during disassembly This chapter describes how to disassemble the planetary gearbox from the machine or chassis frame It is assumed that t...

Page 57: ...rating instructions 15 Close the brake release connection 6 at the planetary gearbox with a corresponding plug according to the parts list For this observe appendix E Parts list of the material number specific operating instructions 16 Loosen the connections of all units and mounting parts that are required for planetary gearbox operation Observe the information on the planetary gearbox dimensione...

Page 58: ...reuse For queries please contact a Rexroth s subsidiary located near you or the main plant directly Refer to www boschrexroth com and the address directory in appendix A Address directory of the material number specific operating instructions for the addresses of our national agencies 1 Carefully close all the openings of the planetary gearbox 2 Clean the planetary gearbox as described in chapter ...

Page 59: ...ary gearbox the hydraulic fluid the lubricating oil and the packaging material according to the national regulations of your country Dispose of hydraulic fluid or lubricating oil remains according to the applicable product data sheets and the safety data sheets for hydraulic fluids or lubricating oils Observe the following supplied instructions for disposing of the planetary gearbox in an environm...

Page 60: ...r the planetary gearbox has performed the required function in the machine or vehicle before the error occurred Try to understand the changes of the machine vehicle where the planetary gearbox is installed Were there changes in the conditions of use or the area where the gearbox was deployed Has maintenance work been performed recently Does an inspection or maintenance log exist Have changes e g c...

Page 61: ... instructions of the system machine or vehicle when the last oil change took place if appropriate proceed to an oil change Proceed as described in chapter 10 2 Inspection Leaking oil Defective output seal Check seals as far as possible replace if necessary If the leak cannot be eliminated Rexroth Service must be notified Seals on partition seams or on the locking screws are defective Lubricating o...

Page 62: ... data of the MOBILEX GFB 8000 planetary gearbox please refer to appendix D Technical data Drawings of the material number specific operating instructions 17 Appendix The documents of chapter 17 Appendix are enclosed in the appendix of the material number specific operating instructions Also refer to chapter 1 2 Required and supplementary documentations ...

Page 63: ...Appendix 63 64 RE 79039 01 B 01 2021 MOBILEX GFB 8000 series 40 general operating instructions Bosch Rexroth AG ...

Page 64: ...ed in Germany RE 79039 01 B 01 2021 Bosch Rexroth AG Gearbox Technology Nortkirchenstr 53 44263 Dortmund Germany Phone 49 231 22819 5 info gears boschrexroth de www boschrexroth com gears Additional information at www boschrexroth com gears ...