Bosch rexroth 60 Series, Instruction Manual

Page 1: ...Instruction manual RE 92704 01 B 2020 01 21 Replaces English Axial piston variable pump A10VOH Series 60 ...

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: ...f delivery 17 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 22 6 2 Storing the axial piston unit 24 7 Installation 26 7 1 Unpacking 26 ...

Page 4: ...pply 44 8 1 3 Performing a functional test 44 8 2 Running in phase 45 8 3 Recommissioning after standstill 45 9 Operation 46 10 Maintenance and repair 47 10 1 Cleaning and care 47 10 2 Inspection 47 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 component...

Page 5: ...pplementary documentation Title Document number Document type Order confirmation Contains the order related technical data for your axial piston variable pump A10VOH Order confirmation Installation drawing Contains the outer dimensions all ports and the hydraulic circuit diagram for your axial piston variable pump A10VOH Please request the installation drawing from your contact at Bosch Rexroth In...

Page 6: ...sociated with the use of this product Safety instructions are set out as follows SIGNAL WORD Type and source of danger Consequences of noncompliance Danger prevention measures Warning 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 d...

Page 7: ...a term for axial piston variable pump A10VOH 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 ANSI American National Standards Institute is an organization that coordinates the development of voluntary standards in the United States ATEX EC directive on explosion protec...

Page 8: ...tem has been established in accordance with 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 Observe the technical data the application and operating conditions and the performance limits as specified in the data sheet 92704 and in the order confirmation Information about approved hydra...

Page 9: ...liarity 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 professiona...

Page 10: ...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 and wear appr...

Page 11: ...ry 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 for ...

Page 12: ... the closed loop control and or open loop control function Risk of injury or property damage Under certain circumstances moving parts in control equipment e g valve spools can get stuck in an undefined position due to contamination e g impure hydraulic fluid abrasion or residual dirt from components As a result the hydraulic fluid flow and the build up of torque in the axial piston unit can no lon...

Page 13: ...ody can fall over them that 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 m...

Page 14: ...erations 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 f...

Page 15: ...missioning 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 req...

Page 16: ...d water Always place a drip tray under the axial piston unit when filling and draining hydraulic fluid Use a suitable binding agent to collect any leaked hydraulic fluid Observe the parameters in the safety data sheet for the hydraulic fluid and the specifications provided by the machine system manufacturer Danger due to heat development in components Adjacent products may be damaged Due to a heat...

Page 17: ...d 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 Connector protective covers 3 For version with through drive spacer 4 made of plastic serves as transport protection For version with through drive protective cover incl mounting bolts 5 ...

Page 18: ...n open circuit hydraulic system Flow is proportional to drive speed and displacement The flow can be steplessly changed by controlling the cradle 13 For axial piston units with swashplate design the pistons 11 are arranged axially to the drive shaft 1 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 ...

Page 19: ...acement On the suction side 9 hydraulic fluid flows into the piston chamber as the piston recedes At the same time on the high pressure side 6 the hydraulic fluid is pushed out of the cylinder chamber into the hydraulic system by the pistons The swivel angle of the cradle 13 is infinitely variable Adjusting the swivel angle changes the piston stroke and with it the displacement The swivel angle is...

Page 20: ...R FD A10VOH145DR00 60DRVC2R102B2S40000 19W48 1 2 3 4 9 10 11 12 6 7 8 13 14 5 Fig 3 Name plate A10VOH 1 Trademark 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 Mat...

Page 21: ...ines according to SAE J617 with through drive kg 77 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 Up to a specific maximum weight axial piston units can be transported by hand for a short distance Observe the national regulat...

Page 22: ...sling chain can bear the total weight of the axial piston unit plus approx 20 You can lift the axial piston unit as shown in Fig 4 via the transport lug 1 Fig 4 Transport lug on the housing WARNING Danger due to suspended loads During transport with lifting strap the axial piston unit can topple out of the lifting strap and cause injury Use the widest possible lifting strap Make sure that the axia...

Page 23: ...Transport and storage 23 60 RE 92704 01 B 2020 01 21 A10VOH Series 60 Bosch Rexroth AG Fig 5 Transport with lifting strap ...

Page 24: ...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 v...

Page 25: ...Cleaning 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 Filling is carried out via the drain port L1 L2 or L4 optional see chapter 7 4 Installing the axial pis...

Page 26: ... for transport damage and completeness see chapter 4 Scope of delivery on page 17 Dispose of the packaging in accordance with the regulations in your 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...

Page 27: ... Please note that the values stated in the data sheet for the maximum rotational speed are valid for a suction pressure of 1 bar absolute at suction port S See data sheet for other pressure values 0 2 0 8 abs 1 2 3 0 0 1 2 1 2 1 S Fig 6 Suction pressure 1 Absolute pressure gauge 2 Standard pressure gauge relative The suction conditions improve with below and inside reservoir installation Make sure...

Page 28: ...ir installation means that the axial piston unit is installed outside of the reservoir below the minimum fluid level ht min SB F h min S L2 L1 L2 L1 S SB F ht min h min 1 2 Fig 7 Below reservoir installation A10VOH with installation positions 1 2 F Filling air bleeding ht min Minimum required immersion depth 200 mm L1 L2 Drain port hmin Minimum required distance to reservoir bottom 100 mm S Suctio...

Page 29: ...e 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 30 Axial piston units with electric components e g electric controls sensors must not be installed in a reservoir below the fluid level Our advice is to fit a suction pipe to the suction port S and to fit a pipe to case drain port L1 L2 or L4 In this c...

Page 30: ...id 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 5 6 F SB hs max ht min h min S L2 L1 F SB hs max ht min h min L4 L1 S Fig 9 Above reservoir installation A10VOH with installation positions 5 6 F Filling air bleeding hmin Minimum required distance to reservoir bottom 100 mm L1 L4 Drain po...

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 10 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 id...

Page 32: ...e that 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 condition particularly at cold start If this is not possible separate drain line must be laid if necessary The version of installation for the axial piston unit depends on the connecti...

Page 33: ...shaft of the axial piston unit installation length Protect the drive shaft against frictional corrosion by providing permanent lubrication Fasten the axial piston unit at the installation location No gearing forces higher than the permissible axial and radial forces should act on the shaft if necessary support the gear wheel at the gearbox output separately 7 4 6 Installation with cardan shaft The...

Page 34: ...sioning Remove the spacer 1 The spacer must be removed before the second pump is fitted If you operate a further axial piston unit without installing an additional pump on the through drive it is absolutely necessary to remove the spacer and the hub Since the metallic protective cover 3 is not pressure resistant it must be replaced with a pressure resistant cover If you need a pressure resistant c...

Page 35: ... Rexroth service partner or the service department of the manufacturer s plant of the axial piston unit 1 1 2 2 5 3 4 Fig 12 Removing transport protection 1 Protective covers 2 Protective plugs threaded plugs 3 Connector protective covers 4 For version with through drive spacer made of plastic serves as transport protection 5 For version with through drive protective cover and mounting bolts Ports...

Page 36: ...piston unit to the rest of the hydraulic system in accordance with the hydraulic circuit diagram of the machine system manufacturer The ports and fastening threads are designed for the maximum permissible pressures pmax see in Table 11 Ports A10VOH series 60 on page 38 The machine system manufacturer is required to ensure that the connecting elements and lines correspond to the specified applicati...

Page 37: ... used in application areas that use the metric system as well as the Anglo American 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 ...

Page 38: ...stallation position L1 L2 or L4 must be connected see chapter 7 3 Installation position on page 28 5 Available as an option The following tightening torques apply Fittings Observe the manufacturer s specifications regarding the tightening torques of the fittings used Female threads in the axial piston unit The max permissible tightening torques MG max are the maximum values for the female threads ...

Page 39: ...B 540 Nm 270 Nm 5 8 in 1 5 8 12 UN 2B 960 Nm 320 Nm 3 4 in 1 7 8 12 UN 2B 1200 Nm 390 Nm 3 4 in To connect the axial piston unit to the hydraulic system 1 Remove the protective plugs and 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 Us...

Page 40: ... protection and matching mating connector can also be found in data sheet 92704 The mating connector is not included in the scope of delivery 1 Switch off the power supply to the relevant machine system component 2 Electrically connect the axial piston unit 12 or 24 V Before connecting check whether the connector protective covers 3 are off see Fig 12 Removing transport protection on page 35 and t...

Page 41: ... Bosch Rexroth recommends a flushing cycle for the hydraulic system before the first 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 42: ...nded use detailed in chapter 2 Safety instructions on page 8 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 technical data at first operation During commissioning monitor the temperature of the hydraulic fluid in the reservoir to ensure that it lies within perm...

Page 43: ...ficient for the requirements of 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 and air bleed the axial piston unit via the appropriate ports see chapter 7 3 Installation position on page 28 Also fill the hydraulic lines of the system NOTICE Risk of property damage due to inadequ...

Page 44: ...ed 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 92704 for the permissible value 6 At maximum working pressure check the case pressure at the port L1 L2 or L4 optional Refer to data sheet 92704 for the permissible value 8 1 3 Performing a functional test WARNING Improperly connected a...

Page 45: ...umetric 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 procedure after the running in phase After the running in phase have a hydraulic fluid sample analyzed for the required cleanliness level Chan...

Page 46: ...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 47: ... 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 48: ...ston 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 hydraulic fluid This is why we rec...

Page 49: ...arts 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 orderin...

Page 50: ...orming the disassembly 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 seal the connection to the reservoir and or drain the reservoir 4 Place a drip tray under...

Page 51: ...ssemble the axial piston unit into its constituent 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 and or its assembled parts This also includes adjusting the setting screws Changes to settings on the customer side should only be made using the p...

Page 52: ... 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 53: ...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 31 Improper mounting of the axial piston unit Check the mounting of the axial piston unit according to the specificatio...

Page 54: ...tion 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 us...

Page 55: ...ice 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 s...

Page 56: ... g malfunction in the cooler insufficient hydraulic fluid in the reservoir Wrong setting or malfunction in the pressure relief and pressure control valves e g high pressure relief valve pressure cut off 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 Rexro...

Page 57: ...al data The permissible technical data for your axial piston unit can be found on the data sheet 92704 The data sheet can be found in the online product catalog at www boschrexroth com p A10VOH 6x Order related technical data for your axial piston unit can be found in the order confirmation ...

Page 58: ...ing cycle 41 Functional description Control 19 Functional test 44 I Identification 20 Inside reservoir installation 29 Inspection 47 Installation 26 Completion 35 General instructions 32 On a gearbox 33 On gearbox 33 Preparation 31 With cardan shaft 33 With coupling 32 Installation conditions 26 Installation position Above reservoir installation 30 Below reservoir installation 28 Inside reservoir ...

Page 59: ...ing in phase 45 S Safety instructions 8 General 10 Product specific 11 Signal word 6 Scope of delivery 17 Slipper pad 18 Solenoid position Changing 40 Spare parts 49 Storage 21 24 Storage time 24 Stroking piston 18 Suction side 18 Symbols 7 T Technical data 57 Tightening torques 38 Tools 50 Transport 21 By hand 21 with eye bolt 22 with lifting strap 22 Transporting 21 Transport protection 35 Troub...

Page 60: ...rwiesen 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 92704 01 B 2020 01 21 Your local contact person can be found at www boschrexroth com addresses ...