Bosch Rexroth A10VGT, Instruction Manual

Page 1: ...Instruction manual RE 92770 01 B 11 2016 Replaces English Axial piston variable pump A10VGT 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: ... of the axial piston unit 19 5 2 2 Functional description 20 5 3 Product identification 21 6 Transport and storage 22 6 1 Transporting the axial piston unit 22 6 1 1 Transporting by hand 22 6 1 2 Transporting with a lifting device 22 6 2 Storing the axial piston unit 24 7 Installation 26 7 1 Unpacking 26 7 2 Installation conditions 26 7 3 Installation position 28 7 3 1 Below reservoir installation...

Page 4: ...rride of the electrical control 45 10 Maintenance and repair 46 10 1 Cleaning and care 46 10 2 Inspection 47 10 3 Maintenance 47 10 4 Repair 48 10 5 Spare parts 48 11 Removal and replacement 49 11 1 Required tools 49 11 2 Preparing for removal 49 11 3 Performing removal 49 11 4 Preparing the components for storage or further use 49 12 Disposal 50 13 Extension and conversion 51 14 Troubleshooting 5...

Page 5: ...dimensions all connections and the hydraulic circuit diagram for your Axial piston variable pump A10VGT Please request the installation drawing from your contact at Bosch Rexroth Installation drawing Axial piston variable pump A10VGT Contains the permissible technical data 92770 Data sheet Mineral oil based hydraulic fluids and related hydrocarbons Describes the requirements on a mineral oil based...

Page 6: ...sures must be observed Safety instructions are set out as follows Signal word Type and source of danger Consequences of noncompliance Measures to prevent danger 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 the safety instructions are not complied...

Page 7: ...Threaded plug Metal screw pressure resistant Protective plug Made out of plastic not pressure resistant only for transportation As a generic term for Axial piston variable pump A10VGT the designation axial piston unit will be used hereinafter 1 3 4 Abbreviations This documentation uses the following abbreviations Table 5 Abbreviations Abbreviation Meaning ATEX EC directive on explosion protection ...

Page 8: ...y directive This product is intended for the following use The axial piston unit A10VGT is only approved as a pump for hydrostatic drum drives of concrete mixer trucks in a closed circuit The pump has been specifically designed and constructed for the load collectives in this particular application The performance data given is based on this load collective Observe the technical data the applicati...

Page 9: ...ications The activities described in this documentation require basic mechanical electrical and hydraulics expertise as well as knowledge of the associated technical terms For transporting and handling the product additional knowledge is necessary with regard to working with lifting devices and their slings In order to ensure safe use these activities should only be performed by skilled personnel ...

Page 10: ...d permitted in the product documentation for example in explosion protection applications or in safety related parts of a control system functional safety You may 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 applica...

Page 11: ...ken bones 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 stand or put your hands under a suspended load Make sure the unit remains stable during transport Wear your personal protective equipment e g safety goggles safety gloves suitable working clothes safety shoes Use suitable lifting d...

Page 12: ...achine 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 additional protective measures are necessary for the application on your machine in orde...

Page 13: ...low the axial piston unit to cool down sufficiently before touching it Wear heat resistant protective clothing e g gloves Improper routing of cables and lines Risk of stumbling and property damage Improper routing of cables and lines can cause a risk of stumbling as well as damage to equipment and components e g lines and connectors tearing Always lay cables and lines in such a way that no one can...

Page 14: ...climbing on the axial piston unit Never grab or climb onto the axial piston unit Check how to safely get on top of the machine system 2 7 Personal protective equipment Personal protective equipment is the responsibility of the user of the axial piston unit Observe the safety regulations and provisions in your country All pieces of personal protective equipment must be intact ...

Page 15: ...y damage due to inadequate lubrication Product can get 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 filled during operation ...

Page 16: ...mize solid particle contamination and water in the hydraulic system Improper cleaning Product can get damaged Plug all openings with the appropriate protection equipment in order to prevent cleaning agents from entering the hydraulic system Never use solvents or corrosive cleaning agents Use only water and if necessary a mild cleaning agent to clean the axial piston unit Do not point a high pressu...

Page 17: ...n the safety data sheet for the hydraulic fluid and the specifications provided by the system manufacturer Danger from hot components Nearby products can get damaged Components which heat up e g solenoids can cause damage to nearby products if they are too close during installation When installing the axial piston unit check the distances to nearby products to ensure that they do not get damaged T...

Page 18: ... 01 B 11 2016 4 Scope of delivery 1 2 2 Fig 1 Axial piston unit The following is included in the scope of delivery Axial piston unit as per order confirmation The following parts are also assembled prior to delivery Protective covers 1 Protective plug threaded plug 2 ...

Page 19: ...with swashplate design for hydrostatic drives in closed circuits The flow is proportional to the drive speed and displacement The flow can be steplessly changed by controlling the cradle 11 For axial piston units with swashplate design the pistons are arranged axially relative to the drive shaft In the closed circuit the hydraulic fluid flows from the hydraulic pump to the consumer e g hydraulic m...

Page 20: ...pressure change The boost pump 7 continuously supplies a sufficient volume of fluid boost volume from a small reservoir to the low pressure side of the closed circuit via a check valve to replenish the internal leakage of the variable pump and consumer The boost pump is an internal gear pump which is driven directly via the drive shaft Actuation of the sequence valve establishes pressure equilibri...

Page 21: ...0VGT090EP3P0 11NRNC4C9 2G0000AS0 0 R90XXXXXXX SC X 12345678 Rexroth 16W45 n XXXX min 1 P XXX kW m XXX kg CN30 1 2 3 4 5 6 7 8 9 10 11 12 13 Fig 3 Name plate A10VGT 1 Manufacturer 2 Internal plant designation 3 Sample category optional 4 Direction of rotation viewed on drive shaft here clockwise 5 Specified area for inspection stamp 6 Weight 7 Power 8 Bar code 9 Rotational speed 10 Manufacturing da...

Page 22: ...e transported manually for a short time if necessary Caution Danger from heavy loads Health hazard from carrying axial piston units Use suitable lifting lowering and moving methods Wear your personal protective equipment e g safety goggles safety gloves suitable working clothes safety shoes Do not use sensitive attachments to transport the axial piston unit e g sensors or valves Carefully place th...

Page 23: ...stated in the installation drawing Make sure that the eye bolt can bear the total weight of the axial piston unit plus 20 You can hoist 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 WARNING Danger from suspended loads During transport with a lifting device the axial piston unit can topple out of the lifting str...

Page 24: ... 20 C Minimum storage temperature 50 C Maximum storage temperature 60 C Keep out of direct sunlight Do not stack axial piston units and store them in a shock proof manner Do not store the axial piston unit on the drive shaft or attachments e g sensors or valves For further storage conditions see Table 7 Check the axial piston unit monthly to ensure proper storage The axial piston units are provide...

Page 25: ...ctions only refer to axial piston units which are operated with a mineral oil based hydraulic fluid Other hydraulic fluids require preservation measures that are specifically designed for them In such cases consult Bosch Rexroth Service see Chapter 10 5 Spare parts on page 48 for the address Bosch Rexroth recommends the following procedure 1 Clean the axial piston unit see Chapter 10 1 Cleaning an...

Page 26: ...n your country 7 2 Installation conditions The installation location and position of the axial piston unit essentially determine the procedures during installation and commissioning such as when filling and air bleeding the axial piston unit Fix the axial piston unit so that the expected forces and torques can be transferred without any danger The machine system manufacturer is responsible for dim...

Page 27: ...ge 2 Standard pressure gauge relative The suction conditions improve with below reservoir installation Make sure that the working environment at the installation site is fully free of dust and foreign substances The axial piston unit must be installed in clean condition Contamination of the hydraulic fluid can considerably affect the function and service life of the axial piston unit and its suita...

Page 28: ...r installation standard Below reservoir installation means that the axial piston unit is installed outside of the reservoir and below the minimum fluid level of the reservoir Recommended installation position 1 and 2 1 2 SB ht min hmin T2 S T1 R S ht min hmin SB X1 X2 Fig 8 Below reservoir installation A10VGT with installation position 1 2 T1 T2 Highest drain port ht min Minimum required immersion...

Page 29: ...n A10VGT with installation position 3 4 T1 T2 Highest drain port ht min Minimum required immersion depth 200 mm F1 F2 Filling air bleeding hmin Minimum required distance to reservoir bottom 100 mm R Air bleeding hS max Maximum permissible suction height 800 mm S Suction port SB Baffle baffle plate X1 X2 Control pressure port Ports F1 and F2 are part of the external piping and must be provided on t...

Page 30: ...used in the machine system 4 Check the 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 specified on the name plate determines the direction of rotation of the axial piston unit as viewed on the...

Page 31: ... cause vibrations and impermissible rotary angular accelerations Depending on the frequency and temperature they may result in leakage on the shaft seal and damage to the rotary group If a shared drain line is used for several units make sure that the respective case pressure is not exceeded The shared drain line must be dimensioned to ensure that the maximum permissible case pressure of all conne...

Page 32: ...impermissible axial and radial forces act on the drive shaft 9 For bell housing installation check the coupling axial play through the bell window according to the manufacturer s specifications 10 Details on the required tools and tightening torques for the mounting bolts are available from the machine system manufacturer 11 When using flexible couplings check that the drive is free of resonance a...

Page 33: ... unit 4 Bring the axial piston unit to the installation position and secure If necessary details on the required tools and tightening torque for the mounting bolts can be obtained from the system manufacturer 7 4 7 Completing installation 1 Remove any mounted transport screws Caution Operation with protective plugs Operating the axial piston unit with protective plugs may result in injury or damag...

Page 34: ... plugs are not pressure resistant Setting screws are protected against unauthorized resetting by means of tamper proof caps Removal of the tamper proof caps will void the warranty If you need to change settings contact your Bosch Rexroth service partner for address see Chapter 10 5 Spare parts on page 48 7 4 8 Changing the lever position of the HW control If necessary you can change the position o...

Page 35: ...and lines correspond to the specified application conditions pressure flow hydraulic fluid temperature with the necessary safety factors Connect only hydraulic lines that are appropriate for the axial piston unit port pressure level size system of units Observe the following notes when routing the suction pressure and drain lines Lines and hoses must be installed without pre charge pressure so tha...

Page 36: ...Moreover various kinds of seal are 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 The limited ways of telling them apart visually poses a risk of confusing them Warning Leaky or bursting stud ends For fittings if a stud end which is of a different measurement system kind of seal and size with respect to the female thread is pr...

Page 37: ...ssure port upstream of orifice 40 X PS Pilot pressure port 40 X MA MB Measuring port pressure A B 420 X 1 The measuring system and thread size can be taken from the installation drawing 2 Depending on the application short term pressure peaks can occur Keep this in mind when selecting measuring devices and fittings 3 Depending on the installation position T1 or T2 must be connected see chapter 7 3...

Page 38: ...max Required tightening torque of the threaded plugs MV WAF hexagon socket of the threaded plug Standard Thread size DIN 3852 M8 1 10 Nm 7 Nm1 3 mm M10 1 30 Nm 15 Nm2 5 mm M12 1 5 50 Nm 25 Nm2 6 mm M14 1 5 80 Nm 35 Nm1 6 mm M16 1 5 100 Nm 50 Nm1 8 mm M18 1 5 140 Nm 60 Nm1 8 mm M22 1 5 210 Nm 80 Nm1 10 mm M26 1 5 230 Nm 120 Nm1 12 mm M27 2 330 Nm 135 Nm1 12 mm M33 2 540 Nm 225 Nm1 17 mm M42 2 720 N...

Page 39: ...ween direction of rotation and flow direction see data sheet 92770 7 4 10Electrically connecting the axial piston unit NOTICE Short circuit in event of 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 inside reservoir installation The ma...

Page 40: ...o the desired position 3 Re tighten the mounting nut Tightening torque of the mounting nut 5 1 Nm 7 5 Performing flushing cycle In order to remove foreign particles from the system Bosch Rexroth recommends a flushing cycle for the entire system before the initial commissioning To avoid internal contamination the axial piston unit must not be included in the flushing cycle The flushing cycle must b...

Page 41: ...duct with original accessories from Bosch Rexroth 8 1 Initial commissioning During all work for commissioning the axial piston unit observe the general safety instructions and intended use detailed in chapter 2 Safety instructions on page 8 Connect the pressure gauge for the boost pressure working pressure case pressure and suction pressure to the specified measuring points on the axial piston uni...

Page 42: ...ystem to filter hydraulic fluids during filling to minimize solid impurities 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 The hydraulic lines of the system must also be filled Notice Risk of property damage due to inadequate lubrication Product can get damaged or destroyed When using a shut o...

Page 43: ...ithstand the maximum 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 92770 for the permissible value 6 At maximum working pressure check the case pressure at port T1 or T2 Refer to data sheet 92770 for the permissible value 8 1 3 Performing functional test WARNING Improperly connected axial piston unit Mixing up...

Page 44: ... and mechanical hydraulic efficiency increases as well through the conclusion of the running in phase of approx 10 operating hours 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 C...

Page 45: ...ctuate the manual override with a sharp tool The valves of the electrical control EP are equipped with a manual override Where necessary or in the event of a fault e g electrical fault the adjustment of the axial piston unit can be changed manual via manual override The manual override is only designed for brief manual actuation it must not be moved to a specific switch position by means of mechan...

Page 46: ...stem 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 following Check whether all seals and fittings on the plug in connections are securely seated to ensure that no moisture can penetrate into the axial piston unit during cleaning Use only water and ...

Page 47: ...ystem and to rectify them For this reason Bosch Rexroth recommends that the axial piston unit and system are always kept in a clean condition Daily Check axial piston unit for unusual noise development Daily Check fastening 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 un...

Page 48: ... by Bosch Rexroth can cause injury and property damage Use exclusively original spare parts from Rexroth to repair the Rexroth axial piston units otherwise the functional reliability of the axial piston unit cannot be assured and the warranty is void The spare parts lists for axial piston units are order specific When ordering spare parts quote the material and serial number of the axial piston un...

Page 49: ... 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 complete system seal the connection to the reservoir or drain the reservoir 4 Place a collecting pan under the ax...

Page 50: ...piston unit of hydraulic fluid 2 Dispose of the axial piston unit and packaging material in accordance with the national regulations in your country 3 Dispose of the hydraulic fluid according to the national regulations in your country Also observe the applicable safety data sheet for the hydraulic fluid 4 Disassemble the axial piston unit into its individual parts and properly recycle these parts...

Page 51: ...he product specific setting instructions The warranty by Bosch Rexroth only applies to the product as delivered The warranty is void if the unit is modified or extended Setting screws are protected against unauthorized resetting by means of tamper proof caps Removal of the tamper proof caps will void the warranty If you need to change settings contact your Bosch Rexroth service partner for address...

Page 52: ...ow your 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 Were there any changes to the product s application conditions or operating range Has maintenance work recently been carried out...

Page 53: ...the filter system and change the filter as necessary 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 30 Improper mounting of the axial piston unit Check the mounting of the axial piston unit according to the specifications of the machine system manuf...

Page 54: ... too small etc 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 Check the filter system and change the filter as necessary Hydraulic fluid not in optimum viscosity range Machine system manufacturer check temperature range and use suitable hydraulic fluid ...

Page 55: ...stem 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 Check the filter system and change the filter as necessary Hydraulic fluid not in optimum viscosity range Machine system manufacturer check temperature range and use suitable hydraulic fluid Insufficient boost pressu...

Page 56: ...es from the suction line Check the filter system and change the filter as necessary Pressure relief valves of the axial piston unit swing boost pressure relief valve high pressure relief valve Air bleed axial piston unit and hydraulic system Contact Bosch Rexroth Service Unstable control signal Contact machine system manufacturer or Bosch Rexroth Service Malfunction in the control devices or the c...

Page 57: ...piston unit can be found on the data sheet 92770 The data sheet can be found on the Internet at www boschrexroth com mediadirectory Additional information can be found in the online product catalog Mobile Hydraulics www boschrexroth com axial piston pumps Order related technical data for your axial piston unit can be found in the order confirmation ...

Page 58: ...Eye bolt 22 23 F Filling 41 Flushing cycle 40 Functional description Control 20 Functional test 43 I Identification 21 Inspection 47 Installation 26 30 completing 33 general instructions 31 on a gearbox 32 on gearbox 32 Preparation 30 with cardan shaft 33 with coupling 31 Installation conditions 26 Installation position Above reservoir installation 29 Below reservoir installation 28 Instructions g...

Page 59: ...ety instructions 8 General 10 Product specific 11 Signal word 6 Scope of delivery 18 Slipper pad 19 Solenoid position changing 40 Spare parts 48 Storage 22 Storage time 24 Storing 24 Stroking piston 19 Suction side 19 Symbols 7 T Technical data 57 Tightening torques 38 Tools 49 Transportation 22 by hand 22 with eye bolt 22 23 with lifting strap 23 Transporting 22 Transport protection 34 Troublesho...

Page 60: ...s Glockeraustraße 4 89275 Elchingen Germany Tel 49 7308 82 0 info ma boschrexroth de www boschrexroth com Subject to change Printed in Germany RE 92770 01 B 11 2016 Your local contact person can be found at www boschrexroth com addresses ...