Bosch rexroth A21VG 10 Series, Instruction Manual

Page 1: ...Instruction manual RE 93223 01 B 09 2020 Replaces English Axial Piston Variable Double Pump A21VG Series 10 ...

Page 2: ...ion of own judgment and verification Our products are subject to a natural wear and aging process This document as well as the data specifications and other information set forth in it are the exclusive property of Bosch Rexroth AG It may not be reproduced or given to third parties without its consent The cover shows an example application The product delivered may differ from the image on the cov...

Page 3: ...5 2 Product description 18 5 2 1 Assembly of the axial piston unit 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 Transporting by hand 21 6 1 2 Transporting with lifting device 21 6 2 Storing the axial piston unit 23 7 Installation 25 7 1 Unpacking 25 7 2 Installation conditions 25 7 3 Installation positio...

Page 4: ... Operation 43 10 Maintenance and repair 43 10 1 Cleaning and care 43 10 2 Inspection 44 10 3 Maintenance 44 10 4 Repair 45 10 5 Spare parts 45 11 Removal and replacement 46 11 1 Required tools 46 11 2 Preparing for removal 46 11 3 Removal of the axial piston unit 46 11 4 Preparing the components for storage or further use 46 12 Disposal 47 13 Extension and conversion 47 14 Troubleshooting 48 14 1 ...

Page 5: ...s all ports and the hydraulic schematic for your axial piston variable double pump A21VG Please request the installation drawing via your contact person at Bosch Rexroth Installation drawing Axial piston variable double pumpA21VG Contains the permissible technical data ports main dimensions and circuit diagrams 93223 Data sheet Mineral oil based hydraulic fluids and related hydrocarbons Describes ...

Page 6: ... Type and source of danger Consequences in case of noncompliance Measure for danger prevention List Warning sign draws attention to the danger Signal word identifies the degree of the danger Type and source of danger identifies the type and source of the danger Consequences describes what occurs if the safety instructions are not complied with Precautions states how the danger can be avoided Table...

Page 7: ...tation As umbrella term for A21VG axial piston variable double pump 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 EU directive for explosion protection Atmosphère explosible DIN Deutsche Industrie Norm German Institute for Standardization EP Proportional control...

Page 8: ... intended and the safety of the entire system has been established in accordance with the machine directive The product is intended for the following use The axial piston unit is only approved as a pump for hydrostatic drives in closed circuit Observe the technical data application and operating conditions and performance limits as specified in data sheet 93223 and in the order confirmation Inform...

Page 9: ...nel Qualified personnel are those who can recognize possible hazards and institute the appropriate safety measures due to their professional training knowledge and experience as well as their understanding of the relevant regulations pertaining to the work to be done Qualified personnel must observe the rules relevant to the subject area and have the necessary hydraulic knowledge Hydraulic knowled...

Page 10: ...ds for the application Use tools appropriate for the work being performed and wear appropriate protective clothing to prevent punctures and cuts e g when removing protective covers disassembly There is a risk of entanglement when operating the axial piston unit with a bare shaft end Check whether or not your machine requires additional safety measures for your application If necessary make sure th...

Page 11: ...o injury e g crushing or fracture or damage to the product Make sure that the load bearing capacity of the lifting device is sufficient to safely bear the weight of the axial piston unit Never step or grip under suspended loads Ensure a stable transport position Use your personal protective equipment e g safety goggles safety gloves suitable working clothes safety shoes Use suitable lifting device...

Page 12: ... 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 to avoid unintent...

Page 13: ...ection 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 clothes safety sho...

Page 14: ...mage 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 filled during operation Check...

Page 15: ... system and to achieve the required cleanliness level Improper cleaning Product can be damaged Plug 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 sensiti...

Page 16: ...aulic 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 ensure that...

Page 17: ... 4 Scope of supply Included in the scope of supply are Axial piston unit as per order confirmation The following parts are also installed on delivery Protection plug threaded plug 1 For version with through drive metallic protection cover and mounting bolts 2 1 2 Fig 1 Axial piston unit ...

Page 18: ...isplacement The flow can be steplessly changed by controlling the cradle 11 Both circuits can be adjusted independent of one another For axial piston units with swashplate design the pistons are arranged axially with respect to the drive shaft In the closed circuit the hydraulic fluid flows from the hydraulic pump to the consumer e g the hydraulic motor and from there directly back to the hydrauli...

Page 19: ...four high pressure relief valves protect the hydrostatic transmission pump and engine against overloading They limit the maximum pressure in the relevant high pressure line and at the same time act as boost valves High pressure relief valves are not working valves and are only suitable for pressure spikes or high rates of pressure change In order to replenish internal leakage in the variable doubl...

Page 20: ...XX SC X 12345678 2013W28 n XXXX min 1 P XXX kW m XXX kg 7202 Typ A21VG45ET1PD0 10ARNB2S73UB2S4 0 1 2 8 3 4 5 6 7 14 9 13 12 11 10 Fig 3 Name plate A21VG 1 Manufacturer 2 Sample category optional 3 Internal plant designation 4 Specified area for inspection stamp 5 Direction of rotation viewed on drive shaft here clockwise 6 Weight optional 7 Power 8 Bar code 9 Rotational speed 10 Manufacturing date...

Page 21: ...ent and relocation equipment Use your personal protection equipment e g safety glasses safety gloves suitable working clothes safety shoes Do not transport the axial piston unit at sensitive attachment parts e g sensors or valves Carefully place the axial piston unit on the seating to prevent it from being damaged 6 1 2 Transporting with lifting device For transporting the axial piston unit can be...

Page 22: ...trap and cause injuries Use the widest possible lifting strap Make sure that the axial piston unit is securely fixated with the lifting strap Only guide the axial piston unit by hand for fine positioning and to avoid oscillations Never stand under or put you hands under suspended loads Place the lifting strap around the axial piston unit in such a way that it neither passes over the attachment par...

Page 23: ...um permissible storage times for an originally packed 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 Closed dry room uniform temperature between 5 C and 20 C Undamaged and closed corrosion protection film Maximum 12 months Maximum 24 months Entitlement to warranty will ...

Page 24: ...aning and care on page 43 2 Empty the axial piston unit 3 For storage time 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 time up to 24 months Fill the axial piston unit with corrosion protection medium VCI 329 20 ml Filling is performed via the reservoir port T see chapter 7 4 Installing the axial piston unit Fig 10...

Page 25: ... completeness see chapter 4 Scope of supply on page 17 Dispose of the packaging according to the environmental regulations of 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 ...

Page 26: ...ad into the reservoir below the minimum fluid level in all operating conditions This will prevent air from being drawn in and foam from being formed 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 a clean condition Dirt contaminati...

Page 27: ...axial piston unit is installed outside of the reservoir below the minimum fluid level Recommended installation position 1 and 2 without boost pump 1 2 T X1 X2 X2 R X1 ht min hmin SB T ht min hmin SB Fig 6 Below reservoir installation A21VG without boost pump installation position 1 2 R Air bleed port ht min Minimum required immersion depth 200 mm T Reservoir port case drain SB Baffle baffle plate ...

Page 28: ...installation A21VG without boost pump installation position 3 4 L1 Filling air bleed ht min Minimum required immersion depth 200 mm R Air bleed port T Reservoir port case drain hmin Minimum required spacing to reservoir bottom 100 mm SB Baffle baffle plate hS max Maximum permissible suction height 800 mm Table 9 Above reservoir installation Installation position Air bleeding the housing Air bleed ...

Page 29: ...e name plate and make sure that this corresponds to the direction of rotation of the output drive shaft of the machine system The direction of rotation as specified 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 identification on page 20 7 4 2 Dimensions The installation drawing contains the dimensions for all co...

Page 30: ...put drive On the input or output drive of an axial piston unit a cardan shaft may cause vibrations and impermissible rotary angle accelerations Depending on the frequency and temperature they may result in leakage on the shaft seal and damage to the rotary group For combinations of multiple units make sure that the respective case pressure in each unit is not exceeded In the event of differential ...

Page 31: ... coupling manufacturer The axial piston unit may not be bolted down until the coupling has been correctly installed 6 Fix the axial piston unit at the installation location 7 Align the drive shaft of the axial piston unit and the output shaft of the diesel engine so that there is no angular deviation 8 Make sure that no impermissible axial and radial forces act on the drive shaft 9 For bell housin...

Page 32: ...essary details on the required tools and tightening torques 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 protection plug Operating the axial piston unit with protection plugs may result in injuries or damage to the axial piston unit Before commissioning remove all protection plugs and ...

Page 33: ...regarded malfunction or damage may result If a port is not connected it must be plugged with a threaded plug because protection plugs are not pressure resistant The setting screws are protected against unauthorized resetting by means of protection caps Removing the protection caps will void the warranty If you need to change settings contact your responsible Bosch Rexroth Service partner for addre...

Page 34: ...data sheet The machine system manufacturer must 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 appropriate for the axial piston unit port pressure level size system of units Observe the following notes when routing the suction pressure ...

Page 35: ...l measuring system and in regions using the Japanese measuring system JIS Japan Industrial Standard Moreover various kinds of seal are used The system of units the kind of seal and the size of female thread and threaded plugs e g locking screw must all match Due to the limited options for visually detecting differences there is a risk of mix ups WARNING Leaky or popped out threaded plugs If a thre...

Page 36: ...ressure inlet ISO 11926 3 4 16 UNF 2B 15 deep 30 O YBR Brake release pressure ISO 11926 9 16 18 UNF 2B 13 deep 30 X PS Pilot pressure supply filtered internally ISO 11926 9 16 18 UNF 2B 13 deep 30 X G1 Boost pressure inlet only for DA control valve ISO 11926 9 16 18 UNF 2B 13 deep 30 X 1 Thread according to ASME B1 1 2 The spot face can be deeper than specified in the appropriate standard 3 For no...

Page 37: ...m 18 Nm 3 16 in 9 16 18 UNF 2B 80 Nm 35 Nm 1 4 in 3 4 16 UNF 2B 160 Nm 70 Nm 5 16 in 7 8 14 UNF 2B 240 Nm 110 Nm 3 8 in 1 1 16 12 UN 2B 360 Nm 170 Nm 9 16 in 1 5 16 12 UN 2B 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 protection plugs and threaded plugs at the ports at which the ...

Page 38: ...an also be found in data sheet 93223 The mating connector is not included in the scope of supply 1 Switch off power supply to the relevant system component 2 Electrically connect the axial piston unit 12 or 24V Before connecting check that the connector including all seals are intact If necessary you can change the connector orientation by turning the solenoid housing This is dependent on the conn...

Page 39: ...rve the general safety instructions and intended use detailed in chapter 2 Safety instructions on page 8 Connect the gauge for the operating 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 the commissioning process monitor the temperature of the hydraulic fluid in...

Page 40: ...at may leak NOTICE Contaminated hydraulic fluid The cleanliness levels of hydraulic fluids on delivery do not normally conform to the requirements for our components Use a suitable filter system 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 po...

Page 41: ...ating pressure rises as expected 4 Carry out a leak test to ensure that the hydraulic system is sealed and can withstand the maximum pressure 5 Check the suction pressure at port S of the axial piston pump at nominal speed and maximum swivel angle only on the version with boost pump Refer to data sheet 93223 for the permissible value 6 At maximum pressure check the case drain pressure at port T Re...

Page 42: ...d 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 specimen analyzed for the required cleanliness level Ch...

Page 43: ... work at the intervals described in this manual 10 1 Cleaning and care NOTICE Damage to seals and electrical system by mechanical effects The water jet of a high pressure cleaner may damage the seals and electrical system of the axial piston unit Do not point the high pressure cleaner at sensitive components e g shaft seal electrical connections and components For cleaning and care of the axial pi...

Page 44: ...unit and system are always kept in a clean condition Daily Check axial piston unit for unusual noise development Daily Check fastener 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 h...

Page 45: ...ts specified by Bosch Rexroth may cause personal injury or property damage Only use Rexroth original spare parts to repair the Rexroth axial piston units otherwise the functional reliability of the axial piston unit can not be assured and you lose your entitlement under warranty The spare parts lists for axial piston units are order specific When ordering spare parts specify the material and seria...

Page 46: ... of the axial piston unit Proceed as follows to remove the axial piston unit 1 Check whether the hydraulic system is depressurized 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 drip tray under the...

Page 47: ...ta sheet for the hydraulic fluid 4 Remove the axial piston unit into its individual parts and properly recycle these parts 5 Separate according to for instance 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 Changes to settings on the customer side should only be made using the produ...

Page 48: ...r product works in conjunction with the entire system Try to find out whether or not the product was working properly in conjunction with the entire system before the fault occurred Try to determine any changes to the entire system in which the product is installed Have there been any changes to the application conditions or operating range of the product Has maintenance work recently been carried...

Page 49: ...valve of the axial piston unit boost pressure high pressure Air bleed the axial piston unit Check viscosity of the hydraulic fluid Contact Bosch Rexroth Service Mechanical damage to the axial piston unit e g bearing damage Exchange axial piston unit contact Bosch Rexroth Service No or insufficient flow Faulty mechanical drive e g defective coupling Machine system manufacturer Drive speed too low M...

Page 50: ...ct Bosch Rexroth Service Mechanical damage to the axial piston unit e g bearing damage Exchange axial piston unit contact Bosch Rexroth Service Output unit defective e g hydraulic motor or cylinder Machine system manufacturer Pressure flow fluctuations Axial piston unit not or insufficiently air bled Completely air bleed axial piston unit Insufficient suction conditions e g air in the suction line...

Page 51: ...l data The permissible values of the technical data of your axial piston unit can be found in data sheet 93223 The data sheet can be found in the online product catalog at www boschrexroth com p A21VG The order related technical data of your axial piston unit can be found in the order confirmation ...

Page 52: ...52 56 Bosch Rexroth Corporation A21VG Series 10 RE 93223 01 B 09 2020 ...

Page 53: ...illing 39 Flushing cycle 38 Functional description Control 19 Functional test 41 I Identification 20 Inspection 44 Installation 25 Completing 32 General instructions 29 On a gearbox 31 Preparation 29 With cardan shaft 32 With coupling 31 Installation conditions 25 Installation position Above reservoir installation 28 Below reservoir installation 27 Installing 29 Intended use 8 L Lifting device 21 ...

Page 54: ... Product specific 11 Signal word 6 Scope of supply 17 Slipper pad 18 Solenoid position Changing 38 Spare parts 45 Storage 21 Storage time 23 Storing 23 Stroking piston 18 Swashplate 18 Symbols 6 T Technical data 51 Tightening torques 37 Tools 46 Transport 21 By hand 21 With eye bolt 21 With lifting strap 22 Transporting 21 Transport protection 33 Troubleshooting 48 U Unpacking 25 W Warranty 16 33 ...

Page 55: ...Alphabetical index 55 56 RE 93223 01 B 09 2020 A21VG Series 10 Bosch Rexroth Corporation ...

Page 56: ... 2020 Printed in the USA Find your local contact person here www boschrexroth us com contactus Bosch Rexroth Corporation 8 Southchase Court Fountain Inn SC 29644 9018 Telephone 864 967 2777 Facsimile 864 962 5338 www boschrexroth us com ...