Bosch Rexroth A4VG 35 Series, Instruction Manual

Page 1: ...Instruction manual RE 92035 01 B 2019 11 25 Replaces 04 2018 English Axial piston variable pump A4VG Series 35 ...

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: ... this product 20 5 1 Performance description 20 5 2 Product description 20 5 2 1 Axial piston unit layout 20 5 2 2 Functional description 21 5 3 Bypass function 22 5 3 1 Activating and deactivating the bypass function 22 5 4 Product identification 24 6 Transport and storage 25 6 1 Transporting the axial piston unit 25 6 1 1 Transport by hand 25 6 1 2 Transport with lifting devices 25 6 2 Storing t...

Page 4: ...ctional test 47 8 2 Running in phase 47 8 3 Recommissioning after standstill 48 9 Operation 49 10 Maintenance and repair 50 10 1 Cleaning and care 50 10 2 Inspection 51 10 3 Maintenance 51 10 4 Repair 52 10 5 Spare parts 52 11 Removal and replacement 53 11 1 Required tools 53 11 2 Preparing for removal 53 11 3 Performing the disassembly 53 11 4 Preparing the components for storage or further use 5...

Page 5: ...iston variable pump A4VG Order confirmation Installation drawing Contains the outer dimensions all ports and the hydraulic circuit diagram for your axial piston variable pump A4VG Please request the installation drawing from your contact at Bosch Rexroth Installation drawing Axial piston variable pump A4VG Contains the permissible technical data ports main dimensions and circuit diagrams 92035 Dat...

Page 6: ... low temperatures Contains additional information on the application of Rexroth axial piston units at low temperatures 90300 03 B Manual Storage and preservation of axial piston units Contains additional information on storage and preservation 90312 Data sheet 1 3 Representation of information Uniform safety instructions symbols terms and abbreviations are used throughout this documentation to ens...

Page 7: ...following symbols indicate notices that are not safety relevant but increase understanding of the documentation Table 3 Meaning of symbols Symbol Meaning If this information is disregarded the product cannot be used and or operated to its full extent Single independent action 1 2 3 Numbered instruction The numbers indicate that the actions must be completed in order 1 3 3 Designations This documen...

Page 8: ...n Atmosphère explosible DIN Deutsches Institut für Normung German Institute for Standardization ET Electric control direct operated with two pressure reducing valves PRV ISO International Organization for Standardization RE Rexroth document in the English language VDI 2230 Directive for the systematic calculation of high duty screwed joints and cylindrical screw joints from the VDI Verein Deutsche...

Page 9: ...ed after it has been installed in the machine system for which it is intended and the safety of the entire system 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 closed circuit Observe the technical data the application and operating conditions and the performan...

Page 10: ...rosive atmosphere Use of the axial piston unit in aircraft or spacecraft 2 4 Personnel qualifications The activities described in this documentation require a basic understanding of mechanics electricity and hydraulics as well as familiarity with associated technical terms For transporting and handling the product knowledge regarding the use of lifting devices and lifting accessories is required I...

Page 11: ... 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 appro...

Page 12: ...y 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 t...

Page 13: ...ine 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 unint...

Page 14: ...e the relevant machine system component and repair the leak Never attempt to block or seal the leak or hydraulic fluid jet with a cloth CAUTION High noise development during operation Danger of hearing damage hearing loss The noise emission of axial piston units depends on rotational speed working pressure and installation conditions among other factors The sound pressure level may rise above 70 d...

Page 15: ...les safety gloves suitable working clothes safety shoes Immediately seek medical attention however if hydraulic fluid gets into your eyes or blood circuit or if you swallow it accidentally Danger from improper handling Slip hazard Risk of slipping on wet surfaces when 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 syst...

Page 16: ...ge 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 t...

Page 17: ...nt 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 required cleanliness level Improper cleaning Product can be damaged Plug all openings with appropriate protective covers in order to prevent cleaning agents from e...

Page 18: ...he ground 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 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 developme...

Page 19: ... 1 Axial piston unit Included 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 Protective covers for sensors and connectors 3 For version with through drive protective cover incl mounting bolts 4 ...

Page 20: ...is proportional to drive speed and displacement The flow can be smoothly changed using the control cradle 12 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 motor and from there directly back to the hydraulic pump There is a high pressure ...

Page 21: ...serve simultaneously as boost valves High pressure relief valves are not working valves and are only suitable for pressure peaks or high rates of pressure change The boost pump 6 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 T...

Page 22: ...e deactivated again before restarting the machine 5 3 1 Activating and deactivating the bypass function 2 1 1 2 2 1 Fig 3 Activating the bypass function To activate the bypass function 1 Switch off the combustion engine 2 Loosen the lock nut 2 by turning it counterclockwise one half turn with an external hexagon wrench WAF 13 3 Use a hexagon socket wrench WAF 4 to turn the screw 1 clockwise until ...

Page 23: ...ion activated the closed hydraulic circuit drains itself This can result in unintended functions when restarting the travel drive Start the travel drive only after completely filling and air bleeding the hydraulic circuit see chapter 8 1 Initial commissioning on page 44 To deactivate the bypass function 1 Immediately following towing switch off the bypass function 2 Restore the function of the hig...

Page 24: ...en Made in Germany A4VG090ET10P 35MRNC4T1 20G0000AS000 0 R90XXXXXXX SC X 12345678 19W10 n XXXX min 1 P XXX kW m XXX kg 7202 Fig 4 Name plate A4VG 1 Trademark 2 Internal plant designation 3 Sample category optional 4 Direction of rotation viewed on drive shaft here clockwise 5 Designated area for inspection stamp 6 Weight optional 7 Power optional 8 Bar code 9 Rotational speed optional 10 Manufactu...

Page 25: ...be transported by hand for a short distance Observe the national regulations in your country To prevent health damage we recommend renouncing any transport by hand CAUTION Risk of injury due to heavy loads Health hazard from carrying axial piston units Only manually transport the axial piston unit for a short period of time Observe the national regulations in your country for manual transport Alwa...

Page 26: ... in the installation drawing Make sure that the eye bolt can bear the total weight of the axial piston unit plus 20 You can lift the axial piston unit as shown in Fig 5 with the eye bolt screwed into the drive shaft Fig 5 Mounting the eye bolt For all female threads use a stud end from the same system of units and of the correct size M8 Screw an eye bolt fully into the female thread in the housing...

Page 27: ...Make sure that the axial piston unit is securely fixed with the lifting strap Only guide the axial piston unit by hand for fine positioning and to avoid swinging Never step or grip under suspended loads Place the lifting strap around the axial piston unit in such a way that it does not pass over assembled parts e g valves piping and that the axial piston unit is not suspended from assembled parts ...

Page 28: ...come in corrosion protection packaging corrosion protection film provided at the factory Table 7 lists the 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 ...

Page 29: ...chrexroth com addresses Bosch Rexroth recommends the following procedure 1 Clean the axial piston unit see chapter 10 1 Cleaning and care on page 50 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 ...

Page 30: ...Remove the packaging from the axial piston unit Check the axial piston unit for transport damage and completeness see chapter 4 Scope of delivery on page 19 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 fil...

Page 31: ...ute is present at port S 0 5 bar abs for cold start during operation in all installation positions and installation locations for the axial piston pump see Fig 8 See data sheet for other pressure values 0 2 0 8 abs 1 2 3 0 0 1 2 1 2 1 S Fig 8 Suction pressure 1 Absolute pressure gauge 2 Standard pressure gauge relative The suction conditions improve with below reservoir installation Make sure that...

Page 32: ...on the installation position 7 3 1 Below reservoir installation standard Below reservoir installation means that the axial piston unit is installed outside of the reservoir below the minimum fluid level Recommended installation position 1 and 2 X2 X1 T2 S ht min hmin SB 1 2 3 4 5 T1 X1 X2 S R SB ht min hmin SB ht min hmin T2 S T1 hmin SB X2 S X1 ht min hmin X2 T2 SB S X1 R R F1 F2 F2 ht min F1 F2 ...

Page 33: ...ermissible suction height hS max 800 mm The permissible suction height hS is derived from the total pressure loss 6 7 8 9 10 ht min hmin SB hS max F1 X1 X2 S R F2 T1 F2 F1 T2 S hS max SB ht min hmin ht min hmin X2 X1 hS max F2 SB F1 T2 S F1 T1 S X1 ht min hmin hS max SB X2 F2 ht min hmin hS max SB F2 F1 S X2 T2 X1 R R Fig 10 Above reservoir installation A4VG with installation positions 6 10 T1 T2 ...

Page 34: ...f the material number for the axial piston unit does not match the one in the order confirmation contact your local contact person for clarification You can find their contact information at www boschrexroth com addresses 3 Before installing completely drain the axial piston unit to prevent mixing with the hydraulic fluid used in the machine system 4 Check the permissible direction of rotation of ...

Page 35: ...elt or V belt drives Belts can lose much of their pre charge pressure after just a short operating time An automatic clamping device can lessen the speed variations and vibrations and thus avoid subsequential damage When using drives with toothed belts or V belts always use an automatic clamping device On the drive of an axial piston unit a cardan shaft may cause vibrations and excessive rotary an...

Page 36: ... shaft of the drive motor in accordance with the specifications provided by the coupling manufacturer Do not fasten down the axial piston unit until the coupling has been correctly installed 6 Fasten the axial piston unit at the installation location 7 Align the drive shaft of the axial piston unit and the output shaft of the drive motor so there is no angular deviation 8 Make sure no excessive ax...

Page 37: ...t of the drive motor 3 Push the axial piston unit to the cardan shaft and place the cardan shaft on the drive shaft of the axial piston unit 4 Bring the axial piston unit to the installation position and fasten it Details of the required tools and tightening torque for the mounting bolts can be obtained from the system manufacturer 7 4 7 Completion of assembly 1 Remove any installed transport scre...

Page 38: ... series 35Series 35 on page 41 Failure to do so could lead to malfunctions or damage If a port is not being used plug it with a threaded plug since the protective plugs are not pressure resistant Setting screws are protected against unauthorized adjustment by tamper proof caps Removal of the tamper proof caps will void the warranty If you need to change the settings please contact your local conta...

Page 39: ...ts A4VG series 35Series 35 on page 41 The machine system manufacturer is required to ensure that the connecting elements and lines correspond to the specified application conditions pressure flow hydraulic fluid temperature with the necessary safety factors Connect only hydraulic lines that are match the axial piston unit port pressure level size system of units Observe the following information w...

Page 40: ... of units Various kinds of seals are also used The system of units the kind of seal and the size of female thread and stud ends e g threaded plug must all match There is a risk of confusion due to the limited ways of visually telling them apart WARNING Leaky and bursting stud ends For fittings if a stud end that does not match the system of units kind of seal and size of the female thread is press...

Page 41: ...cted for filtration in the pressure line 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 and should not be exceeded For values see Table 11 Threaded plugs For the metallic ...

Page 42: ... 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 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...

Page 43: ...orrect pin assignment Recommended electrical control units Exact details on the connector type of protection and matching mating connector can also be found in data sheet 92035 The mating connector is not included in the scope of delivery 1 Switch off the power supply to the relevant machine system part 2 Electrically connect the axial piston unit 12 or 24 V Before connecting check whether the con...

Page 44: ...n the danger zone of the machine system The emergency stop button for the machine system should be within the operator s reach Always follow the instructions of the machine system manufacturer during commissioning CAUTION Commissioning an improperly installed product Risk of injury and property damage Make sure all electrical and hydraulic ports are connected or plugged Commission only a fully ins...

Page 45: ...mponents pumps and motors The hydraulic fluid should be selected so that the operating viscosity in the operating temperature range is within the optimum range νopt see selection diagram in the data sheet 92035 To ensure the functional reliability of the axial piston unit the hydraulic fluid must have a min cleanliness level of 20 18 15 as defined in ISO 4406 At a hydraulic fluid viscosity of less...

Page 46: ...e fluid 8 1 2 Testing the hydraulic fluid supply The axial piston unit should always have a sufficient supply of hydraulic fluid For this reason the supply of hydraulic fluid must be ensured at the start of the commissioning process When you test the hydraulic fluid supply constantly monitor noise development and check the hydraulic fluid level in the reservoir If the axial piston unit becomes lou...

Page 47: ...ied pressures e g working pressure boost pressure and case pressure Perform a leak test without and with load prior to normal operation If necessary remove the pressure gauge and plug the ports with the specified threaded plugs 8 2 Running in phase NOTICE Property damage due to insufficient viscosity Elevated hydraulic fluid temperature may excessively reduce viscosity and damage the product Monit...

Page 48: ...if the required cleanliness level is not reached If a laboratory test is not carried out after the running in phase it is recommended to change the hydraulic fluid 8 3 Recommissioning after standstill Depending on the installation conditions and ambient conditions changes may occur in the hydraulic system which make recommissioning necessary The following criteria may make recommissioning necessar...

Page 49: ... 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 50: ...cal system of the axial piston unit Do not point a high pressure cleaner at sensitive components e g shaft seal electrical connections and components For cleaning and care of the axial piston unit observe the 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 ...

Page 51: ...iston unit and system clean Daily Check axial piston unit for unusual noise development Daily Check mounting elements for tight seating All fasteners have to be checked when the hydraulic system is switched off depressurized and cooled down Monthly 10 3 Maintenance The axial piston unit is low maintenance when used as intended The service life of the axial piston unit is heavily dependent on the q...

Page 52: ...parts Spare parts that do not meet the technical requirements specified by Bosch Rexroth can cause injury and property damage Only use original spare parts from Rexroth to repair the Rexroth axial piston units otherwise the functional reliability of the axial piston unit cannot be guaranteed and the warranty will be voided The spare parts lists for axial piston units are order specific When orderi...

Page 53: ...rming 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 54: ...y drain the axial piston unit 2 Dispose of the axial piston unit and packaging material in accordance with the regulations in your country 3 Dispose of the hydraulic fluid in accordance with the regulations of your country Also observe the applicable safety data sheet for the hydraulic fluid 4 Disassemble the axial piston unit into its constituent parts for proper recycling 5 For example separate ...

Page 55: ...specific setting instructions The warranty from Bosch Rexroth only applies to the configuration as delivered The warranty will be voided if the unit is modified or extended Setting screws are protected against unauthorized adjustment by tamper proof caps Removal of the tamper proof caps will void the warranty If you need to change the settings please contact your local contact person you can find ...

Page 56: ...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 o...

Page 57: ...he 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 34 Improper mounting of the axial piston unit Check the mounting of the axial piston unit according to the specifications of the machine system manufacturer observe tightening tor...

Page 58: ...ilter too small or blocked 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 optimal viscosity range Machine system manufacturer Check temperature range and use suitable ...

Page 59: ...d 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 optimal viscosity range Machine system manufacturer Check temperature range and use suitable hydraulic fluid Insuffici...

Page 60: ...alves and pressure control valves in the axial piston unit boost pressure relief valve high pressure relief valve pressure reducing valve Air bleed the 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 controller Contact Bosch Rexroth Service Excessively...

Page 61: ...al data The permissible technical data for your axial piston unit can be found on the data sheet 92035 The data sheet can be found in the online product catalog at www boschrexroth com p A4VG 35 Order related technical data for your axial piston unit can be found in the order confirmation ...

Page 62: ...ressure supply 21 Eye bolt 26 F Filling 45 Flushing cycle 43 Functional description Control 21 Functional test 47 I Identification 24 Inspection 51 Installation 30 34 Completion 37 General instructions 35 On a gearbox 36 On gearbox 36 Preparation 34 With cardan shaft 37 With coupling 36 Installation conditions 30 Installation position Above reservoir installation 33 Below reservoir installation 32...

Page 63: ...ate 20 Running in phase 47 S Safety instructions 9 General 11 Product specific 12 Signal word 6 Scope of delivery 19 Slipper pad 20 Spare parts 52 Storage 25 28 Storage time 28 Stroking piston 20 Symbols 7 T Technical data 61 Tightening torques 41 Tools 53 Transport 25 By hand 25 with eye bolt 26 with lifting strap 27 Transporting 25 Transport protection 38 Troubleshooting 56 U Unpacking 30 W Warr...

Page 64: ...raße 4 89275 Elchingen Germany Phone 49 7308 82 0 info ma boschrexroth de www boschrexroth com Subject to change Printed in Germany RE 92035 01 B 2019 11 25 Your local contact person can be found at www boschrexroth com addresses ...