Bosch rexroth HyDrotrAC GFt, Operating Instructions Manual

Page 1: ...Operating Instructions RE 79094 Issue 10 2019 Replaces 10 2014 EN Hydrostatic drives HyDrotrAC GFt 130 knm Correction copy 1 17 10 2019 ONLY FOR INTERNAL USE ...

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

Page 3: ...el 20 5 5 Identification of the product 21 5 5 1 Standard name plate 21 6 Transport and storage 22 6 1 Transporting the HYDROTRAC GFT 22 6 2 Storing the HYDROTRAC GFT 23 6 2 1 Preservation 23 6 2 2 Maximum storage periods 24 7 Assembly 25 7 1 Unpacking 25 7 1 1 Delivery on pallet 25 7 1 2 Delivery in wood transport box 26 7 2 Installation conditions 26 7 3 Installation position 27 7 3 1 Operation ...

Page 4: ... the planetary gearbox 44 10 2 3Acoustic inspections 46 10 2 4Checking and tightening screw connections 46 10 3 Maintenance schedule planetary gearbox 47 10 4 Maintenance 47 10 4 1Approved lubricating oils 48 10 4 2Changing the lubricating oil 48 10 4 3Maintaining the static multiple disk parking brake if included 50 10 5 Repair 50 10 5 1Repairing the static multiple disk parking brake 51 10 6 Spa...

Page 5: ...product is referred to as HYDROTRAC GFT planetary gearbox or as planetary gearbox in the following chapters This documentation addresses installers service technicians machine or vehicle operators This documentation contains important information on the safe and appropriate transport storage assembly commissioning use maintenance disassembly and simple troubleshooting of the planetary gearbox f f ...

Page 6: ...ety instructions are structured as follows SIGNAL WORD Type and source of danger Consequences in the case of non compliance f f Measures for danger aversion f f List Warning symbol draws attention to the danger Signal word identifies the degree of the danger Type and source of danger identifies the type and source of danger Consequences describes what occurs if the safety instructions are not comp...

Page 7: ... Jia HE L HL15 Hydraulic oil PERIGOL VCI 230 Preservative CUSTOS 10 38 Preservative HAKUTEX 74 Detergent to remove preservative HAKUPUR 236 Detergent to remove preservative L XBCHA3 GB 7324 94 FAG Arcanol MULTI3 Klüberplex BE 31 222 Lithium multi purpose grease Screw plug Metallic screw pressure resistant Plug Made of plastic not pressure resistant only for transport 1 3 4 Abbreviations The follow...

Page 8: ...e and not for private use Intended use includes that this documentation especially chapter 2 Safety instructions has been read and understood 2 3 IMPROPER USE Any use other than described in intended use is not in accordance with the requirements and therefore is not permitted Bosch Rexroth AG assumes no liability for damage resulting from improper use The risks associated with improper use lie so...

Page 9: ...use Rexroth products which are in perfect technical condition Observe all instructions on the planetary gearbox Persons who assemble commission operate disassemble or maintain Rexroth products must not consume alcohol drugs or pharmaceuticals that may affect their ability to respond Only use Rexroth original accessories and spare parts in order to prevent any hazards to persons due to improper spa...

Page 10: ...ata sheets and safety data sheets of the respective manufacturer f f Do not use fire or naked light when working on the planetary gearbox its mounting parts and when handling with combustible materials f f Do not smoke in the vicinity of combustible materials f f Always wear the protective equipment which is specified in the safety data sheets of the respective substance f f When the planetary gea...

Page 11: ...ebounding parts Risk of injury f f Carefully remove any attached tension belts and chains f f When cutting tension belts and detaching chains always wear protective goggles and cut resistant safety gloves Danger in the case of mix up with metrical and inch threads Risk of injury and damaging to the gearbox f f Only assemble the planetary gearbox if you have the dimensioned drawing available indica...

Page 12: ...ristics of the safety gloves are determined by the conditions encountered in practice f f Wear resistant safety gloves of the corresponding classification according to action step for example heat resistant oil resistant cut resistant Protective goggles sealed Safety shoes Heat resistant safety wear if necessary flameproof protective clothing If necessary safety helmet f f When in contact with lub...

Page 13: ...dge when handling a crane or wrong slinging equipment may lead to uncontrolled movements of the planetary gearbox and therefore damage the machine or vehicle f f Use a crane with sufficient lifting capacity for lifting the planetary gearbox f f Only use approved transport equipment f f Use e g eye bolts straps chains swivel hooks shackles or suitable equipment as slinging equipment Damage caused b...

Page 14: ...oil When commissioning the planetary gearbox and the static multiple disk parking brake integrated in the planetary gearbox with too much lubricating oil thermal overloads may occur causing damage to the gears seals and bearings as well as failure of the static multiple disk parking brake f f When commissioning or recommissioning the machine or a vehicle fill the planetary gearbox with the correct...

Page 15: ...ating oil or pressure medium f f Place a catch basin with sufficient capacity under the planetary gearbox when replacing draining lubricating oil or working with a pressure medium f f Bond any passing flow of lubricating oil or spilled lubricating oil or pressure medium with appropriate absorption material such as oil absorbent granule f f Dispose the lubricating oil or pressure medium in accordan...

Page 16: ...lanetary gearbox and its mounting parts f f Take the planetary gearbox out of service and contact the nearest Rexroth Service point if you find any irregularities during maintenance work or inspections Unpunctual inspection and maintenance work Risk of damage f f Adhere to the planetary gearbox s maintenance intervals schedule when carrying out mandatory maintenance work 4 Scope of supply Refer to...

Page 17: ...ntegrated static multiple disk parking brake Mounting parts Connections Special equipment Lubrication etc The entire planetary gearbox which is mounted in rolling bearings is equipped with a splash oil lubrication The externally toothed planet gears are case hardened A special output seal ensures optimum protection against dust and dirt of the output bearing Drive and output have opposite directio...

Page 18: ...ements per axle after any malfunction thermal overload and during any repair work on the multiple disk parking brake Danger of delayed holding of the static multiple disk parking brake The delayed application of the static multiple disk brake may cause the vehicle to roll away accidentally f f Make sure that the brake line of the static piston is pressureless within 0 5 s The multiple disk brake i...

Page 19: ...isconnect mechanism You may set the bores 5 and 6 in the cover of the planetary gearbox to different positions by turning the ring gear The positioning of the bores 5 and 6 to each other remains however fixed Fig 1 view B shows the possible position of the cover only in an exemplary manner For the exact arrangement refer to the planetary gearbox dimensioned drawing in the appendix D Technical data...

Page 20: ...earbox has two oil drain bores 8 9 use the bore at the lowest position when installed You may set the bores 8 and 10 in the cover of the planetary gearbox to different positions by turning the ring gear The positioning of the bores 9 and 10 to each other remains however fixed Fig 2 view B shows the possible position of the cover only in an exemplary manner For the exact arrangement refer to the pl...

Page 21: ...cated on the planetary gearbox enabling you to identify the product 5 5 1 Standard name plate The following information is indicated on the name plate Fig 3 Example of a planetary gearbox name plate 1 Internal factory code 2 Date of manufacture 3 Product material number 4 Serial number 5 Factory specific order number 6 Ratio of the gearbox 7 Type code 8 Customer material number 9 Manufacturer The ...

Page 22: ...ust the lifting means crane or forklift and attachment means chains and shackles or straps or ropes to the weight and the dimensions of the planetary gearbox f f Design the load carrying capacity of the lifting means to match the weight of the planetary gearbox f f Tighten the means of attachment before lifting the planetary gearbox f f You may only lift the planetary gearbox with a forklift if it...

Page 23: ...s described in this chapter For queries concerning preservation and storage please contact a Rexroth s subsidiary located near you or the main plant directly For the addresses of our national agencies refer to www boschrexroth com addresses and the address directory in appendix A Address directory of the material number specific operating instructions 6 2 1 Preservation Rexroth delivers the planet...

Page 24: ...s to the output seal For the output seal refer to the spare parts drawing view B in appendix D Technical data Drawings of the material number specific operating instructions f f Use a brush to apply the preservative evenly onto the bright spots 6 2 2 Maximum storage periods The following storage conditions must be met to ensure a maximum storage period of 12 months Temperature 30 60 C relative air...

Page 25: ...To unpack the planetary gearbox 1 Remove the shrink wrap and the oiled paper 2 Remove the clamping bands 3 Check the scope of supply for transport damage and completeness see chapter 4 Scope of supply 4 Compare material number and designation type code with those specified in the order confirmation If the material number of the planetary gearbox does not match the one in the order confirmation con...

Page 26: ...that the surface is stable 7 Place the planetary gearbox with the cover plate down on two suitable squared timbers Secure the planetary gearbox against tipping over 8 Dispose of the packaging in accordance with regulations in your local country 7 2 INSTALLATION CONDITIONS The assembly conditions depend on the machine the chassis frame or the equipment frame where the planetary gearbox is integrate...

Page 27: ...ical data Drawings of the material number specific operating instructions Damage to the planetary gearbox through misalignment with the machine frame Property damage f f Do not tilt the planetary gearbox during installation and insert it into the machine frame torsion free and tension free f f Avoid misalignment of the planetary gearbox during installation f f Align the gearbox exactly with the ma...

Page 28: ... Compare the connecting dimensions of the planetary gearbox with the sprocket Turas or the rim The mounting order depends on the machine the vehicle or the chassis or equipment frame design Refer to the instructions in chapter 7 2 Installation conditions In addition observe the assembly instructions of the machine or vehicle manufacturer The dimensioned drawing contains the dimensions of all conne...

Page 29: ...tor into the machine or chassis frame If the HYDROTRAC GFT planetary gearbox is supplied together with the axial piston motor the axial piston motor is mounted on the planetary gearbox Depending on the existing opening in the machine or chassis frame the axial piston motor has to be removed from the planetary gearbox prior to assembly CAUTION Failure or damage to the planetary gearbox Depending on...

Page 30: ...es in the operating instructions of the axial piston motor in appendix C Mounting parts in the material number specific operating instructions 13 Remove all means of attachment transport and lifting equipment Installing the planetary gearbox at into the machine or chassis frame 1 For installation strictly observe the corresponding data in the dimensioned drawing of the planetary gearbox in appendi...

Page 31: ...ment without lifting the axial piston motor 4 Lift the axial piston motor to the planetary gearbox in the machine or chassis frame 5 Assemble the axial piston motor to the planetary gearbox Proceed as described in chapter Assembly of the supplied axial piston motor operating instructions The operating instructions for the axial piston motor can be found in chapter C Mounting parts of the material ...

Page 32: ...n any other installation position than the one permitted by Rexroth the planetary gearbox may be damaged or fail The warranty claim lapses f f Only install the planetary gearbox in an approved Rexroth mounting position as indicated in the dimensioned drawing in appendix D Technical data Drawings of the material number specific operating instructions f f Observe the operating instructions of the ax...

Page 33: ... the necessary tightening torques is the machine or vehicle manufacturer liable The required mounting screws are not included within the scope of supply 12 Remove all means of attachment transport and lifting equipment 13 Remove the dust cap 18 and the thrust cup Installing the axial piston motor to the planetary gearbox CAUTION Failure or damage to the planetary gearbox An O ring forgotten during...

Page 34: ...t nor foreign substances penetrate in the brake release connection f f Ensure that the brake release connection is carefully sealed f f Assemble hydraulic lines and hoses without mechanical stress f f Use e g copper sealing rings according to DIN 7603 as sealing means f f Make sure that no dynamic pressure occurs in the brake line f f Only use pressure fluid based on mineral oil for operating the ...

Page 35: ...mends to flush the planetary gearbox when changing the lubricating oil type or the lubricating oil manufacturer as well as after carrying out a major repair Before commissioning the axial piston motor Rexroth recommends a rinsing run of the entire system Observe the information in the operating instructions of the axial piston motor manufacturer The flushing cycle is to be performed using an addit...

Page 36: ...PPLY If the planetary gearbox is equipped with connections for a circulating oil lubrication refer to the dimensioned drawing of the planetary gearbox in appendix D Technical data drawings of the material number specific operating instructions for information on the permissible operating conditions The machine or vehicle manufacturer must ensure that these are complied with For information on conn...

Page 37: ...ge Improperly installed products may cause injuries or damages to the product f f Make sure that all electrical or hydraulic connections are connected or sealed f f Only commission a completely installed product 8 1 INITIAL COMMISSIONING Before commissioning the planetary gearbox following documents must be at hand Dimensioned drawing of the planetary gearbox Technical data of the planetary gearbo...

Page 38: ...ubricating oil NOTE Danger of environmental contamination by leaking lubricating oil Ground water and or soil contamination by escaping lubricating oil f f Install the axial piston motor before filling the planetary gearbox with lubricating oil This chapter describes how to fill the planetary gearbox with lubricating oil In order to fill the planetary gearbox with lubricating oil you need the foll...

Page 39: ...ry gearbox Filling the planetary gearbox T model with lubricating oil f f Refer to the figure on the left Bore 5 for filling or checking the lubricating oil Bore 6 for draining the lubricating oil 1 Turn the planetary gearbox as shown in the figure on the left Bore 6 in 6 o clock position 2 Place a catch basin with sufficient capacity under the planetary gearbox 3 Loosen the screw plugs of the bor...

Page 40: ...he screw plug from bore 10 5 Refer to the technical data sheet in appendix D Technical data Drawings of the material number specific operating instructions for information on oil viscosity and oil capacity 6 Fill the planetary gearbox with clean lubricating oil via the bore 10 Fill sufficient lubricating oil until some oil drains from bore 10 7 Check whether the seal on the screw plug thread of th...

Page 41: ...l mounting screws are tightly secured Proceed as described in chapter 10 2 4 Checking and retightening screw connections f f For this put the planetary gearbox out of service Proceed as described in the instructions of the machine or the overall vehicle f f After reaching the operating temperature check that the planetary gearbox does not show any leakage The maximum operating temperature is 90 C ...

Page 42: ... off hydraulic pressure when the planetary gearbox is blocked f f Avoid contamination caused by unclean pressure fluids rubbed off parts or residual dirt from system components f f Ensure proper installation of an emergency stop function so that the consumer driven machine can be brought into a safe situation f f Always replace the disks springs and sealing elements per axle after any malfunction ...

Page 43: ...n to approx 50 C before touching it 10 1 CLEANING AND CARE NOTE Penetrating dirt and liquids Damage to the planetary gearbox f f Extreme cleanness is required when working on the planetary gearbox f f Do not use a high pressure cleaner for the cleaning of the planetary gearbox f f Seal all openings with suitable protective caps and or protection devices so that no detergents can penetrate into the...

Page 44: ...olid particles such as metal particles or metal abrasion which are in the lubricating oil or on the screw plug can cause injury f f Wear appropriate protective clothing NOTE Risk of damaging the planetary gearbox If the oil level is too high or too low damage or failure may result to the planetary gearbox If the oil level is too high this may indicate that a foreign fluid e g pressure fluid or wat...

Page 45: ...ry gearbox dimensioned drawing in appendix D Technical data Drawings of the material number specific operating instructions Bore 5 for filling or checking the lubricating oil Bore 6 for draining the lubricating oil 1 Allow the planetary gearbox cool down to approx 50 C after standstill 2 Turn the planetary gearbox as shown in the figure on the left Bore 6 in 6 o clock position 3 Place a catch basi...

Page 46: ... Filling the planetary gearbox with lubricating oil 7 Check whether the seal on the screw plug thread of the bore 10 is still in perfect condition and can be reused Replace a damaged seal 8 Seal bore 10 with the corresponding screw plug 10 2 3 Acoustic inspections f f Perform daily noise tests A grinding or whistling noise that possibly occurs at high speeds indicates a malfunction Inform the comp...

Page 47: ...edule included in the machine vehicle manufacturer s operating instructions Table 6 Maintenance schedule planetary gearbox Interval Action After 150 motor operating hours Perform the first oil change refer to chapter 10 4 2 Daily Perform noise test refer to chapter 10 2 3 Weekly Perform visual inspection refer to chapter 10 2 1 Perform oil level check refer to chapter 10 2 2 Monthly Check that the...

Page 48: ...serve the lubricating oil manufacturer s product data sheets and safety data sheets when handling lubricating oil These data sheets are not included within Rexroth s scope of supply Change the lubricating oil at the intervals specified in the maintenance schedule If existing observe the maintenance schedule in the material number specific operating instructions Performing the lubricating oil chang...

Page 49: ...box out of service Proceed as described in the machine vehicle operating instructions 2 Check the oil level as described in chapter 10 2 2 Checking the oil level of the planetary gearbox 3 Turn the planetary gearbox as shown in the figure on the left Bore 9 in 6 o clock position 4 Place a catch basin with sufficient capacity under the planetary gearbox 5 Loosen the screw plugs of the bore 10 slowl...

Page 50: ... and during any repair work on the multiple disk parking brake Danger of delayed holding of the static multiple disk parking brake The delayed application of the static multiple disk brake may cause the vehicle to roll away accidentally f f Make sure that the brake line of the static piston is pressureless within 0 5 s 10 5 REPAIR Rexroth offers a comprehensive range of service for repair of the H...

Page 51: ...y repair work on the multiple disk parking brake f f Please contact Rexroth Service in your area in case repairs are required The corresponding contact is indicated in appendix A Address directory of the material number specific operating instructions If functional impairment or thermal overload makes repairs necessary these must only be performed by trained staff or employees of the Rexroth Servi...

Page 52: ...e parts kits f f Place spare parts orders in writing In cases of urgency you can also order by phone if you confirm your order promptly by fax or f f e mail f f The parts list of the HYDROTRAC GFT planetary gearbox is material number specific f f Place spare parts orders with the Rexroth Service f f Please provide the following information from the name plate with your order Material number planet...

Page 53: ...GFT planetary gearbox is a subassembly that does not have to be decommissioned For this reason the chapter in this manual contains no information How to disassemble and replace the HYDROTRAC GFT planetary gearbox is described in chapter 12 Disassembly and replacement Correction copy 1 17 10 2019 ONLY FOR INTERNAL USE ...

Page 54: ... disassembly instructions in the following document included in the material number specific operating instructions Chapter G Supplementary connections In addition observe the instructions of the machine or vehicle manufacturer If the material number specific operating instructions includes action steps for Disassembly that deviate from the general operating instructions the action steps in the in...

Page 55: ...damage the planetary gearbox f f Avoid strong impacts on the planetary gearbox during disassembly f f Avoid exerting axial forces and high compression forces on the gearbox housing f f Make sure that the planetary gearbox is not tilted during disassembly This chapter describes how to disassemble the planetary gearbox from the machine or chassis frame It is assumed that the machine or vehicle part ...

Page 56: ...can be reused Replace the damaged seals 12 Seal bore 5 and bore 6 with the corresponding screw plugs Continue with step 13 in chapter 12 3 2 12 3 2 Draining the lubricating oil K model f f Observe the information on the planetary gearbox dimensioned drawing in appendix D Technical data Drawings of the material number specific operating instructions Bore 10 for filling or checking the lubricating o...

Page 57: ...l data Drawings of the material number specific operating instructions 18 Protect the supply lines against contamination 19 Make sure that neither dirt nor foreign substances penetrate in the lines or the planetary gearbox 20 If necessary the axial piston motor has to be removed from the planetary gearbox before disassembling the planetary gearbox 21 For the weight of the axial piston motor refer ...

Page 58: ...ment without lifting the planetary gearbox Make sure that the planetary gearbox is not tilted 33 Untighten and remove the mounting screws of the connection between machine or chassis frame and planetary gearbox 34 Lift the planetary gearbox carefully from the machine or chassis frame 35 Make sure that the surface is stable 36 Place the disassembled planetary gearbox vertically with the cover plate...

Page 59: ...box as described in chapter 10 1 Cleaning and Care 3 For preservation fill the planetary gearbox with lubricating oil approved for this planetary gearbox See selection list industrial gear oils in appendix B Required and supplementary documentations in the material number specific operating instructions Fill the planetary gearbox as described in chapter 8 1 3 Filling the planetary gearbox with lub...

Page 60: ...bricating oil and the packaging material according to the national regulations of your country f f Dispose of hydraulic fluid or lubricating oil remains according to the applicable product data sheets and the safety data sheets for hydraulic fluids or lubricating oils f f Observe the following supplied instructions for disposing of the planetary gearbox in an environmentally friendly manner RE 779...

Page 61: ...he required function in the machine or vehicle before the error occurred f f Try to understand the changes of the machine vehicle where the planetary gearbox is installed Were there changes in the conditions of use or the area where the gearbox was deployed Has maintenance work been performed recently Does an inspection or maintenance log exist Have changes e g conversions or repairs been performe...

Page 62: ...last oil change took place if appropriate proceed to an oil change Proceed as described in chapter 10 2 Inspection Leaking oil Defective output seal Check seals as far as possible replace if necessary If the leak cannot be eliminated Rexroth Service must be notified Seals on partition seams or on the locking screws are defective Lubricating oil is foaming Incompatibility of the filled in lubricati...

Page 63: ...box please refer to appendix D Technical data Drawings of the material number specific operating instructions 17 Appendix The documents of chapter 17 Appendix are enclosed in the appendix of the material number specific operating instructions Also refer to chapter 1 2 Required and supplementary documentations Correction copy 1 17 10 2019 ONLY FOR INTERNAL USE ...

Page 64: ...44263 Dortmund Germany Phone 49 0 231 22819 5 info gears boschrexroth de www boschrexroth com Subject to change without notice Printed in Germany RE 79094 Additional information at www boschrexroth com gears Correction copy 1 17 10 2019 ONLY FOR INTERNAL USE ...