Bosch Rexroth 3 Series Instruction Manual Download | Manualshive

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Extension and conversion

Bosch Rexroth AG

, A4CSG, Series 3x, RE 92105-01-B/06.2017

13 Extension and conversion

Do not modify the axial piston unit or its assembled parts. This also includes
changing the wiring.
Changes to settings on the customer side should only be made using the product-
specific setting instructions.

The warranty from Bosch Rexroth only applies to the product configuration as
delivered. The warranty is void if the unit is modified or extended.

The setting screws are protected against unintentional adjustment by caps.
Adjusting the setting screw will void the warranty. If you need to change settings,
contact your Bosch Rexroth service partner, for the address, see chapter 10.5
“Spare parts” on page 55.

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Summary of Contents for Rexroth 3 Series

Page 1: ...Axial piston variable pump A4CSG Series 3x Instruction manual RE 92105 01 B 06 2017 Replaces English ...

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: ...uct 19 5 1 Performance description 19 5 2 Product description 19 5 2 1 Layout of the axial piston unit 19 5 2 2 Functional description 20 5 3 Product identification 21 5 3 1 Name plate of the axial piston unit 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 23 6 2 Storing the axial piston unit 24 7 Insta...

Page 4: ...still 47 9 Operation 48 9 1 Operating the optional auxiliary activation device 48 10 Maintenance and repair 49 10 1 Cleaning and care 49 10 2 Inspection 49 10 3 Maintenance 51 10 4 Repair 54 10 5 Spare parts 55 11 Removal and replacement 56 11 1 Required tools 56 11 2 Preparing for removal 56 11 3 Performing removal 56 11 4 Preparing the components for storage or further use 56 12 Disposal 57 13 E...

Page 5: ...e understood and observed it Table 1 Required and supplementary documentation Title Document number Document type Order confirmation Contains the technical data relevant to the Axial piston variable pump A4CSG ordered Order confirmation Installation drawing Contains the outer dimensions all ports and the hydraulic circuit diagram for your Axial piston variable pump A4CSG Please request the install...

Page 6: ...ed Safety instructions are set out as follows Signal word Type and source of danger Consequences of noncompliance Measures to prevent danger List 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 with Precautio...

Page 7: ... Metal screw pressure resistant Protective plug Made out of plastic not pressure resistant only for transportation As an umbrella term for Axial piston variable pump A4CSG 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 EC directive on explosion protection Atmosph...

Page 8: ...rective 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 performance limits as specified in data sheet 92105 and in the order confirmation Information about approved hydraulic fluids can be found in data sheet 92105 The axial piston uni...

Page 9: ...his documentation require basic knowledge of mechanics electrics hydraulics and ATEX 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 or an instructed person under th...

Page 10: ...ed 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 for example machinery or system in which the Rexroth products are installed complies with the country specific provisions safety regulations and standards for the applicat...

Page 11: ...er transportation may cause the axial piston unit to fall down and lead to injuries for example crushing or broken bones or damage to the product Make sure that the forklift truck or lifting device has adequate lifting capacity 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 gl...

Page 12: ... so that it is free of electrical voltage before you install the product or when connecting and disconnecting connectors Protect the machine system against being re energized Restriction of the control function Risk of injury or property damage Moving parts in control equipment e g valve spools can under certain circumstances get stuck in position as a result of contamination e g impure hydraulic ...

Page 13: ...ines in such a way that no one can trip over them that they do not become kinked or twisted do not rub on edges and do not run without adequate protection through sharp edged ducts Contact with hydraulic fluid Risk of adverse health effects e g eye injury skin irritation poisoning from inhalation Avoid contact with hydraulic fluids When working with hydraulic fluids strictly observe the safety ins...

Page 14: ... 92105 01 B 06 2017 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: ...ions Make sure that the electronic components for example sensors do not become electrostatically charged for example during painting operations Risk of property damage due to inadequate lubrication Damage or destruction of product possible Never operate the axial piston unit with insufficient hydraulic fluid Specifically make sure that the rotary group has sufficient lubrication When commissionin...

Page 16: ...e ports when they are plugged Before commissioning make sure that all hydraulic connections are tight and that all of the seals and plug in connections are installed correctly to ensure that they are leak proof and fluids and foreign particles are prevented from penetrating the product Use a suitable filter system to filter hydraulic fluid during filling to minimize solid particle contamination an...

Page 17: ...nit when filling and draining the hydraulic fluid Use an oil binding agent if hydraulic fluid is spilled Observe the parameters in the safety data sheet for the hydraulic fluid and the specifications provided by the system manufacturer Danger from hot components Nearby products can become damaged Components which heat up for example solenoids can cause damage to nearby products if they are too clo...

Page 18: ... 2 1 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 For version with through drive metallic protection cover and mounting bolts ...

Page 19: ...design the cylinder 11 with pistons 12 is to be aligned axially to the drive shaft 1 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 then a high pressure side 7 and a low pressure side 9 which can change according to loading The integrated boost pump 8 feeds into the low pressure...

Page 20: ...n the high pressure side 7 the hydraulic fluid is pushed out of the cylinder chamber and into the hydraulic system by the pistons At the same time hydraulic fluid flows into the growing piston chamber on the low pressure side 9 In a closed circuit supported by the return flow and boost pressure The swivel angle of the cradle 14 is infinitely variable Controlling the swashplate swivel angle changes...

Page 21: ...y 12345678 xxxxxxxxxxxx MNR FD Rexroth A4CSG250EPG 33R VPB35K99 17W12 1 5 2 3 4 9 10 11 12 6 7 8 13 14 Fig 3 Name plate A4CSG 1 Manufacturer 2 Manufacturing date 3 Internal plant designation 4 Direction of rotation viewed on drive shaft here clockwise 5 Bar code 6 Power setting optional 7 Rotational speed 8 Flow setting optional 9 Pressure control setting optional 10 Minimum displacement 11 Serial...

Page 22: ...unpacking can be found in chapter 7 1 Unpacking on page 27 6 1 Transporting the axial piston unit The following transportation options are available depending on the weight and duration of transport Manual transport chapter not relevant for this axial piston unit Transporting with a lifting device eye bolt or lifting strap Table 6 Dimensions and weights Size 250 355 500 Weight kg 250 245 350 Width...

Page 23: ...can be connected to a lifting device via an eye bolt or a lifting strap The axial piston unit can be transported suspended from an eye bolt screwed into the drive shaft as long as only outward pulling axial forces are applied For all female threads use a stud end from the same system of units and of the correct size To do this screw an eye bolt completely into the female thread on the drive shaft ...

Page 24: ...port with the lifting strap 6 2 Storing the axial piston unit The storage areas must be free of corrosive materials and gases To prevent damage to the seals ozone forming equipment for example mercury vapor lamps high voltage equipment electric motors sources of electrical sparks or electrical discharge must not be operated in storage areas The storage areas must be dry Recommended relative humidi...

Page 25: ... you have the axial piston unit inspected by your Bosch Rexroth service partner In the event of questions regarding repair and spare parts contact your responsible Bosch Rexroth service partner or the service department of the manufacturer s plant for the axial piston unit see chapter 10 4 Repair on page 54 A dismounted axial piston unit must be preserved with corrosion protection for the duration...

Page 26: ... of the axial piston unit with mineral oil or suitable easily removable corrosion protection for example acid free grease 6 Package the axial piston unit with desiccant in corrosion protection film so it is airproof 7 Store the axial piston unit in a shock proof manner see Requirements on page 24 in this chapter ...

Page 27: ...he installation position 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 dimensioning the fasteners Observe the permissi...

Page 28: ... and service life of the axial piston unit Use fiber free cloths for cleaning Use suitable mild cleaning agents to remove lubricants and other difficult to remove contamination Cleaning agents must not enter the hydraulic system 7 3 Installation position The following installation positions are permissible The pipeline routing shown illustrates the basic layout Before installation fill the pump ho...

Page 29: ...ion port hmin Minimum required distance to reservoir bottom 100 mm SB Baffle baffle plate Table 8 Below reservoir installation Installation position Filling air bleeding the housing1 1 drive shaft horizontal R L 2 drive shaft horizontal Plug T R L 3 drive shaft horizontal Plug K2 R L 4 drive shaft horizontal Plug K3 R L 5 drive shaft vertically upward Plug T R L 1 To air bleed the stroking chamber...

Page 30: ...allation the housing area may drain via the drain line after longer periods of disuse air enters via the shaft seal or via the working line gap leakage The bearings are thus insufficiently lubricated when recommissioning Make sure that the suction line is always filled with hydraulic fluid during commissioning and operation Make sure that the bearing flushing is working properly for above tank ins...

Page 31: ...m required immersion depth 200 mm T R L K2 K3 Highest drain port leakage hmin Minimum required distance to reservoir bottom 100 mm S Suction port hS max Maximum permissible suction height 800 mm SB Baffle baffle plate Table 9 Above reservoir installation Installation position Filling air bleeding the housing1 6 drive shaft horizontal R L 7 drive shaft horizontal Plug T R L 8 drive shaft horizontal...

Page 32: ...at 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 drive shaft see chapter 5 3 Product identification on page 21 For information on the direction of rotation of the drive motor pleas...

Page 33: ...his is not possible separate drain lines must be laid if necessary Please refer to chapter 8 The type of installation to be used for the axial piston unit depends on the connecting elements to the drive side The following descriptions explain the installation of the axial piston unit with a coupling on a gearbox with cardan shaft 7 4 4 Installation with coupling The following describes how to inst...

Page 34: ...When using flexible couplings check that the drive is free of resonance after completing the installation 7 4 5 Installation on a gearbox The following describes how to install the axial piston unit on a gearbox After installing on a gearbox the axial piston unit is covered and is difficult to access Therefore before installing make sure that the spigot diameter centers the axial piston unit obser...

Page 35: ... unit to the installation position and secure If necessary 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 protective plugs Operating the axial piston unit with protective plugs may result in injuries or damage to the axial piston unit ...

Page 36: ...0 Ports A4CSG series 1x and 3x on page 39 Failure to do so could lead to malfunctions or damage If a port is not connected it must be plugged with a threaded plug because protective plugs are not pressure resistant The setting screws are protected against unintentional adjustment by caps Adjusting the setting screw will void the warranty If you need to change settings contact your Bosch Rexroth se...

Page 37: ...ies 1x and 3x on page 39 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 notices when routing the s...

Page 38: ...he Anglo American imperial and 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 stud ends for example threaded plug must all match There is a risk of confusion due to the limited ways of visually telling them apart Warning Leaky or bursting stud ends For fittings if a stud end ...

Page 39: ...pressure measurement 40 X K4 Accumulator external 40 X MK4 Flushing pressure measurement 40 X R L Fluid filling air bleeding 4 O4 T Fluid drain 4 X4 T1 DB valve relief port X4 U Flushing port bearing flushing 7 X XA2 XB2 XAB Pilot pressure port for pressure controller 400 O 1 The measuring system and thread size can be taken from the installation drawing 2 Short term pressure spikes may occur depe...

Page 40: ...1 Tightening torques for female threads and threaded plugs Ports Maximum permissible tightening torque of the female threads MG max Required tightening torque of the threaded plugs MV WAF hexagon socket of the threaded plug Standard Thread size ISO 6149 M8 x 1 10 Nm 7 Nm 4 mm M10 x 1 30 Nm 15 Nm 5 mm M12 x 1 5 50 Nm 25 Nm 6 mm M14 x 1 5 80 Nm 45 Nm 6 mm M16 x 1 5 100 Nm 55 Nm 8 mm M18 x 1 5 140 Nm...

Page 41: ... and for reduced MV 10 Nm for M10 x 1 and 17 Nm for M12 x 1 5 the maximum permissible pressure is 420 bar To connect the axial piston unit to the hydraulic system 1 Remove the protective plugs or threaded plugs at the ports at which the connections are to be made according to the hydraulic circuit diagram 2 Make sure that the sealing surfaces of the hydraulic ports and functional surfaces are not ...

Page 42: ... 92105 such as Permissible voltage range Permissible current Correct 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 92105 The mating connector is not included in the scope of delivery 1 Switch off the power supply to the relevant system component 2 Electrically connect the axial pis...

Page 43: ...ANN connector 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 be performed with an additional flushing unit Follow the instructions of the flushing...

Page 44: ...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 working pressure case pressure boost pressure and suction pressure to the specified measuring points on the axial piston unit or in th...

Page 45: ...in line make sure that the drive of the axial piston unit can only be started when the shut off valves are open 3 When using a shut off valve in the suction and or drain line only operate the axial piston unit when the shut off valves are open 4 Test the direction of rotation of the drive motor To do this rotate the drive motor briefly at the lowest rotational speed inching Make sure that the dire...

Page 46: ... 3 Performing a functional test WARNING Improperly connected axial piston unit Mixing up the ports will lead to malfunctions for example lift instead of lower and thus to corresponding danger to persons and equipment Before the functional test check whether the piping specified in the hydraulic circuit diagram has been installed Once you have tested the hydraulic fluid supply you must perform a fu...

Page 47: ...eases until the running in phase of about 10 operating hours is concluded To ensure that contamination in the hydraulic system does not damage the axial piston unit the following procedure is recommended after the running in phase After the running in phase have a hydraulic fluid sample analyzed for the required cleanliness level Filter in the bypass until the required cleanliness level has been r...

Page 48: ...ected consumer NOTICE Property damage to the proportional solenoids Property damage to the proportional solenoids There is a risk of damage to the proportional solenoids Do not actuate the auxiliary activation device with sharp edged tools There is a risk of damage to the proportional solenoids The valves of the electro hydraulic control device are fitted with an auxiliary activation device This a...

Page 49: ...t no moisture can penetrate into the axial piston unit during cleaning Use only water and if necessary a mild cleaning agent to clean the axial piston unit Never use solvents or corrosive cleaning agents Remove major external contamination and keep sensitive and important components such as solenoids valves displays and sensors clean 10 2 Inspection In order to enable long and reliable operation o...

Page 50: ...in a clean condition Daily Check axial piston unit for unusual noise development Daily Visual inspection for external integrity housing damage 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 Change the filter element in optionally mounted filters The replacement interval may vary depen...

Page 51: ...intenance interval for replacing the bearings and the shaft seal is to be observed Have the service performed by Bosch Rexroth Service upon reaching the operating hours listed in the following table or every four years whichever comes first for the address see chapter 10 5 Spare parts on page 55 If your application data differs from that shown here request an individual calculation from your sales...

Page 52: ...00 L 10h 10000 L 10h 20000 L 10h 30000 L 10h 40000 L 10h 60000 L 10h 100000 pA B bar 0 5 10 15 α Fig 15 Service life size 250 for 1800 rpm L 10h 4000 0 0 5 10 15 50 100 150 200 250 300 350 L 10h 6000 L 10h 10000 L 10h 20000 L 10h 30000 L 10h 40000 L 10h 60000 L 10h 100000 pA B bar α Fig 16 Service life size 355 for 1500 rpm Size 355 ...

Page 53: ...0 L 10h 6000 L 10h 10000 L 10h 20000 L 10h 30000 L 10h 40000 L 10h 60000 L 10h 100000 pA B bar α Fig 17 Service life size 355 for 1800 rpm L 10h 4000 0 0 5 10 15 50 100 150 200 250 300 350 L 10h 6000 L 10h 10000 L 10h 20000 L 10h 30000 L 10h 40000 L 10h 60000 L 10h 100000 pA B bar α Fig 18 Service life size 500 for 1500 rpm Size 500 ...

Page 54: ...nance work on the axial piston unit must only be performed by Bosch Rexroth Service for the address see chapter 10 5 Spare parts on page 55 10 4 Repair Bosch Rexroth offers a comprehensive range of services for the repair of Rexroth axial piston units Repairs on the axial piston unit and its assembled parts may only be performed by service centers certified by Bosch Rexroth Use exclusively origina...

Page 55: ...axial piston units are order specific When ordering spare parts quote the material and serial number of the axial piston unit as well as the material numbers of the spare parts Address all questions regarding spare parts to your responsible Bosch Rexroth Service partner or the service department of the manufacturer s plant for the axial piston unit Bosch Rexroth AG An den Kelterwiesen 14 72160 Hor...

Page 56: ...d 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 from the complete system seal the connection to the reservoir or drain the reservoir 4 Place a drip tray under the axi...

Page 57: ...iston 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 58: ... only be made using the product specific setting instructions The warranty from Bosch Rexroth only applies to the product configuration as delivered The warranty is void if the unit is modified or extended The setting screws are protected against unintentional adjustment by caps Adjusting the setting screw will void the warranty If you need to change settings contact your Bosch Rexroth service par...

Page 59: ...f how 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 ...

Page 60: ... 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 32 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 t...

Page 61: ...filter too small or blocked Machine system manufacturer check the system for example 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 suit...

Page 62: ...ed Machine system manufacturer check the system for example 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 Insu...

Page 63: ...ressure limitation and pressure control valves of the axial piston unit boost pressure relief valve high pressure relief valve pressure cut off 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 Exces...

Page 64: ...und in the data sheet 92105 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 Industrial Hydraulics www boschrexroth com ics Order related technical data for your axial piston unit can be found in the order confirmation ...

Page 65: ...Technical data 65 68 RE 92105 01 B 06 2017 A4CSG Series 3x Bosch Rexroth AG ...

Page 66: ...23 F Filling 44 Flushing cycle 43 Functional description Control 20 Functional test 46 H High pressure side 19 I Identification 21 Inspection 49 Installation 27 32 Completing 35 general instructions 32 On a gearbox 34 On gearbox 34 Preparation 32 with cardan shaft 35 With coupling 33 Installation conditions 27 Installation position Above reservoir installation 29 Below reservoir installation 28 In...

Page 67: ...e 46 S Safety instructions 8 General 10 Product specific 11 Signal word 6 Scope of delivery 18 Slipper pad 19 Solenoid position Changing 42 Storage 22 Storage time 25 Storing 24 Stroking piston 19 Suction port 19 Symbols 7 T Technical data 64 Tightening torques 40 Tools 56 Transportation 22 By hand 22 with eye bolt 23 with lifting strap 24 Transporting 22 Transport protection 36 Troubleshooting 59...

Page 68: ...n den Kelterwiesen 14 72160 Horb a N Germany Phone 49 7451 92 0 info ma boschrexroth de www boschrexroth com Subject to change Printed in Germany RE 92105 01 B 06 2017 Your local contact person can be found at www boschrexroth com addresses ...

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