Bosch Rexroth 31 Series Instruction Manual Download Page 1

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Instruction manual
RE 92701-01-B/04.2018

Replaces: 01.2012
English

Axial piston variable pump

A10VO, A10VSO

Series 31

Summary of Contents for Rexroth 31 Series

Page 1: ...Instruction manual RE 92701 01 B 04 2018 Replaces 01 2012 English Axial piston variable pump A10VO A10VSO Series 31 ...

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: ...t 19 5 1 Performance description 19 5 2 Product description 19 5 2 1 Axial piston unit layout 19 5 2 2 Functional description 20 5 3 Product identification 21 6 Transport and storage 22 6 1 Transporting the axial piston unit 22 6 1 1 Transporting by hand 22 6 1 2 Transporting with a lifting device 22 6 2 Storing the axial piston unit 24 7 Installation 26 7 1 Unpacking 26 7 2 Installation condition...

Page 4: ...erforming a functional test 45 8 2 Running in phase 45 8 3 Recommissioning after standstill 46 9 Operation 47 10 Maintenance and repair 47 10 1 Cleaning and care 47 10 2 Inspection 48 10 3 Maintenance 48 10 4 Repair 49 10 5 Spare parts 49 11 Removal and replacement 50 11 1 Required tools 50 11 2 Preparing for removal 50 11 3 Removal 50 11 4 Preparing components for storage or further use 50 12 Dis...

Page 5: ...ram for your axial piston variable pump A10VO or A10VSO Please request the installation drawing from your contact at Bosch Rexroth Installation drawing Axial piston variable pump A10V S O size 18 A10VSO size 28 to 140 A10VO Contains the permissible technical data 92701 Data sheet Axial piston variable pump A10VSO size 18 to 140 Contains the permissible technical data 92711 Data sheet Hydraulic flu...

Page 6: ...sheet Pump safety block 25880 Data sheet Pump safety block 25891 Data sheet Pressure and flow control system 30030 Data sheet 1 3 Representation of information Standardized safety instructions symbols terms and abbreviations are used throughout this documentation so that you can work quickly and safely with your product For clarification they are explained in the sections below 1 3 1 Safety instru...

Page 7: ...t avoided CAUTION Identifies a dangerous situation that may result in minor to moderate injury if it is not avoided NOTICE Property damage The product or surrounding area may be damaged 1 3 2 Symbols The following symbols indicate information that is not safety relevant but increases understanding of the documentation Table 3 Meaning of symbols Symbol Meaning If this information is disregarded the...

Page 8: ... axial piston unit is 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 Atmosphère explosible DG Two point control directly controlled DFLR Pressure flow power controller DFR DFR1 DRSC Pressure flow controller DIN Deutsches Institut für Normung German Institute for Stand...

Page 9: ...The axial piston unit is only approved as a pump for hydrostatic drives in an open circuit Observe the technical data application and operating conditions and performance limits as specified in data sheet 92701 and 92711 and in the order confirmation Information about approved hydraulic fluids can be found in data sheet 92701 and 92711 The axial piston unit is only intended for commercial use and ...

Page 10: ...th the use of lifting devices and lifting accessories is required In order to ensure safe use these activities should only be performed by skilled personnel or an instructed person under the direction and supervision of skilled personnel Skilled personnel refers to persons who possess the professional training knowledge and experience as well as the understanding of the regulations relevant to the...

Page 11: ...sion protection applications 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 or 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 appr...

Page 12: ...rushing 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 stand or reach under suspended loads Make sure the unit remains stable during transport Wear your personal protective equipment e g safety goggles safety gloves suitable working clothes safety shoes Use suitable lifting d...

Page 13: ...ect the relevant part of the machine system before installing the product or when inserting removing connectors Protect the machine system against being re energized Restriction of 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 fluid abrasio...

Page 14: ...ate protection 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 follow the safety instructions provided by the lubricant manufacturer Wear your personal protective equipment e g safety goggles safety gloves suitable working clothes safety shoes Consult...

Page 15: ...ficient 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 Avoid air inclusions in the forward drive shaft bearing especially with the axial piston unit installed with the drive shaft up Check the hydraulic fluid level in the housing regularly and recommiss...

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

Page 17: ...d is spilled Observe the safety data sheet for the hydraulic fluid and the specifications provided by the system manufacturer Danger from hot components Nearby products can be damaged Components that heat up e g solenoids can cause damage to nearby products if they are too close When installing the axial piston unit check the distances to nearby products to ensure that they are not damaged The war...

Page 18: ...10VSO The scope of delivery includes the following Axial piston unit as per order confirmation The following parts come assembled on the unit Protective covers 1 Protective threaded plugs 2 For version with through drive protective cover and mounting bolts 3 For version with through drive spacer 4 made of plastic serves as transport protection ...

Page 19: ...late design for hydrostatic drive in an open circuit Flow is proportional to drive speed and displacement The flow can be steplessly changed by controlling the cradle 14 For axial piston units with swashplate design the pistons are arranged axially relative to the drive shaft 1 In an open circuit the hydraulic fluid flows from the reservoir to the hydraulic pump from where it is fed to the consume...

Page 20: ...out through the two control slots in the control plate 6 according to the stroke displacement On the suction side 8 hydraulic fluid flows into the piston chamber as the piston recedes At the same time on the high pressure side 5 the fluid is pushed out of the cylinder chamber into the hydraulic system by the pistons The swivel angle of the cradle 14 is infinitely variable Adjusting the swivel angl...

Page 21: ...MNR FD Rexroth A10VO71DR 31R VSC41N00 17W41 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Rotation Fig 3 A10VO name plate 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 Displacement 11 Serial number 12 Material numbe...

Page 22: ...eight of up to 15 kg can be transported by hand for a short time if necessary Caution Danger from heavy loads Health hazard from carrying axial piston units Use appropriate lifting lowering and moving techniques Wear your personal protective equipment e g safety goggles safety gloves suitable working clothes safety shoes Do not transport the axial piston unit by sensitive assembled parts e g senso...

Page 23: ...ng strap and cause injury Use the widest possible lifting strap 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 stand or reach 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...

Page 24: ...missible 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 at a consistent temperature between 5 C and 20 C Undamaged and sealed corrosion protection film Max 12 months Max 24 months The warranty will be voided if th...

Page 25: ...chapter 10 1 Cleaning and care on page 47 2 Drain the axial piston unit 3 For storage times up to 12 months Coat the inside of the axial piston unit with mineral oil and fill with approx 100 ml of mineral oil For storage times up to 24 months Fill the axial piston unit with VCI 329 corrosion protection 20 mL Fill via the drain port L or L1 see chapter 7 4 Installing the axial piston unit Fig 13 an...

Page 26: ...ns The installation position and location of the axial piston unit essentially determine how it is installed and commissioned such as when filling and air bleeding the axial piston unit Install the axial piston unit so that the expected forces and torque can be transferred without any danger The machine system manufacturer is responsible for sizing the fasteners Observe the maximum permissible rad...

Page 27: ...pressure gage 2 Standard pressure gage relative The suction conditions improve with installation below and inside the reservoir Make sure that the working environment at the installation site is completely free of dust and foreign substances The axial piston unit should be clean when installed Contamination of the hydraulic fluid can considerably affect the function and service life of the axial p...

Page 28: ...the customer side to make filling and air bleeding easier Table 8 Below reservoir installation Installation position Air bleed Filling 1 drive shaft horizontal F L F 2 drive shaft up F L1 F 3 drive shaft horizontal F L1 F 4 drive shaft down F L F 7 3 2 Inside reservoir installation NOTICE Risk of damage with inside reservoir installation To prevent damage to the axial piston unit all plastic parts...

Page 29: ... position prior to installation 5 6 7 8 L L1 S L1 S L S hmin ht min SB hmin ht min SB hmin ht min SB hmin ht min S L1 SB Fig 8 Inside reservoir installation A10VO A10VSO with installation position 5 8 L L1 Highest drain port hmin Minimum required distance to reservoir bottom 100 mm S Suction port SB Baffle baffle plate ht min Minimum required immersion depth 200 mm Table 9 Inside reservoir install...

Page 30: ...on before installation hES min 9 ht min hmin L1 L S 10 L1 S 11 12 S S L1 L hS max ht min hmin SB hS max F T F T ht min hmin SB hS max F T ht min hmin SB hS max F T SB Fig 9 Above reservoir installation A10VO A10VSO with installation position 9 12 L L1 Highest drain port hmin Minimum required distance to reservoir bottom 100 mm F Filling air bleeding hES min Minimum required height needed to protec...

Page 31: ...is 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 indicated 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 please ref...

Page 32: ...rly at cold start If this is not possible lay separate drain lines if necessary The type of installation 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 On a cardan shaft 7 4 4 Installation with a coupling The following describes how to install the axial pis...

Page 33: ...ces are acting on the drive shaft of the axial piston unit installation length Protect the drive shaft against frictional corrosion by providing permanent lubrication Fasten the axial piston unit at the installation location No gearing forces higher than the permissible axial and radial forces should act on the shaft if necessary support the gear wheel at the gearbox output separately 7 4 6 Instal...

Page 34: ...commissioning Remove the spacer 1 The spacer must be removed before the second pump is fitted If you operate the axial piston unit without installing a further pump on the through drive it is absolutely necessary to remove the spacer and the hub Since the metallic protective cover 3 is not pressure resistant it must be replaced with a pressure resistant cover If you need a pressure resistant cover...

Page 35: ...ct your Bosch Rexroth service partner or the service department of the factory that manufactured the axial piston unit 1 2 3 2 1 4 Fig 12 Removing transport protection 1 Protective covers 2 Protective plugs threaded plugs 3 For version with through drive protective cover and mounting bolts 4 For version with through drive spacer made of plastic serves as transport protection Ports intended for con...

Page 36: ...e rest of the hydraulic system in accordance with the hydraulic circuit diagram of the machine system manufacturer The ports and fastening threads are designed for the maximum permissible pressures pmax see Table 11 Ports A10VO A10VSO Series 31 on page 38 The machine system manufacturer should make sure the connecting elements and lines correspond to the specified application conditions pressure f...

Page 37: ...sed in application areas that use the metric system as well as the Anglo American imperial and the Japanese measuring system JIS Japan Industrial Standard 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 Le...

Page 38: ...O S Suction port standard pressure series 10 O L Drain port 2 O4 L1 Drain port 2 X4 X Pilot pressure 350 O X Pilot pressure with DG control 350 O 1 The measuring system and thread size can be found in the installation drawing 2 Momentary pressure peaks may occur depending on the application Keep this in mind when selecting measuring devices and fittings 3 O Must be connected plugged when delivered...

Page 39: ...ter the pilot pressure port X has an ISO 11926 thread of size 7 16 20 UNF 2B 11 5 deep 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 maximum permissible tightening torques MG max are the max values of the female threads and should not be exceeded For values ...

Page 40: ...10 Nm and to 17 Nm for M12 1 5 To connect the axial piston unit to the hydraulic system 1 Remove the protective plugs 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 3 Use only clean hydraulic lines or flush them before installation Observ...

Page 41: ...n assignment Recommended electrical control units Exact details on the connector type of protection and matching mating connector can also be found in data sheets 92701 and 92711 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 piston unit 12 or 24 V Before connecting check that the connect...

Page 42: ...g 15 HIRSCHMANN 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 prior to initial commissioning To avoid internal contamination do not include the axial piston unit in the flushing cycle Use an additional flushing unit to perform the flushing cycle Follow the instructions of the flushing uni...

Page 43: ...fety instructions on page 9 Connect the pressure gage for the working 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 commissioning monitor the temperature of the hydraulic fluid in the reservoir to ensure that it lies within permissible viscosity limits 8 1 1 Fil...

Page 44: ... valves are open 4 Test the direction of rotation of the drive motor To do this run the drive motor briefly at the lowest rotational speed inching Make sure the direction of rotation of the axial piston unit matches the specification on the name plate see section 5 3 Product identification Fig 3 A10VO name plate on page 21 5 Operate the axial piston pump at a low rotational speed starter speed for...

Page 45: ...d performance before delivery according to the technical data During commissioning make sure the axial piston unit was installed properly in the machine system After starting the drive motor check in particular the specified pressures e g working pressure and case pressure Perform a leak test without and with load prior to normal operation If necessary disconnect the pressure gage and plug the por...

Page 46: ...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 necessary A...

Page 47: ...he intervals described in this manual 10 1 Cleaning and care NOTICE Damage to seals and electrical system due to mechanical effects The jet of a high pressure cleaner may damage the seals and electrical 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 obse...

Page 48: ...aults on the machine system and rectify them This is why Bosch Rexroth recommends always keeping the axial piston unit and system clean Daily Check axial piston unit for unusual noise development Daily Check fastening elements for tight seating All fasteners have to be checked when the hydraulic system is switched off depressurized and cooled down Monthly 10 3 Maintenance The axial piston unit is ...

Page 49: ...spare 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 ...

Page 50: ...ed 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 entire system seal the connection to the reservoir or drain the reservoir 4 Place a drip tray under the axia...

Page 51: ...id 4 Disassemble the axial piston unit into its constituent parts for proper recycling 5 For example separate into the following Castings Steel Aluminum Non ferrous metal Electronic waste Plastic Seals 13 Extension and conversion Do not convert the axial piston unit This is also including a modification of the setting screws Changes to settings on the customer side should only be made using the pr...

Page 52: ...of 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 53: ...lic fluid Fill the suction line with hydraulic fluid Remove foreign particles from the suction line 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 31 Improper mounting of the axial piston unit Check the mounting of the axial piston unit according to...

Page 54: ...gh suction pressure too low foreign particles in the suction line impermissible filter in the suction line 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 Hydraulic fluid not in optimal viscosity range Machine system manufacturer Check temperatur...

Page 55: ...ch Rexroth Service Malfunction of the control device or controller of the axial piston unit Contact Bosch Rexroth Service Control of the control device defective Check control contact machine system manufacturer or Bosch Rexroth Service Wear or mechanical damage to the axial piston unit Replace axial piston unit Contact Bosch Rexroth Service Output unit defective e g hydraulic motor or cylinder Co...

Page 56: ... e g malfunction in the cooler insufficient hydraulic fluid in the reservoir Wrong setting or malfunction in the pressure relief and pressure control valves e g high pressure relief valve pressure cut off pressure controller Optimize the adjustment of the pressure limitation and pressure control valves of the axial piston unit and the pressure safeguarding in the hydraulic system Contact Bosch Rex...

Page 57: ...nd in data sheets 92701 and 92711 The data sheets can be found on the internet at www boschrexroth com mediadirectory Additional information can be found in the Mobile Hydraulics online product catalog 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 58: ...50 Preparing 50 Disposal 51 Distributor plate 19 Drive shaft 19 E Eye bolt 22 F Filling 43 Flushing cycle 42 Functional description Control 20 Functional test 45 H High pressure side 19 I Identification 21 Inside reservoir installation 28 Inspection 48 Installation 26 31 Completing 35 General instructions 31 On a gearbox 33 On gearbox 33 Preparation 31 With cardan shaft 33 With coupling 32 Install...

Page 59: ... documentation 5 Retaining plate 19 Running in phase 45 S Safety instructions 9 General 11 Product specific 12 Signal word 6 Scope of delivery 18 Slipper pad 19 Solenoid position Changing 41 Spare parts 49 Spring 19 Storage 22 Storage time 24 Storing 24 Stroking piston 19 Suction side 19 Symbols 7 T Technical data 57 Tightening torques 39 Tool 50 Transportation 22 By hand 22 With eye bolt 22 With ...

Page 60: ...erwiesen 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 92701 01 B 04 2018 Your local contact person can be found at www boschrexroth com addresses ...

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