Bosch Rexroth RE 90300-B Instruction Manual Download Page 64

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Bosch Rexroth AG

Glockeraustraße 4
89275 Elchingen
Germany
Tel. +49 (0) 7308 82-0
[email protected]
www.boschrexroth.com

Subject to change
RE 90300-B/2021-01-19

Bosch Rexroth AG

An den Kelterwiesen 14
72160 Horb a.N.
Germany
Tel. +49 (0) 7451 92-0
[email protected]
www.boschrexroth.com

Your local contact person can be found at:

www.boschrexroth.com/addresses

Summary of Contents for Rexroth RE 90300-B

Page 1: ...Instruction manual RE 90300 B 2021 01 19 replaces 06 2012 EN General Instruction Manual for Axial Piston Units ...

Page 2: ...ements 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...

Page 3: ...servicio en un idioma que entienda y haya entendido su contenido En caso contrario diríjase a su persona de contacto de Bosch Rexroth o al servicio técnico competente que podrá encontrar también en la dirección www boschrexroth com ET Toodet tohib kasutada ainult siis kui teil on olemas teie jaoks arusaadavas keeles kasutusjuhend ja te saate selle sisust aru Kui see nii ei ole pöörduge oma Bosch R...

Page 4: ...bilă pentru dumneavoastră şi aţi înţeles conţinutul său Dacă aceste condiţii nu sunt îndeplinite adresaţi vă persoanei dumneavoastră de contact de la Bosch Rexroth sau la service ul Bosch Rexroth competent Găsiţi aceste service uri la www boschrexroth com RU Использование данного продукта разрешается только после получения Вами настоящего руководства по эксплуатации на русском языке и его внимател...

Page 5: ...e description 23 5 2 Product description 23 5 3 Product identification 23 6 Transport and storage 24 6 1 Transporting the axial piston unit 24 6 1 1 Transport by hand 24 6 1 2 Transport with lifting devices 25 6 2 Storing the axial piston unit 26 7 Installation 29 7 1 Unpacking 29 7 2 Installation conditions 29 7 3 Installation position 31 7 3 1 Below reservoir installation standard 31 7 3 2 Insid...

Page 6: ...leaning 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 Performing the removal 50 11 4 Preparing the components for storage or further use 50 12 Disposal 51 13 Extension and conversion 51 14 Troubleshooting 52 14 1 How to proceed for troubleshooting 52 14 2 Axial piston pum...

Page 7: ...n Installation drawing Contains the outer dimensions all ports and the hydraulic circuit diagram for your axial piston unit Please request the installation drawing from your contact at Bosch Rexroth Installation drawing Product specific instruction manual Contains special information for the axial piston unit concerned The product specific instruction manual can be found in the internet see chapte...

Page 8: ...HFDR HFDU HFA HFB HFC and contains the technical data for operation with Rexroth hydraulic components 90225 Data sheet Bosch Rexroth Fluid Rating List for Rexroth hydraulic components pumps and motors Contains the hydraulic fluids positively evaluated by Bosch Rexroth 90245 Data sheet Information on the application of hydrostatic drives at low temperatures Contains additional information on the ap...

Page 9: ...ING Identifies a dangerous situation that may result in death or serious injury if it is not 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 notices that are not safety relevant but increase understanding of the documen...

Page 10: ...ment of voluntary standards in the United States ATEX EC directive on explosion protection Atmosphère explosible DIN Deutsches Institut für Normung German Institute for Standardization ISO International Organization for Standardization JIS Japan Industrial Standard RE Rexroth document in the English language VDI 2230 Standard for the systematic calculation of heavy duty threaded connections and cy...

Page 11: ...component should only be commissioned 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 Product Use Axial piston pump in open circuit The axial piston unit is only approved as a pump for hydrostatic drives in an open circuit Axi...

Page 12: ...explosive environments unless the component or machine system has been certified as compliant with the ATEX Directive 2014 34 EU Use of the axial piston unit in a corrosive 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 fami...

Page 13: ...g 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 appr...

Page 14: ...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 transpo...

Page 15: ...eak or hydraulic fluid jet with a cloth Hydraulic fluid will explode when making contact with water Risk of explosion and fire Do not bring hot hydraulic fluids in contact with water Electrical voltage Danger to life or risk of injury due to electric shock or property damage Always diskonnect the voltage supply to the relevant machine system part before assembling the product and or connecting or ...

Page 16: ...ving parts in control equipment e g valve spools can get stuck in an undefined position due to contamination e g impure hydraulic fluid abrasion or residual dirt from components As a result the hydraulic fluid flow and the build up of torque in the axial piston unit can no longer respond correctly to the operator s specifications Even the use of various filter elements external or internal flow fi...

Page 17: ...cation conditions Always wear hearing protection near a running axial piston unit Hot surfaces on axial piston unit Risk of burning Allow the axial piston unit to cool down sufficiently before touching it Wear heat resistant protective clothing e g gloves Improper cable and line routing Risk of stumbling and property damage Improper routing of cables and lines can cause a risk of stumbling as well...

Page 18: ...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 system 2 7 Personal protective equipment Personal protective equipment is the responsibility of the user of the axial piston unit Observe the safety regulations in your country All pieces of personal protective equipment should be intact ...

Page 19: ...r 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 Air intrusions in the forward drive shaft bearing are to be prevented especially...

Page 20: ...missioning ensure that all hydraulic connections are tight and that all seals and plugs of the plug in connection are correctly installed and undamaged to prevent 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 req...

Page 21: ...and contamination of 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 parameters in the safety data sheet for the hydraulic fluid and the specifications provided by the machine system manufacturer Danger from hot components Nearby products can be damaged Compone...

Page 22: ...e of delivery Included in the scope of delivery Axial piston unit as per order confirmation The following parts may also be installed on delivery Protective covers Protective plugs threaded plugs Connector protective covers for version with through drive protective cover and mounting bolts ...

Page 23: ...covers the following categories Function type Pump or motor Type of circuit Open or closed hydraulic circuit Design Bent axis or swashplate Displacement Fixed or variable 5 3 Product identification The axial piston unit can be identified by the name plate The following example shows the name plate of an axial piston variable pump A4VG 1 2 3 4 5 6 71 8 91 10 11 12 13 TYP MNR SN FD Rotation D 89275 ...

Page 24: ...1 1 Transport by hand Up to a specific maximum weight axial piston units can 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 ti...

Page 25: ... 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 The thread size is indicated 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 2 with the eye bolt screwed into the drive shaft Fig ...

Page 26: ...Fig 4 Transport with lifting strap 6 2 Storing the axial piston unit Storage areas should be free of corrosive materials and gases To prevent damage to the seals do not operate ozone forming equipment e g mercury vapor lamps high voltage equipment electric motors sources of electrical sparks or electrical discharge in storage areas Storage areas should be dry Recommended relative humidity 60 Ideal...

Page 27: ...axial piston unit for proper functioning and leak tightness 3 If storage time exceeds 24 months replace the shaft seal Once the max storage time has elapsed we recommend that you have the axial piston unit checked by your Bosch Rexroth service partner For questions regarding repair and spare parts contact your proper Bosch Rexroth service partner or the service department of the manufacturer s pla...

Page 28: ...l and fill with approx 100 ml mineral oil For storage times up to 24 months Fill the axial piston unit with VCI 329 corrosion protection 20 ml The unit is filled through the drain port 4 Plug all ports so they are airtight 5 Coat unpainted areas of the axial piston unit with mineral oil or suitable easily removable corrosion protection e g acid free grease 6 Pack the axial piston unit with desicca...

Page 29: ...nsport damage and completeness see chapter 4 Scope of delivery on page 22 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 filling and air bleeding the axial piston unit Fasten the axial piston unit so that th...

Page 30: ...on locations of the axial piston pump see Fig 5 See product specific data sheet for further pressure values and conditions S 0 2 0 8 abs 1 2 3 0 0 1 2 1 2 1 Fig 5 Suction pressure for axial piston pump 1 Absolute pressure gauge 2 Standard pressure gauge relative The suction conditions improve with installation below and inside the reservoir Make sure that the working environment at the installatio...

Page 31: ...ne case drain air bleed port Inside reservoir installation is when the axial piston unit is installed in the reservoir below the minimum fluid level The axial piston unit is completely below the hydraulic fluid If the minimum fluid level is equal to or below the upper edge of the pump see chapter 7 3 3 Above reservoir installation on page 31 Axial piston units with electric components e g electric...

Page 32: ...system L R W Fig 6 Direction of rotation W Bi directional can rotate counterclockwise and clockwise 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 23 For information on the direction of rotation of the drive motor please...

Page 33: ...all connected units is not exceeded in any operating condition particularly at cold start If this is not possible separate drain line must be laid if necessary The installation method for the axial piston unit depends on the connecting elements to the drive or output side The following descriptions explain the installation of the axial piston unit With a coupling On a gearbox On a cardan shaft 7 4...

Page 34: ...all the axial piston unit on a gearbox After installing on a gearbox the axial piston unit is covered and is difficult to access Before installing make sure that the spigot diameter centers the axial piston unit observe tolerances and that no excessive axial or radial forces are acting on the drive shaft of the axial piston unit installation length Protect the drive shaft against frictional corros...

Page 35: ... removed prior to connection Use a suitable tool for this to prevent damage to the sealing and functional surfaces If sealing or functional surfaces are damaged contact your Bosch Rexroth service partner or the service department of the manufacturer s plant of the axial piston unit Ports intended for connecting lines come with protective plugs and or threaded plugs which serve as transport protect...

Page 36: ...duct specific data sheet 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 when routing t...

Page 37: ...s 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 Leaky and bursting stud ends For fittings if a stud end...

Page 38: ...he metallic threaded plugs supplied with the axial piston unit the required tightening torques of threaded plugs MV apply For values see Table 7 Mounting bolts For mounting bolts with metric ISO threads according to DIN 13 and or ASME B1 1 threads we recommend checking the tightening torque in individual cases in accordance with VDI 2230 For axial piston units there may be openings that are closed...

Page 39: ...5 Nm 8 mm M18 1 5 140 Nm 70 Nm 8 mm M20 1 5 170 Nm 80 Nm 10 mm M22 1 5 210 Nm 100 Nm 10 mm M27 2 330 Nm 170 Nm 12 mm M30 2 420 Nm 215 Nm 17 mm M33 2 540 Nm 310 Nm 17 mm M42 2 720 Nm 330 Nm 22 mm M48 2 900 Nm 420 Nm 22 mm ISO 11926 5 16 24 UNF 2B 10 Nm 7 Nm 1 8 in 3 8 24 UNF 2B 20 Nm 10 Nm 5 32 in 7 16 20 UNF 2B 40 Nm 18 Nm 3 16 in 9 16 18 UNF 2B 80 Nm 35 Nm 1 4 in 3 4 16 UNF 2B 160 Nm 70 Nm 5 16 i...

Page 40: ...ing condition 7 4 9 Electrically connecting the axial piston unit NOTICE Short circuit due to penetrating hydraulic fluid Fluid can penetrate the product and cause a short circuit Do not install axial piston units with electric components e g electric controls sensors in a reservoir below the fluid level inside reservoir installation unless they have been explicitly released for use under hydrauli...

Page 41: ...ut 5 1 Nm WAF 26 12 sided DIN 3124 On axial piston units with a Hirschmann connector according to DIN EN 175 301 803 A ISO 4400 the following tightening torques apply when mounting plug in connectors Mounting bolt M3 1 0 5 Nm Union nut M16 1 5 2 1 5 2 5 Nm 1 2 Fig 7 Tightening torque for HIRSCHMANN connector 7 5 Performing flushing cycle In order to remove foreign particles from the system Bosch R...

Page 42: ...ny work for commissioning the axial piston unit note the general safety instructions and intended use in chapter 2 Safety instructions on page 11 and the specifications for commissioning in the product specific instruction manual for your axial piston unit Connect the pressure gauge for the working pressure case pressure and suction pressure to the specified measuring points on the axial piston un...

Page 43: ...viscosities and admissible temperatures in the product specific data sheet Proceed as follows to fill the axial piston unit 1 Place a drip tray under the axial piston unit to collect any hydraulic fluid that may leak NOTICE Contaminated hydraulic fluid The cleanliness levels of commercial hydraulic fluids are usually insufficient for the requirements of our components Use a suitable filter system ...

Page 44: ...rease the load and check whether the working pressure rises as expected 4 Perform a leak test to ensure the hydraulic system is sealed and can withstand the max pressure 5 Check the suction pressure at port S of the axial piston pump at nominal speed and max swivel angle Refer to the product specific data sheet for the permissible value 6 At maximum working pressure check the case pressure at a su...

Page 45: ...umetric and mechanical hydraulic efficiency is also greater 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 Bosch Rexroth recommends the following procedure after the running in phase After the running in phase have a hydraulic fluid sample analyzed for the required cleanliness level Chan...

Page 46: ...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 Discrepancies are explained as necessary in the product specific instruction manual ...

Page 47: ...al 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 observe the following Check whether all seals and plug in connections are securely seated to ensure ...

Page 48: ...al 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 Change the filter element in optionally mounted filters The replacement interval may vary depending on the cleanliness of the hydraulic fluid We recommend using a contamination indicator Half ye...

Page 49: ...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 ordering spare parts specify the material and serial number of the axial piston unit as well as...

Page 50: ...forming the removal 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 th...

Page 51: ...example separate the parts into Castings Steel Aluminum Non ferrous metal Electronic waste Plastic Seals 13 Extension and conversion Do not modify the axial piston unit and or its assembled parts This also includes changing the wiring or software Changes to settings on the customer side should only be made using the product specific setting instructions The warranty from Bosch Rexroth only applies...

Page 52: ...ne the original cause of the fault First get a general idea 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 Have there been any changes to the application conditions or ope...

Page 53: ...ry check the filter system and replace the filter Drive speed too high Machine system manufacturer Reduce drive speed Wrong direction of rotation Machine system manufacturer Check correct direction of rotation see chapter 1 1 10 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 manufac...

Page 54: ...e suction line 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 If necessary check the filter system and replace the filter Hydraulic fluid not in optimal viscosity range Machine system manufacturer Check temperature range and use suitable hydraulic fluid...

Page 55: ...stem 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 If necessary check the filter system and replace the filter Hydraulic fluid not in optimal viscosity range Machine system manufacturer Check temperature range and use suitable hydraulic fluid Insufficient boost press...

Page 56: ... piston unit and the pressure limitation in the hydraulic system Air bleed the axial piston unit and hydraulic system Contact Bosch Rexroth Service Optimize the setting of the pressure limitation and pressure control valve Unstable control signal Contact machine system manufacturer or Bosch Rexroth Service Malfunction in the control devices or the controller Contact Bosch Rexroth Service Excessive...

Page 57: ...ation Bearings worn Contact Bosch Rexroth Service No or insufficient pressure Insufficient air bleeding of the hydraulic system Fill the axial piston unit suction line for the hydraulic pump and the reservoir Check correct installation position Faulty mechanical output drive e g defective coupling Contact machine system manufacturer Drive power too low Contact machine system manufacturer Malfuncti...

Page 58: ...rvice Wear or mechanical damage to the hydraulic pump Replace hydraulic pump Contact Bosch Rexroth Service Wrong direction of rotation Check function of the hydraulic pump Machine system manufacturer Check correct direction of rotation see chapter 1 1 10 Preparation on page 32 Excessively high temperature of hydraulic fluid and housing Excessively high inlet temperature at the axial piston unit Ma...

Page 59: ...al data of your axial piston unit can be found in the product specific data sheet The product specific data sheet can be found in the online product catalog at www boschrexroth com axial piston pumps www boschrexroth com axial piston motors Order related technical data for your axial piston unit can be found in the order confirmation ...

Page 60: ...h com p A18VO Variable double pump A20VO www boschrexroth com p A20VO Variable double pump A28VLO www boschrexroth com p A28VLO Variable pump A4VG 32 www boschrexroth com p A4VG 32 Variable pump A4VG 35 www boschrexroth com p A4VG 35 Variable pump A4VG 40 www boschrexroth com p A4VG 40 Variable pump A4VTG www boschrexroth com p A4VTG Variable pump A4CSG www boschrexroth com p A4CSG Variable pump A...

Page 61: ...w boschrexroth com p A10VM Variable motor A10VE www boschrexroth com p A10VE Variable motor A10VER www boschrexroth com p A10VER BODAS speed sensor DSA www boschrexroth com p DSA BODAS speed sensor DSM www boschrexroth com p DSM BODAS speed sensor HDD www boschrexroth com p HDD If there are no product specific instruction manuals for your axial piston unit please consult your responsible contact p...

Page 62: ...orming 50 Preparing 50 Disposal 51 E Eye bolt 25 F Filling 42 Flushing cycle 41 Functional test 44 I Identification 23 Inside reservoir installation 31 Inspection 48 Installation 29 Completion 35 General instructions 32 On a gearbox 34 On gearbox 34 Preparation 32 With cardan shaft 34 With coupling 33 Installation conditions 29 Installation position Above reservoir installation 31 Below reservoir ...

Page 63: ...dstill 45 Repair 49 Replacement 50 Required documentation 7 Running in phase 45 S Safety instructions 11 General 13 Product specific 14 Signal word 9 Scope of delivery 22 Spare parts 49 Storage 24 26 Storage time 27 Symbols 9 T Technical data 59 Tightening torques 38 Tools 50 Transport 24 By hand 24 with eye bolt 25 with lifting strap 26 Transporting 24 Troubleshooting 52 U Unpacking 29 W Warranty...

Page 64: ...fo ma boschrexroth de www boschrexroth com Subject to change RE 90300 B 2021 01 19 Bosch Rexroth AG An den Kelterwiesen 14 72160 Horb a N Germany Tel 49 0 7451 92 0 info ma boschrexroth de www boschrexroth com Your local contact person can be found at www boschrexroth com addresses ...

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