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48/68 Commissioning

Bosch Rexroth AG

, A4VG Series 32, RE 92003-01-B/12.2015

8 Commissioning

wARnInG

Danger while working in the danger zone of a machine/system.

Danger to life or risk of injury or serious injury.

▶

Pay attention to and eliminate potential sources of danger before operating the
axial piston unit.

▶

Make sure no one is in the danger zone of the machine/system.

▶

The emergency stop button for the machine/system must be within the
operator’s reach.

▶

Always follow the instructions of the machine/system manufacturer during
commissioning.

CAUTIOn

Commissioning an improperly installed product.

Risk of injury and property damage.

▶

Make sure that all electrical and hydraulic ports are connected or plugged.

▶

Only commission a completely installed, fully functioning product with 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 9.

▶

Connect the pressure gauge for the boost pressure, 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 the commissioning process, monitor the temperature of the hydraulic fluid
in the reservoir to ensure that it remains within the permissible viscosity limits.

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Содержание A4VG A4VG 32 Series

Страница 1: ...Instruction manual RE 92003 01 B 12 2015 Replaces 04 2008 English Axial piston variable pump A4VG Series 32 ...

Страница 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 ...

Страница 3: ...on 20 5 2 Product description 20 5 2 1 Layout of the axial piston unit 20 5 2 2 Functional description 21 5 3 Bypass function 22 5 3 1 Bypass function size 28 to 56 23 5 3 2 Bypass function size 71 90 24 5 3 3 Bypass function size 125 to 180 26 5 4 Product identification 27 6 Transport and storage 28 6 1 Transporting the axial piston unit 28 6 1 1 Transporting by hand 28 6 1 2 Transporting with a ...

Страница 4: ... functional test 50 8 2 Running in phase 51 8 3 Recommissioning after standstill 51 9 Operation 52 10 Maintenance and repair 53 10 1 Cleaning and care 53 10 2 Inspection 54 10 3 Maintenance 54 10 3 1 Changing the filter element 55 10 4 Repair 55 10 5 Spare parts 56 11 Removal and replacement 57 11 1 Required tools 57 11 2 Preparing for removal 57 11 3 Performing removal 57 11 4 Preparing the compo...

Страница 5: ...your contact at Bosch Rexroth Installation drawing Axial piston variable pump A4VG Series 32 Contains the permissible technical data 92003 Data sheet Mineral oil based hydraulic fluids and related hydrocarbons Describes the requirements for a mineral oil based hydraulic fluid and related hydrocarbons for operation with Rexroth hydraulic components and assists you in selecting a hydraulic fluid for...

Страница 6: ...n chapter 3 General instructions on damage to property and the product on page 16 and before a sequence of actions or an instruction for action involving a risk of personal injury or damage to equipment The described danger prevention measures must be observed Safety instructions are set out as follows Signal word Type and source of danger Consequences of noncompliance Measures to prevent danger W...

Страница 7: ...lowing symbols indicate information that is not safety relevant but increases understanding of the documentation Table 3 Meaning of the symbols Symbol Meaning If this information is disregarded the product cannot be used and or operated to the optimum extent Single independent action 1 2 3 Numbered instruction The numbers indicate that the steps must be completed one after the other 1 3 3 Designat...

Страница 8: ...ated DG Hydraulic control directly operated DIN Deutsches Institut für Normung German Institute for Standardization EP Proportional control electric HD Proportional control hydraulic ISO International Organization for Standardization JIS Japan Industrial Standard RE Rexroth document in the English language VDI 2230 Directive for the systematic calculation of high duty bolted joints and joints with...

Страница 9: ... has been established in accordance with the machinery directive This product is intended for the following use The axial piston unit is only approved as a pump for hydrostatic drives in closed circuit Observe the technical data the application and operating conditions and the performance limits as specified in data sheet 92003 and in the order confirmation Information about approved hydraulic flu...

Страница 10: ...ibed in this documentation require basic mechanical electrical and hydraulics expertise 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 qualified personnel or an instructed person und...

Страница 11: ...d permitted 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 e g machinery or system in which the Rexroth products are installed complies with the country specific provisions safety regulations and standards for the applica...

Страница 12: ...jury e g crushing or fractures or damage to the product Make sure that the load bearing capacity of the lifting gear is sufficient to safely bear the weight of the axial piston unit 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 gloves suitable working clothes safety shoes Use...

Страница 13: ...achine movements Use the manual override only for functional testing or in the event of technical malfunctions Using the manual override permanently e g by wedging blocking is not permitted The use of the manual override is only permitted with limited technical data e g 0 25 maximum data Check whether additional protective measures are necessary for the application on your machine in order to avoi...

Страница 14: ... in the vicinity of the operating axial piston unit Hot surfaces on the axial piston unit Risk of burns Allow the axial piston unit to cool down sufficiently before touching it Wear heat resistant protective clothing e g gloves Improper routing of cables and lines Risk of stumbling and property damage Improper routing of cables and lines can cause a risk of tripping as well as damage to equipment ...

Страница 15: ...the leak or oil jet with a cloth Danger from improper handling Risk of slipping Risk of slipping on wet surfaces when climbing on the axial piston unit Never grab or climb onto the axial piston unit Check how to safely get on top of the machine 2 7 Personal protective equipment Personal protective equipment is the responsibility of the user of the axial piston unit Observe the safety regulations a...

Страница 16: ...r lubrication Product can be damaged or destroyed Never operate the axial piston unit with insufficient hydraulic fluid Specifically make sure that the rotary group has sufficient lubrication When commissioning a machine system make sure that the housing area and the working lines of the axial piston unit are filled with hydraulic fluid and remain filled during operation Air inclusions in the forw...

Страница 17: ...ze solid impurities and water in the hydraulic system Improper cleaning Product can be damaged Plug all openings with the appropriate protection equipment 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 cleaner at s...

Страница 18: ...formation in the safety data sheet for the hydraulic fluid and the specifications provided by the system manufacturer Danger from hot components Nearby products can get damaged Components which 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 warranty ...

Страница 19: ... 1 2 2 2 3 Fig 1 Axial piston unit The delivery includes the following 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 protective cover and mounting bolts 3 ...

Страница 20: ...ed and displacement The flow can be steplessly changed by controlling the cradle 12 For axial piston units with swashplate design the pistons are arranged axially relative to the drive shaft In the closed circuit the hydraulic fluid flows from the hydraulic pump to the consumer e g hydraulic motor and from there directly back to the hydraulic pump There is a high pressure side and a low pressure s...

Страница 21: ... pump 7 continuously supplies a sufficient volume of fluid boost volume from a small reservoir to the low pressure side of the closed circuit via a check valve to replenish the internal leakage of the variable pump and consumer The boost pump is an internal gear pump which is driven directly via the drive shaft In order to replenish the internal leakage in the variable pump and consumers port Fa m...

Страница 22: ...g the angle results in a corresponding reduction in displacement Various control units are available depending on requirements Information about this can be found in data sheet 92003 5 3 Bypass function For vehicles with hydrostatic travel drive as long as there is no downstream mechanical interruption of the drive train switch to idle free running the flow can be altered using a bypass function i...

Страница 23: ...inst the spring seat This is apparent by the increased resistance Then screw the screw 1 one half turn into the spring seat 5 Tighten the lock nut 2 clockwise with a torque of 22 Nm The plastic tamper proof cap is destroyed when removing The maximum towing speed is dependent on the gear ratio in the vehicle and must be calculated by the vehicle manufacturer The corresponding flow of qV 30 l min ma...

Страница 24: ...the bypass function in the reverse order Loosen the lock nut 2 with a hexagon head screw WAF 13 then turn the screw 1 counter clockwise with a hexagon socket wrench WAF 4 to the stop 3 Retighten the lock nut 2 turning clockwise with a torque of 22 Nm 4 Equip the screw 2 with a tamper proof cap again to protect the pressure relief valve against unauthorized resetting 5 3 2 Bypass function size 71 9...

Страница 25: ...ay only be towed out of the immediate danger zone Notice Draining the hydraulic circuit Risk of damage While towing with the bypass function activated the closed hydraulic circuit drains itself This can result in unintended functions when restarting the travel drive Start the travel drive only after completely filling and air bleeding the hydraulic circuit see chapter 8 1 Initial commissioning on ...

Страница 26: ...nd long towing distances result in impermissible heat generation and insufficient lubrication This overheats and damages the axial piston unit Wear heat resistant protective clothing e g gloves Only tow the vehicle out of the immediate danger zone The vehicle may only be towed out of the immediate danger zone Notice Draining the hydraulic circuit Risk of damage While towing with the bypass functio...

Страница 27: ...9275 Elchingen Made in Germany A4VG125EP4D1 32R NSF02F001SP R90XXXXXXX SC X 12345678 15W12 n XXXX min 1 P XXX kW m XXX kg 7202 Fig 6 Name plate A4VG 1 Manufacturer 2 Internal plant designation 3 Sample category optional 4 Direction of rotation viewed on drive shaft here clockwise 5 Specified area for inspection stamp 6 Weight optional 7 Power 8 Bar code 9 Rotational speed 10 Manufacturing date 11 ...

Страница 28: ...h mm Weight may vary by equipment 6 1 1 Transporting by hand Axial piston units with a weight of up to 15 kg can be transported manually for a short time if necessary Caution Danger from heavy loads Health hazard from carrying axial piston units Use suitable lifting lowering and moving methods Wear your personal protective equipment e g safety goggles safety gloves suitable working clothes safety ...

Страница 29: ... suspended loads During transport with a lifting device the axial piston unit can slip out of the lifting strap and result in 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 oscillations Never stand or put your hands under a suspended load Place the ...

Страница 30: ...for an originally packed 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 uniform temperature between 5 C and 20 C and an undamaged and sealed corrosion protection film Maximum 12 months Maximum 24 months Warranty is void if the requirements ...

Страница 31: ... 53 2 Empty the axial piston unit 3 For storage periods up to 12 months Coat the inside of the axial piston unit with mineral oil and fill with approx 100 ml mineral oil For storage periods up to 24 months Fill the axial piston unit with VCI 329 corrosion protection 20 ml Filling is done through the drain port T1 or T2 see Chapter 7 4 Installing the axial piston unit Fig 15 to Fig 17 on page 44 4 ...

Страница 32: ...our country 7 2 Installation conditions The installation location 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 dimens...

Страница 33: ...t for pressure values 0 2 0 8 abs S 2 1 1 2 3 0 0 1 2 1 Fig 9 Suction pressure 1 Absolute pressure gauge 2 Standard pressure gauge relative The suction conditions improve with below reservoir installation Make sure that the working environment at the installation site is fully free of dust and foreign substances The axial piston unit must be installed in clean condition Contamination of the hydrau...

Страница 34: ...ds you need the additional air bleed port R1 in the flange area for the sizes 71 to 180 This port is not provided in the standard version and must be stated in plain text when ordering If filling the stroking chambers via X1 to X4 is not possible in the final installation position then this must be effected before installation e g in installation position 2 To prevent unexpected actuation and dama...

Страница 35: ...g 10 Below reservoir installation with installation position 1 6 T1 T2 Highest drain port ht min Minimum required immersion depth 200 mm R R1 Air bleeding hmin Minimum required distance to reservoir bottom 100 mm S Suction port SB Baffle baffle plate X1 X2 Control pressure X3 X4 Stroking chamber pressure port Table 8 Below reservoir installation Installation position Air bleeding the housing Air b...

Страница 36: ...T1 R T2 X2 X1 8 F2 S SB ht min hmin hS max F1 T1 T2 9 T1 T2 S F2 SB ht min hmin hS max F1 X2 X1 10 R F2 R1 T1 T2 0 5 bar S ht min hmin hS max SB F1 X3 X4 11 T1 T2 S F2 SB ht min hmin hS max F1 X3 12 T1 T2 S F2 SB ht min hmin hS max F1 X4 Fig 11 Above reservoir installation A4VG with installation position 7 12 T1 T2 Highest drain port ht min Minimum required immersion depth 200 mm F1 F2 Filling air...

Страница 37: ...ype code with the details in the order confirmation If the material number for the axial piston unit does not correspond to the one in the order confirmation contact Bosch Rexroth Service for clarification see Chapter 10 5 Spare parts on page 56 3 Before installing completely empty the axial piston unit to prevent mixing with the hydraulic fluid used in the machine system 4 Check the permissible d...

Страница 38: ...large part of its tension after just a short time An automatic tensioning device can lessen the speed variations and vibrations and thus avoid consequential damage When using toothed belts or v belts to transfer the input or output drive always use an automatic tensioning device On the input or output drive of an axial piston unit a cardan shaft may cause vibrations and impermissible rotary angle ...

Страница 39: ... corrosion and the associated wear 3 Transport the axial piston unit to the installation location 4 Remove dirt and foreign particles from the installation location 5 Install the coupling on the output shaft of the drive motor in accordance with the specifications provided by the coupling manufacturer The axial piston unit must not be tightened down until the coupling has been correctly installed ...

Страница 40: ... the gear wheel must be supported separately at the gearbox output 7 4 6 Completing installation 1 Remove any mounted transport screws Caution Operation with protection plugs Operating the axial piston unit with protection plugs may result in injury or damage to the axial piston unit Before commissioning remove all protection plugs and replace them with suitable pressure proof metal threaded plugs...

Страница 41: ...be connected see Table 10 Ports A4VG Series 32 on page 45 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 protection plugs are not pressure resistant Setting screws are protected against unauthorized resetting by means of tamper proof caps Removal of the tamper proof caps will void the warranty If you need to change t...

Страница 42: ...air Make sure that the necessary suction pressure is not undercut This is influenced by the piping e g suction cross section pipe diameter length of suction line the position of the reservoir the viscosity of the hydraulic fluid a filter cartridge or check valve in the suction line if these are fitted regularly check the level of soiling of the filter cartridge The machine system manufacturer is r...

Страница 43: ...it values specified for the axial piston unit in the data sheet The drain line joint in the reservoir must always be below the minimum fluid level see Chapter 7 3 Installation position on page 34 If the axial piston unit is equipped with installed screw fittings these must not be unscrewed Screw the stud end of the fitting directly into the installed screw fitting Axial piston units are employed i...

Страница 44: ...2 R X1 X2 A B PS T1 G MA MB MH S Fa Fe Y2 Y1 Fig 15 Port overview A4VG size 28 T2 R X1 X2 A B PS T1 MH S Fa Fe MB MA G Fa1 FS Y2 Y1 Fig 16 Port overview A4VG size 40 56 T1 T2 A PS MH S Fe MB MA G Fa1 FS R X1 X2 B Fa Y2 Y1 Fig 17 Port overview A4VG size 71 to 180 Port overview ...

Страница 45: ... be taken from the installation drawing 2 Depending on the application short term pressure peaks can occur Keep this in mind when selecting measuring equipment and fittings 3 Closed with external feed in supply 4 Depending on the installation position T1 or T2 must be connected see chapter 7 3 Installation position on page 34 5 Optional 6 O Must be connected plugged when delivered X Plugged in nor...

Страница 46: ...for the condition dry and lightly oiled 2 The tightening torques for the threaded plugs are valid for the condition dry in the condition lightly oiled the tightening torques for M10 1 are reduced to 10 Nm and for M12 1 5 to 17 Nm To connect the axial piston unit to the hydraulic system 1 Remove the protective plugs and threaded plugs at the ports at which the connections are to be made according t...

Страница 47: ...be found in data sheet 92003 The mating connector is not included in the scope of delivery 1 Switch off power supply to the relevant system component 2 Electrically connect the axial piston unit 12 or 24 V Before connecting check that the connector including all seals is intact If necessary you can change the connector orientation by turning the solenoid This is dependent on the connector version ...

Страница 48: ...f injury and property damage Make sure that all electrical and hydraulic ports are connected or plugged Only commission a completely installed fully functioning product with 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 pa...

Страница 49: ...tice Contaminated hydraulic fluid The cleanliness levels of hydraulic fluids on delivery do not normally conform to the requirements for our components Use a suitable filter system to filter hydraulic fluids during filling to minimize solid impurities and water in the hydraulic system 2 Fill and air bleed the axial piston unit via the appropriate ports see Chapter 7 3 Installation position on page...

Страница 50: ... the maximum pressure 5 Check the suction pressure at port S of the axial piston pump at nominal speed and maximum swivel angle Refer to data sheet 92003 for the permissible value 6 At maximum working pressure check the case pressure at port T1 or T2 Refer to data sheet 92003 for the permissible value 8 1 3 Performing a functional test WARNING Improperly connected axial piston unit Mixing up the p...

Страница 51: ...etric and mechanical hydraulic efficiency also increases up to the conclusion of the running in phase of approx 10 operating hours 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 C...

Страница 52: ...tings or changes during operation For this reason this chapter of the manual does not contain any information on adjustment options Use the product only within the performance range specified in the technical data The machine system manufacturer is responsible for the proper project planning of the hydraulic system and its control ...

Страница 53: ...l system of the axial piston unit Do not point the 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 fittings on the connections are securely seated to ensure that no moisture can penetrate into the axial piston unit during cleaning Use only water and if...

Страница 54: ... 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 change interval may vary depending on the degree of contamination of the hydraulic fluid We recommend using a contamination indicator Half yearly or every 500 operating hours whichever occurs first 10 3 Maintenance The...

Страница 55: ...ter housing 4 5 Check the O ring 2 and O ring groove for damage wear and contamination 6 If required replace the O ring 2 Lightly grease the O ring 2 7 Screw the filter housing 4 onto the filter head 1 8 Tighten the filter housing 4 with 45 Nm 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 ass...

Страница 56: ...ring 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 Details for the manufacturer s plant can be found on the name plate of the axial piston unit Bos...

Страница 57: ... 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 collecting pan under the ax...

Страница 58: ...ston 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 5...

Страница 59: ...t specific setting instructions The warranty by Bosch Rexroth only applies to the product as delivered The warranty is void if the unit is modified or extended Setting screws are protected against unauthorized resetting by means of tamper proof caps Removal of the tamper proof caps will void the warranty If you need to change the settings contact your responsible Bosch Rexroth Service partner for ...

Страница 60: ... how your product functions in conjunction with the overall 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 operating conditions or operating range Has maintenance work recently been carrie...

Страница 61: ...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 Preparation on page 37 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 torques Impr...

Страница 62: ...ilter too small etc Machine system manufacturer check the system e g optimize inlet conditions use suitable hydraulic fluid Fill the suction line with hydraulic fluid Remove contaminants 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 ...

Страница 63: ...ne system manufacturer check the system e g optimize inlet conditions use suitable hydraulic fluid Fill the suction line with hydraulic fluid Remove contaminants 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 Insufficient boost pressu...

Страница 64: ...on and pressure control valves of the axial piston unit boost pressure relief valve high pressure relief valve pressure cut off Air bleed 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 Excessive hydraulic fluid...

Страница 65: ...can be found on the data sheet 92003 The data sheet can be found on the Internet at www boschrexroth com various utilities mediadirectory Additional information can be found in the online product catalog Mobile hydraulics www boschrexroth com axialkolbenpumpen The order related technical data for your axial piston unit can be found in the order confirmation ...

Страница 66: ...8 F Filling 49 Filter 54 55 changing 55 Flushing cycle 47 Functional description Control 22 Functional test 50 I Identification 27 Inspection 54 Installation 32 37 completing 40 general instructions 38 on a gearbox 40 on gearbox 40 Preparation 37 with coupling 39 Installation conditions 32 Installation position Above reservoir installation 36 Below reservoir installation 35 Instructions general 38...

Страница 67: ... 51 S Safety instructions 9 General 11 Product specific 12 Signal word 6 Scope of delivery 19 Slipper pad 20 Solenoid position changing 47 Spare parts 56 Storage 28 Storage time 30 Storing 30 Stroking piston 20 Symbols 7 T Technical data 65 Tightening torques 45 Tools 57 Transportation 28 by hand 28 with eye bolt 28 with lifting strap 29 Transporting 28 Transport protection 41 Troubleshooting 60 U...

Страница 68: ...ions Glockeraustraße 4 89275 Elchingen Germany Tel 49 7308 82 0 info ma boschrexroth de www boschrexroth com Subject to change Printed in Germany RE 92003 01 B 12 2015 Your local contact can be found at www boschrexroth com addresses ...

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