Bosch Rexroth A4VG 35 Series Manual de usuario

Instruction manual

RE 92035-01-B/04.2018

Replaces: –.–

English

Axial piston variable pump

A4VG

Series 35

also regarding any disposal, exploitation,

reproduction, editing, distribution, as well

as in the event of applications for industrial

property rights.

The data speciﬁed within only serves

to describe the product. No statements

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.

The original instruction manual was created in

the German language.

Contents 3/64

RE 92035-01-B/04.2018, A4VG, Series 35, Bosch Rexroth AG

1 About this documentation 5

1.1 Applicability 5

1.2 Required and supplementary documentation 5

1.3 Representation of information 6

1.3.1 Safety instructions 6

1.3.2 Symbols 7

1.3.3 Designations 7

1.3.4 Abbreviations 8

2 Safety instructions 9

2.1 About this chapter 9

2.2 Intended use 9

2.3 Improper use 9

2.4 Personnel qualiﬁcations 10

2.5 General safety instructions 11

2.6 Product-speciﬁc safety instructions 12

2.7 Personal protective equipment 15

3 General instructions regarding property and product damage 16

4 Scope of delivery 19

5 About this product 20

5.1 Performance description 20

5.2 Product description 20

5.2.1 Axial piston unit layout 20

5.2.2 Functional description 21

5.3 Bypass function 22

5.3.1 Activating and deactivating the bypass function 22

5.4 Product identiﬁcation 24

6 Transport and storage 25

6.1 Transporting the axial piston unit 25

6.1.1 Transporting by hand 25

6.1.2 Transporting with a lifting device 25

6.2 Storing the axial piston unit 28

7 Installation 30

7.1 Unpacking 30

7.2 Installation conditions 30

7.3 Installation position 31

7.3.1 Below-reservoir installation (standard) 32

7.3.2 Above-reservoir installation 33

Contents

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Bosch Rexroth AG, Series 35 A4VG, RE 92035-01-B/04.2018

7.4 Installing the axial piston unit 34

7.4.1 Preparation 34

7.4.2 Dimensions 34

7.4.3 General instructions 34

7.4.4 Installation with a clutch 35

7.4.5 Installation on a gearbox 36

7.4.6 Installation with cardan shaft 36

7.4.7 Completing installation 37

7.4.8 Hydraulically connecting the axial piston unit 38

7.4.9 Electrically connecting the axial piston unit 42

7.5 Performing ﬂushing cycle 43

8 Commissioning 44

8.1 Initial commissioning 44

8.1.1 Filling the axial piston unit 45

8.1.2 Testing the hydraulic ﬂuid supply 46

8.1.3 Performing a functional test 46

8.2 Running-in phase 47

8.3 Recommissioning after standstill 47

9 Operation 48

10 Maintenance and repair 49

10.1 Cleaning and care 49

10.2 Inspection 50

10.3 Maintenance 50

10.4 Repair 51

10.5 Spare parts 51

11 Removal and replacement 52

11.1 Required tools 52

11.2 Preparing for removal 52

11.3 Removal 52

11.4 Preparing the components for storage or further use 52

12 Disposal 53

13 Extension and conversion 54

14 Troubleshooting 55

14.1 How to proceed for troubleshooting 55

14.2 Malfunction table 56

15 Technical data 60

16 Alphabetical index 61

Contents

About this documentation 5/64

RE 92035-01-B/04.2018, Series 35 A4VG, Bosch Rexroth AG

1 About this documentation

1.1 Applicability

This documentation applies to the following products:

•Axial piston variable pump A4VG Series 35

This manual is intended for machine/system manufacturers, assemblers and service

engineers.

It contains important information on the safe and proper transport, installation,

commissioning, operation, maintenance, removal and simple troubleshooting of the

axial piston unit.

▶ Read this documentation completely, in particular Chapter 2 “Safety instructions”

on page 9 and Chapter 3 “General instructions regarding property and

product damage” on page 16 before you start work with the axial piston unit.

1.2 Required and supplementary documentation

▶ Only commission the axial piston unit if the documentation marked with the book

symbol is available to you and you have understood and observed it.

Table 1: Required and supplementary documentation

Title Document number Document type

Order conﬁrmation

Contains the order-related technical data for your axial piston variable

pump A4VG.

– Order conﬁrmation

Installation drawing

Contains the outer dimensions, all ports and the hydraulic circuit diagram

for your axial piston variable pump A4VG.

Please request the

installation drawing

from your contact at

Bosch Rexroth.

Installation drawing

Axial piston variable pump A4VG

Contains the permissible technical data.

92035 Data sheet

Hydraulic ﬂuids based on mineral oils and related hydrocarbons

Describes the requirements on a hydraulic ﬂuid based on mineral oil and

related hydrocarbons for operation with Rexroth hydraulic components, and

assists you in selecting a hydraulic ﬂuid for your system.

90220 Data sheet

Environmentally acceptable hydraulic ﬂuids

Describes the requirements on an environmentally acceptable hydraulic ﬂuid

for operation with Rexroth hydraulic components and assists you in selecting

a hydraulic ﬂuid for your hydraulic system.

90221 Data sheet

Fire-resistant, water-free hydraulic ﬂuids (HFDR/HFDU)

Describes the requirements on ﬁre-resistant, anhydrous hydraulic ﬂuids

(HFDR/HFDU) for operation with Rexroth hydraulic components and assists

you in selecting a hydraulic ﬂuid for your hydraulic system.

90222 Data sheet

Axial piston units for operation with ﬁre-resistant hydraulic ﬂuids –

anhydrous and hydrous (HFDR, HFDU, HFA, HFB, HFC)

Describes the requirements on ﬁre-resistant, anhydrous and hydrous

hydraulic ﬂuids (HFDR, HFDU, HFA, HFB, HFC) and contains the technical

data for operation with Rexroth hydraulic components.

90225 Data sheet

6/64 About this documentation

Bosch Rexroth AG, Series 35 A4VG, RE 92035-01-B/04.2018

Table 1: Required and supplementary documentation

Title Document number Document type

Component class: 92003-CC-0011_ETPump

The component class speciﬁcation explains what data is available, how this

data was obtained, and what else should be observed.

92003-CC-0011_ETPump Component class

speciﬁcation

BODAS-drive eDA application software

BODAS-drive eDA is a software solution integrated in the Rexroth SRC-

eDA1/31 control unit for controlling the hydrostatic drive train in wheeled

vehicles.

95315 Data sheet

Information on the use of hydrostatic drives at low temperatures

Contains additional information on the use of Rexroth axial piston units at

low temperatures.

90300-03-B Manual

Storage and preservation of axial piston units

Contains additional information on storage and preservation.

90312 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 instructions

This documentation includes safety instructions in chapter2.6 “Product-speciﬁc

safety instructions” on page12 and in chapter3 “General instructions regarding

property and product damage” on page16 and before a sequence of actions or

an instruction for action involving a risk of personal injury or damage to property.

Always follow the instructions on avoiding the dangers associated with the use of

this product.

Safety instructions are set out as follows:

SIGNAL WORD

Type and source of danger!

Consequences of noncompliance

▶ Measures to prevent danger

•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 safety instructions are not complied with

•Precautions: states how the danger can be avoided

About this documentation 7/64

RE 92035-01-B/04.2018, Series 35 A4VG, Bosch Rexroth AG

Table 2: Danger classes as deﬁned in ANSI Z535.6

Warning sign, signal word Meaning

DANGER Identiﬁes a dangerous situation that will result in death or

serious injury if it is not avoided.

WARNING 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 the environment may get

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 product cannot be used and/or

operated to its full extent.

▶ Single, independent action

Numbered instruction:

The numbers indicate that the actions must be completed in order.

1.3.3 Designations

This documentation uses the following designations:

Table 4: Designations

Designation Meaning

A4VG Axial piston variable pump and closed circuit

Threaded plug Metal screw, pressure-resistant

Protective plug Made out of plastic, not pressure-resistant, only for transportation

As umbrella term for “axial piston variable pump A4VG” the designation “axial piston

unit” will be used in the following.

8/64 About this documentation

Bosch Rexroth AG, Series 35 A4VG, RE 92035-01-B/04.2018

1.3.4 Abbreviations

This manual uses the following abbreviations:

Table 5: Abbreviations

Abbreviation Meaning

ATEX EC directive on explosion protection (Atmosphère explosible)

DIN Deutsches Institut für Normung (German Institute for Standardization)

ET Electric control, direct-operated with two pressure reducing valves

(PRV)

ISO International Organization for Standardization

RE Rexroth document in the English language

VDI2230 Standard for the systematic calculation of heavy-duty thread connections

and cylindrical screw joints from the VDI (VereinDeutscherIngenieure -

Association of German Engineers)

Safety instructions 9/64

RE 92035-01-B/04.2018, Series 35 A4VG, Bosch Rexroth AG

2 Safety instructions

2.1 About this chapter

The axial piston unit has been manufactured to generally accepted engineering

standards. There is still, however, a risk of personal injury or property damage if this

chapter and the safety instructions in this documentation are not observed.

▶ Read this documentation completely and thoroughly before working with the axial

piston unit.

▶ Keep it in a location where it is accessible to all users at all times.

▶ Always include the required documentation when you pass the axial piston unit

on to third parties.

2.2 Intended use

Axial piston units are hydraulic components, meaning that in their application area

they are classiﬁed neither as complete nor as partly completed machinery as deﬁned

in the EC Machinery Directive (2006/42/EC). The component is exclusively intended

to form partly completed machinery or complete machinery together with other

components. The component may 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:

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92035 and in the order

conﬁrmation. Information about approved hydraulic ﬂuids can be found in data

sheet 92035.

The axial piston unit is only intended for commercial use and not for private use.

Intended use includes having fully read and understood this documentation,

especially Chapter 2 “Safety instructions” on page 9.

2.3 Improper use

Any use other than that described as intended use is considered improper.

Bosch Rexroth AG is not liable for damages resulting from improper use.

The user is solely responsible for any risks arising from improper use.

The following foreseeable misuses are also considered improper (this list is not

exhaustive):

•Use outside the operating parameters approved in the data sheet or in the order

conﬁrmation (unless speciﬁcally approved by the customer)

•Use of non-approved ﬂuids, e.g. water or polyurethane components

•Changes to factory settings by unauthorized persons

•Use of add-ons (e.g., control unit, valves) not in combination with the speciﬁed

Rexroth components

•Use of the axial piston unit with assembled parts under water at a depth of

more than 10meters without the necessary additional measures, e.g. pressure

equalization. Units with electrical components (e.g. sensors) generally cannot

come into contact with water.

10/64 Safety instructions

Bosch Rexroth AG, Series 35 A4VG, RE 92035-01-B/04.2018

•Use of the axial piston unit under a continuous pressure diﬀerential between

housing and ambient pressure greater than 2bar, with the ambient pressure always

lower than the case pressure. Momentary (t<0.1s) pressure peaks of up to 10bar

are allowed, but no more than 1000 pressure peaks over the entire service life.

Beyond this, the maximum permissible case pressure speciﬁed in the data sheet

should not be exceeded.

•Use of the axial piston unit in explosive environments unless the component

or machine/system has been certiﬁed as compliant with the ATEX

directive 2014/34/EC

•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 manual require a basic understanding of mechanics,

electricity and hydraulics, as well as familiarity with associated technical terms.

For transporting and handling the product, additional familiarity with 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 a skilled person.

Qualiﬁed personnel refers to persons who possess the professional training,

knowledge and experience, as well as the understanding of the regulations relevant

to the work to be done that are necessary to recognize possible hazards and take the

appropriate safety measures. Qualiﬁed personnel must follow the rules relevant to

their ﬁeld and have the necessary hydraulics expert knowledge.

Hydraulic expert knowledge includes:

•Being able to read and fully understand hydraulic circuit diagrams

•In particular, fully understanding the relationships with regard to safety devices

•Understanding how hydraulic components work and are put together.

Bosch Rexroth oﬀers training support for specialized ﬁelds. An overview of the

training contents can be found online at: www.boschrexroth.com/training.

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