Bosch Rexroth A4VG 35 Series Manual de usuario

Instruction manual

RE92035-01-B/2019-11-25

Replaces: 04.2018

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

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1 About this documentation 5

1.1 Validity of the documentation 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 on property damage 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 Transportby hand 25

6.1.2 Transportwith lifting devices 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 32

7.3.1 Below-reservoir installation (standard) 32

7.3.2 Above-reservoir installation 33

7.4 Installing the axial piston unit 34

Contents

7.4.1 Preparation 34

7.4.2 Dimensions 35

7.4.3 General instructions 35

7.4.4 Installation with a coupling 36

7.4.5 Installation on a gearbox 36

7.4.6 Installation with cardan shaft 37

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Bosch Rexroth AG, A4VG Series35, RE92035-01-B/2019-11-25

7.4.7 Completion of assembly 37

7.4.8 Hydraulically connecting the axial piston unit 39

7.4.9 Electrically connecting the axial piston unit 43

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 47

8.2 Running-in phase 47

8.3 Recommissioning after standstill 48

9 Operation 49

10 Maintenance and repair 50

10.1 Cleaning and care 50

10.2 Inspection 51

10.3 Maintenance 51

10.4 Repair 52

10.5 Spare parts 52

11 Removal and replacement 53

11.1 Required tools 53

11.2 Preparing for removal 53

11.3 Performing the disassembly 53

11.4 Preparing the components for storage or further use 53

12 Disposal 54

13 Extension and conversion 55

14 Troubleshooting 56

14.1 How to proceed for troubleshooting 56

14.2 Malfunction table 57

15 Technical data 61

16 Alphabetical index 62

Contents

About this documentation 5/64

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1 About this documentation

1.1 Validity of the documentation

This documentation is valid for the following products:

• Axial piston variable pump A4VG Series35

This documentation is intended for machine/system manufacturers, assemblers and

service engineers.

This documentation 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 on property damage 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, ports, main dimensions and

circuit diagrams.

92035 Data sheet

Hydraulic ﬂuids based on mineral oils and related hydrocarbons

Describes the requirements for hydraulic ﬂuids on mineral oil basis and

related hydrocarbons for operation with Rexroth hydraulic components

and provides supportfor selection of suitable hydraulic ﬂuids for the

hydraulic system.

90220 Data sheet

Environmentally acceptable hydraulic ﬂuids

Describes the requirements for environmentally acceptable hydraulic

ﬂuids on mineral oil basis and related hydrocarbons for operation with

Rexroth hydraulic components and provides supportfor selection of

suitable hydraulic ﬂuids for the hydraulic system.

90221 Data sheet

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

Describes the requirements on ﬁre-resistant, water-free 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

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Bosch Rexroth AG, A4VG Series35, RE92035-01-B/2019-11-25

Table 1: Required and supplementary documentation

Title Document number Document type

Axial piston units for operation with ﬁre-resistant

hydraulic ﬂuids – water-free, water-containing

(HFDR, HFDU, HFA, HFB, HFC)

Describes the requirements on ﬁre-resistant, water-free and

water-containing hydraulicﬂuids (HFDR, HFDU, HFA, HFB, HFC) and

contains the technical data for operation

with Rexroth hydraulic components.

90225 Data sheet

Component class: 92035-CC-0001_ETPump

The component class speciﬁcation explains what data is available,

howthis data was obtained, and gives further notices to be observed.

92035-CC-0001_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

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 application 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

Uniform safety instructions, symbols, terms and abbreviations are used throughout

this documentation to ensure safe and proper use of the product. For clariﬁcation,

they are explained in the sections below.

1.3.1 Safety instructions

This documentation contains safety instructions in chapter 2.6 "Product-speciﬁc

safety instructions" on page12 and in chapter 3 "General instructions on property

damage and product damage" on page16, as well as before a sequence of actions

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

Always follow the measures for danger prevention associated with the use of this

product.

Safety instructions are set out as follows:

SIGNAL WORD

Type and source of danger!

Consequences of noncompliance

▶ Danger prevention measures

•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 disregarded

•Precautions: states how the danger can be avoided

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Table 2: Hazard 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 surrounding area may be

damaged.

1.3.2 Symbols

The following symbols indicate notices that are not safety-relevant but increase

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, A4VG Series35, RE92035-01-B/2019-11-25

1.3.4 Abbreviations

This documentation 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 Directive for the systematic calculation of high duty screwed

joints and cylindrical screw joints from the VDI(Verein Deutscher

Ingenieure-Association of German Engineers)

Safety instructions 9/64

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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 this documentation 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 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:

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 the 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 forms of faulty usage are also considered improper

(thislist is not exhaustive):

• Use outside the operating parameters approved in the datasheetand in the order

conﬁrmation (unless speciﬁcally approved by the customer)

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Bosch Rexroth AG, A4VG Series35, RE92035-01-B/2019-11-25

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

• Changes to factory settings by unauthorized persons.

• Use of assembled parts (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.

• 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.

• Application 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/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 familiarity with associated technical

terms. For transporting and handling the product, knowledge regarding 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 work to be done that are necessary to recognize possible dangers and take

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

their ﬁeld and have the necessary hydraulic 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

• Knowledge regarding the function and interaction of hydraulic components

BoschRexroth offers you measures supporting training in speciﬁc areas.

Youcanﬁnd an overview of the training contents on the Internet at:

www.boschrexroth.com/training.

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