RE 92 012/04.

00

RE 92 012/04.00
replaces: 11.94

Variable Displacement Pump A4VTG

for drum drives on mobile concrete mixers for closed circuits Sizes 56...90 Series 3 Nominal pressure 400 bar Peak pressure 450 bar

A4VTG...HW

Index
Features Ordering Code Technical Data Pressure Relief Valve Filtration HW - Hydraulic Control, Mechanical Servo EP - Electrical Control, with Proportional Solenoid Unit Dimensions, Size 71 Unit Dimensions, Size 90 Dimensions for Through Drives Permissible Input and Through Drive Rotation Torques Mechanical Stroke Limiter, M Ports X3 and X4 for Positioning Pressure, T Speed Sensor, G Installation Situation for Coupling Assembly Installation and Commissioning Guidelines 1 2...3 4 5 5 6 6 7 8 9 9 10 10 11 11 12

Features
variable displacement axial piston pump of swashplate design for hydrostatic closed circuit transmissions flow is proportional to drive speed and displacement and is infinitely variable output flow increases with swivel angle from 0 to its maximum value swivelling the pump over centre smoothly changes the direction of flow the pump is equipped with two pressure relief valves on the high pressure ports to protect the hydrostatic transmission (pump and motor) from overloads these valves also function as boost inlet valves an integral auxiliary pump serves as boost and pilot oil pump the maximum boost pressure is limited by a built-in boost pressure relief valve

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Ordering Code
Hydraulic fluid Mineral oil (no code) Axial piston unit Variable swashplate design, for drum drives on mobile concrete mixers Operation Pump in closed circuits Size Displacement Vg max in cm3 Control device Hydraulic control, mechanical servo Electrical control with proportional solenoid

A4VT

56 56 12V 24V

71 71

90 90 HW EP1 EP2

Mechanical stroke limiter without mechanical stroke limiter (no code) with mechanical stroke limiter Ports X3, X4 for positioning pressure without ports X3, X4 (no code) with ports X3, X4 Series

3 Index 2 Direction of rotation viewed on shaft end

clockwise anti-clockwise

R L

Seals NBR, shaft seal in FKM (fluor-caoutchouc) Shaft end Splined shaft SAE

without coupling flange with coupling flange 56 71 90

S L

Mounting flange SAE C, 2-hole SAE C, 4-hole Service line connections Ports A/B SAE, (metric fixing screws) at side (same side)

C D

10

= available = in preparation = not available Brueninghaus Hydromatik 2/12 A4VTG

RE 92 012/04.00

A4VT G
Axial piston unit Operation Size Control device Series Index Direction of rotation Seals Shaft end Mounting flange Service line connections

/ 3 2

10

Auxiliary pump and through drive auxiliary pump through drive flange SAE A. 2-Loch SAE B, 2-Loch

hub SAE A SAE B

(N 5/8"-9T 16/32DP) (N 7/8"-13T 16/32DP) 56 71 90

F00 F01 F02

Valves with high pressure relief valve, pilot controlled; with bypass with high pressure relief valve, direct controlled; with bypass Filtration Filtration in the suction line of the auxiliary (boost) pump Speed sensor without speed sensor (no code) with speed sensor

1 5

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Technical Data
Fluid To review the application of A4VTG pumps with the selected hydraulic fluid, detailed fluid compatibility and application data can be found in data sheets RE 90220 (mineral oil), RE 90221 (environmentally acceptable hydraulic fluids) and RE 90223 (fire resistant fluids, HF). The variable pump A4VTG is not suitable for operation with HFA, HFB and HFC. When using HFD or environmentally acceptable hydraulic fluids limitations for the technical data have to be taken into consideration. If necessary please consult our technical department (please indicate type of the hydraulic fluid used for your application on the order sheet). Operating viscosity range In order to obtain optimum efficiency and service life, we recommend that the operating viscosity (at operating temperature) be selected from within the range: opt = operating viscosity 16...36 mm2/s referred to the circuit temperature (closed circuit). Viscosity limits The limiting values for viscosity are as follows: min = 5 mm2/s short term at a max. permissible temp. of tmax = 115C. Please note that the max. fluid temperature is also not exceeded in certain areas (for instance bearing area). max = 1600 mm2/s short term on cold start ( (n 1000 rpm, tmin = -40C). At temperatures of -25C up to -40C special measures are required. Please contact us for further information. Selection diagram
2500-40 1600 1000 600 400 200 -20 0 20 40 60 80 100 1600

Notes on the selection of the hydraulic fluid In order to select the correct fluid, it is necessary to know the operating temperature in the circuit (closed circuit) in relation to the ambient temperature. The hydraulic fluid should be selected so that within the operating temperature range, the operating viscosity lies within the optimum range (opt) (see shaded section of the selection diagram). We recommend that the highest possible viscosity range should be chosen in each case. Example: At an ambient temperature of XC circuit temperature is 60C. Within the operating viscosity range (opt; shaded area) this corresponds to viscosity ranges VG 46 or VG 68. VG 68 should be selected. Important: The leakage oil (case drain oil) temperature is influenced by pressure and pump speed and is always higher than the circuit temperature. However, at no point in the circuit may the temperature exceed 115C. If it is not possible to comply with the above conditions because of extreme operating parameters or high ambient temperatures please consult us. Temperature range of the radial shaft seal The FKM shaft seal is admissible for a housing temperature range from -25C to +115C. Note: For applications below -25C a NBR shaft seal is necessary (admissible temperature range -40C to +90C). When ordering, please state in clear text: with NBR shaft seal Working pressure range - inlet Auxiliary pump: suction pressure ps min ( 30 mm2/s) ______ 0,8 bar absolute for cold start ________________________ 0,5 bar absolute Working pressure range - outlet Variable pump: Pressure at port A or B nominal pressure pN ______________________________________ 400 bar peak pressure pmax ________________________________________ 450 bar Auxiliary pump: peak pressure pH max ________________________________________ 40 bar (pressure data to DIN 24312)

0 10 G V 68 G V 46 G V 32 G V 2 2

VG

viscosity in mm2/s

100 60 40 20 10

36 opt. 16

Case drain pressure 5 5 Permissible case drain pressure at ports T1 and T2 -40 -25 -10 0 10 30 50 70 90 115 pL _______________________________________ 4 bar abs. temperature t in C short term (at start) __________________________ 6 bar abs. tmin = -40C tmax = +115C fluid temperature range

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Technical Data
Table of values (theoretical values, without considering mh and v: values rounded) Size Displacement variable pump auxiliary pump (at p = 20 bar) Speed max. speed with Vg max minimum speed Flow at nmax contin. and Vg max Power at nmax contin. p = 400 bar Torque at Vg max p = 400 bar (variable pump without aux. pump) p = 100 bar Moment of inertia (about drive axis) Weight (standard model without through drive) approx.

Vg max Vg H nmax contin. nmin qv max Pmax Tmax T J m

cm3 cm3 rpm rpm L/min kW Nm Nm kgm2 kg

71 71 19,6 3300 500 234 156 451 112,8 0,0072 46

90 90 28,3 3050 500 275 183 572 143 0,0106 48

Pressure Relief Valve

The two high pressure relief valves are protecting the hydrostatic transmission (pump and motor) against overcharge. They are limiting the max. pressure of the respective high pressure line and are serving at the same time for boost valves. The boost pressure is set via boost pressure valve. Standard setups: - boost pressure valve: pSP _________________________________ 22 bar - high pressure valve: pmax ______________________________ 420 bar Note: The valve setups are carried out at n = 1000 rpm and Vg max. At other operating parameters differences in the opening pressures may occur. high pressure relief valve

Filtration
The finer the filtration the better the achieved cleanliness level of the pressure fluid and the longer the life of the axial piston unit. To ensure the functioning of the axial piston unit a minimum cleanliness level of 9 to NAS 1638 18/15 to ISO/DIS 4406 is necessary. At very high temperatures of the hydraulic fluid (90C to max. 115C) at least cleanliness level 8 to NAS 1638 17/14 to ISO/DIS 4406 necessary. If above mentioned grades cannot be maintained please consult supplier. Standard: Filtration in the suction line of the auxiliary pump, S Filter type: ________________________ filter without bypass Recommendation: ____________ with contamination indicator Through flow resistance at filter element: at = 30 mm2/s, n = nmax ___________________________ p 0,1 bar at = 1000 mm2/s, n = nmax ________________________ p 0,3 bar Pressure at port S of the auxiliary pump: at = 30 mm2/s ___________________________ p 0,8 bar at cold start ( = 1600 mm2/s, n 1000 rpm) ______ p 0,5 bar

boost pressure valve

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HW

Hydraulic Control, Mechanical Servo

EP

Electrical Control, with Proportional Solenoid

The positioning cylinder of the pump and therefore the swivel angle is varied in proportion to the movement of the control lever. The pump control is steplessly variable. Each direction of flow is assigned to one direction of lever movement.
in

In relation to the preselected current, control pressure is applied to the positioning cylinder of the pump via two proportional solenoids on control device EP. The displacement of the pump is thus steplessly variable. One solenoid is assigned to each direction of flow. Operating curve: EP2
800 700 600 500 400 300 200 100 0 1,0 0,8 0,6 0,4 0,2 0 200 300 400 500 600 700 800

40 35 30 25 20 15 10 5 0 1,0 0,8 0,6 0,4 0,2 Vg 50 10 Vg max 15 20 25 30 35 40

I in mA

0,2 0,4 0,6 0,8 1,0 V g

Vg max

Vg Vg max

0,2 0,4 0,6 0,8 1,0 V g

Vg max

in

I in mA

model Swivel angle of control lever: - from 0 to Vg max _______________________________ = 0 to 29 - mech. stop: _________________________________ 40 Torque at control lever - necessary torque for displacement ______ approx. 85 to 210 Ncm - max. torque __________________________ 700 Ncm (7 Nm) Dependant from the operation conditions of the pump (operation pressure, oil temperature) changes of the curve can occur.

control voltage (DC) 12 V 24 V

EP1 EP2

control current I start of control end of control at Vg 0 at Vg max 400 mA 1200 mA 200 mA 600 mA

To control the proportional solenoids the following electronic amplifiers and microcontroller are available: proportional amplifier PVR (RE 95022), chopper amplifier CV (RE 95029) and microcontroller MC with software solutions related to the field of application (RE 95050) (e.g. CSD). Standard: proportional solenoid with manual emergency (without spring return)

MA S
A

MA S

Graph Direction of rotation - Control - Direction of through flow Direction of rotation clockwise anti-clockwise Lever direction (HW) Operated solenoid (EP) a b X2 B to A MA b a X1 A to B MB a b X2 A to B MB b a X1 B to A MA clockwise anticlockwise
MB

anticlockwise
b a

MB X1
S

X1 proportional solenoid a
S

Control pressure
MA X2
A,B

Direction flow Working pressure

clockwise

MA X2
A,B

proportional solenoid b

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Unit Dimensions, Size 71

Prior to finalising your design, please obtain a certified drawing.

Hydraulic control, mechanical servo HW

(SAE C)

HD-valve boost pressure valve

M12; 17 deep

Connections A,B Service line ports SAE 1" 420 bar (6000 psi) (high pressure series) T1 Case drain or filling port M 26x1,5; 16 deep T2 Case drain M 26x1,5; 16 deep MA Pressure gauge - working pressure A M 12x1,5; 12 deep MB Pressure gauge - working pressure B M 12x1,5; 12 deep R Air bleed M 16x1,5; 12 deep S Boost suction port M 42x2; 18 deep X1, X2 Control pressure ports M 12x1,5; 12 deep (before the orifice) pS Control pressure supply M 14x1,5; 12 deep

Shaft ends detail A-A

Electrical control, with proportional solenoid, EP

L
Splined shaft SAE 13/8" with coupling flange

S
Splined shaft SAE 13/8" pressure angle 30, 21 teeth, 16/32 pitch, flat root side fit, tolerance class 5 ANSI B92.1a-1976

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Unit Dimensions, Size 90

Hydraulic control, mechanical servo HW
Prior to finalising your design, please obtain a certified drawing.

(SAE C)

HD-valve boost pressure valve

M12; 17 deep

298,9

Connections A,B Service line ports SAE 1" 420 bar (6000 psi) (high pressure series) T1 Case drain or filling port M 26x1,5; T2 Case drain M 26x1,5; Pressure gauge - working pressure A M 12x1,5; MA MB Pressure gauge - working pressure B M 12x1,5; R Air bleed M 16x1,5; S Boost suction port M 42x2; X1, X2 Control pressure ports M 12x1,5; (before the orifice) pS Control pressure supply M 14x1,5;

16 deep 16 deep 12 deep 12 deep 12 deep 18 deep 12 deep 12 deep

Shaft ends

detail A-A

Electrical control, with proportional solenoid, EP

L
Splined shaft SAE 11/2" with coupling flange

S
Splined shaft SAE 11/2" pressure angle 30, 23 teeth, 16/32 pitch, flat root side fit, tolerance class 5 ANSI B92.1a-1976
33,4

Brueninghaus Hydromatik

R2 ,5

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Dimensions for Through Drives

Prior to finalising your design, please obtain a certified drawing.

Through drive SAE A (F01) Size 71 splined hub SAE A

N 5/8"-9T 16/32 DP

Size 90 splined hub SAE A

N 5/8"-9T 16/32 DP

M10; 15 deep

A3

A3

Size 71 90

A1 297,6 297,6

A2 9 9

A3 10 8

A4 17

17,5 82,55

suitable for connection of: gear pump G2 (RE 10030) variable pump A10VSO10 (RE 92713) variable pump A10VSO18 (RE 92712)

106,4 A1

A2 A4 A1

A2

(to mounting flange)

(to mounting flange)

Through drive SAE B (F02) Sizes 71, 90 M12; 21 deep splined hub SAE B
N 7/8"-13T 16/32 DP A3

82,55

106,4

Size 71 90

A1 A2 300,6 12,5 313,6 13

A3 9,8 9,8

A4 15,5 19

suitable for connection of: gear pump G3 (RE 10039) gear pump G4 (RE 10042) variable pump A10VG18 (RE 92750) variable pump A10VO28 (RE 92701/ RE 92703)

24

146

A1

A2 A4

(to mounting flange)

Permissible Input and Through Drive Rotation Torques

Size Corner torque (when Vgmax and p = 400 bar) 1) Tmax Nm Max. perm. through drive rotation torque TD perm. Nm Max. permissible input torque 2) TE perm. Nm
1) 2)

101,6

146

71 451 660 970 (W 1 3/8")

90 572 822 1305 (W 1 1/2")

efficiency not taken into consideration drive shaft without side load

Code explanations TD perm. = max. permissible through drive torque in Nm TE perm. = max. permissible input torque at the drive shaft in Nm

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Mechanical Stroke Limiter, M

Adjustment screws to both Vg max values
86,3

max. 135

28,5

Circuit diagram A4VTG 71HWM

Ports X3 and X4 for Positioning Pressure, T

max. 135

86,3

28,5

X1 X3

X4 X2

X3

113,5

113,5

Circuit diagram A4VTG 71HWT

X4

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Installation Situation for Coupling Assembly

In order to assure that rotating parts (coupling hub) and fixed parts (housing, circlip) do not contact each other the installation situations are described in this leaflet have to be observed. At design "shaft end L" (SAE splined shaft with mounted coupling flange) Brueninghaus Hydromatik already considered this fact. At design "shaft end S" (SAE splined shaft) it has to be considered when selecting the coupling, that the external diameter of the coupling hub in the area of the shaft collar (size x2 x3) has to be smaller than the internal diameter of the circlip d2.
x2 x1

coupling hub

d4 d3

d2

x3

Size d1 71 90 45 45

d2 min 66,5 66,5

d 3 81 0,1 81 0,1

d 4 127 127

x1 7,0+0,2

d1

x2 12,7-0,5

x3 8 -0,6
+0,9

7,0+0,2 12,7-0,5

Speed Sensor, G
The design "with speed sensor G" is facilitating at electronically piloted drives a speed record of the variable pump A4VTG. In connection with a microcontroller MC (RE 95050) and software CSD an alternating input speed of the pump can thus be picked up and the constant flow qV is resulting. Consequently a constant output speed (mixer drum speed) is generated at the output shaft of the so driven hydromotor.
programming diagnostics speed specification

BB-3

MC + CSD

A1

speed

n = variable

n = constant

qV = constant speed sensor ID

(is supplied as individual item)

The design "with speed sensor G" is including a gears spline at the rotary group of the variable pump and an additional port for the speed record, in which an inductive speed sensor type IDR 18/20-L250 (as to RE 95130) is screwed in. Note: The sensor inclusively necessary mating connector (mating connector for IDR elbow) is supplied as individual item and has to be screwed into the provided port before start-up. To avoid measurment errors, the max. tightening torque of 50 Nm should not be exceeded.

mating connector AMP

(is supplied as individual item)

Size No. of teath A1 A2

71 46 176 170

90 50 176 170

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Installation and Commissioning Guidelines

General At start-up and during operation the pump housing has imperatively to be filled up with hydraulic fluid (filling of the case chamber). Startup has to be carried out at low speed and without load till the system is completely bleeded. At a longer standstill the case may discharge via operating line. At new start-up a sufficient filling of the housing has to be granted. The leakage oil in the housing has to be discharged to the tank via highest positioned case drain port. The min. suction pressure at port S should not fall below 0,8 bar absolute (cold start 0,5 bar absolute). Installation position Shaft horizontal, further installation positions as to agreement. Installation below tank level Pumps below min. oil level in the tank (standard) Fill up axial piston pump before start-up via highest positioned case drain port Recommendation: Fill up suction lines. Operate pump at low speed (igniton speed) till pump system is completely filled up (Verification: oil is leaking out without bubbles at port pS, discharge oil via gauge pipe into reservoir). Bleed pump at installation position "control device on top" via port R. Bleed closed loop: - variable motor A6VM: via port G - fixed motor A2FM: via operating port A, B - motor with flushing valve: bleeding not necessary Minimal depth of immersion of the suction resp. case drain line in the tank: 200 mm (corresponding to the min. oil level in the tank) Installation on top of tank level Pump on top of min. oil level in the tank Actions as installation below tank level Note: - max. admissible suction height hmax = 800 mm - min. admissible presssure at port S (min. suction pressure)
S T1

R S T1 T2

Brueninghaus Hydromatik GmbH Elchingen Plant Glockeraustrae 2 D89275 Elchingen Phone +49 (0) 73 08 82-0 Telefax +49 (0) 73 08 72 74 Internet: www.rexroth.com/brueninghaushydromatik / E-Mail: [email protected] The specified data is for product description purposes only and may not be deemed to be guaranteed unless expressly confirmed in the contract.

All rights reserved Subject to revision

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