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8904 Operating Instructions A4VG

service manual pump

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Eduardo Cramer
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100% found this document useful (2 votes)
2K views40 pages

8904 Operating Instructions A4VG

service manual pump

Uploaded by

Eduardo Cramer
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 40

Electric Drives

and Controls

Hydraulics

Linear Motion and


Assembly Technologies

Axial Piston Variable Pump


A4VG 71180
Series 32

Pneumatics

Service

RE 92 003-21-B/05.06

Product-Specic Operating Instructions

A4VG 180

A4VG 71125

2/40

Bosch Rexroth AG

Product-Specic Operating Instructions A4VG 71180

Manufacturer
Bosch Rexroth AG
Hydraulics
Product Unit Axial Piston Units
Elchingen Plant
Glockeraustrae 2
89275 Elchingen, Germany
Telephone +49 (0) 73 08 82-0
Fax
+49 (0) 73 08 72-74
[email protected]
www.boschrexroth.com/addresses
Information on contacts in the various countries is available at
this Internet address.

Details on the manufacturer are available on the axial piston


units name plate.

RE 92 003-21-B/05.06

Contents
1
1.1
1.2

About these instructions ............................................................3


Structure and requirements ....................................................3
Hazard markings and pictograms .........................................6

2
2.1

Safety ...................................................................................................7
Basic safety instructions .........................................................7

3
3.1
3.2
3.3

Product description.................................................................... 11
Identication of the axial piston unit....................................11
Functional description............................................................12
Bypass function of the high-pressure relief valves ..........19

4
4.1
4.2
4.3
4.4
4.5

Installation ......................................................................................23
Installation notes .................................................................... 24
Assembling the axial piston unit ......................................... 27
Connecting lines .................................................................... 27
Connecting the electric controller ......................................31
Preparing the axial piston unit for storage.........................31

5
5.1
5.2

Commissioning ............................................................................33
Filling the axial piston unit .................................................... 34
Testing the hydraulic uid supply ...................................... 35

Troubleshooting ...........................................................................37
Index ..................................................................................................39

RE 92 003-21-B/05.06

Product-Specific Operating Instructions A4VG 71180

Bosch Rexroth AG

3/40

Avoiding dangers

! ! DANGER!

To ensure reliable operation and to avoid damage when performing an installation, commissioning or servicing, study these operating instructions carefully and thoroughly!
Bosch Rexroth AG cannot be held liable for any personal injuries or machine damage arising
from non-adherence to these operating instructions. In case of damage induced by disregard
of these operating instructions, any warranty provided by Bosch Rexroth AG will be rendered
null and void and liability placed with the operating company.

Documents

About these instructions

1.1

Structure and requirements

Operating instructions for Rexroth axial piston units consist of three sub-documents:
General operating instructions for axial piston units, RE 90 300-B
The general operating instructions for axial piston units will assist you during installation,
commissioning, operation and servicing of Rexroth axial piston units. These include axial
piston pumps and motors for use in open or closed hydraulic circuits.
Unless stated differently, the information in the general operating instructions applies to all
Rexroth axial piston units. Information which only applies to specic pumps or motors or
hydraulic concepts is marked in the text accordingly.
Product-specic operating instructions, RE 92 003-21-B
These product-specic operating instructions for the axial piston variable displacement
pump A4VG, sizes 71180 contain additional, specic information on installation,
commissioning and operation.
Always observe both the details in the product-specic operating instructions and the
details in the general operating instructions.
Technical data sheet, RE 92 003
The technical data sheet for the axial piston variable displacement pump A4VG contains
the complete technical data.
Please contact Rexroth to request the missing parts of the documentation if you are not in
possession of the entire set of documents. Safe operation of Rexroth axial piston units can
only be guaranteed if you observe the details in all available sub-documents.

General operating
instructions

The general operating instructions will assist you during installation, commissioning and operation of Rexroth axial piston units. The chapter sequence is the same in both the general
as well as the product-specic operating instructions. The general operating instructions
contain additional chapters however:
In "Servicing", you will nd information about maintenance, inspection and repair of Rexroth
axial piston units.
In the appendix, you will nd project planning notes for the selection of hydraulic uid, the
design of the tank, the lters and the heat exchanger as well as the correct piping of the
hydraulic system.

4/40

Bosch Rexroth AG

Operating
instructions
A4VG 71180

Product-Specic Operating Instructions A4VG 71180

RE 92 003-21-B/05.06

The chapters of these product-specic operating instructions are structured analogous to


the chapters in the general operating instructions and supplement the general operating
instructions with specic information on the axial piston variable displacement pump A4VG.
Therefore, always observe the general operating instructions as well.
You will need the individual chapter of these instruction during the various phases of working with the axial piston variable displacement pump A4VG, sizes 71180:
"Safety" on page 7 explains how the instructions in this document are to be understood
and contains several basic safety instructions on working with axial piston units.
"Product description" on page 11 provides you with information on the identication of the
axial piston variable displacement pump A4VG, sizes 71180 as well as its conventional use.
"Installation" on page 23 provides you with information on the installation as well as on
the disassembly and storage of the axial piston variable displacement pump A4VG, sizes
71180.
"Commissioning" on page 31 explains what you must observe during commissioning of the
axial piston variable displacement pump A4VG, sizes 71180 and the machine or system.
The overview in "Troubleshooting" on page 35 assists you in searching for and tracing
faults on the axial piston variable displacement pump A4VG, sizes 71180 and the entire
machine or system.

Note

Always observe the safety instructions in "Safety".

Area of validity for


these instructions

These operating instructions are valid for the axial piston variable displacement pump
A4VG, sizes 71180 for operation with approved hydraulic uids. Information on the approved hydraulic uids is available in technical data sheet RE 92 003.
These operating instructions are for the:
machine or system manufacturer,
the operating company,
the operator.
The respective installation drawing, technical data sheet and order conrmation of
Bosch Rexroth AG are also binding for the machine or system manufacturer.

Important documents

Before starting with the tasks described in these operating instructions, make sure that the
following documents are already available:
General operating instructions for axial piston units, RE 90 300-B
The general operating instructions contain all general information which is to be observed
independent of the specic axial piston unit. During work with the axial piston variable
displacement pump A4VG, sizes 71180, always observe the general operating
instructions and the product-specic operating instructions.
Order conrmation
The order conrmation contains the preset technical data. The axial piston variable
displacement pump A4VG, sizes 71180 may only be operated using the values and
conditions specied in the order conrmation.
Installation drawing
The installation drawing of the axial piston variable displacement pump A4VG, sizes 71
180 contains the outer dimensions, all connections and the hydraulic circuit diagram for
the axial piston unit.

RE 92 003-21-B/05.06

Product-Specific Operating Instructions A4VG 71180

Bosch Rexroth AG

5/40

Technical data sheet "Axial piston variable displacement pump A4VG", RE 92 003
The technical data sheet contains, among other information, the permissible technical data
for the axial piston variable displacement pump A4VG, sizes 71180.
General circuit diagram of the machine or system
The hydraulic and electrical circuit diagrams of the machine or system contain the
information of the hydraulic or electrical connections. You need these data to work with the
axial piston variable displacement pump A4VG, sizes 71180 as part of the machine or
system. You will receive the documents from the machine or system manufacturer.
The following Rexroth documents provide further information about installation and operation
of the axial piston unit:
RE 90 220: Mineral-oil based hydraulic uids
Describes the requirements on a mineral-oil based hydraulic uid for the operation with
Rexroth axial piston units and assists you in selecting a hydraulic uid for your system.
RE 90 221: Environmentally acceptable hydraulic uids HEES, HEPG, HETG for axial
piston units
Describes the requirements on an environmentally acceptable hydraulic uid for the
operation with Rexroth axial piston units and assists you in selecting a hydraulic uid for
your system.
RE 90 223: Axial piston units for operation with HF hydraulic uids
Contains additional information on the use of Rexroth axial piston units with
HF hydraulic uids.
RE 90 300-03-B: Information on using hydraulic drives at low temperatures.
Contains additional information on the use of Rexroth axial piston units at low
temperatures.
Note

Also observe the details on "staff requirements" given in the general operating instructions
RE 90 300-B.

6/40

Bosch Rexroth AG

1.2

Product-Specic Operating Instructions A4VG 71180

RE 92 003-21-B/05.06

Hazard markings and pictograms

These instructions differentiate between categories of dangers as per ISO Guide 37:

! ! DANGER!

This hazard marking warns of high risk, lethal dangers and severe injuries.

! WARNING

This hazard marking warns of medium risk, injuries and severe property damage.

! CAUTION

This hazard marking warns of low risk and property damage.

Note

This marking refers to information which helps to better understand the machine processes
or which refers to special or important circumstances.

Tip

This marking refers to information which assists in improving work efciency.

RE 92 003-21-B/05.06

Product-Specic Operating Instructions A4VG 71180

Bosch Rexroth AG

7/40

Safety

Due to its special importance, this chapter repeats the basic safety instructions in the general operating instructions RE 90 300-B.
Read this chapter carefully before starting to work with the axial piston unit.
Rexroth axial piston units are to be installed as components in machines or systems.
The safety directives in these instructions relate to axial piston units only. Please also note
the manufacturers safety directives for the machine or system.

2.1

Basic safety instructions

Please strictly observe the following safety instructions as well as the safety instructions of
the machine or system manufacturer to avoid any injuries and health damages as well as
property damage and environmental pollution.

! ! DANGER!

Danger to life
Working on operating machines or systems poses a danger to life and limb.
The work described in this document may only be performed on disconnected machines
or systems. Before beginning work:
Ensure that the engine is switched off and cannot be switched on.
Ensure that all power-transmitting components and connections (electric, pneumatic,
hydraulic) are switched off according to the manufacturer's instructions and cannot be
switched on again. If possible, remove the main fuse on the machine or system.
Ensure that the machine or system is completely hydraulically relieved (depressurized).
Please follow the instructions of the machine or system manufacturer.

! WARNING

Risk of injury
To prevent injuries, observe the following recommendations regarding
safety clothing:
While working on the machine or system, always wear safety shoes with steel caps.
While working with hazardous materials (for example hydraulic uids), always wear safety
gloves, safety glasses and suitable working clothes.

! ! DANGER!

Risk of toxication and injury


Contact with hydraulic uids may damage your health (e.g. eye injuries, skin and tissue damage, toxication resulting from the inhalation of vapors).
Check the lines for wear or damage before each commissioning.
Wear safety gloves and safety glasses when performing this inspection.
If hydraulic uid should, nevertheless, come into contact with your eyes or penetrate your
skin, consult a doctor immediately.
When working with hydraulic uids, strictly observe the safety instructions provided by the
hydraulic uid manufacturer.

8/40

Bosch Rexroth AG

! WARNING

Product-Specic Operating Instructions A4VG 71180

RE 92 003-21-B/05.06

Risk of burns!
The axial piston unit heats up during operation. The solenoids on the axial piston unit heat up
during operation as well. Touching the axial piston unit or solenoids could result in severe burn
injuries.
Always allow the axial piston unit to cool down before touching it.
Protect yourself by wearing heat-resistant gloves and protective clothing.

! ! DANGER!

Risk of toxication and injury


While searching for leakages, escaping hydraulic uid can penetrate the skin and cause
severe toxication and injuries.
Only search for leakages when the machine is switched off and depressurized.

! WARNING

Risk of injury and damage


Incorrectly connected components can cause severe malfunctions.
Ensure that piping is connected according to the circuit diagram.
Perform component-oriented functional tests.

! ! DANGER!

Fire hazard
Hydraulic uid is ammable.
Keep open ames and ignition sources from the axial piston unit.

! WARNING

Hearing damage
The noise emission of axial piston units depends on, among other factors, speed, operating
pressure and installation conditions. You can be certain that the sound pressure level will rise
above 70 dBA during normal application conditions. This may cause hearing damage.
Always wear hearing protection while working in the vicinity of the operating axial piston unit.

RE 92 003-21-B/05.06

! WARNING

Product-Specic Operating Instructions A4VG 71180

Bosch Rexroth AG

9/40

Environmental pollution
Hydraulic uids are water-endangering uids. Leaking hydraulic uid can cause toxication of
the groundwater and ground contamination.
Place a catch pan under the axial piston unit.
Remedy the leakage immediately.
National laws and regulations must be observed at all times. In Germany, hydraulic
machines or systems are classied as "systems for working with water-endangering materials within the scope of the Federal Water Act (WHG)". In this context, please especially
note 1 and 19 of the WHG (19g, 19i, 19l).
Further information is available in the Rexroth publication "Mineral-oil based hydraulic
uids", RE 90 220 , "Environmentally Acceptable Hydraulic Fluids HEPG, HEES for Axial
Piston Unit", RE 90 221 and "Axial piston units for operation with HF hydraulic uids", RE
90 223.

Note

Also observe the information regarding "due diligence of the operating company and the
operator" and "responsibility of the machine or system manufacturer" in the general operating
instructions RE 90 300-B.

10/40

Bosch Rexroth AG

Product-Specic Operating Instructions A4VG 71180

RE 92 003-21-B/05.06

RE 92 003-21-B/05.06

Bosch Rexroth AG

Product-Specic Operating Instructions A4VG 71180

11/40

Product description

This chapter explains how to identify an axial piston variable displacement pump A4VG using
the name plate. In addition, the basic function of the axial piston variable displacement pump
A4VG is described.
In the general operating instructions RE 90 300-B you will nd additional information on the
supply volume, technical data and the conventional use of Rexroth axial piston units.

3.1

Identication of the axial piston unit

The axial piston unit can be identied with the name plate. The following example shows the
name plate of an axial piston variable displacement pump A4VG, size 90:

3FYSPUI

D-89275 Elchingen

2
3

TYP: A4VG90DA2D2/32R-NZF02F001SP
MNR: R90XXXXXXX

4
5

SN:
FD:

12345678
05W28

7202

Rotation:

n = XXXX min-1

P = XXX kW

Made in Germany

The name plate contains the following information:


1

Manufacturer

Ordering code

Material number of the axial piston unit

Serial number

Production date

Speed

Internal plant designation

Direction of rotation (looking at the shaft; here: clockwise)

Specied area for test stamp

10 Power

9
10

12/40

Bosch Rexroth AG

3.2

Product-Specic Operating Instructions A4VG 71180

RE 92 003-21-B/05.06

Functional description

The A4VG is an axial piston variable displacement pump with swashplate design for hydrostatic drives in closed circuits. In this chapter, you will learn more about the method of operation, assembly and function of this variable displacement pump.
Details on the technical data of the axial piston variable displacement pump A4VG can be
found in technical data sheet RE 92 003.

Basic method of operation of a variable displacement pump


This section describes the basic method of operation of an axial piston variable displacement
pump for closed circuits.
Closed circuit

A hydraulic system is considered to be closed if the hydraulic uid which ows back from
the consumer is directed directly back to the pump. Here, there is a high-pressure side and
a low-pressure side depending on the load direction (output torque on the consumer).

Assembly of the
pump

The A4VG is an axial piston variable displacement pump with swashplate design for hydrostatic drives in closed circuits.
For axial piston pumps with swashplate design, the pistons are arranged axially relative to the
drive shaft. The pistons are guided in the rotating cylinder and support themselves with the
slipper pads on a slanted, non-rotating shim (swasher).
Cylinder

Drive shaft

Swasher
Piston
Slipper pad

Division of forces (piston forces/torque) occurs via the slipper pad on the slanted plate.
The change in the shim's pitch results in a change in the stroke of the piston in each rotation,
thereby changing the specic displacement.
Control and pressure valves are integrated. Auxiliary pumps can be mounted at the through
drive of the pumps.

RE 92 003-21-B/05.06

Product-Specic Operating Instructions A4VG 71180

Bosch Rexroth AG

13/40

Design and method of operation of the axial piston variable displacement


pump A4VG, sizes 71180
The following gure illustrates the assembly and the components of an axial piston variable
displacement pump A4VG, sizes 71180:
Control plate

Control unit (using the EP


as an example here)

Stroke piston

Pressure cut-off
Service line port

Retaining plate
Auxiliary pump
Drive shaft

Swasher
Slipper pad

Piston

Cylinder

Service line port

Pump function

The drive shaft, which is driven by the engine, turns and engages the cylinder by means of
gearing.

NOTE

In these operating instructions the term "engine" is used as a generic term for diesel,
gasoline, gas and electric engines.

The cylinder turns with the drive shaft, turning with it the 9 pistons. The pistons are supported with slipper pads on the glide surface of the swasher and perform a stroke movement
which is dened by the pitch of the swasher (swashplate). The slipper pads are held on and
guided along the glide surface by a retaining plate.
During a rotation, each piston moves over the bottom and top dead centers back to its starting position. As it moves from dead center (here, the piston rotates around its axis) to dead
center, the piston moves a full stroke. During this action, the uid volume dened by the piston
surface and the stroke is fed in or removed through the two control slits in the control plate.
On the intake stroke, uid ows into the enlarging piston chamber in a closed circuit this is
supported by the return and boost pressures.
On the other side, during the pressure stroke the uid is pushed out of the cylinder chamber
into the hydraulic system by the pistons.

14/40

Bosch Rexroth AG

Pressure cut-off

Product-Specic Operating Instructions A4VG 71180

RE 92 003-21-B/05.06

The operating pressure is limited by the pressure cut-off.


The pressure cut-off is a pressure regulator which reduces the pump capacity once the set
specied pressure value is reached so that the set pressure is maintained but not exceeded.

High-pressure
protection

The peak pressures which occur during very rapid swiveling operation as well as the
maximum pressure are safeguarded by the superordinate high-pressure relief valves.
These valves open if the set value is exceeded, thereby depressurizing the low-pressure
side. The uid quantity remains constant in the closed circuit. The leakage at the pump and
motor is replenished by the boost pump (auxiliary pump).

Auxiliary pump

The auxiliary pump supplies a sufcient volume of uid (boost volume) from a small tank to
the low-pressure side of the closed circuit via a check valve to replenish the internal leakage of the variable displacement pump and consumer.
The auxiliary pump is an internal gear pump which is driven directly via the drive shaft.

Controls
General

For a variable displacement pump, the swivel angle of the swashplate is innitely variable
within certain limits. Changing the swivel angle of the swashplate results in a different piston stroke and, thus, a variable displacement.

The swivel angle of the swashplate is controlled hydraulically via the stroke piston. The
swashplate/swasher is mounted for easy motion in roller bearings and the neutral position
spring centered. Increasing the swivel angle increases the displacement; reducing the angle
results in a corresponding reduction in displacement. If the swashplate is not swiveled out,
the displacement is equal to zero.
NOTE

Additional information on the controls, such as the circuit diagram or characteristics, can be
found in technical data sheet RE 92 003.

Bosch Rexroth AG

15/40

RE 92 003-21-B/05.06

Product-Specic Operating Instructions A4VG 71180

HW control unit

Depending on the swivel angle of the control lever and on the actuation direction (a or b),
the stroke cylinder of the pump is supplied with control pressure via the HW control unit.
Thus, the swashplate and, therefore, the displacement are innitely adjustable. A different ow direction is associated with each direction of control lever actuation.

16/40

Bosch Rexroth AG

HD control unit

Product-Specic Operating Instructions A4VG 71180

RE 92 003-21-B/05.06

Depending on the pressure difference of the pilot pressure pSt in the two control lines
(port Y1 or Y2), the stroke cylinder of the pump is supplied with control pressure via the
HD control unit. Thus, the swashplate and, therefore, the displacement are innitely
adjustable. A different ow direction is associated with each control line.

Y1

Y2

Bosch Rexroth AG

17/40

RE 92 003-21-B/05.06

Product-Specic Operating Instructions A4VG 71180

EP control unit

Depending on the preselected current I at the two proportional solenoids (a) or (b), the
stroke cylinder of the pump is supplied with control pressure via the EP control unit. Thus,
the swashplate and, therefore, the displacement are innitely adjustable. A different
ow direction is associated with each proportional solenoid.

18/40

Bosch Rexroth AG

DA control unit

Product-Specic Operating Instructions A4VG 71180

RE 92 003-21-B/05.06

Depending on the drive speed, the DA control valve generates a pilot pressure which
charges the stroke cylinder of the pump with control pressure via a 4/3-directional valve,
allowing the swashplate and, therefore, the displacement to be innitely adjusted. Each
ow direction is assigned an on/off solenoid (a or b) on the 4/3-directional valve.
You can nd details on DA closed loop control in operating instructions "Hydrostatic drive
with DA closed loop control" - RE 90 330-01-B and in RE 90 330-03-B (functional description and project planning note).

RE 92 003-21-B/05.06

Product-Specic Operating Instructions A4VG 71180

3.3

Bosch Rexroth AG

19/40

Bypass function of the high-pressure relief valves

For vehicles with hydrostatic drive, as long as there is no downstream mechanical interruption of the drive train (switch to idle/free running), the ow can be altered using a bypass
function in order to tow the vehicle out of the immediate danger zone.
Turning the corresponding screw on the two high-pressure relief valves allows the hydraulic
uid to ow freely.

3.3.1

Sizes 71, 90
2
1

Activating the
bypass function

To activate the bypass function:

Switch off the internal combustion engine.

Remove the plastic protective cap (1) on the high-pressure relief valve with a suitable
tool (e.g. gripper).

Loosen the one screw (2) by turning counter-clockwise two rotations with an Allen key
(WAF 5).

Note

The plastic protective cap is destroyed when removing.

Towing speed

The maximum towing speed is dependent on the gear ratio in the vehicle and must be
calculated by the vehicle manufacturer. The corresponding ow of Q = 50 l/min must not
be exceeded.

Towing distance

The vehicle may only be towed out of the immediate danger zone.

! WARNING

Higher towing speeds and longer towing distances result in impermissible heat generation
and insufcient lubrication. This damages the axial piston unit.
Only tow the vehicle out of the immediate danger zone

! WARNING

During and after towing, the axial piston unit is hot.


Wear protective clothing.

20/40

Bosch Rexroth AG

Deactivating the
bypass function

! WARNING

Product-Specic Operating Instructions A4VG 71180

RE 92 003-21-B/05.06

To deactivate the bypass function:

Immediately following towing, switch off the bypass function.

Restore the function of the high-pressure relief valve. To do this, tighten the screw (2)
with an Allen key (WAF 5) by turning clockwise with a torque of 10 1 Nm.

Ret the screw (2) with a protective cap to prevent unauthorized changes to the position
of the pressure-relief valve.

While towing with the bypass function activated, the closed hydraulic circuit empties itself.
This can result in unintended functions when restarting the travel drive.
Start the travel drive only after completely lling and air bleeding the hydraulic circuit
(see also "5.1 Filling the axial piston unit").

3.3.2

Sizes 125, 180

Activating the
bypass function

To activate the bypass function:

Switch off the internal combustion engine.

Loosen the screw (1) by turning counter-clockwise one rotation with a hex wrench
(WAF 36).

NOTE

An optimal seal is not ensured if the high-pressure relief valve is loosened. If hydraulic uid
leaks from the high-pressure relief valve, clear away the uid immediately and clean the valve.

Towing speed

The maximum towing speed is dependent on the gear ratio in the vehicle and must be
calculated by the vehicle manufacturer. The corresponding ow of Q = 100 l/min must not
be exceeded.

Towing distance

The vehicle may only be towed out of the immediate danger zone.

! WARNING

Higher towing speeds and longer towing distances result in impermissible heat generation
and insufcient lubrication. This damages the axial piston unit.
Only tow the vehicle out of the immediate danger zone

RE 92 003-21-B/05.06

! WARNING

Product-Specic Operating Instructions A4VG 71180

Bosch Rexroth AG

21/40

During and after towing, the axial piston units are hot.
Wear protective clothing.

Deactivating the
bypass function

! WARNING

To deactivate the bypass function:

Immediately following towing, switch off the bypass function.

Restore the function of the high-pressure relief valve. To do this, tighten the screw (1)
with a hex wrench (WAF 36) by turning clockwise with a torque of 200 10 Nm.

While towing with the bypass function activated, the closed hydraulic circuit empties itself.
This can result in unintended functions when restarting the travel drive.
Start the travel drive only after completely lling and air bleeding the hydraulic circuit
(see also "5.1 Filling the axial piston unit").

22/40

Bosch Rexroth AG

Product-Specic Operating Instructions A4VG 71180

RE 92 003-21-B/05.06

RE 92 003-21-B/05.06

Product-Specic Operating Instructions A4VG 71180

Bosch Rexroth AG

23/40

Installation

This chapter describes the essential, generally valid steps for the installation of Rexroth axial
piston units of type A4VG sizes 71180. Read this chapter if you would like to install an axial
piston unit in a stationary or mobile hydraulic system.
Note

Observe the fundamental safety instructions on page 7 of these operating instructions for all
work performed during the installation of the axial piston unit.

The following warning notice applies to all variable displacement pumps with the control
units HD and EP:

! CAUTION

The spring return in the control unit is not a security device.


The slide valve of the control unit can be blocked in an undened position by internal contamination e.g. impure hydraulic uid, abrasion or residual contamination from system components. As a result, the variable displacement pump can no longer supply the ow specied
by the operator.
Install an appropriate emergency-off function to ensure that the driven consumer can be
brought to a safe position (e.g. immediate stop).
Maintain the specied cleanliness level 20/18/15 (< 90 C) or 19/17/14 (> 90 C) in
accordance with ISO 4406.
Information on selecting the hydraulic uid and design on the tanks, the lters and the
heat exchanger as well as on the correct piping of the hydraulic system can be found in
the appendix of the general operating instructions RE 90 300-B.

General
installation instructions

You can nd additional topics which should be observed during the installation of the A4VG
axial piston variable displacement pump in the general operating instructions
RE 90 300-B:
Information on unpacking the axial piston unit
Preparations for assembly
Transporting to the installation location
Information on disassembly and disposal of the axial piston unit

Specic installation This chapter supplements the installation instructions provided in the general operating
instructions RE 90 300-B with information specic to the axial piston variable displacement
instructions
pump A4VG:
"4.1 Installation notes" on page 24 contains notes that must be observed during and after
installation.
"4.2 Assembling the axial piston unit" on page 27 explains how to install the axial piston
unit via coupling, gear and cardan shaft.
"4.3 Connecting lines" on page 28 provides information on how to correctly pipe the axial
piston unit and connect the electric lines.
"4.4 Connecting the electric open loop control" on page 30 provides information on how
to correctly pipe the axial piston unit and connect the electric lines.
Information on storing the axial piston unit can be found in "4.5 Preparing the axial piston
unit for storage" on page 30.

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Bosch Rexroth AG

4.1

Product-Specic Operating Instructions A4VG 71180

RE 92 003-21-B/05.06

Installation notes

This section supplements the general installation notes provided in the general operating
instructions RE 90 300-B.
Note

! CAUTION

Note that when the variable axial piston units are assembled in certain installation positions,
the control or closed loop control may be affected. Because of gravity, dead weight and case
internal pressure, minor characteristic displacements and changes in actuating time may occur.

Risk of damage to the axial piston unit


The axial piston unit must always be lled with hydraulic uid.
During commissioning and operation, ensure that the axial piston unit is supplied with
sufcient hydraulic uid.
Ensure that the entire hydraulic system is tight.
Should unusual noises or vibrations develop, immediately switch off the machine or system
and check whether the axial piston unit is lled with hydraulic uid.

General
During commissioning and operation, the axial piston unit must be lled with hydraulic uid
and air bled. This is also to be observed following a relatively long standstill as the system
may empty via the hydraulic lines.
The leakage uid in the case interior must be directed to the tank via the highest leakage uid
port. During operation and cold starting, the suction pressure at port S must not drop below
the minimum permissible values (for values, see technical data sheet RE 92 003).
In all operating states, the suction line and leakage uid line must ow into the tank below
the minimum uid level.

RE 92 003-21-B/05.06

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Product-Specic Operating Instructions A4VG 71180

25/40

Installation position
Examples of permissible installation positions are shown below. The shown piping routes
are only intended to serve as a reference point to illustrate the general routes. Additional
installation positions are available upon request. Also observe the special notes for specic
installation positions provided in "Filling the axial piston unit" on page 32.
Note

"Shaft upwards" installation position (positions 4 and 8)


For the "shaft upwards" installation position, you will also need the additional R1 bleeding
port in the ange area. This port is not included in the standard version and must be specied in plain text when ordering.

Below-tank
installation

Below-tank installation is when the pump is installed below the minimum tank uid level
(next to, in or below the tank).
L2

L2

S
T1
T2

T1
S

L2

T2

L2

R1
R
T2

T1

T2
S

Installation
position

Air bleeding

Filling

S + T1 (L2)

L2

S + T2 (L2)

L2

S + T2 (L2)

R1 + L2

S + T2 (L2)

Recommended installation positions: 1 and 2.

T1

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Bosch Rexroth AG

Above-tank
installation

Product-Specic Operating Instructions A4VG 71180

RE 92 003-21-B/05.06

Above-tank installation is when the pump is installed above the minimum tank uid level
(next to, in or above the tank).
L2

5
R

L3
S

L3

T2

T1
T1
T2 S

L3

R1

L2

Note

T2
T2

0,5 bar

T1

L3
T1

Installation
position

Air bleeding

Filling

T1 + L3

L2

S (L3) + T2 (L2)

L2 + L3

S (L3) + T2 (L2)

R1 + L3

S (L3) + T2

Observe the maximum permissible suction height hmax = 800 mm.


Recommendation for installation position 8 (shaft upwards): A check valve in the leakage
uid line (opening pressure 0.5 bar) can prevent draining of the case interior.

! CAUTION

Risk of damage to the axial piston unit


An air pocket in the area near the bearings will damage the axial piston unit.
With the "shaft upwards" installation position, it is especially important that the pump case
be completely lled with hydraulic uid during commissioning and during operation.
With above-tank installation, the case interior may drain via the leakage uid line after longer standstill periods (air enters via the shaft seal ring) or via the service line (gap leakage). The bearings are thus insufciently lubricated when the pump is restarted.Therefore,
check the hydraulic uid level in the case interior regularly; if necessary, recommission.
During commissioning and during operation, the suction line must be lled with hydraulic
uid.

RE 92 003-21-B/05.06

Product-Specic Operating Instructions A4VG 71180

4.2

Bosch Rexroth AG

27/40

Assembling the axial piston unit

Information on assembling the axial piston unit can be found in the "Installation" chapter of
the general operating instructions RE 90 300-B.
Note

Observe the following note:


To ensure that rotating components (coupling hub) and xed components (case, retaining
ring) do not touch one another, certain installation conditions must be taken into account
depending on the size and the drive shaft. The exact values can be found in technical data
sheet RE 92 003, section "Installation situation for coupling assembly".

Transport
protection

The following diagram shows the protective covers and plastic plugs which you must remove
from the axial piston variable displacement pump A4VG at the completion of assembly:
Example:
A4VG with HD control unit

4.3

Connecting lines

The machine or system manufacturer is responsible for dimensioning the lines.


The axial piston unit must be connected to the rest of the hydraulic system in accordance
with the hydraulic circuit diagram of the machine or system manufacturer.
Observe the following safety instructions.

! CAUTION

Risk of damage
Hydraulic lines and hoses that are installed under tension generate additional mechanical
forces during operation and thus reduce the service life of the axial piston unit and of the
overall machine or system.
Install all lines and hoses free of tension.

! CAUTION

Risk of damage
Generally, a minimum permissible suction pressure at port "S" is specied for axial piston
pumps in all installation positions. If the pressure at port "S" drops below the specied values, damage may occur which may lead to destruction of the pump.
Make certain that the required suction pressure is reached by using the appropriate piping
(suction cross-section, pipe diameter, tank position) as well as appropriate viscosity.

28/40

Bosch Rexroth AG

Product-Specic Operating Instructions A4VG 71180

RE 92 003-21-B/05.06

Note

The service line ports and function ports are designed exclusively for connecting hydraulic
lines.

Note

Observe the notes for routing the suction-, hydraulic- and leakage uid lines provided in the
general operating instructions RE 90 300-B.

! WARNING

Risk of wear and malfunctions


The cleanliness of the hydraulic fluid affects the cleanliness and the service life of the hydraulic system. Contamination of the hydraulic fluid leads to wear and malfunctions. In particular,
solid contaminants in the hydraulic lines such as welding beads and metal shavings may
damage the axial piston unit.
Absolute cleanliness is required. The axial piston unit must be installed in a clean condition. Contaminants in the hydraulic fluid could considerably impact the function and
service life of the axial piston unit.
Pay particular attention during installation to ensure that ports, hydraulic lines and attachment parts (e.g. testers) are clean. Thoroughly clean these items before opening ports.
Make certain that no contaminants enter the system when closing the ports.
Use suitable liquid cleaning agents to remove lubricants and other difficult-to-remove contaminants. Cleaning agent must not penetrate the hydraulic system.
Do not use any cotton waste or fibrous cloths for cleaning.
Do not use hemp or mastic as sealant.

Procedure

To connect the axial piston unit to the hydraulic system:


1 Remove the transport protection (if not already removed).
2 Clean the lines.
3 Connect the lines according to the hydraulic circuit diagram.
4 Make sure that
the xing elements at ttings and anges are tightened correctly (observe the tightening
torque of the manufacturer!). Mark all checked ttings using e.g. a permanent marker.
the pipes and hose lines and every combination of connecting piece, coupling or
connecting point with hoses or pipes has been inspected by a technically qualied
person for safe working condition.
For the relationship between direction of rotation, control and ow direction, refer to
technical data sheet RE 92 003.

RE 92 003-21-B/05.06

Bosch Rexroth AG

Product-Specic Operating Instructions A4VG 71180

29/40

Connection overview:
T1

X1 Y1

View:
Port plate
(Rear side)

R
Fa

B
X2

Y2

PS

Fa1
Fe

MB

FS

MA

MH
G

S A

T2
S

Note

Connection

Designation

A, B

Service line ports

T1 / T2

Leakage uid and lling/drain ports

Suction port for boost uids

X1 / X2

Control pressure

Fa

Filter output

Fe

Filter input

Fa1

Filter output (mountable lter)

Ps

Control pressure supply

FS

Connection of lter to suction line (cold start)

MA / M B

Measurement point, service line ports A, B

Air bleeding

Pressure port for auxiliary circuits

MH

Port for balanced high pressure

Y1 / Y2

Pilot pressure ports (HD control only)

For the sizes of the ange connections and threaded connections, please refer to technical
data sheet RE 92 003.

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Bosch Rexroth AG

Product-Specic Operating Instructions A4VG 71180

RE 92 003-21-B/05.06

All ports must be connected to either pipes or hoses according to the installation drawing
and machine or system circuit diagram or the ports plugged using suitable locking screws.
The following tightening torques apply:
Internal threads of the axial piston unit: The maximum permissible tightening torques
MG max are the maximum values of the internal threads and must not be exceeded. Refer
to the following table for values.
Fittings: Observe the manufacturer's instruction regarding tightening torques of the
used ttings.
Fixing screws: For xing screws according to DIN 13/ISO 68, we recommend
checking the tightening torque in individual cases as per VDI 2230
Locking screws: For the locking screws supplied with the axial piston unit, the required
tightening torques of locking screws MV apply. Refer to the following table for values.
Threaded size
(DIN 3852)

Required tightening torque of the


Max. permissible tightening
torque of the internal thread MG locking screws MV
max

M10x1

30 Nm

12 Nm

M12x1.5

50 Nm

25 Nm

M14x1.5

80 Nm

35 Nm

M16x1.5

100 Nm

50 Nm

M18x1.5

140 Nm

60 Nm

M22x1.5

210 Nm

80 Nm

M26x1.5

230 Nm

120 Nm

M27x2

330 Nm

135 Nm

M33x2

540 Nm

225 Nm

M42x2

720 Nm

360 Nm

RE 92 003-21-B/05.06

Bosch Rexroth AG

Product-Specic Operating Instructions A4VG 71180

4.4

31/40

Connecting the electric controller

The machine or system manufacturer is responsible for dimensioning the electrical control.
For electrically controlled axial piston units (EP and DA), the electric open loop control must
be connected according to the electric circuit diagram of the machine or system manufacturer.
Note

To prevent malfunctions or incorrect ow directions, make certain that all connections are
correct.

Changing the
solenoid position

If necessary, you can change the position of the connector by turning the solenoid.
b

To do this, proceed as follows:


1 Loosen the xing nut (a) of the solenoid.
2 Turn the solenoid (b) to the desired position.
3 Retighten the xing nut (tightening torque of the xing nut: 5+1 Nm, WAF26, 12-sided
DIN 3124).
For further details and technical data, e.g. regarding the selection of a suitable mating
connector, please refer to technical data sheet RE 92 003.

4.5

Preparing the axial piston unit for storage

When preparing the axial piston unit for storage, please proceed as described in the general
operating instructions RE 90 300-B.
For internal preservation of the axial piston unit, use corrosion protection VCI 329. The
required quantity is 10 ml for sizes 71, 90 and 20 ml for sizes 125, 180.
Fill via leakage uid port T1 or T2.

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Bosch Rexroth AG

Product-Specic Operating Instructions A4VG 71180

RE 92 003-21-B/05.06

RE 92 003-21-B/05.06

Product-Specic Operating Instructions A4VG 71180

Bosch Rexroth AG

33/40

Commissioning

The information in this chapter supplements the "Commissioning" chapter in the general
operating instructions RE 90 300-B with information specic to the axial piston variable
displacement pump A4VG.
Note: The axial piston unit is, within the meaning of Machine Directive 98/37/ EC, a component which is intended for installation in a machine or system. Commissioning is prohibited
until it is determined that the machine or system in which this product is installed complies
with the regulations of the EC directives and all other relevant guidelines.
Observe the following safety instructions when commissioning:

! ! DANGER!

Danger to life
Working in the danger zone of a machine or system poses a danger to life and limb.
Eliminate all potential sources of danger on the machine or system.
Nobody may stand in the danger zone of the machine or system.
The emergency-stop button for the machine or system must be within reach.
Always follow the instructions of the machine or system manufacturer during
commissioning.

! WARNING

Risk of damage
Contamination of the hydraulic uid results in wear and malfunctions. In particular, solid
contaminants in the hydraulic lines such as welding beads and metal shavings may damage
the axial piston unit.
Ensure utmost cleanliness during commissioning.

! CAUTION

Risk of damage
Commissioning or restarting without or with insufcient hydraulic uid in the case interior will
lead to damage or immediate destruction of the rotary group.
When commissioning or restarting a machine or system, make certain that the entire case
interior of the axial piston unit is lled with hydraulic uid and that it remains lled during
operation.

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Bosch Rexroth AG

5.1

Product-Specic Operating Instructions A4VG 71180

RE 92 003-21-B/05.06

Filling the axial piston unit

For information on the possible installation positions, refer to "Installation notes" starting on
page 24.
During commissioning, proceed as follows:
1 Fill and air bleed the axial piston unit via the appropriate ports, see information starting on
page 25.

! CAUTION

Risk of damage to the axial piston unit


An air pocket in the area near the bearings will damage the axial piston unit.
With the "shaft upwards" installation position, it is especially important that the pump case
is completely lled with hydraulic uid during commissioning and during operation.
With above-tank installation, the case interior may drain via the leakage uid line after longer standstill periods (air enters via the shaft seal ring) or via the service line (gap leakage). The bearings are thus insufciently lubricated when the pump is restarted. Therefore,
check the hydraulic uid level in the case interior regularly; if necessary, recommission.
The suction line must be lled with hydraulic uid.

2 Operate the pump at a lower speed (starter speed for internal combustion engines or
inching operation for electric engines) until the pump system is completely lled. To
inspect, drain the hydraulic uid at port G via a mini-measurement line into a tank and wait
until the uid drains without bubbles.
3 Use the appropriate port to air bleed (see description beginning on page 25).
4 Make certain that all ports are either connected with pipes or plugged according to the
general circuit diagram.

RE 92 003-21-B/05.06

Product-Specic Operating Instructions A4VG 71180

5.2

Bosch Rexroth AG

35/40

Testing the hydraulic uid supply

The axial piston unit must always have a sufcient supply of hydraulic uid. For this reason,
the supply of hydraulic uid must be ensured at the start of the commissioning process.
When you test the hydraulic uid supply, constantly monitor the noise development and
check the hydraulic uid level in the tank. If the axial piston unit becomes louder (cavitation)
or the leakage uid is discharged with bubbles, this is an indication that the axial piston unit
is not being sufciently supplied with hydraulic uid.
For information on troubleshooting, see page 35.
An overview of all connections can be found in section "Connecting lines" on page 28.

! ! DANGER!

Dangers posed by faulty commissioning


Faulty commissioning may cause the drive to behave unexpectedly.
Make certain that the vehicle cannot drive away!
Make certain that no persons are present in the danger zone of the machine!
To test the hydraulic uid supply:
1 Allow the engine to run at the slowest speed.
The axial piston unit must be operated without load.
Pay attention to leakage and noise.
2 Check the suction pressure at port S of the axial piston pump.
For the permissible values, refer to technical data sheet RE 92 003.
3 Check whether the boost pressure is present at gauge port G on the pump.
4 If no boost pressure is present, check whether the suction line is leaky.
5 Start the engine as normal and check the boost pressure at port G of the pump.
The pressure value here must not be less than 15 bar and should stabilize after a
short time.
The suction pressure at port Fs of the pump must not drop below the pressure value
specied in the technical data sheet.
The leakage uid pressure at port R, T1 or T2 of the pump must not exceed the pressure
value specied in the technical data sheet.

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Product-Specic Operating Instructions A4VG 71180

RE 92 003-21-B/05.06

RE 92 003-21-B/05.06

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Product-Specic Operating Instructions A4VG 71180

37/40

Troubleshooting

The following table will assist you in fault diagnosis. The table does not claim to be complete.
It supplements the fault table provided in the general operating instructions RE 90 300-B
with typical faults which can occur with the axial piston variable displacement pump A4VG.
For this reason, also observe the table in the "Troubleshooting" chapter of the general operating instructions RE 90 300-B.
In practical use, problems and causes which are not listed here could also occur.
Noise development
Possible cause of fault

Test point

Engine speed too high

Engine speed

Suction line not air tight

Suction line cross-section not sufcient

Air in the hydraulic uid

Boost pressure valve

High-pressure relief valves

MA / M B

Mechanical pump damages

Fan

Coupling defective

Vehicle/system starts prematurely


Possible cause of fault

Test point

Mechanical neutral position not set correctly

MA / M B

Hydraulic neutral position not set correctly

X1 / X2

Control signal on control unit not correct

X1 / X2

Start of control of the DA control valve (optional)


not set correctly

X1 / X2

Operational data not achieved


Possible cause of fault

Test point

Boost pressure too low

Engine speed too low

Engine speed

Filter soiled

Filter

Auxiliary pump worn (defective)

Auxiliary pump

Rotary group worn

Rotary group

Boost pressure OK

Control (control unit) defective

X1 / X2

Pressure cut-off set too low

MA / M B

High-pressure relief valves set too low

MA / M B

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Bosch Rexroth AG

Product-Specic Operating Instructions A4VG 71180

RE 92 003-21-B/05.06

Engine overloaded
Possible cause of fault

Test point

Implement hydraulics

X1 / X2

Control unit

MA / M B

Pressure cut-off set too high

MA / M B

High-pressure relief valves set too high (for DA


control)
Temperature too high

NOTE

Possible cause of fault

Test point

High-pressure relief valves set too low

MA / M B

Pump worn

Cooler soiled / fan defective

Cooler / fan

Hydraulic uid level in tank too low

Tank

Information about maintenance, inspection and repair of Rexroth axial piston units can be
found in the "Servicing" chapter of the general operating instructions RE 90 300-B.

RE 92 003-21-B/05.06

Product-Specic Operating Instructions A4VG 71180

Bosch Rexroth AG

Index
A
About these instructions 3
Above-tank installation 26
Assembly
A4VG 13
Variable displacement pumps in general 12
Auxiliary pump 14
Axial piston unit
Assembling 27
Filling 34
B
Below-tank installation 25
Bypass function of the high-pressure relief valves 19
C
Closed circuit 12
Commissioning 33
Connecting lines 27
Connecting the electric open loop control 31
Control 14
Control unit
DA 18
EP 17
HD 16
HW 15

Installation
Assembling the axial piston unit 27
Connecting lines 27
Connecting the electric open loop control 31
Preparing for storage 31
Installation drawing 4
Installation notes 24
Installation position 25
Above-tank installation 26
Below-tank installation 25
M
Method of operation 13
Method of operation of a variable displacement pump 12
N
Name plate 11
O
Order conrmation 4
P

Data sheet 5

Pressure cut-off 14
Problem solution 37
Product description 11
Pump
Assembly 12
Function 13
Pump function 13

Fault diagnosis 37
Functional description 12

Safety 7
Hazard markings 6
Pictograms 6
Storage
Preparing the axial piston unit 31

G
General circuit diagram 5
H
High-pressure safeguarding 14
Hydraulic uid
Additional documents 5
Testing the supply 35
I
Identication 11
Important documents 3, 4
General circuit diagram 5
Installation drawing 4
Order conrmation 4
Technical data sheet 5

T
Technical data sheet 5
Troubleshooting 37
V
Variable displacement pump
Method of operation 12

39/40

Bosch Rexroth AG
Hydraulics
Product Unit
Axial Piston Units
Elchingen Plant
Glockeraustrae 2
89275 Elchingen, Germany
Phone
+49 (0) 73 08 82-0
Facsimile +49 (0) 73 08 72 74
[email protected]
www.boschrexroth.com/brm

This document, as well as the data,


specications and other information set forth in it, are the exclusive
property of Bosch Rexroth AG. It may
not be reproduced or given to third
parties without its consent.
The data specied above only serve
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 verication. It must
be remembered that our products are
subject to a natural process of wear
and aging.
Subject to change.

Printed in Germany
RE 92 003-21-B/05.06

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