Related Manuals for Bosch Rexroth A4VG 40 Series
Summary of Contents for Bosch Rexroth A4VG 40 Series
- Page 1 Axial piston variable pump A4VG Series 40 Instruction manual Replaces: 04.2008 RE 92004-01-B/05.2017 English...
- Page 2 © Bosch Rexroth AG 2017. All rights reserved, 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.
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Page 3: Table Of Contents
7.3.2 Above-reservoir installation Installing the axial piston unit 7.4.1 Preparation 7.4.2 Dimensions 7.4.3 General instructions 7.4.4 Installation with coupling 7.4.5 Installation on a gearbox 7.4.6 Installation with cardan shaft 7.4.7 Completing installation RE 92004-01-B/05.2017, A4VG Series 40, Bosch Rexroth AG... - Page 4 11.2 Preparing for removal 11.3 Performing removal 11.4 Preparing the components for storage or further use Disposal Extension and conversion Troubleshooting 14.1 How to proceed with troubleshooting 14.2 Malfunction table Technical data Alphabetical index Bosch Rexroth AG, A4VG Series 40, RE 92004-01-B/05.2017...
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Page 5: About This Documentation
Manual Contains additional information on the use of Rexroth axial piston units at low temperatures. Storage and preservation of axial piston units 90312 Data sheet Contains additional information on storage and preservation. RE 92004-01-B/05.2017, A4VG Series 40, Bosch Rexroth AG... -
Page 6: Representation Of Information
• Type and source of danger: indicates the type and source of the danger • Consequences: describes what occurs if the safety instructions are not complied with • Precautions: states how the danger can be avoided Bosch Rexroth AG, A4VG Series 40, RE 92004-01-B/05.2017... -
Page 7: Symbols
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. RE 92004-01-B/05.2017, A4VG Series 40, Bosch Rexroth AG... -
Page 8: Abbreviations
Rexroth document in the English language VDI 2230 Directive for the systematic calculation of high duty bolted joints and joints with one cylindrical bolt from the VDI (Verein Deutscher Ingenieure - Association of German Engineers) Bosch Rexroth AG, A4VG Series 40, RE 92004-01-B/05.2017... -
Page 9: Safety Instructions
Any use other than that described as intended use shall be considered as improper and is therefore impermissible. Bosch Rexroth AG is not liable for damages resulting from improper use. The user shall bear all risks arising from improper use. -
Page 10: Personnel Qualifications
• especially fully understanding the relationships with regard to safety devices • and 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. -
Page 11: General Safety Instructions
Other behavior can result when a modulated direct current (e.g. PWM signal) is applied. Potential electromagnetic interference for persons (e.g. persons with a pacemaker) and other components must be tested by the machine manufacturer. RE 92004-01-B/05.2017, A4VG Series 40, Bosch Rexroth AG... -
Page 12: Product-Specific Safety Instructions
▶ Changes to the factory settings must only be made by Bosch Rexroth specialists. ▶ In addition, a pressure relief valve is required in the hydraulic system as a back- up. - Page 13 Check whether your application requires that remedial measures be taken on your machine in order to bring the driven consumer into a safe position (e.g. safe stop). ▶ If necessary, make sure that these are properly implemented. RE 92004-01-B/05.2017, A4VG Series 40, Bosch Rexroth AG...
- Page 14 ▶ Wear your personal protective equipment (e.g. safety goggles, safety gloves, suitable working clothes, safety shoes). ▶ Consult a doctor immediately if hydraulic fluid gets in your eyes or bloodstream, or is swallowed. Bosch Rexroth AG, A4VG Series 40, RE 92004-01-B/05.2017...
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Page 15: Personal Protective Equipment
Personal protective equipment is the responsibility of the user of the axial piston unit. Observe the safety regulations and provisions in your country. All pieces of personal protective equipment must be intact. RE 92004-01-B/05.2017, A4VG Series 40, Bosch Rexroth AG... -
Page 16: General Instructions On Damage To Property And The Product
Before installation, remove all fluids from the axial piston unit to prevent mixing with the hydraulic fluid used in the machine/system. ▶ Any mixing of hydraulic fluids from different manufacturers or different types from the same manufacturer is generally not permitted. Bosch Rexroth AG, A4VG Series 40, RE 92004-01-B/05.2017... - Page 17 Hydraulic fluid can escape if leaks occur. ▶ Take appropriate steps to protect the axial piston unit from chemical or corrosive environmental conditions. RE 92004-01-B/05.2017, A4VG Series 40, Bosch Rexroth AG...
- Page 18 The warranty only applies to the delivered configuration. The entitlement to warranty cover will be rendered void if the product is incorrectly installed, commissioned or operated, or if it is used or handled improperly. Bosch Rexroth AG, A4VG Series 40, RE 92004-01-B/05.2017...
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Page 19: Scope Of Delivery
• Axial piston unit as per order confirmation The following parts are also assembled prior to delivery: • Protective covers (1) • Protective plug/threaded plug (2) • For version with through drive, metallic protective cover and mounting bolts (3) RE 92004-01-B/05.2017, A4VG Series 40, Bosch Rexroth AG... -
Page 20: About This Product
10 Cylinder (distributor plate) 3 Stroking piston 6 High-pressure side 11 Piston 4 Control unit 7 Boost pump 12 Slipper pad 8 Low-pressure side 13 Cradle (using the EP as an example here) Bosch Rexroth AG, A4VG Series 40, RE 92004-01-B/05.2017... -
Page 21: Functional Description
Use an appropriate emergency-off device to ensure that the drive can be brought to a safe position at any time. The machine or system manufacturer is responsible for the installation of a proper emergency-off device. RE 92004-01-B/05.2017, A4VG Series 40, Bosch Rexroth AG... -
Page 22: Bypass Function
Turning the corresponding screw allows the hydraulic fluid to flow freely. The bypass function must be deactivated again before restarting the machine. Bosch Rexroth AG, A4VG Series 40, RE 92004-01-B/05.2017... -
Page 23: Activating And Deactivating The Bypass Function
Use a hexagon socket wrench (WAF 8) to turn the shuttle valve (1) clockwise to the stop and tighten it with a tightening torque of 50 Nm. The bypass function is no longer active. RE 92004-01-B/05.2017, A4VG Series 40, Bosch Rexroth AG... -
Page 24: Product Identification
4 Direction of rotation (viewed on 11 Serial number drive shaft) – here: clockwise 12 Material number of the axial 5 Specified area for inspection stamp piston unit 6 Weight (optional) 13 Type code 7 Power Bosch Rexroth AG, A4VG Series 40, RE 92004-01-B/05.2017... -
Page 25: Transport And Storage
To do this, screw an eye bolt completely into the female thread on the drive shaft. The thread size is stated in the installation drawing. ▶ Make sure that the eye bolt can bear the total weight of the axial piston unit plus 20%. RE 92004-01-B/05.2017, A4VG Series 40, Bosch Rexroth AG... - Page 26 Place the lifting strap around the axial piston unit in such a way that it does not pass over assembled parts (e.g. valves, piping) and that the axial piston unit is not suspended from assembled parts (see Fig. 6). Fig. 6: Transport with lifting strap Bosch Rexroth AG, A4VG Series 40, RE 92004-01-B/05.2017...
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Page 27: Storing The Axial Piston Unit
Bosch Rexroth service partner. In the event of questions regarding repair and spare parts, contact your responsible Bosch Rexroth service partner or the service department of the manufacturer's plant for the axial piston unit, see chapter 10.5 “Spare parts” on page 54. - Page 28 Package the axial piston unit with desiccant in corrosion protection film so it is airproof. Store the axial piston unit in a shock-proof manner, see “Requirements” on page 27 in this chapter. Bosch Rexroth AG, A4VG Series 40, RE 92004-01-B/05.2017...
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Page 29: Installation
▶ The leakage in the housing area must be directed to the reservoir via the highest drain port. Use the line size which is appropriate for the port. RE 92004-01-B/05.2017, A4VG Series 40, Bosch Rexroth AG... - Page 30 ▶ Use fiber-free cloths for cleaning. ▶ Use suitable mild cleaning agents to remove lubricants and other difficult-to- remove contamination. Cleaning agents must not enter the hydraulic system. Bosch Rexroth AG, A4VG Series 40, RE 92004-01-B/05.2017...
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Page 31: Installation Position
For installation position 4 and 10 (drive shaft upwards), you need the additional air bleed port R in the flange area. This port is not provided in the standard version and must be stated in plain text when ordering. RE 92004-01-B/05.2017, A4VG Series 40, Bosch Rexroth AG... -
Page 32: Below-Reservoir Installation (Standard)
3 (drive shaft vertically downward) – S + T 4 (drive shaft vertically upward) S + T 5 (drive shaft horizontal) – S + T 6 (drive shaft horizontal) – S + T Bosch Rexroth AG, A4VG Series 40, RE 92004-01-B/05.2017... -
Page 33: Above-Reservoir Installation
Suction port Baffle (baffle plate) Control pressure port Ports F and F are part of the external piping and must be provided on the customer side to make filling and air bleeding easier. RE 92004-01-B/05.2017, A4VG Series 40, Bosch Rexroth AG... -
Page 34: Installing The Axial Piston Unit
Check the permissible direction of rotation of the axial piston unit (on the name plate) and make sure that this corresponds to the direction of rotation of the drive motor. Fig. 10: Direction of rotation Counter-clockwise Clockwise Bosch Rexroth AG, A4VG Series 40, RE 92004-01-B/05.2017... -
Page 35: Dimensions
The type of installation to be used for the axial piston unit depends on the connecting elements to the drive side. The following descriptions explain the installation of the axial piston unit: • with a coupling • on a gearbox • to a cardan shaft RE 92004-01-B/05.2017, A4VG Series 40, Bosch Rexroth AG... -
Page 36: Installation With Coupling
Details on the required tools and tightening torques for the mounting bolts are available from the machine/system manufacturer. When using flexible couplings, check that the drive is free of resonance after completing the installation. Bosch Rexroth AG, A4VG Series 40, RE 92004-01-B/05.2017... -
Page 37: Installation On A Gearbox
Operating the axial piston unit with protective plugs may result in injury or damage to the axial piston unit. ▶ Before commissioning, remove all protective plugs and replace them with suitable, pressure-resistant, metallic threaded plugs or connect the appropriate lines. RE 92004-01-B/05.2017, A4VG Series 40, Bosch Rexroth AG... - Page 38 Use a suitable tool for this to prevent damage to the sealing and functional surfaces. If sealing or functional surfaces are damaged, contact your Bosch Rexroth service partner or the service department of the manufacturer's plant for the axial piston unit.
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Page 39: Changing The Lever Position Of The Hw Control
(pressure, flow, hydraulic fluid, temperature) with the necessary safety factors. Connect only hydraulic lines that are appropriate for the axial piston unit port (pressure level, size, system of units). RE 92004-01-B/05.2017, A4VG Series 40, Bosch Rexroth AG... - Page 40 The system of units, the kind of seal and the size of female thread and stud ends (e.g. threaded plug) must all match. There is a risk of confusion due to the limited ways of visually telling them apart. Bosch Rexroth AG, A4VG Series 40, RE 92004-01-B/05.2017...
- Page 41 Fig. 13: Port overview A4VG Series 40, working ports A and B, on left side 45° (viewed on drive shaft) Fig. 14: Port overview A4VG Series 40, working ports A and B, on right side 45° (viewed on drive shaft) RE 92004-01-B/05.2017, A4VG Series 40, Bosch Rexroth AG...
- Page 42 Depending on the installation position, T or T must be connected (see chapter 7.3 “Installation position” on page 31) Optional O = Must be connected (plugged when delivered) X = Plugged (in normal operation) Bosch Rexroth AG, A4VG Series 40, RE 92004-01-B/05.2017...
- Page 43 • Mounting bolts: For mounting bolts with metric ISO thread according to DIN 13 or thread according to ASME B1.1, we recommend checking the tightening torque in individual cases in accordance with VDI 2230. RE 92004-01-B/05.2017, A4VG Series 40, Bosch Rexroth AG...
- Page 44 For relationship between direction of rotation and flow direction, please refer to data sheet 92004. Bosch Rexroth AG, A4VG Series 40, RE 92004-01-B/05.2017...
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Page 45: Electrically Connecting The Axial Piston Unit
Nm. 7.5 Performing flushing cycle In order to remove foreign particles from the system, Bosch Rexroth recommends a flushing cycle for the entire system before the initial commissioning. To avoid internal contamination, the axial piston unit must not be included in the flushing cycle. -
Page 46: Commissioning
▶ During the commissioning process, monitor the temperature of the hydraulic fluid in the reservoir to ensure that it lies within the permissible viscosity limits. Bosch Rexroth AG, A4VG Series 40, RE 92004-01-B/05.2017... -
Page 47: Filling The Axial Piston Unit
Use only a hydraulic fluid that conforms to the following requirements: You can find details of the minimum requirements on hydraulic fluids in Bosch Rexroth data sheets 90220, 90221, 90222, and 90225. The titles of the data sheets can be found in Table 1 “Required and supplementary documentation”... -
Page 48: Testing The Hydraulic Fluid Supply
▶ Perform a leak test without and with load prior to normal operation. ▶ If necessary, disconnect the pressure gauge and plug the ports with the specified threaded plugs. Bosch Rexroth AG, A4VG Series 40, RE 92004-01-B/05.2017... -
Page 49: Running-In Phase
10 operating hours. To ensure that contamination in the hydraulic system does not damage the axial piston unit, Bosch Rexroth recommends the following procedure after the running-in phase: ▶... -
Page 50: Operation
Use the product only within the performance range specified in the technical data. The machine/system manufacturer is responsible for the proper project planning of the hydraulic system and its control. Bosch Rexroth AG, A4VG Series 40, RE 92004-01-B/05.2017... -
Page 51: Maintenance And Repair
Use only water and, if necessary, a mild cleaning agent to clean the axial piston unit. Never use solvents or corrosive cleaning agents. ▶ Remove major external contamination and keep sensitive and important components, such as solenoids, valves, displays and sensors, clean. RE 92004-01-B/05.2017, A4VG Series 40, Bosch Rexroth AG... -
Page 52: Inspection
Maintenance and repair 10.2 Inspection In order for the axial piston unit to be reliable and long-lasting, Bosch Rexroth recommends testing the hydraulic system and axial piston unit on a regular basis, and documenting and archiving the following operating conditions:... -
Page 53: Changing The Filter Element
Screw the filter housing (4) onto the filter head (1). Tighten the filter housing (4) with 45 Nm. 10.4 Repair Bosch Rexroth offers a comprehensive range of services for the repair of Rexroth axial piston units. Repairs on the axial piston unit and its assembled parts may only be performed by service centers certified by Bosch Rexroth. -
Page 54: Spare Parts
Address all questions regarding spare parts to your responsible Bosch Rexroth Service partner or the service department of the manufacturer's plant for the axial piston unit. -
Page 55: Removal And Replacement
Completely drain the axial piston unit of hydraulic fluid. Plug all openings. 11.4 Preparing the components for storage or further use ▶ Proceed as described in chapter 6.2 “Storing the axial piston unit” on page 27. RE 92004-01-B/05.2017, A4VG Series 40, Bosch Rexroth AG... -
Page 56: Disposal
Disassemble the axial piston unit into its individual parts and properly recycle these parts. For example, separate the parts into: – Castings – Steel – Aluminum – Non-ferrous metal – Electronic waste – Plastic – Seals Bosch Rexroth AG, A4VG Series 40, RE 92004-01-B/05.2017... -
Page 57: Extension And Conversion
Changes to settings on the customer side should only be made using the product- specific setting instructions. The warranty from Bosch Rexroth only applies to the product configuration as delivered. The warranty is void if the unit is modified or extended. -
Page 58: Troubleshooting
Try to get a clear idea of the cause of the fault. Directly ask the (machine) operator. ▶ Document the work carried out. ▶ If you cannot rectify the fault, contact one of the contact addresses which can be found at: www.boschrexroth.com/addresses. Bosch Rexroth AG, A4VG Series 40, RE 92004-01-B/05.2017... -
Page 59: Malfunction Table
Optimize the setting of the pressure limitation and pressure control valves Mechanical damage to the axial piston unit Replace axial piston unit (e.g. bearing damage) Contact Bosch Rexroth Service Increased, unusual vibration Bearings worn Contact Bosch Rexroth Service RE 92004-01-B/05.2017, A4VG Series 40, Bosch Rexroth AG... - Page 60 Control of the control device defective Check control (contact machine/system manufacturer or Bosch Rexroth Service) Wear or mechanical damage to the axial piston Replace axial piston unit unit Contact Bosch Rexroth Service Bosch Rexroth AG, A4VG Series 40, RE 92004-01-B/05.2017...
- Page 61 Bosch Rexroth Service) Wear or mechanical damage to the axial piston Replace axial piston unit unit Contact Bosch Rexroth Service Output unit defective (e.g. hydraulic motor or Contact machine/system manufacturer cylinder) RE 92004-01-B/05.2017, A4VG Series 40, Bosch Rexroth AG...
- Page 62 Contact Bosch Rexroth Service Contact machine/system manufacturer Flushing flow of the flushing valve too low Contact Bosch Rexroth Service Axial piston unit worn Replace axial piston unit, contact Bosch Rexroth Service Bosch Rexroth AG, A4VG Series 40, RE 92004-01-B/05.2017...
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Page 63: Technical Data
The data sheet can be found on the Internet at www.boschrexroth.com/mediadirectory Additional information can be found in the online product catalog Mobile Hydraulics: www.boschrexroth.com/axial-piston-pumps Order-related technical data for your axial piston unit can be found in the order confirmation. RE 92004-01-B/05.2017, A4VG Series 40, Bosch Rexroth AG... - Page 64 64/68 Bosch Rexroth AG, A4VG Series 40, RE 92004-01-B/05.2017...
- Page 65 65/68 RE 92004-01-B/05.2017, A4VG Series 40, Bosch Rexroth AG...
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Page 66: Alphabetical Index
▶ P Performance description ▶ F Piston Filling Port overview Filter 52, 53 Pressure side – Changing Product description Flushing cycle Property damage Functional description – Control ▶ Q Functional test Qualifications Bosch Rexroth AG, A4VG Series 40, RE 92004-01-B/05.2017... - Page 67 ▶ T Technical data Tightening torques Tools Transportation – by hand – with eye bolt – with lifting strap Transporting Transport protection Troubleshooting ▶ U Unpacking ▶ w Warranty 18, 38, 57 Weight RE 92004-01-B/05.2017, A4VG Series 40, Bosch Rexroth AG...
- Page 68 Bosch Rexroth AG Mobile Applications Glockeraustraße 4 89275 Elchingen Germany Phone: +49 7308 82-0 info.ma@boschrexroth.de www.boschrexroth.com Your local contact person can be found at: www.boschrexroth.com/addresses Subject to change Printed in Germany RE 92004-01-B/05.2017...