Bosch REXROTH HYDROTRAC GFT 8000 Bedienungsanleitung

Operating Instructions

RE 79022-01-B/04.2020

Replaces: 03.2019

English

HYDROTRAC GFT 8000

Hydrostatic drives for mobile applications

Series 40

Sizes 8105 - 8190

The data specified above serve to describe

the product. If there is also information on

the intended use, it is meant only as

examples of use and suggestions. Catalog

information does not constitute guaranteed

properties. The information given does not

rel

ease the user from obligation of own

judgment and verification. Our products are

subject to a natural process of wear and

aging.

specifications 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 brand, product and company names,

which are mentioned in this operating

instructions, are registered trademarks of

their respective owners. The copying or

changing o

f products with registered

trademarks is not permitted without the

permission of the respective owner.

A CE marking of the gearboxes as well as the

EC declaration of conformity are not

necessary, because the gearboxes are not a

machine for the purposes of

the EC-

machine

directive.

An example configuration is shown on the

title page. The delivered product may,

therefore, differ from the product which is

pictured.

The original operating instructions were

created in the German language.

Contents 3/70

RE 79022-01-B/04.2020, General Operating Instructions HYDROTRAC GFT 8000 series 40, Bosch Rexroth AG

Contents

1About this documentation 5

1.1 Validity of the documentation 5

1.2 Required and supplementary documentations 5

1.3 Presentation of information 6

1.3.1 Safety instructions 6

1.3.2 Symbols 7

1.3.3 Terminology 7

1.3.4 Abbreviations 8

2Safety instructions 9

2.1 About this chapter 9

2.2 Intended use 9

2.3 Improper use 9

2.4 Qualification of Personnel 10

2.5 General safety instructions 10

2.6Product and technology-dependent safety instructions 11

2.7 Personal Safety Equipment (PSA) 14

3General information concerning damage to property and product damages 15

4Scope of supply 18

5About this product 19

5.1 Performance description 19

5.2 Product description 19

5.2.1 Application conditions 19

5.3 Description of the brake 20

5.4 Product overview 21

5.5 Identification of the product 22

5.5.1 Standard name plate 22

6Transport and storage 23

6.1 Transporting the HYDROTRAC GFT 8000 23

6.2 Storing the HYDROTRAC GFT 8000 24

6.2.1 Preservation 24

6.2.2 Maximum storage periods 25

7Assembly 26

7.1 Unpacking 26

7.1.1 Delivery on pallet 26

7.1.2 Delivery in wood transport box 27

7.2 Installation conditions 27

7.3 Installation position 28

7.3.1 Operation with axial-piston motor (if included in the scope of supply) 28

7.4 Required tools 28

7.5 Assembling the HYDROTRAC GFT 8000 29

7.5.1 Preparing assembly 29

7.5.2 Installing the planetary gearbox with assembled axial-piston motor into the

machine or chassis frame 30

7.5.3 Connecting the planetary gearbox's axial-piston motor to the hydraulic system 32

7.5.4 Installing the planetary gearbox with axial-piston motor connection (axial-

piston motor is not included in the scope of supply) 33

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Bosch Rexroth AG, General Operating Instructions HYDROTRAC GFT 8000 series 40, RE 79022-01-B/04.2020

7.6 Connecting the static multiple-disk parking brake 35

7.7 Performing a flushing cycle 36

7.8 Assembling mounting parts 36

7.9 Equipment variants 37

7.10 Completing the assembly 37

8Commissioning 38

8.1 Initial commissioning 38

8.1.1 Initial commissioning the axial-piston motor/axial-piston motor connection 39

8.1.2 Before filling the planetary gearbox with lubricating oil 39

8.1.3 Filling the planetary gearbox with lubricating oil 39

8.1.4 Filling lubricating oil via the oil filler opening on the cover side 40

8.1.5 Filling lubricating oil via the oil filler opening on the motor side 41

8.1.6 Completing commissioning and run-in period 43

8.2 Recommissioning after standstill 43

9Operation 44

10 Servicing and repair 45

10.1 Cleaning and care 45

10.2 Inspection 46

10.2.1 Visual inspections 46

10.2.2 Checking the oil level of the planetary gearbox via the cover side 46

10.2.3 Checking the oil level of the planetary gearbox via the motor side 48

10.2.4 Acoustic inspections 49

10.2.5 Checking and tightening screw connections 49

10.3 Maintenance schedule planetary gearbox 50

10.4 Maintenance 50

10.4.1 Approved lubricating oils 50

10.4.2 Changing the lubricating oil via the cover side 51

10.4.3 Changing the lubricating oil via the motor side 52

10.4.4 Maintaining the static multiple-disk parking brake (if included) 54

10.5 Repair 54

10.5.1 Repairing the static multiple-disk parking brake 55

10.6 Spare parts 56

11 Decommissioning 57

12 Disassembly and replacement 58

12.1 Required tools 58

12.2 Preparing the disassembly 58

12.3 Disassembling the planetary gearbox from the machine or chassis frame 59

12.3.1 Draining the lubricating oil via the cover side: 60

12.3.2 Draining the lubricating oil via the motor side: 60

12.4 Preparing the planetary gearbox for storage reuse 62

13 Disposal 63

13.1 Environmental protection 63

14 Extension and conversion 64

15 Troubleshooting and fault correction 65

15.1 Troubleshooting procedure 65

16 Technical data 67

17 Appendix 67

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RE 79022-01-B/04.2020, General Operating Instructions HYDROTRAC GFT 8000 series 40, Bosch Rexroth AG

1 About this documentation

1.1 Validity of the documentation

This documentation is valid for the following product:

• HYDROTRAC GFT 8000 series 40

These general operating instructions of the hydrostatic drive HYDROTRAC GFT

8000 describes the following configurations:

• Planetary gearbox with connection options for:

– Axial-piston motor

• Planetary gearbox (depending on the scope of supply) with :

– Mounted axial-piston motor

– Integrated static multiple-disk parking brake

– Disconnect mechanisms

 For the valid configuration of your hydrostatic drive HYDROTRAC GFT 8000, see

the chapters “Product description”, “Scope of supply” and appendix D

“Technical data / Drawings” of the material number-specific operating

instructions.

 Also observe the respective chapters of these general operating instructions.

For simplification purposes, the product is referred to as “HYDROTRAC GFT 8000

planetary gearbox” or as “planetary gearbox” in the following chapters.

This documentation addresses installers/service technicians/machine or vehicle

operators.

This documentation contains important information on the safe and appropriate

transport, storage, assembly, commissioning, use, maintenance, disassembly and

simple troubleshooting of the planetary gearbox.

 Please read this documentation completely and in particular the chapter

2 “Safety Instructions” and chapter 3 “General information concerning damage

to property and product damages”, prior to working with the planetary gearbox.

1.2 Required and supplementary documentations

 Please only commission the planetary gearbox once the documentation marked

with the book icon has been made available to you and make sure you have

read, understood and followed it.

Table 1: Required and supplementary documentations

Description

Document type

Material number-specific operating

instructions

Operating instructions (included within

Rexroth's scope of supply)

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Bosch Rexroth AG, General Operating Instructions HYDROTRAC GFT 8000 series 40, RE 79022-01-B/04.2020

1.3 Presentation of information

So that you can work with this documentation fast and with certainty when using

your planetary gearbox, uniform safety instructions, icons, terminology and

abbreviations are being used. For better understanding, these are explained in the

following sections.

1.3.1 Safety instructions

In this documentation, safety notes are located in chapter 2.6 “Product and

technology-dependent safety instructions” and in chapter 3 “General information

concerning damage to property and product damages”, as well as before any

sequence of actions, or sequence of instructions, where there is a danger of

damage to persons or property. The measures described for avoiding hazards must

be observed.

The safety instructions are structured as follows:

• Warning symbol: draws attention to the danger

• Signal word: identifies the degree of the danger

• Type and source of danger: identifies the type and source of danger

• Consequences: describes what occurs if the safety instructions are not complied

with

• Precautions: states how the danger can be avoided.

Table 2: Danger categories according to ANSI Z535.6

Warning symbol, signal word

Meaning

DANGER identifies a dangerous situation where death or

serious personal injury will result if it is not avoided

WARNING

identifies a dangerous situation where death or

serious personal injury may result if it is not avoided

CAUTION identifies a dangerous situation where mild to medium

personal injury will result if it is not avoided

NOTE

identifies damage to property: The product or the

environment can get damaged.

SIGNAL WORD

Type and source of danger

Consequences in the case of non-compliance

 Measures for danger aversion



<List>

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RE 79022-01-B/04.2020, General Operating Instructions HYDROTRAC GFT 8000 series 40, Bosch Rexroth AG

1.3.2 Symbols

The following symbols identify information which is not relevant for safety,

however, does increase the coherency of the documentation.

Table 3: Meaning of symbols

Symbol

Meaning

If this information is not observed, the product cannot be optimally

used and/or operated.



individual, independent action step

numbered action instructions:

The figures show that the action steps follow on each other.

1.3.3 Terminology

The following terminology is used in this documentation:

Table 4: Terminology

Name Meaning

HYDROTRAC

Registered trademark

GFT 8000

= Vehicle gearbox

T = Turas

8000 = Size (e.g. 8130)

Ri Chan Jia HE L-HL15 Hydraulic oil

PERIGOL VCI 230 Preservative

CUSTOS 10-38 Preservative

HAKUTEX 74 Detergent to remove preservative

HAKUPUR 236 Detergent to remove preservative

L-XBCHA3 (GB 7324-

94)

FAG Arcanol MULTI3

Klüberplex BE 31-222

Lithium multi-purpose grease

Screw plug

Metallic screw, pressure-resistant

Plug

Made of plastic, not pressure-resistant, only for transport

8/70 About this documentation

Bosch Rexroth AG, General Operating Instructions HYDROTRAC GFT 8000 series 40, RE 79022-01-B/04.2020

1.3.4 Abbreviations

The following abbreviations are used in this documentation:

Table 5: Abbreviations

Abbreviation

Meaning

Rexroth-Document in English Language

RDE

exroth-Document in German (

) and

nglish Language

DIN

eutsche

ndustrie

orm (German Industrial Standard)

ISO

nternational

rganization for

tandardization

(Internationale Normierungsorganisation)

SAE

ociety of

merican

ngineers

ANSI

merican

ational

tandard

nstitute

PSA

Personal Safety equipment (A)

Safety instructions 9/70

RE 79022-01-B/04.2020, General Operating Instructions HYDROTRAC GFT 8000 series 40, Bosch Rexroth AG

2 Safety instructions

2.1 About this chapter

This HYDROTRAC GFT 8000 planetary gearbox was produced according to the

generally approved good engineering practice. There is, however, still a danger of

personal injury or damage to equipment if the following chapter and the safety

instructions of this documentation are not complied with.

 Read this documentation thoroughly and completely before working with the

HYDROTRAC GFT 8000 planetary gearbox.

 Keep the documentation in a place where it is accessible at all times to all

users.

 When passing on the HYDROTRAC GFT 8000 planetary gearbox to third parties,

always do so together with the required documentation.

2.2 Intended use

The planetary gearbox is a subassembly.

 Refer to the material number-specific operating instructions for the intended

use of your HYDROTRAC GFT 8000 planetary gearbox.

 Observe the operating conditions and power limits as mentioned in the

technical data sheet. For this refer to the material number-specific operating

instructions.

The planetary gearbox is intended only for professional use and not for private

use.

Intended use includes that this documentation, especially chapter 2 “Safety

instructions” has been read and understood.

2.3 Improper use

Any use other than described in intended use is not in accordance with the

requirements and, therefore, is not permitted.

Bosch Rexroth AG assumes no liability for damage resulting from improper use.

The risks associated with improper use lie solely with the user.

Also the following expected foreseeable misuses are not improper use (this list is

not exhaustive):

• Use outside the operating data released in the specifications or the order

confirmation

• The use of inadmissible liquids, e.g. water or unreleased lubricating oils

• The use of the planetary gearbox in other applications than described in

chapter 2.2 “Intended use”

• The use of the planetary gearbox and its mounting parts in explosion-prone

environments

• The use of the planetary gearbox as a safety-related part of a control unit

• The use of the planetary gearbox in an environment with aggressive substances

and gases

• Change of the factory settings by unauthorized persons

• The use of the planetary gearbox when the external pressure exceeds the

internal pressure (housing pressure)

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Bosch Rexroth AG, General Operating Instructions HYDROTRAC GFT 8000 series 40, RE 79022-01-B/04.2020

• The use of mounting parts (e.g. attached filter, controller, valves) other than the

intended Rexroth components

2.4 Qualification of Personnel

The operations described in this documentation require basic knowledge of

mechanics, electrics, hydraulics as well as knowledge of the related technical

terms. Transport and handling of the planetary gearbox require additional

knowledge of handling a crane or forklift (e.g. crane/forklift training, crane/forklift

driver’s license) and the associated means of attachment.

In order to ensure the safe use, all operations should therefore only be carried out

by a respective qualified personnel or an instructed and trained person under the

direction of qualified personnel.

Qualified personnel are those who can recognize possible hazards and institute

the appropriate safety measures due to their professional training, knowledge and

experience, as well as their understanding of the relevant regulations pertaining

the work to be done. Specialists must comply with the applicable specialist

regulations.

2.5 General safety instructions

• Observe all binding regulations for accident prevention and environmental

protection.

• Observe all safety instructions and provisions of the country where the planetary

gearbox is going to be deployed/operated.

• Only use Rexroth products which are in perfect technical condition.

• Observe all instructions on the planetary gearbox.

• Persons, who assemble, commission, operate, disassemble, or maintain Rexroth

products must not consume alcohol, drugs or pharmaceuticals that may affect

their ability to respond.

• Only use Rexroth original accessories and spare parts in order to prevent any

hazards to persons due to improper spare parts.

• You may only start using the HYDROTRAC GFT 8000 planetary gearbox once it

has been established that the end product (see intended use of the material

number-specific operating instructions) in which the Rexroth-products are

installed complies with the country-specific provisions, safety regulations and

standards of the application.

• The assembly, commissioning, maintenance and disassembly of the HYDROTRAC

GFT 8000 planetary gearbox takes place under the responsibility of the end-

product manufacturer. Therefore, the product safety of the HYDROTRAC GFT

8000 planetary gearbox cannot be guaranteed by Rexroth during these life

phases.

• You must adhere to the technical data, operating conditions and performance

limits shown in the product documentation.

• The warranty shall apply to the delivered configuration only.

• The warranty is void in case of faulty installation, commissioning and operation,

as well as in case of improper use and/or improper handling

• You may not modify the HYDROTRAC GFT 8000 planetary gearbox in principle.

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