Bosch A4VG A4VG 32 Series Bedienungsanleitung

Instruction manual

RE 92003-01-B/12.2015

Replaces: 04.2008

English

Axial piston variable pump

A4VG

Series 32

also regarding any disposal, exploitation,

reproduction, editing, distribution, as well as in

the event of applications for industrial property

rights.

The data speciﬁed within only serves to describe

the product. No statements concerning a certain

condition or suitability for a certain application

can be derived from our information. The

information given does not release the user from

the obligation of own judgment and veriﬁcation.

It must be remembered that our products are

subject to a natural process of wear and aging.

The cover shows an example application. The

product delivered may diﬀer from the image

on the cover.

The original instruction manual was created in

the German language.

RE 92003-01-B/12.2015, A4VG Series 32, Bosch Rexroth AG

Contents

1 About this documentation 5

1.1 Validity of the documentation 5

1.2 Required and supplementary documentation 5

1.3 Display of information 6

1.3.1 Safety instructions 6

1.3.2 Symbols 7

1.3.3 Designations 7

1.3.4 Abbreviations 8

2 Safety instructions 9

2.1 About this chapter 9

2.2 Intended use 9

2.3 Improper use 9

2.4 Personnel qualiﬁcations 10

2.5 General safety instructions 11

2.6 Product-speciﬁc safety instructions 12

2.7 Personal protective equipment 15

3 General instructions on damage to property and the product 16

4 Scope of delivery 19

5 About this product 20

5.1 Performance description 20

5.2 Product description 20

5.2.1 Layout of the axial piston unit 20

5.2.2 Functional description 21

5.3 Bypass function 22

5.3.1 Bypass function size 28 to 56 23

5.3.2 Bypass function size 71, 90 24

5.3.3 Bypass function size 125 to 180 26

5.4 Product identiﬁcation 27

6 Transport and storage 28

6.1 Transporting the axial piston unit 28

6.1.1 Transporting by hand 28

6.1.2 Transporting with a lifting device 28

6.2 Storing the axial piston unit 30

7 Installation 32

7.1 Unpacking 32

7.2 Installation conditions 32

7.3 Installation position 34

7.3.1 Below-reservoir installation (standard) 35

7.3.2 Above-reservoir installation 36

7.4 Installing the axial piston unit 37

7.4.1 Preparation 37

7.4.2 Dimensions 38

7.4.3 General instructions 38

7.4.4 Installation with coupling 39

7.4.5 Installation on a gearbox 40

7.4.6 Completing installation 40

Contents 3/68

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Bosch Rexroth AG, A4VG Series 32, RE 92003-01-B/12.2015

Contents

7.4.7 Changing the lever position of the HW control 42

7.4.8 Hydraulically connecting the axial piston unit 42

7.4.9 Electrically connecting the axial piston unit 47

7.5 Performing ﬂushing cycle 47

8 Commissioning 48

8.1 Initial commissioning 48

8.1.1 Filling the axial piston unit 49

8.1.2 Testing the hydraulic ﬂuid supply 50

8.1.3 Performing a functional test 50

8.2 Running-in phase 51

8.3 Recommissioning after standstill 51

9 Operation 52

10 Maintenance and repair 53

10.1 Cleaning and care 53

10.2 Inspection 54

10.3 Maintenance 54

10.3.1 Changing the ﬁlter element 55

10.4 Repair 55

10.5 Spare parts 56

11 Removal and replacement 57

11.1 Required tools 57

11.2 Preparing for removal 57

11.3 Performing removal 57

11.4 Preparing the components for storage or later use 57

12 Disposal 58

13 Extension and conversion 59

14 Troubleshooting 60

14.1 How to proceed with troubleshooting 60

14.2 Malfunction table 61

15 Technical data 65

16 Alphabetical index 66

About this documentation 5/68

RE 92003-01-B/12.2015, A4VG Series 32, Bosch Rexroth AG

1 About this documentation

1.1 Validity of the documentation

This documentation is valid for the following products:

•Axial piston variable pump A4VG Series 32

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

service engineers.

This documentation contains important information on the safe and appropriate

transport, installation, commissioning, operation, maintenance, removal and simple

troubleshooting of the axial piston unit.

▶ Read this documentation completely and in particular the chapter2 “Safety

instructions” on page 9 and chapter3 “General instructions on damage to

property and the product” on page 16 before you start work with the axial

piston unit.

1.2 Required and supplementary documentation

▶ Only commission the axial piston unit if the documentation marked with the book

symbol is available to you and you have understood and observed it.

Table 1: Required and supplementary documentation

Title Document number Document type

Order conﬁrmation

Contains the order-related technical data for your axial piston variable pump

A4VG Series 32.

– Order conﬁrmation

Installation drawing

Contains the outer dimensions, all connections and the hydraulic circuit diagram

for your axial piston variable pump A4VG Series 32.

Please request the

installation drawing

from your contact at

BoschRexroth.

Installation drawing

Axial piston variable pump A4VG Series 32

Contains the permissible technical data.

92003 Data sheet

Mineral oil-based hydraulic ﬂuids and related hydrocarbons

Describes the requirements for a mineral oil-based hydraulic ﬂuid and related

hydrocarbons for operation with Rexroth hydraulic components, and assists you in

selecting a hydraulic ﬂuid for your hydraulic system.

90220 Data sheet

Environmentally acceptable hydraulic ﬂuids

Describes the requirements on an environmentally friendly hydraulic ﬂuid for

operation with Rexroth hydraulic components and assists you in selecting a

hydraulic ﬂuid for your hydraulic system.

90221 Data sheet

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

Describes the requirements on ﬁre-resistant, water-free hydraulic ﬂuids (HFDU/

HFDR) for operation with Rexroth hydraulic components and assists you in

selecting a hydraulic ﬂuid for your hydraulic system.

90222 Data sheet

Fire-resistant, water-containing hydraulic ﬂuids (HFC, HFB, HFAE, HFAS)

Describes the requirements on ﬁre-resistant, water-containing hydraulic ﬂuids

(HFC, HFB, HFAE, HFAS) for operation with Rexroth hydraulic components and

assists you in selecting a hydraulic ﬂuid for your hydraulic system.

90223 Data sheet

Information for the use of hydrostatic drives at low temperatures

Contains additional information on the use of Rexroth axial piston units at

low temperatures.

90300-03-B Manual

Storage and preservation of axial piston units

Contains additional information on storage and preservation.

90312 Data sheet

6/68 About this documentation

Bosch Rexroth AG, A4VG Series 32, RE 92003-01-B/12.2015

1.3 Display of information

Standardized safety instructions, symbols, terms and abbreviations are used

throughout this documentation so that you can work quickly and safely with your

product. To give you a better understanding they are explained in the sections below.

1.3.1 Safety instructions

This documentation includes safety instructions in chapter2.6 “Product-speciﬁc

safety instructions” on page12 and in chapter3 “General instructions on damage

to property and the product” on page 16 and before a sequence of actions or an

instruction for action involving a risk of personal injury or damage to equipment. The

described danger prevention measures must be observed.

Safety instructions are set out as follows:

SIGNAL WORD

Type and source of danger!

Consequences of noncompliance

▶ Measures to prevent danger

•Warning sign: draws attention to the danger

•Signal word: identiﬁes the degree of the danger

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

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

•Precautions: states how the danger can be avoided

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RE 92003-01-B/12.2015, A4VG Series 32, Bosch Rexroth AG

Table 2: Hazard classes as deﬁned in ANSI Z535.6

Warning sign, signal word Meaning

DANGER Identiﬁes a dangerous situation that will result in death or

serious injuries if it is not avoided.

WARNING Identiﬁes a dangerous situation that may result in death or

serious injuries if it is not avoided.

CAUTION Identiﬁes a dangerous situation that may result in minor to

moderate injuries if it is not avoided.

NOTICE Property damage: The product or the environment may

become damaged.

1.3.2 Symbols

The following symbols indicate information that is not safety-relevant but increases

understanding of the documentation.

Table 3: Meaning of the symbols

Symbol Meaning

If this information is disregarded, the product cannot be used and/or

operated to the optimum extent.

▶ Single, independent action

Numbered instruction:

The numbers indicate that the steps must be completed one after the other.

1.3.3 Designations

This documentation uses the following designations:

Table 4: Designations

Designation Meaning

A4VG Axial piston variable pump, closed circuit

Threaded plug Metal screw, pressure-resistant

Protection plug Made out of plastic, not pressure-resistant, only for transportation

As a generic term for “axial piston variable pump A4VG”, the designation “axial piston

unit” will be used hereinafter.

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Bosch Rexroth AG, A4VG Series 32, RE 92003-01-B/12.2015

1.3.4 Abbreviations

This documentation uses the following abbreviations:

Table 5: Abbreviations

Abbreviation Meaning

ATEX EC directive on explosion protection (Atmosphère explosible)

DA Automatic control, speed related

DG Hydraulic control, directly operated

DIN Deutsches Institut für Normung (German Institute for Standardization)

EP Proportional control, electric

HD Proportional control, hydraulic

ISO International Organization for Standardization

JIS Japan Industrial Standard

RE 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)

Safety instructions 9/68

RE 92003-01-B/12.2015, A4VG Series 32, Bosch Rexroth AG

2 Safety instructions

2.1 About this chapter

The axial piston unit has been manufactured according to the generally accepted

rules of current technology. There is, however, still a danger of personal injury

or damage to equipment if this chapter and the safety instructions in this

documentation are not complied with.

▶ Read this documentation completely and thoroughly before working with the axial

piston unit.

▶ Keep this documentation in a location where it is accessible to all users at all times.

▶ Always include the required documentation when you pass the axial piston unit

on to third parties.

2.2 Intended use

Axial piston units are hydraulic components, meaning that in their application they

are classiﬁed neither as complete nor as partly completed machinery in the sense

of the EC Machinery Directive 2006/42/EC. A component is exclusively intended to

form an partly completed machinery or a complete machinery together with other

components. The component may only be commissioned after it has been installed

in the machine/system for which it is intended and the safety of the entire system

has been established in accordance with the machinery directive.

This product is intended for the following use:

The axial piston unit is only approved as a pump for hydrostatic drives in closed circuit.

▶ Observe the technical data, the application and operating conditions and

the performance limits as speciﬁed in data sheet92003 and in the order

conﬁrmation. Information about approved hydraulic ﬂuids can be found in

data sheet92003.

The axial piston unit is only intended for professional use and not for private use.

Intended use includes having read and understood the complete documentation,

especially chapter 2 “Safety instructions” on page9.

2.3 Improper use

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

bears all risks from improper use.

The following forms of forseeable use are also considered to be improper (this list

does not claim to be exhaustive):

•Use outside the operating parameters approved in the data sheet or in the order

conﬁrmation (unless speciﬁcally approved by the customer)

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

•Changes to factory settings by unauthorized persons

•Use of add-ons (e.g., attachment ﬁlter, control unit, valves) not in combination with

the speciﬁed Rexroth components

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Bosch Rexroth AG, A4VG Series 32, RE 92003-01-B/12.2015

•Use of the axial piston unit with assembled parts under water at a depth of

more than 10meters without the necessary additional measures, e.g., pressure

equalization. Units with electrical components (e.g., sensors) generally are not

allowed to come into contact with water.

•Use of the axial piston unit under a continuous pressure diﬀerential between case

to ambient pressure greater than 2bar, whereby the ambient pressure must always

be lower than the case pressure. Momentary (t<0.1s) pressure peaks of up to

10bar are allowed. Beyond this, the maximum case pressure speciﬁed on the data

sheet must not be exceeded.

•Use of the axial piston unit in explosive environments unless the component or

machine/system has been certiﬁed as compliant with the ATEX directive 94/9/EC

•Use of the axial piston unit in a corrosive atmosphere

•Use of the axial piston unit in aircrafts or spacecrafts

2.4 Personnel qualiﬁcations

The activities described in this documentation require basic mechanical, electrical

and hydraulics expertise, as well as knowledge of the associated technical terms.

For transporting and handling the product, additional knowledge is necessary with

regard to working with lifting devices and their slings. In order to ensure safe use,

these activities should only be performed by qualiﬁed personnel or an instructed

person under the direction and supervision of qualiﬁed personnel.

Skilled persons are those who can recognize possible dangers and institute the

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

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

the work to be done. Qualiﬁed personnel must follow the rules relevant to their ﬁeld

and have the necessary hydraulics expertise.

Hydraulics expertise includes:

•Reading and fully understanding hydraulic circuit diagrams.

•Speciﬁcally, fully understanding the relationships with regard to safety devices.

•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.

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