Bosch Rexroth 11 Series Bedienungsanleitung

Instruction manual

RE 92511-01-B/2019-10-09

Replaces: 11.2018

English

Axial piston variable pump

A15V(L)O

Series 11

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.

Contents 3/64

RE 92511-01-B/2019-10-09, A15V(L)O Series 11, BoschRexroth AG

1 About this documentation 5

1.1 Validity of the documentation 5

1.2 Required and supplementary documentation 5

1.3 Representation of information 6

1.3.1 Safety instructions 6

1.3.2 Symbols 7

1.3.3 Designations 7

1.3.4 Abbreviations 7

2 Safety instructions 8

2.1 About this chapter 8

2.2 Intended use 8

2.3 Improper use 8

2.4 Personnel qualiﬁcations 9

2.5 General safety instructions 10

2.6 Product-speciﬁc safety instructions 11

2.7 Personal protective equipment 14

3 General instructions on property damage and product damage 15

4 Scope of delivery 18

5 About this product 19

5.1 Performance description 19

5.2 Product description 19

5.2.1 Axial piston unit layout 19

5.2.2 Functional description 20

5.3 Product identiﬁcation 21

6 Transportand storage 22

6.1 Transporting the axial piston unit 22

6.1.1 Transportby hand 22

6.1.2 Transportwith lifting devices 23

6.2 Storing the axial piston unit 25

7 Installation 27

7.1 Unpacking 27

7.2 Installation conditions 27

7.3 Installation position 29

7.3.1 Below-reservoir installation (standard) 29

7.3.2 Inside-reservoir installation 30

7.3.3 Above-reservoir installation 31

7.4 Installing the axial piston unit 32

7.4.1 Preparation 32

7.4.2 Dimensions 32

7.4.3 General instructions 33

7.4.4 Installation with a coupling 33

7.4.5 Installation on a gearbox 34

7.4.6 Installation with cardan shaft 35

7.4.7 Completion of assembly 35

7.4.8 Hydraulically connecting the axial piston unit 37

7.4.9 Electrically connecting the axial piston unit 44

7.5 Performing ﬂushing cycle 45

Contents

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Bosch Rexroth AG, A15V(L)O Series 11, RE 92511-01-B/2019-10-09

8 Commissioning 46

8.1 Initial commissioning 46

8.1.1 Filling the axial piston unit 46

8.1.2 Testing the hydraulic ﬂuid supply 48

8.1.3 Performing a functional test 48

8.2 Running-in phase 49

8.3 Recommissioning after standstill 49

9 Operation 50

10 Maintenance and repair 51

10.1 Cleaning and care 51

10.2 Inspection 52

10.3 Maintenance 52

10.4 Repair 53

10.5 Spare parts 53

11 Removal and replacement 54

11.1 Required tools 54

11.2 Preparing for removal 54

11.3 Performing the disassembly 54

11.4 Preparing the components for storage or further use 54

12 Disposal 55

13 Extension and conversion 55

14 Troubleshooting 56

14.1 How to proceed for troubleshooting 56

14.2 Malfunction table 57

15 Technical data 61

16 Alphabetical index 62

Contents

About this documentation 5/64

RE 92511-01-B/2019-10-09, A15V(L)O Series 11, 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 A15V(L)O Series 11

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

service engineers.

This documentation contains important information on the safe and proper

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

troubleshooting of the axial piston unit.

▶ Read this documentation completely, in particular chapter 2 "Safety instructions"

on page 8 and chapter 3 "General instructions on property damage and

product damage" on page 15 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

A15V(L)O.

– Order conﬁrmation

Installation drawing

Contains the outer dimensions, all ports and the hydraulic circuit diagram for your

axial piston variable pump A15V(L)O.

Please request the

installation drawing

from your contact at

BoschRexroth.

Installation drawing

Axial piston variable pump A15V(L)O

Contains the permissible technical data, ports, main dimensions and circuit

diagrams of standard versions.

92511 Data sheet

Hydraulic ﬂuids based on mineral oils and related hydrocarbons

Describes the requirements for hydraulic ﬂuids on mineral oil basis and related

hydrocarbons for operation with Rexroth hydraulic components, and provides

supportfor selection of suitable hydraulic ﬂuids for the hydraulic system.

90220 Data sheet

Environmentally acceptable hydraulic ﬂuids

Describes the requirements for environmentally acceptable hydraulic ﬂuids on

mineral oil basis and related hydrocarbons for operation with Rexroth hydraulic

components, and provides supportfor selection of suitable hydraulic ﬂuids for the

hydraulic system.

90221 Data sheet

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

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

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

selecting a hydraulic ﬂuid for your hydraulic system.

90222 Data sheet

BoschRexroth Fluid Rating List for Rexroth hydraulic components

(pumpsandmotors)

Contains the hydraulic ﬂuids positively evaluated by BoschRexroth.

90245 Data sheet

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Bosch Rexroth AG, A15V(L)O Series 11, RE 92511-01-B/2019-10-09

Table 1: Required and supplementary documentation

Title Document number Document type

Information on 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

1.3 Representation of information

Uniform safety instructions, symbols, terms and abbreviations are used throughout

this documentation to ensure safe and proper use of the product. For clariﬁcation,

they are explained in the sections below.

1.3.1 Safety instructions

This documentation contains safety instructions in chapter 2.6 "Product-speciﬁc

safety instructions" on page 11 and in chapter 3 "General instructions on property

damage and product damage" on page 15, as well as before a sequence of actions

or an instruction for action involving a risk of personal injury and property damage.

Always follow the measures for danger prevention associated with the use of this

product.

Safety instructions are set out as follows:

SIGNAL WORD

Type and source of danger!

Consequences of noncompliance

▶ Danger prevention measures

•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 safety instructions are disregarded

•Precautions: states how the danger can be avoided

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 injury if it is not avoided.

WARNING Identiﬁes a dangerous situation that may result in death or

serious injury if it is not avoided.

CAUTION Identiﬁes a dangerous situation that may result in minor to

moderate injury if it is not avoided.

NOTICE Property damage: The product or surrounding area may be

damaged.

About this documentation 7/64

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1.3.2 Symbols

The following symbols indicate notices that are not safety-relevant but increase

understanding of the documentation.

Table 3: Meaning of symbols

Symbol Meaning

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

operated to its full extent.

▶ Single, independent action

Numbered instruction:

The numbers indicate that the actions must be completed in order.

1.3.3 Designations

This documentation uses the following designations:

Table 4: Designations

Designation Meaning

A15VO Axial piston variable pump without charge pump, open circuit, use in

mobile application areas

A15VLO Axial piston variable pump with charge pump, open circuit, use in mobile

application areas

Protective cover Plastic cover to protect the connection surface

Flange cover Steel plate with plastic and mounting bolts to protect the

Connection surface

Threaded plug Metal screw, pressure-resistant

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

As umbrella term for "axial piston variable pump A15V(L)O" the designation

"axialpiston unit" will be used in the following.

1.3.4 Abbreviations

This documentation uses the following abbreviations:

Table 5: Abbreviations

Abbreviation Meaning

ATEX EC directive on explosion protection (Atmosphère explosible)

DIN Deutsches Institut für Normung (German Institute for Standardization)

D2 Pressure controller with swivel on one side, electrically proportional with

integrated pilot valve for external pilot pressure supply, positive identiﬁer 24 V

E2DR Stroke control electric-proportional 24V with pressure controller

LRDRS. Power control with pressure controller and load sensing

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 screwed joints

and cylindrical screw joints from the VDI (Verein Deutscher Ingenieure

-Association of German Engineers)

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Bosch Rexroth AG, A15V(L)O Series 11, RE 92511-01-B/2019-10-09

2 Safety instructions

2.1 About this chapter

The axial piston unit has been manufactured to generally accepted engineering

standards. There is still, however, a risk of personal injury or property damage if this

chapter and the safety instructions in this documentation are not observed.

▶ 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

area they are classiﬁed neither as complete nor as partly completed machinery as

deﬁned in the EC Machinery Directive 2006/42/EC. The component is exclusively

intended to form partly completed machinery or complete machinery together with

other components. The component should 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 an open

circuit.

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

the performance limits as speciﬁed in the datasheet 92511 and in the order

conﬁrmation. Information about approved hydraulic ﬂuids can be found in

datasheet92511.

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

Intended use includes having fully read and understood this documentation,

especially chapter 2 "Safety instructions" on page 8.

2.3 Improper use

Any use other than that described as intended use is considered improper.

BoschRexrothAG is not liable for damages resulting from improper use. The user is

solely responsible for any risks arising from improper use.

The following foreseeable forms of faulty usage are also considered improper

(thislist is not exhaustive):

• Use outside the operating parameters approved in the datasheetand in the order

conﬁrmation (unless speciﬁcally approved by the customer)

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

Safety instructions 9/64

RE 92511-01-B/2019-10-09, A15V(L)O Series 11, Bosch Rexroth AG

• Changes to factory settings by unauthorized persons.

• Use of assembled parts (e.g.control unit, valves) not in combination with the

speciﬁed Rexroth components

• 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 cannot

come into contact with water.

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

housing and ambient pressure greater than 2bar, with the ambient pressure always

lower than the case pressure. Momentary (t< 0.1 s) pressure peaks of up to 10bar

are allowed. Beyond this, the maximum permissible case pressure speciﬁed in the

datasheetshould 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 2014/34/EU

• Use of the axial piston unit in a corrosive atmosphere

• Use of the axial piston unit in aircraft or spacecraft

2.4 Personnel qualiﬁcations

The activities described in this documentation require a basic understanding of

mechanics, electricity and hydraulics, as well as familiarity with associated technical

terms. For transporting and handling the product, knowledge regarding the use of

lifting devices and lifting accessories is required. In order to ensure safe use, these

activities should only be performed by skilled personnel or an instructed person

under the direction and supervision of skilled personnel.

Skilled personnel refers to persons who possess the professional training,

knowledge and experience, as well as the understanding of the regulations relevant

to the work to be done that are necessary to recognize possible dangers and take

the appropriate safety measures. Skilled personnel must follow the rules relevant to

their ﬁeld and have the necessary hydraulic expert knowledge.

Hydraulic expert knowledge includes:

• Being able to read and fully understand hydraulic circuit diagrams

• In particular, fully understanding the relationships with regard to safety devices

• Knowledge regarding the function and interaction of hydraulic components.

BoschRexroth offers you measures supporting training in speciﬁc areas. You can

ﬁnd an overview of the training contents on the Internet at:

www.boschrexroth.com/training.

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Bosch Rexroth AG, A15V(L)O Series 11, RE 92511-01-B/2019-10-09

2.5 General safety instructions

• Observe applicable accident prevention and environmental protection regulations.

• Observe the safety regulations of the country in which the product is used/operated.

• Use Rexroth products only when they are in good working order.

• Observe all notices on the product.

• Do not install, operate, remove or maintain Rexroth products if under the inﬂuence

of alcohol, drugs or medication that may affect your reaction time.

• Only use genuine Rexroth accessories and spare parts to ensure there is no hazard

to persons from unsuitable spare parts.

• Observe the technical data and ambient conditions speciﬁed in the product

documentation.

• If unsuitable products are installed or used in applications that are of relevance to

safety, unexpected operating conditions may occur in the application, which could

result in personal injury or property damage. For this reason, only use the product

in safety-relevant applications if this use is expressly indicated and approved in the

product documentation, e.g.in explosion protection areas or in safety-related parts

of a control system (functional safety).

• Only commission the product if it has been determined that the end product

(e.g.machinery/system) in which the Rexroth products are installed complies with

the country-speciﬁc provisions, safety regulations and standards for the application

• Use tools appropriate for the work being performed and wear appropriate

protective clothing to prevent punctures and cuts (e.g.when removing protective

covers, disassembly).

• There is a risk of entanglement when operating the axial piston unit with abare

shaft end. Check whether or not your machine requires additional safety measures

for your application. If necessary, make sure these are appropriately implemented.

• Depending on the type of control used, electromagnetic effects can be produced

when using solenoids. Applying a direct voltage signal (DC) to solenoids does not

create electromagnetic interference (EMI) nor is the solenoid affected by EMI.

Potential electromagnetic interference (EMI) exists if the solenoid is energized

with a modulated direct current (e.g.PWM signal). The machine manufacturer

should conduct appropriate tests and take appropriate measures to ensure that

other components or operators (e.g.with a pacemaker) are not affected by this

potentiality.

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