Bosch Rexroth 3 Series Bedienungsanleitung

Axial piston variable pump

A4CSG

Series 3x

Instruction manual

RE 92105-01-B/06.2017

Replaces: –.–

English

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 92105-01-B/06.2017, A4CSG, Series 3x, Bosch Rexroth AG

3/68Contents

Contents

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 damage to property and theproduct 15

3.1 Operator's obligations 17

4 Scope of delivery 18

5 About this product 19

5.1 Performance description 19

5.2 Product description 19

5.2.1 Layout of the axial piston unit 19

5.2.2 Functional description 20

5.3 Product identiﬁcation 21

5.3.1 Name plate of the axial piston unit 21

6 Transport and storage 22

6.1 Transporting the axial piston unit 22

6.1.1 Transporting by hand 22

6.1.2 Transporting with a lifting device 23

6.2 Storing the axial piston unit 24

7 Installation 27

7.1 Unpacking 27

7.2 Installation conditions 27

7.3 Installation position 28

7.3.1 Below-reservoir installation (standard) 28

7.3.2 Above-reservoir installation 29

7.4 Installing the axial piston unit 32

7.4.1 Preparation 32

7.4.2 Dimensions 32

7.4.3 General instructions 32

7.4.4 Installation with coupling 33

7.4.5 Installation on a gearbox 34

7.4.6 Installation with cardan shaft 35

7.4.7 Completing installation 35

7.4.8 Hydraulically connecting the axial piston unit 37

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Bosch Rexroth AG, A4CSG, Series 3x, RE 92105-01-B/06.2017

7.4.9 Electrically connecting the axial piston unit 42

7.5 Performing ﬂushing cycle 43

8 Commissioning 44

8.1 Initial commissioning 44

8.1.1 Filling the axial piston unit 44

8.1.2 Testing the hydraulic ﬂuid supply 45

8.1.3 Performing a functional test 46

8.2 Running-in phase 47

8.3 Recommissioning after standstill 47

9 Operation 48

9.1 Operating the optional auxiliary activation device 48

10 Maintenance and repair 49

10.1 Cleaning and care 49

10.2 Inspection 49

10.3 Maintenance 51

10.4 Repair 54

10.5 Spare parts 55

11 Removal and replacement 56

11.1 Required tools 56

11.2 Preparing for removal 56

11.3 Performing removal 56

11.4 Preparing the components for storage or further use 56

12 Disposal 57

13 Extension and conversion 58

14 Troubleshooting 59

14.1 How to proceed with troubleshooting 59

14.2 Malfunction table 60

15 Technical data 64

16 Alphabetical index 66

Contents

About this documentation 5/68

RE 92105-01-B/06.2017, A4CSG, Series 3x, Bosch Rexroth AG

1 About this documentation

1.1 Validity of the documentation

This documentation is valid for the following product:

•Axial piston variable pump A4CSG Series 3x (standard version).

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 8 and chapter 3 “General instructions on damage to

property and theproduct” 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 technical data relevant to the Axial piston variable pump A4CSG

ordered.

– Order conﬁrmation

Installation drawing

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

Axial piston variable pump A4CSG.

Please request the

installation drawing

from your contact at

Bosch Rexroth.

Installation drawing

Axial piston variable pump A4CSG

Contains the permissible technical data.

92105 Data sheet

Mineral oil-based hydraulic ﬂuids and related hydrocarbons

Describes the requirements on 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

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

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Bosch Rexroth AG, A4CSG, Series 3x, RE 92105-01-B/06.2017

1.3 Representation 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 11 and in chapter 3 “Alphabetical index” on

page15 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

▶ <List>

•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

Table 2: Hazard classes as deﬁned in ANSI Z535.6-2006

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 get

damaged.

About this documentation 7/68

RE 92105-01-B/06.2017, A4CSG, Series 3x, Bosch Rexroth AG

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 actions must be completed one after the

other.

1.3.3 Designations

This documentation uses the following designations:

Table 4: Designations

Designation Meaning

A4CSG Axial piston variable pumpClosed circuit

Threaded plug Metal screw, pressure-resistant

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

As an umbrella term for “Axial piston variable pump A4CSG”, 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 Deutsche Industrie Norm (German Institute for Standardization)

EP Electrohydraulic control with Proportional solenoid and pressure control

ISO International Organization for Standardization

JIS Japan Industrial Standard

RD Rexroth document in the Deutsch (German) 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, A4CSG, Series 3x, RE 92105-01-B/06.2017

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

property damage 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 area

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

sense of 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 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 92105 and in the order

conﬁrmation. Information about approved hydraulic ﬂuids can be found in data

sheet 92105.

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 8.

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

shall bear all risks arising from improper use.

Similarly, the following foreseeable forms of misuse are deemed faulty usage:

•Use outside the operating parameters approved in the data sheet 92105 or in the

order conﬁrmation (unless customer-speciﬁc approval has been granted)

•The axial piston variable pump A4CSG is, except for momentary pressure

reduction, not approved for motor/reversing operation.

•Use of non-approved ﬂuids, for example, water or polyurethane components

•Changes to factory settings by unauthorized persons

•Use of assembled parts (e.g. attachment ﬁlter, control unit, valves) other than the

speciﬁed Rexroth components

Safety instructions 9/68

RE 92105-01-B/06.2017, A4CSG, Series 3x, Bosch Rexroth AG

•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 (for example, sensors) generally

cannot 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 permitted. Beyond this, the maximum case pressure speciﬁed on the

data sheet cannot 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/EC

•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 basic knowledge of

mechanics, electrics, hydraulics and ATEX, 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 skilled personnel or an

instructed person under the direction and supervision of skilled personnel.

Skilled persons are those who can recognize possible dangers and take 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. Skilled personnel must follow the rules relevant to their ﬁeld

and have the necessary hydraulics expert knowledge.

Hydraulic expert knowledge includes:

•Reading and fully understanding hydraulic circuit diagrams,

•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: http://www.boschrexroth.com/training.

10/68 Safety instructions

Bosch Rexroth AG, A4CSG, Series 3x, RE 92105-01-B/06.2017

2.5 General safety instructions

•Observe the applicable accident prevention and environmental protection

regulations.

•Observe the safety regulations and provisions 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.

•Persons who install, operate, remove or maintain Rexroth products may not be

under the inﬂuence of alcohol, drugs or medication that may aﬀect their reaction

time.

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

to persons due to 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 injury to personnel or property damage. For this reason, only use

the product in safety-relevant applications if this use is expressly speciﬁed and

permitted in the product documentation, for example in explosion protection

applications or in safety-related parts of a control system (functional safety).

•You may only commission the product if it has been determined that the end

product (for example, machinery or 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 (for example, 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 that these are properly implemented.

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

when using solenoids. When a direct current is applied, solenoids do not cause

electromagnetic interference nor is their operation impaired by electromagnetic

interference. 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.

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