Bosch Rexroth A10VGT Bedienungsanleitung

Instruction manual

RE 92770-01-B/11.2016

Replaces: –.–

English

Axial piston variable pump

A10VGT

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.

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RE 92770-01-B/11.2016, A10VGT/A10VGT 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 Display 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

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

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 22

6.2 Storing the axial piston unit 24

7 Installation 26

7.1 Unpacking 26

7.2 Installation conditions 26

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 30

7.4.1 Preparation 30

7.4.2 Dimensions 30

7.4.3 General instructions 31

7.4.4 Installation with coupling 31

7.4.5 Installation on a gearbox 32

7.4.6 Installation with cardan shaft 33

7.4.7 Completing installation 33

7.4.8 Changing the lever position of the HW control 34

7.4.9 Hydraulically connecting the axial piston unit 35

7.4.10 Electrically connecting the axial piston unit 39

7.5 Performing ﬂushing cycle 40

Contents

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Bosch Rexroth AG, A10VGT Series 11, RE 92770-01-B/11.2016

8 Commissioning 41

8.1 Initial commissioning 41

8.1.1 Filling the axial piston unit 41

8.1.2 Testing the hydraulic ﬂuid supply 43

8.1.3 Performing functional test 43

8.2 Running-in phase 44

8.3 Recommissioning after a standstill 44

9 Operation 45

9.1 Manual override of the electrical control 45

10 Maintenance and repair 46

10.1 Cleaning and care 46

10.2 Inspection 47

10.3 Maintenance 47

10.4 Repair 48

10.5 Spare parts 48

11 Removal and replacement 49

11.1 Required tools 49

11.2 Preparing for removal 49

11.3 Performing removal 49

11.4 Preparing the components for storage or further use 49

12 Disposal 50

13 Extension and conversion 51

14 Troubleshooting 52

14.1 How to proceed for troubleshooting 52

14.2 Malfunction table 53

15 Technical data 57

16 Alphabetical index 58

Contents

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1 About this documentation

1.1 Validity of the documentation

This documentation is valid for the following products:

•Axial piston variable pump A10VGT Series 11

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 order-related technical data of your Axial piston variable pump

A10VGT.

– Order conﬁrmation

Installation drawing

Contains the outer dimensions, all connections and the hydraulic circuit

diagram for your Axial piston variable pump A10VGT.

Please request the

installation drawing

from your contact at

Bosch Rexroth.

Installation drawing

Axial piston variable pump A10VGT

Contains the permissible technical data.

92770 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

Environmentally acceptable hydraulic ﬂuids

Describes the requirements on an environmentally acceptable 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

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, A10VGT Series 11, RE 92770-01-B/11.2016

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11 and in chapter3 “General instructions on damage

to property and theproduct” on page15 and before a sequence of actions or an

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

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

get damaged.

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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

A10VGT Axial piston variable pump, closed circuit, for use in concrete mixer truck

Threaded plug Metal screw, pressure-resistant

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

As a generic term for “Axial piston variable pump A10VGT”, the designation “axial

piston unit” will be used hereinafter.

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)

EP Proportional control, electric

HW Proportional control, hydraulic, mechanical servo

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)

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Bosch Rexroth AG, A10VGT Series 11, RE 92770-01-B/11.2016

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. A component is exclusively

intended to form a partly complete machine or a complete machine 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 A10VGT is only approved as a pump for hydrostatic drum drives

of concrete mixer trucks in a closed circuit. The pump has been speciﬁcally designed

and constructed for the load collectives in this particular application.

The performance data given is based on this load collective.

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

the performance limits as speciﬁed in data sheet92770 and in the order

conﬁrmation. Information about approved hydraulic ﬂuids can be found in

data sheet92770.

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

bears all risks from improper use.

The following foreseeable faulty usages are also be 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

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RE 92770-01-B/11.2016, A10VGT Series 11, Bosch Rexroth AG

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

Rexroth components

•Use of the axial piston unit 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 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 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/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 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 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: www.boschrexroth.com/training.

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Bosch Rexroth AG, A10VGT Series 11, RE 92770-01-B/11.2016

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

(e.g.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 (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 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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