Application & Service Manual - Synergy Industries

1 RA & Service ManualVariable Displacement Pump AA4VG, Series 3RA 92003- of PartsFor Rexroth to supply the correct parts for your unit, please include all of the following informationalong with your parts CodeSerial NumberUnit NumberPart NamePart NumberDue to modifications and improvements to our products, minor changes can occur to the parts,even though the type code may not necessarily reflect these changes. The type number and serialnumber will guarantee that the correct parts for your unit are ExampleTo order a replacement rotary group for an AA4VG variable displacement pump having the abovenameplate, the following information would be required.

2 +Model Code AA4VG125 NVD1/32 LPSFN001S+Serial Number G2014680+Unit Number 5454-005-002*Part Name Charge Pressure Relief Valve*Part Number HU00434856+ This information is taken from the nameplate on the pump.* This information is taken from the Application and Service -PSF52N001S5454-005-002 CCWPART PUMP DIVISIONFOUNTAIN INN IN USARA 92003- Displacement Pump AA4VG, Series 3 Name Tag Information.. Page 2 Type Code.. 4 5 technical Data.. 6 7 Filtration Options.. 7 9 High Pressure Relief Valve.. 10 Pump Controls.. 11 16 Pump Installation.

3 17 18 Start-up Procedure.. 19 Trouble Shooting Procedure.. 20 23 Charge Pressure Relief Adjustments.. 24 Mechanical Centering of Pump.. 24 Hydraulic Centering of Control Modules.. 25 Adjustments of Pressure Override Valve.. 26 Adjustment of High Pressure Relief Valves.. 27 Tow Option Engagement.. 28 Removal an Inspection of Charge Pump.. 29 Removal and Installation of Shaft Seal.. 30 Filter Replacement.. 31 Routine Maintenance.. 32 Replacement Subassemblies and Parts.. 33 36 Filtration Configuration.. 37 IndexRA 92003- Displacement Pump AA4VG, Series 34 Ordering CodeHydraulic FluidPetroleum Oil (For operation with other fluids, consult a Rexroth Application Engineer)Axial Piston UnitVariable swashplate design.

4 Nominal pressure 5800 psi; peak pressure 6500 psiAA4 VMode of OperationPump in closed circuitGSize Displacement Vgmax(cm3)2840567190125180250 Size 28, see RA 92002 Size 250, see RA 92000 Control Options40567190125180 NoneNVllllllNVHydraulic Control Direct OperatedDGllllllDGElectrical Control ProportionalEPllllllEPElectrical Control Non ProportionalEZllllllEZRotary Manual Servo ControlHWllllllHWHydraulic Control Pilot OperatedHDllllllHDHydraulic Control Speed DependentDAllllllDASolenoid Voltage (EP, EZ, or DA only)12 Volt DCllllll124 Volt DCllllll2 Pressure Cut-OffWith Pressure Cut-OffllllllDNeutral Position Switch (HW control only)Without Neutral Position Switch (no code)llllllOmitWith Neutral Position SwitchllllllLMechanical Stroke LimiterWithout Stroke LimiterllllllOmitWith Stroke LimiterllllllMPorts X3, X4for Stroking PressureWithout Ports X3, X4 (no code)llllllOmitWith Ports X3, X4llllllTRegulating (DA)

5 CartridgeNVEZDGEPHWHDDA40567190125180 Without DA Cartridgellllll llllll1 With DA Cartridge, fixed adjustment lllllllllll2 With DA Cartridge, mech. adjustable w/lever llllllllll3 With DA Cartridge, fixed adjustment andHydraulic Inching Valve built on lllllll4 With DA Cartridge, mech. adjust. w/lever andHydraulic Inching Valve built on lllllll5 With DA Cartridge, fixed adjustment andconnection for TH7 master controller lllllllllll7 Series 3 Index2 Direction of Rotation(As viewed from drive shaft)clockwiseRcounter-clockwiseL Shaft Option S is standard for the front pump of tandem See Page Request; With Cold Start bypass valve.

6 See page Factory Not AvailableAxial Piston UnitOperationDisplacementControl & OptionsRegulating CartridgeDesign SeriesIndexDirection of RotationSealsNBRPNBR, FPM shaft sealNShaft Type (For maximum permissible shaft torque refer to page 33)40567190125180 Spline SAE (Standard for single pump)llllllSSpline SAE (Standard for tandem pump, 1stpump) ll llTSpline SAE (Only for tandem pump, 2ndpump)l USpline DIN 5480 (For tandem pump, 2nd pump) l ZMounting Flange40567190125180 SAE2 boltll C4 bolt lD2 + 4 bolt lll FPort Connections40567190125180 Ports A & B (SAE 4-bolt flange), on top and bottomllllll52 Charge Pump40567190125180 With Charge Pump & without Through-DrivellllllF00 Without Charge Pump & without Through-DrivellllllN00 With Charge Pump & with Charge Pump & with A(5 8"9T 16/32P)SAE A, B(7 8"13T-16/32P)SAE B, B B(1"15T-16/32P)SAE B, B B(1"15T-16/32P)SAE C, 2-boltl.

7 09 SAE C(11 4"14T-12/24P)SAE C, 2-bolt (N35x2x30x16x9H DIN 5480)SAE D, 2+4-bolt l ..73 SAE D(13 4"13T-8/16P)SAE D, 2+4-bolt D(13 4"13T-8/16P)SAE E, 4-bolt Valves Adjustment Range40567190125180W/high press. relief valves, pilot psi with bypass llll1 With high pressure relief psi without bypassll 3 Direct operated, fixed settingwith bypassll psiwithout bypassll 4with bypassll 6 Filtration40567190125180 Filtration in Charge Pump suction linellllllSCharge Pressure Filtration (Ports Fe and Fa)llllllDCold start valve and ports for external charge circuit filter (Ports Fe and Fa)mmmmmmKMounted Filter (Without contamination indicator)

8 LlllllFFilter with visual contamination indicator llllllPFilter with electrical contamination indicator llllllLFilter with visual and electrical contamination indicator llllllMExternal Charge Supply (Units without charge pump N00 or )llllllEAA4VG/32 52RA 92003- Displacement Pump AA4VG, Series 35 Variable Displacement Pump AA4VG, Series 3RA 92003- AA4VG is a swashplate design, variable displacement, overcenter, axial piston pump. It has been designed exclusively forclosed circuit hydrostatic transmissions where a self-containedpump package is required.

9 The pump design incorporates acharge pump, a charge pressure relief valve, two combinationhigh pressure relief and make-up check valves, and an inte-grated pressure cut-off AA4VG pump may be mounted in any position around thehorizontal (drive shaft) axis. Other mounting orientations ( shaft vertical) are possible, but should be reviewed with aRexroth Application Engineer prior to finalizing the design. Thecase drain line should be connected to the highest case drainport (T1or T2) so that the pump case always remains full of case drain piping, or hose, should be sized to accept the fullflow of the charge pump at the maximum anticipated drivespeed, with minimal pressure RecommendationsThe AA4VG pumps are supplied as standard for use with goodquality, petroleum oil based, anti-wear hydraulic fluids.

10 Moredetailed information regarding the selection of hydraulic fluidsand their Application limits can be found in our Data SheetsRA90220 (Petroleum Oil), RE90221 (Biodegradable Fluids)and RA90223 (Type HF Fire Resistant/Synthetic Fluids).For applications with biodegradable or Type HF fluids, possiblereduction of the operating specifications may be consult Rexroth and your oil Viscosity RangeIn order to obtain optimum efficiency and Service life, we recom-mend that the operating viscosity (at normal loop operatingtemperature) be selected from within the range:Optimum Viscosity ( opt).