Axial piston variable pump A4VG

1 Instruction manualRE 92003-01- : piston variable pumpA4 VGSeries 32 Bosch Rexroth AG 2016. All rights reserved, 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 original instruction manual was created in the German language. RE 92003-01- , A4VG Series 32, Bosch Rexroth AG Contents1 About this documentation Validity of the documentation Required and supplementary documentation Display of information Safety instructions Symbols Designations Abbreviations 82 Safety instructions About this chapter Intended use Improper use Personnel qualifications General safety instructions Product-specific safety instructions Personal protective equipment 153 General instructions on damage to property and the product 164 Scope of delivery 195 About this product Performance description Product description Layout of the Axial piston unit Functional description Bypass function Bypass function size 28 to 56 Bypass function size 71.

2 90 Bypass function size 125 to 180 Product identification 276 Transport and storage Transporting the Axial piston unit Transporting by hand Transporting with a lifting device Storing the Axial piston unit 307 Installation Unpacking Installation conditions Installation position Below-reservoir installation (standard) Above-reservoir installation Installing the Axial piston unit Preparation Dimensions General instructions Installation with coupling Installation on a gearbox Completing installation 40 Contents 3/684/68 Bosch Rexroth AG, A4VG Series 32, RE 92003-01- Changing the lever position of the HW control Hydraulically connecting the Axial piston unit Electrically connecting the Axial piston unit Performing flushing cycle 478 Commissioning Initial commissioning Filling the Axial piston unit Testing the hydraulic fluid supply Performing a functional test Running-in phase Recommissioning after standstill 519 Operation 5210 Maintenance and repair Cleaning and care Inspection Maintenance Changing the filter element Repair Spare parts 5611 Removal and replacement Required tools Preparing for removal Performing removal Preparing the components for storage or later use 5712 Disposal 5813 Extension and conversion 5914 Troubleshooting How to proceed with troubleshooting

3 Malfunction table 6115 Technical data 6516 Alphabetical index 66 About this documentation 5/68 RE 92003-01- , A4VG Series 32, Bosch Rexroth AG 1 About this Validity of the documentationThis 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 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 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 1: Required and supplementary documentationTitleDocument numberDocument typeOrder confirmationContains the order-related technical data for your Axial piston variable pump A4VG Series 32.

4 Order confirmationInstallation drawingContains the outer dimensions, all connections and the hydraulic circuit diagram for your Axial piston variable pump A4VG Series request the installation drawing from your contact at Bosch drawingAxial piston variable pump A4VG Series 32 Contains the permissible technical sheetMineral oil-based hydraulic fluids and related hydrocarbonsDescribes 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 sheetEnvironmentally acceptable hydraulic fluidsDescribes 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 sheetFire-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.

5 90222 Data sheetFire-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 sheetInformation for the use of hydrostatic drives at low temperaturesContains additional information on the use of Rexroth Axial piston units at low and preservation of Axial piston unitsContains additional information on storage and sheet6/68 About this documentationBosch Rexroth AG, A4VG Series 32, RE 92003-01- Display of informationStandardized 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 Safety instructionsThis documentation includes safety instructions in chapter 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.

6 The described danger prevention measures must be instructions are set out as follows: SIGnAl wORDType 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 About this documentation 7/68 RE 92003-01- , A4VG Series 32, Bosch Rexroth AG Table 2: Hazard classes as defined in AnSI sign, signal wordMeaning DAnGERI dentifies a dangerous situation that will result in death or serious injuries if it is not avoided. wARnInGIdentifies a dangerous situation that may result in death or serious injuries if it is not avoided. CAUTIOnIdentifies a dangerous situation that may result in minor to moderate injuries if it is not damage: The product or the environment may become SymbolsThe following symbols indicate information that is not safety-relevant but increases understanding of the 3: Meaning of the symbolsSymbolMeaningIf this information is disregarded, the product cannot be used and/or operated to the optimum extent.

7 Single, independent action1. 2. 3. Numbered instruction:The numbers indicate that the steps must be completed one after the DesignationsThis documentation uses the following designations:Table 4: DesignationsDesignationMeaningA4 VGAxial piston variable pump, closed circuitThreaded plugMetal screw, pressure-resistantProtection plugMade out of plastic, not pressure-resistant, only for transportationAs a generic term for Axial piston variable pump A4VG , the designation Axial piston unit will be used About this documentationBosch Rexroth AG, A4VG Series 32, RE 92003-01- AbbreviationsThis documentation uses the following abbreviations:Table 5: AbbreviationsAbbreviationMeaningATEXEC directive on explosion protection (Atmosph re explosible)DAAutomatic control, speed relatedDGHydraulic control, directly operatedDIND eutsches Institut f r normung (German Institute for Standardization)EPProportional control, electricHDProportional control, hydraulicISOI nternational Organization for StandardizationJISJ apan Industrial StandardRERexroth document in the English languageVDI 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- , A4VG Series 32, Bosch Rexroth AG 2 Safety About this chapterThe Axial piston unit has been manufactured according to the generally accepted rules of current technology.

8 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 Intended useAxial 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 product is intended for the following use:The Axial piston unit is only approved as a pump for hydrostatic drives in closed circuit.

9 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 Axial piston unit is only intended for professional use and not for private use includes having read and understood the complete documentation, especially chapter 2 Safety instructions on page Improper useAny use other than that described as intended use shall be considered as improper and is therefore Rexroth AG is not liable for damages resulting from improper use. The user bears all risks from improper 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, , water or polyurethane components Changes to factory settings by unauthorized persons Use of add-ons ( , attachment filter, control unit, valves) not in combination with the specified Rexroth components10/68 Safety instructionsBosch Rexroth AG, A4VG Series 32, RE 92003-01- Use of the Axial piston unit with assembled parts under water at a depth of more than 10 meters without the necessary additional measures, , pressure equalization.

10 Units with electrical components ( , 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 < 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 Personnel qualificationsThe 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.