REXROTH A4VSG Instruction Manual
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REXROTH A4VSG Instruction Manual

Axial piston variable pump
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Axial Piston Variable Pump
A4VSG
Series 10, 11 and 30
Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK
Company Registered in England No: 4167649 VAT Registration No: 732 5692 25 BS EN ISO 9001:2008 No: LRQ 0964389
+44 (0)1204 699 959
enquiries@hyquip.co.uk
www.hyquip.co.uk/web/index
Instruction manual
RE 92100-01-B/09.2012
Replaces: –.–
English

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  • Page 1 +44 (0)1204 699 959 enquiries@hyquip.co.uk www.hyquip.co.uk/web/index Axial Piston Variable Pump A4VSG Series 10, 11 and 30 Instruction manual Replaces: –.– RE 92100-01-B/09.2012 English Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK Company Registered in England No: 4167649 VAT Registration No: 732 5692 25 BS EN ISO 9001:2008 No: LRQ 0964389...
  • Page 2 © This document, as well as the data, specifications and other information set forth in it, are the exclusive property of Bosch Rexroth AG. It may not be reproduced or given to third parties without its consent.

  • Page 3: Table Of Contents

    7.4.9 Electrically connecting the axial piston unit Peforming flushing cycle RE 92100-01-B/09.2012, A4VSG Series 10, 11 and 30, Bosch Rexroth AG Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK Company Registered in England No: 4167649 VAT Registration No: 732 5692 25 BS EN ISO 9001:2008 No: LRQ 0964389...
  • Page 4 Technical data Alphabetical index Bosch Rexroth AG, RE 92100-01-B/09.2012 Series 10, 11 and 30, Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK Company Registered in England No: 4167649 VAT Registration No: 732 5692 25 BS EN ISO 9001:2008 No: LRQ 0964389...

  • Page 5: About This Manual

    Title Document number Document type Order confirmation – Order confirmation Contains the order-related technical data of your A4VSG axial piston variable pump. Installation drawing Please request the Installation drawing Contains the outer dimensions, all connections and the hydraulic schematic installation drawing for your A4VSG axial piston variable pump.

  • Page 6: Display Of Information

    fluid for your hydraulic system. Information of the use of hydrostatic drives at low temperatures RE 90300-03-B Manual Contains additional information on the use of Rexroth axial piston units at low temperatures. Storage and preservation of axial piston units RE 90312 Data sheet Contains additional information on storage and preservation.

  • Page 7: Symbols

    Protective plug Made out of plastic, not pressure-resistant, only for transportation As umbrella term for A4VSG "axial piston variable pump" the designation "axial piston unit" will be used in the following. RE 92100-01-B/09.2012, A4VSG Series 10, 11 and 30, Bosch Rexroth AG...

  • Page 8: Abbreviations

    VDI (Verein Deutscher Ingenieure – Association of German Engineers) Bosch Rexroth AG, RE 92100-01-B/09.2012 Series 10, 11 and 30, Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK Company Registered in England No: 4167649 VAT Registration No: 732 5692 25 BS EN ISO 9001:2008 No: LRQ 0964389...

  • Page 9: Safety Instructions

    Any use other than that described as intended use shall be considered as improper and is therefore impermissible. Bosch Rexroth AG shall accept no liability whatsoever for damage resulting from improper use. The user shall bear all risks arising from improper use.

  • Page 10: Personnel Qualifications

    Only use Rexroth original accessories and spare parts to ensure there is no risk to persons from unsuitable spare parts. Conform to the technical data and ambient conditions specified in the product documentation.

  • Page 11: Product-Specific Safety Instructions

    (functional safety). You may only commission the product if it has been determined that the end product (e.g. machinery or a system) into which the Rexroth products are installed complies with the country-specific provisions, safety regulations and standards of the application.
  • Page 12 Protect the machine/system against being energized. Bosch Rexroth AG, RE 92100-01-B/09.2012 Series 10, 11 and 30, Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK...

  • Page 13: Personal Protective Equipment

    Observe the safety regulations and provisions of your country. All components of the personal protective equipment must be intact. RE 92100-01-B/09.2012, A4VSG Series 10, 11 and 30, Bosch Rexroth AG Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK...

  • Page 14: General Instructions On Damage To Equipment And The Product

    Make sure that the suction and boost lines are always filled with hydraulic fluid during commissioning and operation. Bosch Rexroth AG, RE 92100-01-B/09.2012 Series 10, 11 and 30, Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK Company Registered in England No: 4167649 VAT Registration No: 732 5692 25 BS EN ISO 9001:2008 No: LRQ 0964389...
  • Page 15 Dispose of the hydraulic fluid in accordance with the applicable safety data sheet for the hydraulic fluid. RE 92100-01-B/09.2012, A4VSG Series 10, 11 and 30, Bosch Rexroth AG Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK Company Registered in England No: 4167649 VAT Registration No: 732 5692 25 BS EN ISO 9001:2008 No: LRQ 0964389...
  • Page 16 The entitlement to warranty cover will be rendered void if the product is incorrectly installed, commissioned or operated, or if it is used or handled improperly. Bosch Rexroth AG, RE 92100-01-B/09.2012 Series 10, 11 and 30, Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK...

  • Page 17: Delivery Contents

    Protective plug/threaded plug (2) For version with through drive, metallic protective cover and mounting bolts RE 92100-01-B/09.2012, A4VSG Series 10, 11 and 30, Bosch Rexroth AG Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK Company Registered in England No: 4167649 VAT Registration No: 732 5692 25 BS EN ISO 9001:2008 No: LRQ 0964389...

  • Page 18: About This Product

    5.2 About this product The A4VSG is a variable pump with axial piston rotary group in swashplate design for hydrostatic drives in closed circuits. Flow is proportional to drive speed and displacement.

  • Page 19: Functional Description

    (immediate stop). If necessary, make sure that these are properly implemented. RE 92100-01-B/09.2012, A4VSG Series 10, 11 and 30, Bosch Rexroth AG Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK...

  • Page 20: Product Identification

    14 Customer material number 7 Speed Bosch Rexroth AG, RE 92100-01-B/09.2012 Series 10, 11 and 30, Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK Company Registered in England No: 4167649 VAT Registration No: 732 5692 25 BS EN ISO 9001:2008 No: LRQ 0964389...

  • Page 21: Transport And Storage

    Only use the lifting strap if you are unable to achieve the required installation position with transport using the ring screws. RE 92100-01-B/09.2012, A4VSG Series 10, 11 and 30, Bosch Rexroth AG Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK...
  • Page 22 Fig. 5: Mounting ring screw in drive shaft Bosch Rexroth AG, RE 92100-01-B/09.2012 Series 10, 11 and 30, Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK Company Registered in England No: 4167649 VAT Registration No: 732 5692 25 BS EN ISO 9001:2008 No: LRQ 0964389...

  • Page 23: Storing The Axial Piston Unit

    ▶ Check the axial piston unit monthly to ensure proper storage. RE 92100-01-B/09.2012, A4VSG Series 10, 11 and 30, Bosch Rexroth AG Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK Company Registered in England No: 4167649 VAT Registration No: 732 5692 25 BS EN ISO 9001:2008 No: LRQ 0964389...
  • Page 24 Bosch Rexroth Service partner. In the event of questions regarding repair and spare parts, contact your responsible Bosch Rexroth Service partner or the service department of the manufacture's plant for the axial piston unit, see chapter 10.5 "Spare parts" on page 50.
  • Page 25 Store the axial piston unit so that it is protected against jolts, see "Requirements" on page 23 in this chapter. RE 92100-01-B/09.2012, A4VSG Series 10, 11 and 30, Bosch Rexroth AG Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK...

  • Page 26: Installation

    To achieve favorable noise values, decouple all connecting lines from all vibration- capable components (e.g. reservoir) using elastic elements. Bosch Rexroth AG, RE 92100-01-B/09.2012 Series 10, 11 and 30, Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK...
  • Page 27 Use suitable mild detergents to remove lubricants and other difficult-to-remove contamination. Cleaning agents must not enter the hydraulic system. RE 92100-01-B/09.2012, A4VSG Series 10, 11 and 30, Bosch Rexroth AG Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK...

  • Page 28: Installation Position

    Because of gravity, dead weight and case pressure, minor characteristic displacements and actuating time changes may occur. Bosch Rexroth AG, RE 92100-01-B/09.2012 Series 10, 11 and 30, Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK...

  • Page 29: Below-Reservoir Installation (Standard)

    (drive shaft vertically upward) T; R(L) plug RE 92100-01-B/09.2012, A4VSG Series 10, 11 and 30, Bosch Rexroth AG Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK Company Registered in England No: 4167649 VAT Registration No: 732 5692 25 BS EN ISO 9001:2008 No: LRQ 0964389...

  • Page 30: Above-Reservoir Installation

    If an attachment pump is fitted, please note the suction height and minimum inlet pressure stated in the data sheet for the attachment pump. For an overview of attachment pumps, please refer to data sheet RE 92100. Fig. 9: Above-reservoir installation A4VSG with installation position 7–12 T, R(L), Fluid filling + air bleeding...

  • Page 31: Installing The Axial Piston Unit

    "Product identification" on page 20. RE 92100-01-B/09.2012, A4VSG Series 10, 11 and 30, Bosch Rexroth AG Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK...

  • Page 32: Dimensions

    The size of the female thread can be seen in the installation drawing. Bosch Rexroth AG, RE 92100-01-B/09.2012 Series 10, 11 and 30, Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK...

  • Page 33: Installation On A Gearbox

    RE 92100-01-B/09.2012, A4VSG Series 10, 11 and 30, Bosch Rexroth AG Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK...

  • Page 34: Completing Installation

    Ports intended for connecting lines are covered by protective plugs or threaded plugs, which serve as transport protection. All ports required for the function must be connected (see Table 10 "Ports A4VSG Series 10, 11 and 30" on page 38). If this requirement is disregarded, malfunction or damage may result.

  • Page 35: Hydraulically Connecting The Axial Piston Unit

    Connect only hydraulic lines that are appropriate for the axial piston unit port (pressure level, size, system of units). RE 92100-01-B/09.2012, A4VSG Series 10, 11 and 30, Bosch Rexroth AG Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK...
  • Page 36 Due to the limited options for visually detecting differences, there is a risk of mix-ups. Bosch Rexroth AG, RE 92100-01-B/09.2012 Series 10, 11 and 30, Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK Company Registered in England No: 4167649 VAT Registration No: 732 5692 25 BS EN ISO 9001:2008 No: LRQ 0964389...
  • Page 37 R(L) Fig. 13: Port overview A4VSG, HD control, size 500 RE 92100-01-B/09.2012, A4VSG Series 10, 11 and 30, Bosch Rexroth AG Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK Company Registered in England No: 4167649 VAT Registration No: 732 5692 25 BS EN ISO 9001:2008 No: LRQ 0964389...
  • Page 38 38/60 Installation R(L) Fig. 14: Port overview A4VSG with mounted boost pump, HDT control, size 125 R(L) Fig. 15: Port overview A4VSG, HS control, size 250 Table 10: Ports A4VSG Series 10, 11 and 30 Designation Port for Control device (optional)
  • Page 39 O = Must be connected (plugged on delivery) X = Plugged (in normal operation) RE 92100-01-B/09.2012, A4VSG Series 10, 11 and 30, Bosch Rexroth AG Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK Company Registered in England No: 4167649 VAT Registration No: 732 5692 25 BS EN ISO 9001:2008 No: LRQ 0964389...
  • Page 40 M , 10 Nm for M10 x 1 and 17 Nm for M12 x 1.5, the maximum permissible pressure is 420 bar. Bosch Rexroth AG, RE 92100-01-B/09.2012 Series 10, 11 and 30, Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK Company Registered in England No: 4167649 VAT Registration No: 732 5692 25 BS EN ISO 9001:2008 No: LRQ 0964389...

  • Page 41: Electrically Connecting The Axial Piston Unit

    "Required and supplementary documentation" on page 5). The mating connector is not always included in the delivery contents. RE 92100-01-B/09.2012, A4VSG Series 10, 11 and 30, Bosch Rexroth AG Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK Company Registered in England No: 4167649 VAT Registration No: 732 5692 25 BS EN ISO 9001:2008 No: LRQ 0964389...

  • Page 42: Peforming Flushing Cycle

    Fig. 16: HIRSCHMANN connector 7.5 Peforming flushing cycle In order to remove foreign particles from the system, Bosch Rexroth recommends a flushing cycle for the entire system before the first commissioning. To avoid internal contamination, the axial piston unit must not be included in the flushing cycle.

  • Page 43: Commissioning

    The axial piston unit should be filled with a filling unit (10 μm filter grade). The axial piston unit must not be operated while it is being filled by the filling unit. RE 92100-01-B/09.2012, A4VSG Series 10, 11 and 30, Bosch Rexroth AG Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK...
  • Page 44 You can find details of the minimum requirements on hydraulic fluids in Bosch Rexroth data sheets RE 90220, RE 90221 and RE 90222. The titles of the data sheet can be found in Table 1 "Required and supplementary documentation" on page 5.

  • Page 45: Testing The Hydraulic Fluid Supply

    ▶ If necessary, disconnect the gauge and plug the ports with threaded plugs. RE 92100-01-B/09.2012, A4VSG Series 10, 11 and 30, Bosch Rexroth AG Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK Company Registered in England No: 4167649 VAT Registration No: 732 5692 25 BS EN ISO 9001:2008 No: LRQ 0964389...

  • Page 46: Running-In Phase

    ▶ Change the hydraulic fluid if the required cleanliness level is not reached. If a laboratory test is not carried out after the running-in phase, Bosch Rexroth recommends the hydraulic fluid be changed. 8.3 Recommissioning after standstill Depending on the installation conditions and ambient conditions, changes may occur in the hydraulic system which make recommissioning necessary.

  • Page 47: Operation

    The machine/system manufacturer is responsible for the proper project planning of the hydraulic system and its control. RE 92100-01-B/09.2012, A4VSG Series 10, 11 and 30, Bosch Rexroth AG Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK...

  • Page 48: Maintenance And Repair

    Remove coarse external dirt and keep sensitive and important components, such as solenoids, valves, indicators and sensors, clean. Bosch Rexroth AG, RE 92100-01-B/09.2012 Series 10, 11 and 30, Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK Company Registered in England No: 4167649 VAT Registration No: 732 5692 25 BS EN ISO 9001:2008 No: LRQ 0964389...

  • Page 49: Inspection

    Maintenance and repair 49/60 10.2 Inspection In order to enable long and reliable operation of the axial piston unit, Bosch Rexroth recommends testing the hydraulic system and axial piston unit on a regular basis, and documenting and archiving the following operating conditions:...

  • Page 50: Repair

    50/60 Maintenance and repair 10.4 Repair Bosch Rexroth offers a comprehensive range of services for the repair of Rexroth axial piston units. Repairs on the axial piston unit and its fittings may only be performed by service centers certified by Bosch Rexroth.

  • Page 51: Removal And Replacement

    ▶ Proceed as described in chapter 6.2 "Storing the axial piston unit" on page 23. RE 92100-01-B/09.2012, A4VSG Series 10, 11 and 30, Bosch Rexroth AG Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK Company Registered in England No: 4167649 VAT Registration No: 732 5692 25 BS EN ISO 9001:2008 No: LRQ 0964389...

  • Page 52: Disposal

    Do not modify the axial piston unit or its fittings. This includes changes to the setting screws or wiring. The Bosch Rexroth warranty only applies for the delivered configuration. In case of conversion or extension, the entitlement under warranty will be rendered void.

  • Page 53: Troubleshooting

    If you cannot rectify the error, contact one of the contact addresses which can be found at: www.boschrexroth.com/addresses. RE 92100-01-B/09.2012, A4VSG Series 10, 11 and 30, Bosch Rexroth AG Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK...

  • Page 54: Malfunction Table

    Exchange axial piston unit, contact Bosch Rexroth Service. Bosch Rexroth AG, RE 92100-01-B/09.2012 Series 10, 11 and 30, Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK Company Registered in England No: 4167649 VAT Registration No: 732 5692 25 BS EN ISO 9001:2008 No: LRQ 0964389...
  • Page 55 Contact Bosch Rexroth Service. controller. RE 92100-01-B/09.2012, A4VSG Series 10, 11 and 30, Bosch Rexroth AG Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK Company Registered in England No: 4167649 VAT Registration No: 732 5692 25 BS EN ISO 9001:2008 No: LRQ 0964389...

  • Page 56: Technical Data

    The order-related technical data of your axial piston unit can be found in the order confirmation. Bosch Rexroth AG, RE 92100-01-B/09.2012 Series 10, 11 and 30, Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK Company Registered in England No: 4167649 VAT Registration No: 732 5692 25 BS EN ISO 9001:2008 No: LRQ 0964389...

  • Page 57: Alphabetical Index

    ▶ H High-pressure side RE 92100-01-B/09.2012, A4VSG Series 10, 11 and 30, Bosch Rexroth AG Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK Company Registered in England No: 4167649 VAT Registration No: 732 5692 25 BS EN ISO 9001:2008 No: LRQ 0964389...
  • Page 58 Warranty Weight Bosch Rexroth AG, RE 92100-01-B/09.2012 Series 10, 11 and 30, Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK Company Registered in England No: 4167649 VAT Registration No: 732 5692 25 BS EN ISO 9001:2008 No: LRQ 0964389...
  • Page 59 59/60 RE 92100-01-B/09.2012, A4VSG Series 10, 11 and 30, Bosch Rexroth AG Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK Company Registered in England No: 4167649 VAT Registration No: 732 5692 25 BS EN ISO 9001:2008 No: LRQ 0964389...
  • Page 60 +44 (0)1204 699 959 enquiries@hyquip.co.uk www.hyquip.co.uk/web/index Subject to change Printed in Germany RE 92100-01-B/09.2012 Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK Company Registered in England No: 4167649 VAT Registration No: 732 5692 25 BS EN ISO 9001:2008 No: LRQ 0964389...

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