Related Manuals for Bosch Rexroth 3 Series
Summary of Contents for Bosch Rexroth 3 Series
- Page 1 Axial piston variable pump A4CSG Series 3x Instruction manual Replaces: –.– RE 92105-01-B/06.2017 English...
- Page 2 © Bosch Rexroth AG 2017. 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...
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Page 3: Table Of Contents
Installing the axial piston unit 7.4.1 Preparation 7.4.2 Dimensions 7.4.3 General instructions 7.4.4 Installation with coupling 7.4.5 Installation on a gearbox 7.4.6 Installation with cardan shaft 7.4.7 Completing installation 7.4.8 Hydraulically connecting the axial piston unit RE 92105-01-B/06.2017, A4CSG, Series 3x, Bosch Rexroth AG... - Page 4 11.2 Preparing for removal 11.3 Performing removal 11.4 Preparing the components for storage or further use Disposal Extension and conversion Troubleshooting 14.1 How to proceed with troubleshooting 14.2 Malfunction table Technical data Alphabetical index Bosch Rexroth AG, A4CSG, Series 3x, RE 92105-01-B/06.2017...
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Page 5: About This Documentation
Manual Contains additional information on the use of Rexroth axial piston units at low temperatures. Storage and preservation of axial piston units 90312 Data sheet Contains additional information on storage and preservation. RE 92105-01-B/06.2017, A4CSG, Series 3x, Bosch Rexroth AG... -
Page 6: Representation Of Information
Identifies a dangerous situation that may result in minor to CAUTIOn moderate injuries if it is not avoided. NOTICE Property damage: The product or the environment may get damaged. Bosch Rexroth AG, A4CSG, Series 3x, RE 92105-01-B/06.2017... -
Page 7: Symbols
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) RE 92105-01-B/06.2017, A4CSG, Series 3x, Bosch Rexroth AG... -
Page 8: Safety Instructions
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. -
Page 9: Personnel Qualifications
• 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. -
Page 10: General Safety Instructions
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. Bosch Rexroth AG, A4CSG, Series 3x, RE 92105-01-B/06.2017... -
Page 11: Product-Specific Safety Instructions
▶ Changes to the factory settings must only be made by Bosch Rexroth specialists. ▶ If the axial piston unit is equipped with a pressure cut-off and/or a pressure controller, this is not an adequate back-up against pressure overload. - Page 12 Check whether your application requires that remedial measures be taken on your machine in order to bring the driven consumer into a safe position (e.g. safe stop). ▶ If necessary, make sure that these are properly implemented. Bosch Rexroth AG, A4CSG, Series 3x, RE 92105-01-B/06.2017...
- Page 13 Risk of slipping! Risk of slipping on wet surfaces when climbing on the axial piston unit. ▶ Never grab or climb onto the axial piston unit. ▶ Check how to safely get on top of the machine/system. RE 92105-01-B/06.2017, A4CSG, Series 3x, Bosch Rexroth AG...
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Page 14: Personal Protective Equipment
Personal protective equipment is the responsibility of the user of the axial piston unit. Observe the safety regulations and provisions in your country. All pieces of personal protective equipment must be intact. Bosch Rexroth AG, A4CSG, Series 3x, RE 92105-01-B/06.2017... -
Page 15: General Instructions On Damage To Property And The Product
(air enters via the shaft seal) or via the working line (gap leakage). This means the bearings are insufficiently lubricated when the system is turned on. RE 92105-01-B/06.2017, A4CSG, Series 3x, Bosch Rexroth AG... - Page 16 Dispose of the axial piston unit, hydraulic fluid and packaging in accordance with the national regulations in your country. ▶ Dispose of the hydraulic fluid in accordance with the applicable safety data sheet for the hydraulic fluid. Bosch Rexroth AG, A4CSG, Series 3x, RE 92105-01-B/06.2017...
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Page 17: Operator's Obligations
3.1 Operator's obligations The operator has the obligation to check in the order confirmation that the axial piston unit supplied corresponds to the ordering details. RE 92105-01-B/06.2017, A4CSG, Series 3x, Bosch Rexroth AG... -
Page 18: Scope Of Delivery
• Axial piston unit as per order confirmation The following parts are also assembled prior to delivery: • Protective covers (1) • Protective plug/threaded plug (2) • For version with through drive, metallic protection cover and mounting bolts Bosch Rexroth AG, A4CSG, Series 3x, RE 92105-01-B/06.2017... -
Page 19: About This Product
5.1Pressure control 11 Cylinder terminals are located 6 Control plate 12 Piston on the solenoids) (distributor plate) 13 Slipper pad 3 Retaining plate 7 High-pressure side 14 Swashplate 8 Boost pump (cradle) RE 92105-01-B/06.2017, A4CSG, Series 3x, Bosch Rexroth AG... -
Page 20: Functional Description
Increasing the swivel angle increases the displacement; reducing the angle results in a corresponding reduction in displacement. Various control devices are available depending on requirements. Information about this can be found in data sheet 92105. Bosch Rexroth AG, A4CSG, Series 3x, RE 92105-01-B/06.2017... -
Page 21: Product Identification
11 Serial number shaft) – here: clockwise 12 Material number of the axial piston 5 Bar code unit 6 Power setting (optional) 13 Type code 7 Rotational speed 14 Customer material number RE 92105-01-B/06.2017, A4CSG, Series 3x, Bosch Rexroth AG... -
Page 22: Transport And Storage
Weight may vary by equipment. The precise weight can be found on the name plate. 6.1.1 Transporting by hand Axial piston units with a weight of up to 15 kg can be transported manually for a short time if necessary. Bosch Rexroth AG, A4CSG, Series 3x, RE 92105-01-B/06.2017... -
Page 23: Transporting With A Lifting Device
Fig. 4: Mounting the eye bolt in the drive shaft for nG 250 to 355 Fig. 5: Mounting the eye bolt in the housing for nG 500 to 1000 RE 92105-01-B/06.2017, A4CSG, Series 3x, Bosch Rexroth AG... -
Page 24: Storing The Axial Piston Unit
• Do not store the axial piston unit on the drive shaft or assembled parts, for example, sensors or valves. • For further storage conditions, see Table 7. ▶ Check the axial piston unit monthly to ensure proper storage. Bosch Rexroth AG, A4CSG, Series 3x, RE 92105-01-B/06.2017... - Page 25 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 manufacturer's plant for the axial piston unit, see chapter 10.4 “Repair” on page 54.
- Page 26 Package the axial piston unit with desiccant in corrosion protection film so it is airproof. Store the axial piston unit in a shock-proof manner, see “Requirements” on page 24 in this chapter. Bosch Rexroth AG, A4CSG, Series 3x, RE 92105-01-B/06.2017...
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Page 27: Installation
Use the line size which is appropriate for the port. ▶ A check valve in the drain line is only permissible on a case-by-case basis upon request. Please consult your responsible contact person at Bosch Rexroth. ▶ To achieve favorable noise values, decouple all connecting lines from all vibration- capable components (for example, reservoir) using elastic elements. -
Page 28: Installation Position
7.3.1 Below-reservoir installation (standard) Below-reservoir installation means that the axial piston unit is installed outside of the reservoir and below the minimum fluid level of the reservoir. Bosch Rexroth AG, A4CSG, Series 3x, RE 92105-01-B/06.2017... -
Page 29: Above-Reservoir Installation
To air bleed the stroking chamber, use the highest port on the control. 7.3.2 Above-reservoir installation Above-reservoir installation means that the axial piston unit is installed above the minimum fluid level of the reservoir. RE 92105-01-B/06.2017, A4CSG, Series 3x, Bosch Rexroth AG... - Page 30 92105. Observe the maximum permissible suction height h = 800 mm. The s max permissible suction height h is derived from the total pressure loss. Bosch Rexroth AG, A4CSG, Series 3x, RE 92105-01-B/06.2017...
- Page 31 8 (drive shaft horizontal) Plug K3; R(l) 9 (drive shaft horizontal) 10 (drive shaft vertically upward) Plug T; R(l) To air bleed the stroking chamber, use the highest port on the control. RE 92105-01-B/06.2017, A4CSG, Series 3x, Bosch Rexroth AG...
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Page 32: Installing The Axial Piston Unit
If the material number for the axial piston unit does not correspond to the one in the order confirmation, contact Bosch Rexroth Service for clarification, see chapter 10.4 “Repair” on page 54 for the address. Before installing, completely empty the axial piston unit to prevent mixing with the hydraulic fluid used in the machine/system. -
Page 33: Installation With Coupling
Transport the axial piston unit to the installation location. Remove dirt and foreign particles from the installation location. Install the coupling on the output shaft of the machine in accordance with the specifications provided by the coupling manufacturer. RE 92105-01-B/06.2017, A4CSG, Series 3x, Bosch Rexroth AG... -
Page 34: Installation On A Gearbox
No gearing forces higher than the permissible axial and radial forces are to act on gear wheel or helically- the shaft, if necessary the gear wheel must be supported separately at the gearbox toothed shaft output. Bosch Rexroth AG, A4CSG, Series 3x, RE 92105-01-B/06.2017... -
Page 35: Installation With Cardan Shaft
They are not pressure-resistant and have to be removed prior to connection. Use a suitable tool for this to prevent damage to the sealing and functional surfaces. If sealing or functional surfaces are damaged, contact your Bosch Rexroth service partner or the service department of the manufacturer's plant for the axial piston unit. - Page 36 The setting screws are protected against unintentional adjustment by caps. Adjusting the setting screw will void the warranty. If you need to change settings, contact your Bosch Rexroth service partner, for the address, see chapter 10.4 “Repair” on page 54.
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Page 37: Hydraulically Connecting The Axial Piston Unit
– The hose must be pressure-resistant, also regarding external air pressure. • Pressure line – For the pressure lines, use only pipes, hoses and connecting elements rated for the working pressure range specified in the data sheet 92105 (see Table 10). RE 92105-01-B/06.2017, A4CSG, Series 3x, Bosch Rexroth AG... - Page 38 Make sure the right fittings, mounting bolts and threaded plugs are installed. ▶ For all female threads, use a stud end from the same system of units and of the correct size. Bosch Rexroth AG, A4CSG, Series 3x, RE 92105-01-B/06.2017...
- Page 39 Short-term pressure spikes may occur depending on the application. Keep this in mind when selecting measuring devices and fittings. O = Must be connected (plugged when delivered) X = Plugged (in normal operation) Depending on the installation position, K or K must be connected RE 92105-01-B/06.2017, A4CSG, Series 3x, Bosch Rexroth AG...
- Page 40 330 Nm 135 Nm 12 mm M33 x 2 540 Nm 225 Nm 17 mm M42 x 2 720 Nm 360 Nm 22 mm M48 x 2 900 Nm 400 Nm 24 mm Bosch Rexroth AG, A4CSG, Series 3x, RE 92105-01-B/06.2017...
- Page 41 For relationship between direction of rotation and flow direction, please refer to data sheet 92105. RE 92105-01-B/06.2017, A4CSG, Series 3x, Bosch Rexroth AG...
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Page 42: Electrically Connecting The Axial Piston Unit
Loosen the mounting nut with rubber boot (1) on the solenoid. To do this, turn the mounting nut (1) one turn counter-clockwise. Turn the solenoid body (2) to the desired orientation. Re-tighten the mounting nut. Tightening torque of the mounting nut: 5+1 Nm. Bosch Rexroth AG, A4CSG, Series 3x, RE 92105-01-B/06.2017... -
Page 43: Performing Flushing Cycle
Fig. 13: HIRSCHMAnn connector 7.5 Performing flushing cycle In order to remove foreign particles from the system, Bosch Rexroth recommends a flushing cycle for the entire system before the initial commissioning . To avoid internal contamination, the axial piston unit must not be included in the flushing cycle. -
Page 44: 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. Bosch Rexroth AG, A4CSG, Series 3x, RE 92105-01-B/06.2017... -
Page 45: Testing The Hydraulic Fluid Supply
Use only a hydraulic fluid that conforms to the following requirements: You can find details of the minimum requirements on hydraulic fluids in Bosch Rexroth data sheets 90220, 90221 and 90222. The titles of the data sheets can be found in Table 1 “Required and supplementary documentation”... -
Page 46: Performing A Functional Test
Perform a leak test and heat development test with and without load prior to normal operation. ▶ If necessary, disconnect the pressure gauge and plug the ports with the specified threaded plugs. Bosch Rexroth AG, A4CSG, Series 3x, RE 92105-01-B/06.2017... -
Page 47: Running-In Phase
• Air and/or water in the hydraulic system • Old hydraulic fluid • Other contamination ▶ For recommissioning, proceed as described in chapter 8.1 “Initial commissioning” on page 44. RE 92105-01-B/06.2017, A4CSG, Series 3x, Bosch Rexroth AG... -
Page 48: Operation
• The auxiliary activation device is not suitable for frequently recurring manual actuation! • The auxiliary activation device is located on the side of the proportional solenoid facing away from the valve. Bosch Rexroth AG, A4CSG, Series 3x, RE 92105-01-B/06.2017... -
Page 49: Maintenance And Repair
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 Change the filter element in optionally mounted Half-yearly or every filters. The replacement interval may vary depending 500 operating hours on the degree of contamination of the hydraulic fluid. (whichever occurs first) We recommend using a contamination indicator. Bosch Rexroth AG, A4CSG, Series 3x, RE 92105-01-B/06.2017...
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Page 51: Maintenance
The maintenance interval for replacing the bearings and the shaft seal is to be observed. Have the service performed by Bosch Rexroth Service upon reaching the operating hours listed in the following table or every four years, whichever comes first; for the address, see chapter 10.5 “Spare parts”... - Page 52 L 10h 4000 L 10h 6000 L 10h 10000 L 10h 20000 L 10h 30000 L 10h 40000 L 10h 60000 L 10h 100000 [bar] Fig. 16: Service life, size 355 for 1500 rpm Bosch Rexroth AG, A4CSG, Series 3x, RE 92105-01-B/06.2017...
- Page 53 L 10h 4000 L 10h 6000 L 10h 10000 L 10h 20000 L 10h 30000 L 10h 40000 L 10h 60000 L 10h 100000 [bar] Fig. 18: Service life, size 500 for 1500 rpm RE 92105-01-B/06.2017, A4CSG, Series 3x, Bosch Rexroth AG...
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Page 54: Repair
Bosch Rexroth Service; for the address, see chapter 10.5 “Spare parts” on page 55. 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 assembled parts may only be performed by service centers certified by Bosch Rexroth. -
Page 55: Spare Parts
Address all questions regarding spare parts to your responsible Bosch Rexroth Service partner or the service department of the manufacturer's plant for the axial piston unit. -
Page 56: Removal And Replacement
Completely drain the axial piston unit of hydraulic fluid. Plug all openings. 11.4 Preparing the components for storage or further use ▶ Proceed as described in chapter 6.2 “Storing the axial piston unit” on page 24. Bosch Rexroth AG, A4CSG, Series 3x, RE 92105-01-B/06.2017... -
Page 57: Disposal
Disassemble the axial piston unit into its individual parts and properly recycle these parts. Separate according to the following: – Castings – Steel – Aluminum – Non-ferrous metal – Electronic waste – Plastic – Seals RE 92105-01-B/06.2017, A4CSG, Series 3x, Bosch Rexroth AG... -
Page 58: Extension And Conversion
Changes to settings on the customer side should only be made using the product- specific setting instructions. The warranty from Bosch Rexroth only applies to the product configuration as delivered. The warranty is void if the unit is modified or extended. -
Page 59: Troubleshooting
Try to get a clear idea of the cause of the fault. Directly ask the (machine) operator. ▶ Document the work carried out. ▶ If you cannot rectify the fault, contact one of the contact addresses which can be found at: www.boschrexroth.com/addresses. RE 92105-01-B/06.2017, A4CSG, Series 3x, Bosch Rexroth AG... -
Page 60: Malfunction Table
Optimize the settings of the pressure relief and pressure control valves Mechanical damage to the axial piston unit Replace axial piston unit (for example, bearing damage) Contact Bosch Rexroth Service Increased, unusual vibration Bearings worn Contact Bosch Rexroth Service Bosch Rexroth AG, A4CSG, Series 3x, RE 92105-01-B/06.2017... - Page 61 Control of the control device defective Check control (contact machine/system manufacturer or Bosch Rexroth Service) Wear or mechanical damage to the axial piston Replace axial piston unit unit Contact Bosch Rexroth Service RE 92105-01-B/06.2017, A4CSG, Series 3x, Bosch Rexroth AG...
- Page 62 Bosch Rexroth Service) Wear or mechanical damage to the axial piston Replace axial piston unit unit Contact Bosch Rexroth Service Output unit defective (e.g. hydraulic motor or Contact machine/system manufacturer cylinder) Bosch Rexroth AG, A4CSG, Series 3x, RE 92105-01-B/06.2017...
- Page 63 Contact Bosch Rexroth Service Contact machine/system manufacturer Flushing flow of the flushing valve too low Contact Bosch Rexroth Service Axial piston unit worn Replace axial piston unit, contact Bosch Rexroth Service RE 92105-01-B/06.2017, A4CSG, Series 3x, Bosch Rexroth AG...
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Page 64: Technical Data
Additional information can be found in the online product catalog Mobile Hydraulics: www.boschrexroth.com/axial-piston-pumps Industrial Hydraulics: www.boschrexroth.com/ics Order-related technical data for your axial piston unit can be found in the order confirmation. Bosch Rexroth AG, A4CSG, Series 3x, RE 92105-01-B/06.2017... - Page 65 Technical data 65/68 RE 92105-01-B/06.2017, A4CSG, Series 3x, Bosch Rexroth AG...
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Page 66: Alphabetical Index
Operation Eye bolt ▶ P ▶ F Performance description Filling Port overview Flushing cycle Product description Functional description Property damage – Control Pump Functional test ▶ Q ▶ H Qualifications High-pressure side Bosch Rexroth AG, A4CSG, Series 3x, RE 92105-01-B/06.2017... - Page 67 ▶ T Technical data Tightening torques Tools Transportation – By hand – with eye bolt – with lifting strap Transporting Transport protection Troubleshooting ▶ U Unpacking ▶ w Warranty 17, 58 Weight RE 92105-01-B/06.2017, A4CSG, Series 3x, Bosch Rexroth AG...
- Page 68 Bosch Rexroth AG Mobile Applications An den Kelterwiesen 14 72160 Horb a.N. Germany Phone: +49 7451 92-0 info.ma@boschrexroth.de www.boschrexroth.com Your local contact person can be found at: www.boschrexroth.com/addresses Subject to change Printed in Germany RE 92105-01-B/06.2017...