Related Manuals for Bosch Rexroth A4VG 35 Series
Summary of Contents for Bosch Rexroth A4VG 35 Series
- Page 1 Axial piston variable pump A4VG Series 35 Instruction manual Replaces: 04.2018 RE 92035-01-B/2019-11-25 English...
- Page 2 © Bosch Rexroth AG 2019. 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.
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Page 3: Table Of Contents
7.3.1 Below-reservoir installation (standard) 7.3.2 Above-reservoir installation Installing the axial piston unit 7.4.1 Preparation 7.4.2 Dimensions 7.4.3 General instructions 7.4.4 Installation with a coupling 7.4.5 Installation on a gearbox 7.4.6 Installation with cardan shaft RE 92035-01-B/2019-11-25, A4VG Series 35, Bosch Rexroth AG... - Page 4 11.2 Preparing for removal 11.3 Performing the disassembly 11.4 Preparing the components for storage or further use Disposal Extension and conversion Troubleshooting 14.1 How to proceed for troubleshooting 14.2 Malfunction table Technical data Alphabetical index Bosch Rexroth AG, A4VG Series 35, RE 92035-01-B/2019-11-25...
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Page 5: About This Documentation
Fire-resistant, water-free hydraulic fluids (HFDR/HFDU) 90222 Data sheet Describes the requirements on fire-resistant, water-free hydraulic fluids (HFDR/HFDU) for operation with Rexroth hydraulic components and assists you in selecting a hydraulic fluid for your hydraulic system. RE 92035-01-B/2019-11-25, A4VG Series 35, Bosch Rexroth AG... -
Page 6: Representation Of Information
Data sheet BODAS-drive eDA is a software solution integrated in the Rexroth SRC-eDA1/31 control unit for controlling the hydrostatic drive train in wheeled vehicles. Bosch Rexroth Fluid Rating List for Rexroth hydraulic components 90245 Data sheet (pumps and motors) Contains the hydraulic fluids positively evaluated by Bosch Rexroth. -
Page 7: Symbols
Threaded plug Metal screw, pressure-resistant Protective plug Made out of plastic, not pressure-resistant, only for transportation As umbrella term for "axial piston variable pump A4VG" the designation "axial piston unit" will be used in the following. RE 92035-01-B/2019-11-25, A4VG Series 35, Bosch Rexroth AG... -
Page 8: Abbreviations
(PRV) International Organization for Standardization Rexroth document in the English 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) Bosch Rexroth AG, A4VG Series 35, RE 92035-01-B/2019-11-25... -
Page 9: Safety Instructions
2.3 Improper use Any use other than that described as intended use is considered improper. Bosch Rexroth AG is not liable for damages resulting from improper use. The user is solely responsible for any risks arising from improper use. The following foreseeable forms of faulty usage are also considered improper (this list is not exhaustive):... -
Page 10: Personnel Qualifications
• In particular, fully understanding the relationships with regard to safety devices • Knowledge regarding the function and interaction of hydraulic components Bosch Rexroth offers you measures supporting training in specific areas. You can find an overview of the training contents on the Internet at: www.boschrexroth.com/training. -
Page 11: General Safety Instructions
(e.g. PWM signal). The machine manufacturer should conduct appropriate tests and take appropriate measures to ensure that other components or operators (e.g. with a pacemaker) are not affected by this potentiality. RE 92035-01-B/2019-11-25, A4VG Series 35, Bosch Rexroth AG... -
Page 12: Product-Specific Safety Instructions
Operating the unit above the maximum permissible pressure can cause components to burst and hydraulic fluid to escape under high pressure. ▶ Changes to the factory settings may only be made by Bosch Rexroth specialists. ▶ In addition, a pressure relief valve is required in the hydraulic system as back-up. - Page 13 ▶ Check whether your application requires remedial measures on your machine in order to bring the driven consumer to a safe position (e.g. safe stop). ▶ If necessary, make sure these are appropriately implemented. RE 92035-01-B/2019-11-25, A4VG Series 35, Bosch Rexroth AG...
- Page 14 Always install cables and lines in a way that nobody can fall over them, that they are not bend or twisted, do not chafe on edges and are not guided through ducts with sharp edges without sufficient protection. Bosch Rexroth AG, A4VG Series 35, RE 92035-01-B/2019-11-25...
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Page 15: Personal Protective Equipment
2.7 Personal protective equipment Personal protective equipment is the responsibility of the user of the axial piston unit. Observe the safety regulations in your country. All pieces of personal protective equipment should be intact. RE 92035-01-B/2019-11-25, A4VG Series 35, Bosch Rexroth AG... -
Page 16: General Instructions On Property Damage And Product Damage
Before installation, remove all fluids from the axial piston unit to prevent mixing with the hydraulic fluid used in the machine/system. ▶ Any mixture of hydraulic fluids of different manufacturers and/or different types of the same manufacturer is generally not permissible. Bosch Rexroth AG, A4VG Series 35, RE 92035-01-B/2019-11-25... - Page 17 Dispose of the axial piston unit, hydraulic fluid and packaging in accordance with the regulations in your country. ▶ Dispose of the hydraulic fluid in accordance with the applicable safety data sheet of the hydraulic fluid. RE 92035-01-B/2019-11-25, A4VG Series 35, Bosch Rexroth AG...
- Page 18 The warranty exclusively applies to the delivered configuration. The warranty will be voided if the product is incorrectly installed, commissioned or operated, or if it is used or handled improperly. Bosch Rexroth AG, A4VG Series 35, RE 92035-01-B/2019-11-25...
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Page 19: Scope Of Delivery
• Axial piston unit as per order confirmation The following parts come assembled on the unit: • Protective covers (1) • Protective plug/threaded plugs (2) • Protective covers for sensors and connectors (3) • For version with through drive, protective cover incl. mounting bolts (4) RE 92035-01-B/2019-11-25, A4VG Series 35, Bosch Rexroth AG... -
Page 20: About This Product
1 Drive shaft 5 High-pressure side 10 Piston 2 Retaining plate 6 Boost pump 11 Slipper pad 3 Stroking piston 7 Low-pressure side 12 Cradle 4 Control plate 8 Suction port (Distributor plate) 9 Cylinder Bosch Rexroth AG, A4VG Series 35, RE 92035-01-B/2019-11-25... -
Page 21: Functional Description
The cradle is mounted in swivel bearings for smooth operation and the neutral position is spring-centered. Increasing the swivel angle increases the displacement; reducing the angle reduces displacement accordingly. Various control devices are available depending on requirements. Information about this can be found in data sheet 92035. RE 92035-01-B/2019-11-25, A4VG Series 35, Bosch Rexroth AG... -
Page 22: Bypass Function
Turning the corresponding screw allows the hydraulic fluid to flow freely. If necessary, Bosch Rexroth recommends always activating the bypass function on both pressure relief valves (avoiding a function in only one travel direction). The bypass function must be deactivated again before restarting the machine. - Page 23 Loosen the lock nut (2) with an external hexagon wrench (WAF 13), then turn the screw (1) counter-clockwise with a hexagon socket wrench (WAF 4) to the stop. Retighten the lock nut (2), turning clockwise to a torque of 22 Nm. RE 92035-01-B/2019-11-25, A4VG Series 35, Bosch Rexroth AG...
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Page 24: Product Identification
4 Direction of rotation (viewed on 11 Serial number drive shaft) – here: clockwise 12 Material number of the axial piston 5 Designated area for inspection stamp unit 6 Weight (optional) 13 Type code 7 Power (optional) Bosch Rexroth AG, A4VG Series 35, RE 92035-01-B/2019-11-25... -
Page 25: Transport And Storage
For transporting, the axial piston unit can be connected to a lifting device via an eye bolt in the drive shaft or in the housing. Alternatively, it can also be transported with a lifting strap. When selecting the means of transport, consider the permissible total weight. RE 92035-01-B/2019-11-25, A4VG Series 35, Bosch Rexroth AG... - Page 26 Make sure that each eye bolt can bear the total weight of the axial piston unit angle monitoring) plus approx. 20%. You can lift the axial piston unit as shown in Fig. 6 with the eye bolt screwed into the housing. Fig. 6: Mounting eye bolts in housing Bosch Rexroth AG, A4VG Series 35, RE 92035-01-B/2019-11-25...
- Page 27 Place the lifting strap around the axial piston unit in such a way that it does not pass over assembled parts (e.g. valves, piping) and that the axial piston unit is not suspended from assembled parts (see Fig. 7). Fig. 7: Transport with lifting strap RE 92035-01-B/2019-11-25, A4VG Series 35, Bosch Rexroth AG...
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Page 28: Storing The Axial Piston Unit
Perform a test run to check the axial piston unit for proper functioning and leak-tightness. If storage time exceeds 24 months, replace the shaft seal. Once the max. storage time has elapsed, we recommend that you have the axial piston unit checked by your Bosch Rexroth service partner. Bosch Rexroth AG, A4VG Series 35, RE 92035-01-B/2019-11-25... - Page 29 Transport and storage 29/64 For questions regarding repair and spare parts, contact your proper Bosch Rexroth service partner or the service department of the manufacturer's plant of the axial piston unit, see chapter 10.5 "Spare parts" on page 52. An uninstalled axial piston unit must be preserved with corrosion protection for the After removal duration of storage.
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Page 30: Installation
▶ Direct the leakage in the housing area to the reservoir through the highest drain port. Use a line size that matches the port. ▶ No check valve is permitted in the drain line. Bosch Rexroth AG, A4VG Series 35, RE 92035-01-B/2019-11-25... - Page 31 ▶ Use fiber-free cleaning cloths for cleaning. ▶ Use suitable, mild cleaning agents to remove lubricants and other heavy contamination. Do not allow cleaning agents to enter into the hydraulic system. RE 92035-01-B/2019-11-25, A4VG Series 35, Bosch Rexroth AG...
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Page 32: Installation Position
Fig. 9: Below-reservoir installation A4VG with installation positions 1–5 Drain port Control pressure port Filling/air bleeding Minimum required immersion depth t min (200 mm) Air bleed port Minimum required distance to reservoir bottom (100 mm) Suction port Baffle (baffle plate) Bosch Rexroth AG, A4VG Series 35, RE 92035-01-B/2019-11-25... -
Page 33: Above-Reservoir Installation
(800 mm) Suction port Baffle (baffle plate) Control pressure port Ports F and F are part of the external piping and must be provided on the customer side to make filling and air bleeding easier. RE 92035-01-B/2019-11-25, A4VG Series 35, Bosch Rexroth AG... -
Page 34: Installing The Axial Piston Unit
5.4 "Product identification" on page 24. For information on the direction of rotation of the drive motor, please refer to the drive motor manufacturer's instruction manual. Bosch Rexroth AG, A4VG Series 35, RE 92035-01-B/2019-11-25... -
Page 35: Dimensions
The version of installation for the axial piston unit depends on the connecting elements to the drive side. The following descriptions explain the installation of the axial piston unit: • With a coupling • On a gearbox • On a cardan shaft RE 92035-01-B/2019-11-25, A4VG Series 35, Bosch Rexroth AG... -
Page 36: Installation With A Coupling
Before installing, make sure that the spigot diameter centers the axial piston unit (observe tolerances) and that no excessive axial or radial forces are acting on the drive shaft of the axial piston unit (installation length). Bosch Rexroth AG, A4VG Series 35, RE 92035-01-B/2019-11-25... -
Page 37: Installation With Cardan Shaft
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 of the axial piston unit. - Page 38 For versions with through drive, install the auxiliary pump according to the pump manufacturer's instructions. The protective cover (4) is not pressure-resistant and is therefore not permitted during operation. Bosch Rexroth AG, A4VG Series 35, RE 92035-01-B/2019-11-25...
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Page 39: Hydraulically Connecting The Axial Piston Unit
– The hose must be pressure-resistant, also to external air pressure. • Pressure line – For the pressure lines, use only pipes, hoses and connecting elements rated for the working pressure range specified in data sheet 92035 (see Table 10). RE 92035-01-B/2019-11-25, A4VG Series 35, Bosch Rexroth AG... - Page 40 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. Port overview Fig. 13: Port overview A4VG Bosch Rexroth AG, A4VG Series 35, RE 92035-01-B/2019-11-25...
- Page 41 These plugs must not be opened on the customer side! If you have opened the threaded plug accidentally, please contact your local contact person to ensure safe re-closing of the plug. You can find the address at www.boschrexroth.com/addresses RE 92035-01-B/2019-11-25, A4VG Series 35, Bosch Rexroth AG...
- Page 42 Check all pipes and hose lines and every combination of connecting pieces, couplings or connecting points with hoses or pipes to ensure they are in safe working condition. For relationship between direction of rotation and flow direction, see data sheet 92035. Bosch Rexroth AG, A4VG Series 35, RE 92035-01-B/2019-11-25...
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Page 43: Electrically Connecting The Axial Piston Unit
7.5 Performing flushing cycle In order to remove foreign particles from the system, Bosch Rexroth recommends a flushing cycle for the hydraulic system before the first commissioning. To avoid internal contamination, do not include the axial piston unit in the flushing cycle. -
Page 44: Commissioning
▶ During commissioning, monitor the temperature of the hydraulic fluid in the reservoir to ensure that it lies within permissible viscosity limits. Bosch Rexroth AG, A4VG Series 35, RE 92035-01-B/2019-11-25... -
Page 45: Filling The Axial Piston Unit
Use only a hydraulic fluid that corresponds to the following requirements: You can find details on the minimum requirements for hydraulic fluids in Bosch Rexroth data sheets 90220, 90221, 90222, and 90225. The titles of the data sheets can be found in Table 1 "Required and supplementary documentation"... -
Page 46: Testing The Hydraulic Fluid Supply
Check the suction pressure at port S of the axial piston pump at nominal speed and maximum swivel angle. Refer to data sheet 92035 for the permissible value. At maximum working pressure, check the case pressure at port T or T . Refer to data sheet 92035 for the permissible value. Bosch Rexroth AG, A4VG Series 35, RE 92035-01-B/2019-11-25... -
Page 47: Performing A Functional Test
Volumetric and mechanical-hydraulic efficiency is also greater until the running-in phase of about 10 operating hours is concluded. RE 92035-01-B/2019-11-25, A4VG Series 35, Bosch Rexroth AG... -
Page 48: Recommissioning After Standstill
48/64 Commissioning To ensure that contamination in the hydraulic system does not damage the axial piston unit, Bosch Rexroth recommends the following procedure after the running-in phase: ▶ After the running-in phase, have a hydraulic fluid sample analyzed for the required cleanliness level. -
Page 49: Operation
For this reason, this chapter of the manual does not contain any information on adjustment options. Use the product only within the performance range specified in the technical data. The machine/system manufacturer is responsible for proper project planning of the hydraulic system and its control. RE 92035-01-B/2019-11-25, A4VG Series 35, Bosch Rexroth AG... -
Page 50: Maintenance And Repair
Use only water and, if necessary, a mild cleaning agent to clean the axial piston unit. Never use solvents or aggressive cleaning agents. ▶ Remove major external contamination and keep clean sensitive and important components, such as solenoids, valves, indicators and sensors. Bosch Rexroth AG, A4VG Series 35, RE 92035-01-B/2019-11-25... -
Page 51: Inspection
Maintenance and repair 51/64 10.2 Inspection In order for the axial piston unit to be reliable and long-lasting, Bosch Rexroth recommends inspecting the hydraulic system and axial piston unit on a regular basis, and documenting and archiving the following operating conditions:... -
Page 52: Repair
52/64 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 assembled parts should only be performed by service centers certified by Bosch Rexroth. -
Page 53: Removal And Replacement
Remove the axial piston unit. Use a suitable lifting device. Completely drain the axial piston unit. 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 28. RE 92035-01-B/2019-11-25, A4VG Series 35, Bosch Rexroth AG... -
Page 54: Disposal
Disassemble the axial piston unit into its constituent parts for proper recycling. For example, separate the parts into: – Castings – Steel – Aluminum – Non-ferrous metal – Electronic waste – Plastic – Seals Bosch Rexroth AG, A4VG Series 35, RE 92035-01-B/2019-11-25... -
Page 55: 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 configuration as delivered. The warranty will be voided if the unit is modified or extended. Setting screws are protected against unauthorized adjustment by tamper-proof caps. -
Page 56: Troubleshooting
Try to get a clear idea of the cause of the fault. Directly ask the (machine) operator. ▶ Document the work carried out. ▶ If the fault cannot be corrected, please refer to one of the contract addresses at: www.boschrexroth.com/addresses. Bosch Rexroth AG, A4VG Series 35, RE 92035-01-B/2019-11-25... -
Page 57: Malfunction Table
Optimize the setting of the pressure limitation and pressure control valve Mechanical damage to the axial piston unit Replace axial piston unit (e.g. bearing damage) Contact Bosch Rexroth Service Increased, unusual vibration Bearings worn Contact Bosch Rexroth Service RE 92035-01-B/2019-11-25, A4VG Series 35, Bosch Rexroth AG... - Page 58 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 Bosch Rexroth AG, A4VG Series 35, RE 92035-01-B/2019-11-25...
- Page 59 Control of the control device defective Check control (contact machine/system manufacturer or Bosch Rexroth Service) Wear or mechanical damage to the axial Replace axial piston unit piston unit Contact Bosch Rexroth Service Output unit defective (e.g. hydraulic motor or Contact machine/system manufacturer cylinder) RE 92035-01-B/2019-11-25, A4VG Series 35, Bosch Rexroth AG...
- Page 60 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 Bosch Rexroth AG, A4VG Series 35, RE 92035-01-B/2019-11-25...
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Page 61: Technical Data
The permissible technical data for your axial piston unit can be found on the data sheet 92035. The data sheet can be found in the online product catalog at www.boschrexroth.com/p-A4VG-35 Order-related technical data for your axial piston unit can be found in the order confirmation. RE 92035-01-B/2019-11-25, A4VG Series 35, Bosch Rexroth AG... -
Page 62: Alphabetical Index
▶ E External boost pressure supply ▶ P Eye bolt Performance description Piston ▶ F Port overview Filling Product description Flushing cycle Property damage Functional description Pump function – Control Functional test ▶ Q Qualification Bosch Rexroth AG, A4VG Series 35, RE 92035-01-B/2019-11-25... - Page 63 Stroking piston Symbols ▶ T Technical data Tightening torques Tools Transport – By hand – with eye bolt – with lifting strap Transporting Transport protection Troubleshooting ▶ U Unpacking ▶ W Warranty 18, 38, 55 Weight RE 92035-01-B/2019-11-25, A4VG Series 35, Bosch Rexroth AG...
- Page 64 Bosch Rexroth AG Glockeraustraße 4 89275 Elchingen Germany Phone +49 7308 82-0 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 92035-01-B/2019-11-25...