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: –.– RE 92035-01-B/04.2018 English...
- Page 2 © Bosch Rexroth AG 2018. 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
Transporting the axial piston unit 6.1.1 Transporting by hand 6.1.2 Transporting with a lifting device Storing the axial piston unit Installation Unpacking Installation conditions Installation position 7.3.1 Below-reservoir installation (standard) 7.3.2 Above-reservoir installation RE 92035-01-B/04.2018, A4VG, Series 35, Bosch Rexroth AG... - Page 4 11.2 Preparing for removal 11.3 Removal 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, Series 35 A4VG, RE 92035-01-B/04.2018...
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Page 5: About This Documentation
(HFDR, HFDU, HFA, HFB, HFC) Describes the requirements on fire-resistant, anhydrous and hydrous hydraulic fluids (HFDR, HFDU, HFA, HFB, HFC) and contains the technical data for operation with Rexroth hydraulic components. RE 92035-01-B/04.2018, Series 35 A4VG, Bosch Rexroth AG... -
Page 6: Representation Of Information
• Type and source of danger: indicates the type and source of the danger • Consequences: describes what occurs if safety instructions are not complied with • Precautions: states how the danger can be avoided Bosch Rexroth AG, Series 35 A4VG, RE 92035-01-B/04.2018... -
Page 7: Symbols
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/04.2018, Series 35 A4VG, Bosch Rexroth AG... -
Page 8: Abbreviations
International Organization for Standardization Rexroth document in the English language VDI 2230 Standard for the systematic calculation of heavy-duty thread connections and cylindrical screw joints from the VDI (Verein Deutscher Ingenieure - Association of German Engineers) Bosch Rexroth AG, Series 35 A4VG, RE 92035-01-B/04.2018... -
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 misuses are also considered improper (this list is not exhaustive): •... -
Page 10: Personnel Qualifications
• In particular, fully understanding the relationships with regard to safety devices • 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: www.boschrexroth.com/training. -
Page 11: 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. RE 92035-01-B/04.2018, Series 35 A4VG, 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 should only be made by Bosch Rexroth specialists. ▶ In addition, a pressure relief valve is required in the hydraulic system as a back- up. - Page 13 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. RE 92035-01-B/04.2018, Series 35 A4VG, Bosch Rexroth AG...
- Page 14 Wear your personal protective equipment (e.g. safety goggles, safety gloves, suitable working clothes, safety shoes). ▶ Consult a doctor immediately if hydraulic fluid gets in your eyes or bloodstream, or is swallowed. Bosch Rexroth AG, Series 35 A4VG, RE 92035-01-B/04.2018...
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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/04.2018, Series 35 A4VG, Bosch Rexroth AG... -
Page 16: General Instructions Regarding Property 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. ▶ Never mix hydraulic fluids from different manufacturers or different types from the same manufacturer. Bosch Rexroth AG, Series 35 A4VG, RE 92035-01-B/04.2018... - Page 17 Hydraulic fluid can escape if leaks occur. ▶ Take appropriate steps to protect the axial piston unit from chemical or corrosive environmental conditions. RE 92035-01-B/04.2018, Series 35 A4VG, Bosch Rexroth AG...
- Page 18 The warranty only applies to the machine as delivered. 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, Series 35 A4VG, RE 92035-01-B/04.2018...
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Page 19: Scope Of Delivery
The following parts come assembled on the unit: • Protective covers (1) • Protective plug/threaded plug (2) • Protective covers for sensors and connectors (3) • For version with through drive, metallic protective cover and mounting bolts (4) RE 92035-01-B/04.2018, Series 35 A4VG, Bosch Rexroth AG... -
Page 20: About This Product
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 9 Cylinder (distributor plate) Bosch Rexroth AG, Series 35 A4VG, RE 92035-01-B/04.2018... -
Page 21: 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 them can be found in data sheet 92035. RE 92035-01-B/04.2018, Series 35 A4VG, 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 (WAF 4) as far as it will go. Retighten the lock nut (2), turning clockwise to a torque of 22 Nm. Place a tamper-proof cap on the screw (1) to protect the pressure relief valve against unauthorized adjustment. RE 92035-01-B/04.2018, Series 35 A4VG, Bosch Rexroth AG...
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Page 24: Product Identification
4 Direction of rotation (viewed on drive 11 Serial number shaft) – here: clockwise 12 Material number of the axial 5 Designated area for inspection stamp piston unit 6 Weight (optional) 13 Type code 7 Power Bosch Rexroth AG, Series 35 A4VG, RE 92035-01-B/04.2018... -
Page 25: Transport And Storage
Alternatively, it can also be transported with a lifting strap. Only use the lifting strap if you are unable to achieve the required installation position by transporting with the eye bolt. RE 92035-01-B/04.2018, Series 35 A4VG, Bosch Rexroth AG... - Page 26 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, Series 35 A4VG, RE 92035-01-B/04.2018...
- 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/04.2018, Series 35 A4VG, Bosch Rexroth AG...
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Page 28: Storing The Axial Piston Unit
Once the maximum storage time has elapsed, we recommend that you have the axial piston unit examined by your Bosch Rexroth service partner. For questions regarding repair and spare parts, contact your proper Bosch Rexroth service partner or the service department of the plant that manufactured the axial piston unit, see chapter 10.5 “Spare parts”... - Page 29 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 28 in this chapter. RE 92035-01-B/04.2018, Series 35 A4VG, Bosch Rexroth AG...
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Page 30: Installation
Use a line size appropriate for the port. ▶ Do not put a check valve in the drain line. ▶ To keep noise levels low, use elastic elements to isolate all connecting lines from all vibration-capable components (e.g., reservoir). Bosch Rexroth AG, Series 35 A4VG, RE 92035-01-B/04.2018... -
Page 31: Installation Position
2. To prevent unexpected actuation and damage, bleed all air out of the stroking chambers via the ports X or X , depending on the installation position. RE 92035-01-B/04.2018, Series 35 A4VG, Bosch Rexroth AG... -
Page 32: Below-Reservoir Installation (Standard)
2 (drive shaft horizontal) – – S + T 3 (drive shaft down) – S + T 4 (drive shaft horizontal) – S + T 5 (drive shaft horizontal) – S + T Bosch Rexroth AG, Series 35 A4VG, RE 92035-01-B/04.2018... -
Page 33: Above-Reservoir Installation
(S) + F ) + X 9 (drive shaft horizontal) (S) + F (S) + F ) + X 10 (drive shaft horizontal) (S) + F (S) + F ) + X RE 92035-01-B/04.2018, Series 35 A4VG, Bosch Rexroth AG... -
Page 34: Installing The Axial Piston Unit
Follow these general instructions when installing the axial piston unit: • Note that certain installation positions will affect the control device. Gravity, dead weight and case pressure can cause minor characteristic shifts and changes in response time. Bosch Rexroth AG, Series 35 A4VG, RE 92035-01-B/04.2018... -
Page 35: Installation With A Clutch
Transport the axial piston unit to the installation location. Remove dirt and foreign particles from the installation location. Install the clutch on the output shaft of the drive motor in accordance with the specifications provided by the clutch manufacturer. RE 92035-01-B/04.2018, Series 35 A4VG, Bosch Rexroth AG... -
Page 36: Installation On A Gearbox
Bring the axial piston unit to the installation position and fasten it down. If necessary, details on the required tools and tightening torque for the mounting bolts can be obtained from the system manufacturer. Bosch Rexroth AG, Series 35 A4VG, RE 92035-01-B/04.2018... -
Page 37: Completing Installation
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 plant that manufactured the axial piston unit. -
Page 38: Hydraulically Connecting The Axial Piston Unit
(pressure, flow, hydraulic fluid, temperature) with the necessary safety factors. Connect only hydraulic lines that are appropriate for the axial piston unit port (pressure level, size, system of units). Bosch Rexroth AG, Series 35 A4VG, RE 92035-01-B/04.2018... - Page 39 The system of units, the kind of seal and the size of female thread and stud ends (e.g., threaded plug) must all match. There is a risk of confusion due to the limited ways of visually telling them apart. RE 92035-01-B/04.2018, Series 35 A4VG, Bosch Rexroth AG...
- Page 40 Depending on the installation position, T or T must be connected (see Chapter 7.3 “Installation position” on page 31) Pressure sensor installed or M plugged. Must be connected for filtration in the pressure line. Bosch Rexroth AG, Series 35 A4VG, RE 92035-01-B/04.2018...
- Page 41 The tightening torques for the threaded plugs apply when the plugs are dry or lightly oiled. The tightening torques for the threaded plugs apply when the plugs are dry – when lightly oiled, the tightening torques for M10 × 1 are reduced to 10 Nm and to 17 Nm for M12 × 1.5. RE 92035-01-B/04.2018, Series 35 A4VG, Bosch Rexroth AG...
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Page 42: Electrically Connecting The Axial Piston Unit
For axial piston units with electrical control and/or mounted sensors, observe the information in data sheet 92035, e.g.: • Permissible voltage range • Permissible current • Correct pin assignment • Recommended electrical control units Bosch Rexroth AG, Series 35 A4VG, RE 92035-01-B/04.2018... -
Page 43: Performing Flushing Cycle
37), and the connector and all seals are intact. 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 initial 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, Series 35 A4VG, RE 92035-01-B/04.2018... -
Page 45: Filling The Axial Piston Unit
Use only a hydraulic fluid that meets 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
▶ Perform a leak test without and with load prior to normal operation. ▶ If necessary, disconnect the pressure gauge and plug the ports with the specified threaded plugs. Bosch Rexroth AG, Series 35 A4VG, RE 92035-01-B/04.2018... -
Page 47: Running-In Phase
To ensure that contamination in the hydraulic system does not damage the axial piston unit, Bosch Rexroth recommends the following after the running-in phase: ▶ After the running-in phase, have a hydraulic fluid sample analyzed for the required cleanliness level. -
Page 48: Operation
Use the product only within the performance range specified in the technical data. The machine/system manufacturer is responsible for the proper planning of the hydraulic system and its control system. Bosch Rexroth AG, Series 35 A4VG, RE 92035-01-B/04.2018... -
Page 49: Maintenance And Repair
Use only water and, if necessary, a mild cleaning agent to clean the axial piston unit. Never use solvents or corrosive cleaning agents. ▶ Remove major external contamination and keep clean sensitive and important components, such as solenoids, valves, displays and sensors. RE 92035-01-B/04.2018, Series 35 A4VG, Bosch Rexroth AG... -
Page 50: Inspection
Maintenance and repair 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 51: Repair
Maintenance and repair 51/64 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 52: 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. Bosch Rexroth AG, Series 35 A4VG, RE 92035-01-B/04.2018... -
Page 53: 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 RE 92035-01-B/04.2018, Series 35 A4VG, Bosch Rexroth AG... -
Page 54: 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 delivered product configuration. The warranty will be voided if the unit is modified or extended. -
Page 55: 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, get in touch with one of the contact addresses found at: www.boschrexroth.com/addresses. RE 92035-01-B/04.2018, Series 35 A4VG, Bosch Rexroth AG... -
Page 56: Malfunction Table
Mechanical damage to the axial piston unit (e.g. Replace axial piston unit bearing damage) Contact Bosch Rexroth Service Increased, unusual vibration Bearings worn Contact Bosch Rexroth Service Bosch Rexroth AG, Series 35 A4VG, RE 92035-01-B/04.2018... - Page 57 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 92035-01-B/04.2018, Series 35 A4VG, Bosch Rexroth AG...
- Page 58 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 Contact machine/system manufacturer or cylinder) Bosch Rexroth AG, Series 35 A4VG, RE 92035-01-B/04.2018...
- Page 59 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 92035-01-B/04.2018, Series 35 A4VG, Bosch Rexroth AG...
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Page 60: Technical Data
The data sheet can be found online at www.boschrexroth.com/mediadirectory Additional information can be found in the Mobile Hydraulics online product catalog: www.boschrexroth.com/axial-piston-pumps Order-related technical data for your axial piston unit can be found in the order confirmation. Bosch Rexroth AG, Series 35 A4VG, RE 92035-01-B/04.2018... -
Page 61: Alphabetical Index
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 RE 92035-01-B/04.2018, Series 35 A4VG, Bosch Rexroth AG... - Page 62 ▶ T Technical data Tightening torques Tool Transporting – By hand – With eye bolt – With lifting strap Transport protection Troubleshooting ▶ U Unpacking ▶ w Warranty 18, 38, 54 Weight Bosch Rexroth AG, Series 35 A4VG, RE 92035-01-B/04.2018...
- Page 63 63/64 RE 92035-01-B/04.2018, Series 35 A4VG, 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/04.2018...