Bosch rexroth 1 Series Instruction Manual
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Bosch rexroth 1 Series Instruction Manual

Axial piston variable double pump
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Axial piston variable
double pump
A20V(L)O
Series 1
Instruction manual
RE 93100-01-B/2019-09-10
Replaces: –.–
English

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Summary of Contents for Bosch rexroth 1 Series

  • Page 1 Axial piston variable double pump A20V(L)O Series 1 Instruction manual Replaces: –.– RE 93100-01-B/2019-09-10 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. The information given does not release the user from the obligation of own judgment and verification.

  • Page 3: Table Of Contents

    Installation position 7.3.1 Below-reservoir installation (standard) 7.3.2 Inside-reservoir installation 7.3.3 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 RE 93100-01-B/2019-09-10, A20V(L)O/A10VE Series 1, Bosch Rexroth AG...
  • Page 4 11.1 Required tools 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, A20V(L)O Series 1, RE 93100-01-B/2019-09-10...

  • Page 5: About This Documentation

    Hydraulic fluids based on mineral oils and related hydrocarbons 90220 Describes the requirements for hydraulic fluids on mineral oil basis and related hydrocarbons for operation with Rexroth hydraulic components, and provides support for selection of suitable hydraulic fluids for the hydraulic system. RE 93100-01-B/2019-09-10, A20V(L)O Series 1, Bosch Rexroth AG...

  • Page 6: Representation Of Information

    Describes the requirements on fire-resistant, water-containing hydraulic fluids (HFAE, HFAS, HFB, HFC) for operation with Rexroth hydraulic components and assists you in selecting a hydraulic fluid for your hydraulic system. Bosch Rexroth Fluid Rating List for Rexroth hydraulic components 90245 (pumps and motors) Contains the hydraulic fluids positively evaluated by Bosch Rexroth.

  • Page 7: Symbols

    Table 3: Meaning of symbols Symbol Meaning If this information is disregarded, the product cannot be used and/or operated to its full extent. ▶ Single, independent action Numbered instruction: The numbers indicate that the actions must be completed in order. RE 93100-01-B/2019-09-10, A20V(L)O Series 1, Bosch Rexroth AG...

  • Page 8: Designations

    International Organization for Standardization Japan Industrial Standard 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, A20V(L)O Series 1, RE 93100-01-B/2019-09-10...

  • 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 • comprising of knowledge regarding the function and layout 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. Bosch Rexroth AG, A20V(L)O Series 1, RE 93100-01-B/2019-09-10...

  • Page 11: General Safety Instructions

    Potential electromagnetic interference (EMI) exists if the solenoid is energized with a modulated direct current (e.g. PWM signal). Appropriate testing and measures should be taken by the machine manufacturer to ensure other components or operators (e.g. with pacemaker) are not affected by this potential. RE 93100-01-B/2019-09-10, A20V(L)O Series 1, 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. If the axial piston unit is equipped with a pressure cut-off and/or pressure controller, this is not an adequate safeguard against pressure overload.
  • Page 13 (external or internal flow filtration) will not rule out a fault but merely reduce the risk. ▶ 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 93100-01-B/2019-09-10, A20V(L)O Series 1, Bosch Rexroth AG...
  • Page 14 Never attempt to block or seal the leak or hydraulic fluid jet with a cloth. Danger from improper handling! Slip hazard! 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. Bosch Rexroth AG, A20V(L)O Series 1, RE 93100-01-B/2019-09-10...

  • Page 15: Personal Protective Equipment

    Safety instructions 15/68 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 93100-01-B/2019-09-10, A20V(L)O Series 1, Bosch Rexroth AG...

  • Page 16: General Instructions On Property Damage And Product Damage

    With above-reservoir installation, an axial piston unit must be moved to full swivel angle after no more than three seconds during commissioning and recommissioning. Make sure that the axial piston unit really does suck in hydraulic fluid and build up pressure. Bosch Rexroth AG, A20V(L)O Series 1, RE 93100-01-B/2019-09-10...
  • 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 93100-01-B/2019-09-10, A20V(L)O Series 1, Bosch Rexroth AG...
  • Page 18 When installing the axial piston unit, check the safety distances to nearby products to ensure that they are not damaged. 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, A20V(L)O Series 1, RE 93100-01-B/2019-09-10...

  • 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) • for version with through drive, protective cover incl. mounting bolts (3) RE 93100-01-B/2019-09-10, A20V(L)O Series 1, Bosch Rexroth AG...

  • Page 20: About This Product

    From the consumer, the hydraulic fluid flows directly back to the reservoir. 5.2.1 Axial piston unit layout 5 7 8 8 7 5 11 12 Fig. 2: Layout of A20VLO, size 260 Bosch Rexroth AG, A20V(L)O Series 1, RE 93100-01-B/2019-09-10...

  • Page 21: Functional Description

    The swivel angle is controlled hydraulically by means of the stroking piston. 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 93100. RE 93100-01-B/2019-09-10, A20V(L)O Series 1, Bosch Rexroth AG...

  • Page 22: Product Identification

    4 Direction of rotation (viewed on drive 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 (optional) 14 Customer material number Bosch Rexroth AG, A20V(L)O Series 1, RE 93100-01-B/2019-09-10...

  • Page 23: Transport And Storage

    Use your personal protective equipment (e.g. safety goggles, safety gloves, suitable working clothes, safety shoes). ▶ Do not transport the axial piston unit by sensitive assembled parts (e.g. sensors or valves). ▶ Carefully place the axial piston unit on the seating to prevent it from being damaged. RE 93100-01-B/2019-09-10, A20V(L)O Series 1, Bosch Rexroth AG...

  • Page 24: Transport With Lifting Devices

    Make sure that the eye bolts can bear the total weight of the axial piston unit plus approx. 20%. You can hoist the axial piston unit as shown in Fig. 6 with the eye bolts screwed into the housing. Bosch Rexroth AG, A20V(L)O Series 1, RE 93100-01-B/2019-09-10...
  • Page 25 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 93100-01-B/2019-09-10, A20V(L)O Series 1, Bosch Rexroth AG...

  • Page 26: Storing The Axial Piston Unit

    Once the max. storage time has elapsed, we recommend that you have the axial piston unit checked 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 manufacturer's plant of the axial piston unit, see chapter 10.5 "Spare parts" on page 56.
  • Page 27 Coat unpainted areas of the axial piston unit with mineral oil or suitable, easily removable corrosion protection, e.g. acid-free grease. 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 "Requirement" on page 26 in this chapter. RE 93100-01-B/2019-09-10, A20V(L)O Series 1, Bosch Rexroth AG...

  • Page 28: Installation

    (e.g. reservoir). ▶ Make sure the suction, drain, and return lines flow into the reservoir below the minimum fluid level under all operating conditions. This will prevent air from being drawn in and foam from forming. Bosch Rexroth AG, A20V(L)O Series 1, RE 93100-01-B/2019-09-10...

  • Page 29: Installation Position

    Use suitable, mild cleaning agents to remove lubricants and other heavy contamination. Do not allow cleaning agents to enter into the hydraulic system. 7.3 Installation position The axial piston unit can be installed in the following positions. The pipeline routing shown illustrates the basic layout. RE 93100-01-B/2019-09-10, A20V(L)O Series 1, Bosch Rexroth AG...

  • Page 30: Below-Reservoir Installation (Standard)

    Air bleed Filling 1 (drive shaft horizontal) S + L 2 (drive shaft horizontal) S + L 3 (drive shaft vertically up) S + L 4 (drive shaft vertically down) S + L Bosch Rexroth AG, A20V(L)O Series 1, RE 93100-01-B/2019-09-10...
  • Page 31 (100 mm) R(L) Drain port Baffle (baffle plate) Suction port Table 10: Below-reservoir installation Installation position Air bleed Filling 7 (drive shaft horizontal) S + R(L) 8 (drive shaft horizontal) S + T RE 93100-01-B/2019-09-10, A20V(L)O Series 1, Bosch Rexroth AG...

  • Page 32: Inside-Reservoir Installation

    The housing of the axial piston unit must be filled before fitting the piping and filling the reservoir with hydraulic fluid. To prevent draining of the housing, the reservoir has to be filled with hydraulic fluid as quickly as possible. Bosch Rexroth AG, A20V(L)O Series 1, RE 93100-01-B/2019-09-10...
  • Page 33 S, by position below the hydraulic fluid level 12 (drive shaft horizontal) via the highest open port T automatically via the open port T and S, by position below the hydraulic fluid level RE 93100-01-B/2019-09-10, A20V(L)O Series 1, Bosch Rexroth AG...

  • Page 34: Above-Reservoir Installation

    17, the axial piston unit should be air bled and filled in a horizontal position before installation. To prevent the axial piston unit from draining, a height difference h of at least ES min 25 mm at port F is required in installation position 14 and 15. Bosch Rexroth AG, A20V(L)O Series 1, RE 93100-01-B/2019-09-10...
  • Page 35 Table 14: Above-reservoir installation Installation position Air bleed Filling 14 (drive shaft horizontal) F (L 15 (drive shaft horizontal) F (L 16 (drive shaft vertically up) F (L 17 (drive shaft vertically down) F (L RE 93100-01-B/2019-09-10, A20V(L)O Series 1, Bosch Rexroth AG...

  • Page 36: Installing The Axial Piston Unit

    Before installing, completely drain the axial piston unit to prevent mixing with the hydraulic fluid used in the machine/system. Check the permissible direction of rotation of the axial piston unit (on the name plate) and make sure that this corresponds to the direction of rotation of the drive motor. Bosch Rexroth AG, A20V(L)O Series 1, RE 93100-01-B/2019-09-10...

  • Page 37: Dimensions

    • On the drive of an axial piston unit, a cardan shaft may cause vibrations and excessive rotary angular acceleration. Depending on the frequency and temperature, this may cause leaks in the shaft seal and damage the rotary group. RE 93100-01-B/2019-09-10, A20V(L)O Series 1, Bosch Rexroth AG...

  • Page 38: Installation With A Coupling

    Details on the required tools and tightening torques for the mounting bolts are available from the machine/system manufacturer. When using elastic couplings, check that the drive does not resonate after completing the installation. Bosch Rexroth AG, A20V(L)O Series 1, RE 93100-01-B/2019-09-10...

  • Page 39: Installation On A Gearbox

    Push the axial piston unit to the cardan shaft and place the cardan shaft on the drive shaft of the axial piston unit. Bring the axial piston unit to the installation position and fasten it. Details of the required tools and tightening torque for the mounting bolts can be obtained from the system manufacturer. RE 93100-01-B/2019-09-10, A20V(L)O Series 1, Bosch Rexroth AG...

  • Page 40: Completion Of Assembly

    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. Fig. 18: Removing transport protection (e.g. A20VLO, size 260)

  • Page 41: Hydraulically Connecting The Axial Piston Unit

    93100 (see Table 16, Table 17 and Table 18). • Drain line – Always route the drain lines so that the housing is constantly filled with hydraulic fluid and to ensure no air gets through the shaft seal, even during extended standstill periods. RE 93100-01-B/2019-09-10, A20V(L)O Series 1, Bosch Rexroth AG...
  • Page 42 Use the drawings (installation drawing) to determine the required stud end for each fitting. ▶ 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, A20V(L)O Series 1, RE 93100-01-B/2019-09-10...
  • Page 43 43/68 Port overview Fig. 19: Port overview A20VO size 60 1(2) 2(1) 1(1) 2(2) Fig. 20: Port overview A20V(L)O size 95 to 260 R(L) R(L) Fig. 21: Port overview A20VO size 520 RE 93100-01-B/2019-09-10, A20V(L)O Series 1, Bosch Rexroth AG...
  • Page 44 Dependent on the installation position, R(L) and/or R(L) and/or must be connected (see chapter 7.3 "Installation position" on page 29). For version with stroke limiter (H.., U2), HD and EP with fitting GE10-PL M14x1.5 (otherwise, port G plugged). Bosch Rexroth AG, A20V(L)O Series 1, RE 93100-01-B/2019-09-10...
  • Page 45 The tightening torques for the threaded plugs are valid for the condition "dry" and "lightly oiled". The tightening torques for the threaded plugs are valid for the condition "dry" – in the condition "lightly oiled", the tightening torques for M10 × 1 are reduced to 10 Nm and for M12 × 1.5 to 17 Nm. RE 93100-01-B/2019-09-10, A20V(L)O Series 1, Bosch Rexroth AG...

  • Page 46: Electrically Connecting The Axial Piston Unit

    For axial piston units with electrical control and/or mounted sensors, observe the information in data sheet 93100, e.g.: • Permissible voltage range • Permissible current • Correct pin assignment • Recommended electrical control units Bosch Rexroth AG, A20V(L)O Series 1, RE 93100-01-B/2019-09-10...
  • Page 47 On axial piston units with a Hirschmann connector according Hirschmann connectors to DIN EN 175 301-803-A/ISO 4400, the following tightening torques apply when mounting plug-in connectors: • Mounting bolt M3 (1): 0.5 Nm • Union nut M16 × 1.5 (2): 1.5–2.5 Nm Fig. 22: Hirschmann connector RE 93100-01-B/2019-09-10, A20V(L)O Series 1, Bosch Rexroth AG...

  • Page 48: Performing Flushing Cycle

    48/68 Installation 7.5 Performing flushing cycle In order to remove foreign particles from the system, Bosch Rexroth recommends a flushing cycle for the entire system prior to initial commissioning. To avoid internal contamination, do not include the axial piston unit in the flushing cycle. Use an additional flushing unit to perform the flushing cycle. Follow the instructions of the flushing unit's manufacturer for the exact procedure during...

  • Page 49: Commissioning

    Usually, the cleanliness level of commercial hydraulic fluids is insufficient for our components. These hydraulic fluids must be filtered during filling using an appropriate filter system to minimize solid particle contamination and water in the system. RE 93100-01-B/2019-09-10, A20V(L)O Series 1, Bosch Rexroth AG...
  • Page 50 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 90223. The titles of the data sheets can be found in Table 1 "Required and supplementary documentation" on page 5.

  • Page 51: Testing The Hydraulic Fluid Supply

    After starting the drive motor, check in particular the specified pressures, e.g. working pressure and case pressure. ▶ 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. RE 93100-01-B/2019-09-10, A20V(L)O Series 1, Bosch Rexroth AG...

  • Page 52: Running-In Phase

    Volumetric and mechanical-hydraulic efficiency is also greater until the running-in phase of about 10 operating hours is concluded. 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 53: 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 93100-01-B/2019-09-10, A20V(L)O Series 1, Bosch Rexroth AG...

  • Page 54: Maintenance And Repair

    Remove major external contamination and keep clean sensitive and important components, such as solenoids, valves, indicators and sensors. 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 55: Maintenance

    You can ask your local contact person about service life based on load cycle. You can find their contact information at www.boschrexroth.com/addresses Based on these details, a maintenance interval should be determined by the system manufacturer for the replacement of the bearings and included in the maintenance schedule of the hydraulic system. RE 93100-01-B/2019-09-10, A20V(L)O Series 1, Bosch Rexroth AG...

  • Page 56: Repair

    Only use original spare parts from Rexroth to repair the Rexroth axial piston units, otherwise the functional reliability of the axial piston unit cannot be guaranteed and the warranty will be voided. For questions regarding repairs, 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" on page 56.

  • Page 57: 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 26. RE 93100-01-B/2019-09-10, A20V(L)O Series 1, Bosch Rexroth AG...

  • Page 58: 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, A20V(L)O Series 1, RE 93100-01-B/2019-09-10...

  • Page 59: 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 as delivered. The warranty will be voided if the unit is modified or extended. Adjusting the setting screws will render the warranty void. If you need to change the settings, please contact your local contact person;...

  • Page 60: Troubleshooting

    – How does the malfunction appear? ▶ 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 www.boschrexroth.com/addresses. Bosch Rexroth AG, A20V(L)O Series 1, RE 93100-01-B/2019-09-10...

  • Page 61: Malfunction Table

    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 93100-01-B/2019-09-10, A20V(L)O Series 1, Bosch Rexroth AG...
  • Page 62 Malfunction of the control device or controller Contact Bosch Rexroth Service of the axial piston unit 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 Bosch Rexroth AG, A20V(L)O Series 1, RE 93100-01-B/2019-09-10...
  • Page 63 Valve and controller vibrate Optimize the adjustment of the controller of the axial piston unit and the pressure limitation in the hydraulic system Unstable control signal Contact machine/system manufacturer or Bosch Rexroth Service Malfunction in the control devices Contact Bosch Rexroth Service or the controller RE 93100-01-B/2019-09-10, A20V(L)O Series 1, Bosch Rexroth AG...
  • Page 64 (e.g. high-pressure relief valve, pressure of the axial piston unit and the pressure controller) safeguarding in the hydraulic system Contact Bosch Rexroth Service Contact machine/system manufacturer Axial piston unit worn Replace axial piston unit; contact Bosch Rexroth Service Bosch Rexroth AG, A20V(L)O Series 1, RE 93100-01-B/2019-09-10...

  • Page 65: Technical Data

    The permissible technical data for your axial piston unit can be found on the data sheet 93100. The data sheet can be found in the online product catalog at www.boschrexroth.com/p-A20VO Order-related technical data for your axial piston unit can be found in the order confirmation. RE 93100-01-B/2019-09-10, A20V(L)O Series 1, Bosch Rexroth AG...

  • Page 66: Alphabetical Index

    ▶ E – general Eye bolt ▶ O ▶ F Operation Filling Opposed piston Flushing cycle Functional description ▶ P – Control Performance description Functional test Piston Port overview Product description Property damage Bosch Rexroth AG, A20V(L)O Series 1, RE 93100-01-B/2019-09-10...
  • Page 67 Safety instructions Warranty 18, 59 – General Weight – Product-specific – Signal word Scope of delivery Slipper pad Solenoid position – Changing Spare parts Storage 23, 26 Storage time Stroking piston Suction side Symbols RE 93100-01-B/2019-09-10, A20V(L)O Series 1, Bosch Rexroth AG...
  • Page 68 Bosch Rexroth AG Glockeraustraße 4 89275 Elchingen Germany Tel. +49 7308 82-0 info.ma@boschrexroth.de www.boschrexroth.com Bosch Rexroth AG An den Kelterwiesen 14 72160 Horb a.N. Germany Tel. +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...

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A20v(l)o

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