Bosch rexroth HyDrotrAC GFt Operating Instructions Manual
Hydrostatic drives
Frequently Asked Questions (5)
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What types of industrial applications are best suited for the Bosch Rexroth HydroTrac GFT DC Drive?
The HYDROTRAC GFT planetary gearbox is intended exclusively for use in the technical environment approved by Rexroth for the application referred to in the material number-specific instructions. The planetary gearboxes are designed for use in environmental temperatures between -25°C and +40°C. Environmental factors such as salt water, salt air, sand, dust, pressure, severe shocks, extreme shock loads, and aggressive media affect the function, and such influences must be pre-announced for a secure gearbox design.
For more information, see page 17 of the manual. -
What are the primary safety mechanisms built into the Bosch Rexroth HydroTrac GFT DC Drive?
The static multiple-disk parking brake is a safety device of the planetary gearbox. It is designed to be operated only after a complete stop of the vehicle. If the multiple-disk parking brake is used as a dynamic brake, it may lead to its destruction. Additionally, the brake is designed to be maintenance-free if used as intended. In case of malfunction, thermal overload, or any repair work, the disks, springs, and sealing elements per axle should always be replaced. A delayed application of the static multiple-disk brake can cause the vehicle to roll away accidentally, so it's important to ensure the brake line of the static piston is pressureless within 0.5 seconds.
For more information, see pages 34 and 50 of the manual. -
How do I perform the initial commissioning and setup of a Bosch Rexroth HydroTrac GFT DC Drive?
Before initial commissioning, ensure the following documents are at hand:
Only commission the planetary gearbox if it has been mounted and installed according to the instructions in these operating instructions, the material number-specific operating instructions, and the overall machine or vehicle operating instructions. For all commissioning work, observe the general safety instructions and intended use as specified in chapter 2 "Safety instructions".
If the planetary gearbox is delivered with an axial-piston motor or a connection to attach one, it is essential to observe the operating instructions of the axial-piston motor. If Rexroth delivers the hydrostatic drive without an axial-piston motor, the operating instructions for the axial-piston motor (provided by its manufacturer) should be observed for assembly and commissioning.
Before filling the planetary gearbox with lubricating oil, install the axial-piston motor if applicable. To fill the gearbox, you need information on the position of the oil filler, level control, and drain openings, approved lubricating oils, and the lubricating oil viscosity and quantity. Only fill the gearbox with approved lubricating oil according to the selection list in appendix B of the material number-specific operating instructions.
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What are the primary troubleshooting steps for common issues with a Bosch Rexroth HydroTrac GFT DC Drive?
When troubleshooting issues with the planetary gearbox, it is recommended to proceed systematically and targeted. Random disassembly and adjustment of individual values can prevent the determination of the original cause of a malfunction. Key steps include:
- Get an overview of the planetary gearbox operation in connection with the machine or vehicle.
- Clarify whether the planetary gearbox performed the required function in the machine or vehicle before the error occurred.
- Understand changes to the machine or vehicle where the planetary gearbox is installed, such as changes in conditions of use, maintenance work performed, or if the lubricating oil or hydraulic fluid has been changed.
- Gain a clear picture of what caused the malfunction, asking the direct operator if necessary.
- Record the situation by taking digital photographs and send them to Rexroth Service, if appropriate.
For more information, see page 61 of the manual. -
What routine maintenance is recommended for Bosch Rexroth HydroTrac GFT DC Drives?
Routine maintenance for the planetary gearbox includes:
- After 150 motor operating hours: Perform the first oil change.
- Daily: Perform a noise test.
- Weekly: Perform a visual inspection and an oil level check.
- Monthly: Check that the planetary gearbox mounting screws are tightly secured and retighten if necessary.
- Every year, or not later than after 1500 motor operating hours: Perform an oil change.
Regular care, maintenance, and inspection extend the service life of the planetary gearbox. The service life also depends on the quality of its lubricating oil, and it is recommended to change the lubricating oil at least once a year or every 1,500 operating hours, whichever comes earlier.
For more information, see page 47 of the manual.
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Summary of Contents for Bosch rexroth HyDrotrAC GFt
- Page 1 Operating Instructions Hydrostatic drives HyDrotrAC GFt >130 knm CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe RE 79094, Issue 10.2019, Replaces: 10.2014, EN...
- 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.
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Page 3: Table Of Contents
........ 32 Connecting the static multiple-disk parking brake ........ 34 Performing a flushing cycle ............... 35 Assembling mounting parts ............... 35 CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe RE 79094, Issue 10.2019, Bosch Rexroth AG... - Page 4 12.4 Preparing the planetary gearbox for storage reuse ........ 59 Disposal .................... 60 13.1 Environmental protection ................ 60 Extension and conversion .............. 60 Troubleshooting and fault correction ............ 61 15.1 Troubleshooting procedure ............... 61 Technical data .................. 63 Appendix .................... 63 CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe Bosch Rexroth AG, Issue 10.2019, RE 79094...
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Page 5: About This Documentation
1: required and supplementary documentations title Document type Material number-specific operating Operating instructions (included within instructions Rexroth's scope of supply) CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe RE 79094, Issue 10.2019, Bosch Rexroth AG... -
Page 6: Presentation Of Information
Property damage: The product or the environment can get NOTE damaged. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe Bosch Rexroth AG, Issue 10.2019, RE 79094... -
Page 7: Symbols
Deutsche industrie norm (German Industrial Standard) international organization for Standardization (Internationale Normierungsorganisation) Society of American engineers ANSI American national Standard institute personal Safety equipment (A) CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe RE 79094, Issue 10.2019, Bosch Rexroth AG... -
Page 8: Safety Instructions
Any use other than described in intended use is not in accordance with the requirements and, therefore, is not permitted. Bosch Rexroth AG assumes no liability for damage resulting from improper use. The risks associated with improper use lie solely with the user. -
Page 9: Qualification Of Personnel
• The warranty is void in case of faulty installation, commissioning and operation, as well as in case of improper use and/or improper handling • You may not modify the HYDROTRAC GFT planetary gearbox in principle. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe RE 79094, Issue 10.2019, Bosch Rexroth AG... -
Page 10: Product And Technology-Dependent Safety Instructions
See a doctor immediately if you have inhaled, for example, solvent-based detergents or have swallowed harmful substances. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe Bosch Rexroth AG, Issue 10.2019, RE 79094... - Page 11 Always load the planetary gearbox on a load-bearing surface. f Secure the planetary gearbox against tipping over by the use of chocks, wooden bars or the load boards provided by Rexroth. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe RE 79094, Issue 10.2019, Bosch Rexroth AG...
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Page 12: Personal Safety Equipment (Psa)
All components of the personal safety equipment must be intact. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe Bosch Rexroth AG, Issue 10.2019, RE 79094... -
Page 13: General Information Concerning Damage To Property And Product Damages
Only commission a completely installed product. f Take the required connections from the dimensioned drawing in appendix D “Technical data / Drawings” of the material number-specific operating instructions. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe RE 79094, Issue 10.2019, Bosch Rexroth AG... - Page 14 Only use clean connections. f Exclusively install clean hydraulic lines. f No dirt shall penetrate when closing the ports. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe Bosch Rexroth AG, Issue 10.2019, RE 79094...
- Page 15 Material damage caused by securing and lifting equipment! f When lifting the planetary gearbox, take care that mounting parts do not get damaged by securing or lifting equipment. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe RE 79094, Issue 10.2019, Bosch Rexroth AG...
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Page 16: Scope Of Supply
Adhere to the planetary gearbox’s maintenance intervals schedule when carrying out mandatory maintenance work. 4 Scope of supply Refer to your material number-specific operating instructions for the complete scope of supply. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe Bosch Rexroth AG, Issue 10.2019, RE 79094... -
Page 17: About This Product
Such influences must be pre-announced in order for a secure gearbox design. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe RE 79094, Issue 10.2019, Bosch Rexroth AG... -
Page 18: Description Of The Brake
The static multiple-disk parking brake acts negatively, i.e. it is released by means of pressure fluid and applied by spring action when pressureless. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe Bosch Rexroth AG, Issue 10.2019, RE 79094... -
Page 19: Product Overview
8.1.3 “Filling the planetary gearbox with lubricating oil”, 10.2.2 “Checking the oil level of the planetary gearbox” and 10.4.2 “Changing the lubricating oil”, the cover is shown in the required position. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe RE 79094, Issue 10.2019, Bosch Rexroth AG... -
Page 20: K Model
10.2.2 “Checking the oil level of the planetary gearbox” and 10.4.2 “Changing the lubricating oil”, the cover is shown in the required position. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe Bosch Rexroth AG, Issue 10.2019, RE 79094... -
Page 21: Identification Of The Product
In addition, the serial number is engraved on the gearbox housing. For this information, please refer to the front side/motor connection side on the spindle. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe RE 79094, Issue 10.2019, Bosch Rexroth AG... -
Page 22: Transport And Storage
(see illustration on the left) to the crane hook or transport the planetary gearbox in a suitable transport frame using a suitable forklift. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe Bosch Rexroth AG, Issue 10.2019, RE 79094... -
Page 23: Storing The Hydrotrac Gft
Observe the manufacturer's product data sheets and safety data sheets when using preservative. These data sheets are not included within Rexroth's scope of supply. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe RE 79094, Issue 10.2019, Bosch Rexroth AG... -
Page 24: Maximum Storage Periods
12 months: • Temperature -30 … 60°C, relative air humidity of max. 70% • Dry and dust-free • Protected against rain, snow and sunlight CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe Bosch Rexroth AG, Issue 10.2019, RE 79094... -
Page 25: Assembly
7. Place the planetary gearbox with the cover plate down on two suitable squared timbers. Secure the planetary gearbox against tipping over. 8. Dispose of the packaging in accordance with regulations in your local country. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe RE 79094, Issue 10.2019, Bosch Rexroth AG... -
Page 26: Delivery In Wood Transport Box
Use cloths made of lint-free fabric for cleaning. f Use mild detergents for removing lubricants and other heavy contaminations. No detergents may penetrate into the hydraulic system. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe Bosch Rexroth AG, Issue 10.2019, RE 79094... -
Page 27: Installation Position
For the instructions, please refer to chapter C "Mounting parts" of the material number-specific operating instructions. reQUireD tooLS The planetary gearbox can be assembled with standard tools. No special tool is required. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe RE 79094, Issue 10.2019, Bosch Rexroth AG... -
Page 28: Assembling The Hydrotrac Gft
These data sheets are not included within Rexroth's scope of supply. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe Bosch Rexroth AG, Issue 10.2019, RE 79094... -
Page 29: Installing The Planetary Gearbox With Assembled Axial-Piston Motor Into The Machine Or Chassis Frame
3. For the planetary gearbox weight, refer to appendix D “Technical data / Drawings” of the material number-specific operating instructions. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe RE 79094, Issue 10.2019, Bosch Rexroth AG... - Page 30 9. Make sure that the part of the machine or chassis frame to which the planetary gearbox is to be mounted is free of dirt and foreign objects. 10. Lift the planetary gearbox into the machine or chassis frame. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe Bosch Rexroth AG, Issue 10.2019, RE 79094...
- Page 31 9. Connect all power units and mounting parts required for operation of the planetary gearbox. For this, observe the instructions in chapter 7 “Assembly”. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe RE 79094, Issue 10.2019, Bosch Rexroth AG...
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Page 32: Connecting The Axial-Piston Motor Of The Planetary Gearbox To The Hydraulic System
3. For the planetary gearbox weight, refer to appendix D “Technical data / Drawings” of the material number-specific operating instructions. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe Bosch Rexroth AG, Issue 10.2019, RE 79094... - Page 33 (provided by the manufacturer of the axial-piston motor). This is where you will find all the required information on assembly and commissioning of the axial- piston motor. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe RE 79094, Issue 10.2019, Bosch Rexroth AG...
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Page 34: Connecting The Static Multiple-Disk Parking Brake
The delayed application of the static multiple-disk brake may cause the vehicle to roll away accidentally. f Make sure that the brake line of the static piston is pressureless within 0.5 s CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe Bosch Rexroth AG, Issue 10.2019, RE 79094... -
Page 35: Performing A Flushing Cycle
• Appendix F “Optional equipment variant” f Connect all units, supply lines, and connections necessary for operating the planetary gearbox and its mounting parts. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe RE 79094, Issue 10.2019, Bosch Rexroth AG... -
Page 36: Equipment Variants
All connections used for connecting lines are sealed with plugs or screw plugs during transport. These plastic plugs are not pressure-resistant. f Seal the unused connections with metallic, pressure-resistant screw plugs. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe Bosch Rexroth AG, Issue 10.2019, RE 79094... -
Page 37: Commissioning
For all work related commissioning of the planetary gearbox, observe the general safety instructions and intended use as specified in chapter 2 “Safety instructions”. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe RE 79094, Issue 10.2019, Bosch Rexroth AG... -
Page 38: Initial Commissioning The Axial-Piston Motor/Axial-Piston Motor Connection
– industrial gear oils in appendix B "Required and supplementary documentations" in the material number-specific operating instructions for these planetary gearboxes. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe Bosch Rexroth AG, Issue 10.2019, RE 79094... -
Page 39: Filling Lubricating Oil Via The Oil Filler Opening
9. Let the HYDROTRAC GFT planetary gearbox run for approx. 5-10 minutes. 10. Allow the planetary gearbox to cool down to approx. 50°C after switching off. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe RE 79094, Issue 10.2019, Bosch Rexroth AG... - Page 40 14. Check whether the seal on the screw plug thread of the bore 10 is still in perfect condition and can be reused. Replace a damaged seal. 15. Seal bore 10 with the corresponding screw plug. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe Bosch Rexroth AG, Issue 10.2019, RE 79094...
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Page 41: Completing Commissioning And Run-In Period
• Air and/or water in the hydraulic system • Aged hydraulic fluid • Other contaminations f Proceed for recommissioning as described in chapter 8.1 “Initial commissioning”. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe RE 79094, Issue 10.2019, Bosch Rexroth AG... -
Page 42: Operation
The service life of the HYDROTRAC GFT planetary gearbox depends on the proper assembly, installation, commissioning and application conditions, such as for following factors, for example: speed, torque, duty cycle, operating conditions and temperatures. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe Bosch Rexroth AG, Issue 10.2019, RE 79094... -
Page 43: Servicing And Repair
Damage to the seals by aggressive detergent or solvent! f Do not use any aggressive detergents or solvents. f Use a dry cloth made of lint-free fabric to clean the planetary gearbox. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe RE 79094, Issue 10.2019, Bosch Rexroth AG... -
Page 44: Inspection
Refer to the dimensioned drawing of the planetary gearbox for information about the position of the oil filler opening, the oil level control system and the oil drain. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe Bosch Rexroth AG, Issue 10.2019, RE 79094... - Page 45 7. Check whether the seal on the screw plug thread of the bore 5 is still in perfect condition and can be reused. Replace the damaged seals. 8. Seal bore 5 with the corresponding screw plug. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe RE 79094, Issue 10.2019, Bosch Rexroth AG...
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Page 46: Acoustic Inspections
D “Technical data / Drawings” of the material number-specific operating instructions. Also observe the frame drawing of the machine/vehicle manufacturer. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe Bosch Rexroth AG, Issue 10.2019, RE 79094... -
Page 47: Maintenance Schedule Planetary Gearbox
The service life of the planetary gearbox essentially depends on the quality of its lubricating oil. We therefore recommend changing the lubricating oil at least once a year or every 1,500 operating hours (whichever is earlier). CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe RE 79094, Issue 10.2019, Bosch Rexroth AG... -
Page 48: Approved Lubricating Oils
5. Loosen the screw plugs of the bore 5 slowly, so that any existing pressure can be released. 6. Then remove the screw plugs from bores 5 and 6. 7. Drain the lubricating oil completely in the catch basin. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe Bosch Rexroth AG, Issue 10.2019, RE 79094... - Page 49 14. Then fill the planetary gearbox with clean lubricating oil according to the selection list – industrial gear oils. Proceed as described in chapter 8.1.3 “Filling the planetary gearbox with lubricating oil”. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe RE 79094, Issue 10.2019, Bosch Rexroth AG...
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Page 50: Maintaining The Static Multiple-Disk Parking Brake (If Included)
Please contact Rexroth Service in your area in case repairs are required. The corresponding contact is indicated in appendix A “Address directory” of the material number-specific operating instructions. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe Bosch Rexroth AG, Issue 10.2019, RE 79094... -
Page 51: Repairing The Static Multiple-Disk Parking Brake
Rexroth does not assume any liability for damage of any kind due to non-observance of these provisions. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe RE 79094, Issue 10.2019, Bosch Rexroth AG... -
Page 52: Spare Parts
For the addresses of our national agencies, refer to www.boschrexroth.com and the address directory in appendix A “Address directory” of the material number-specific operating instructions. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe Bosch Rexroth AG, Issue 10.2019, RE 79094... -
Page 53: Decommissioning
For this reason the chapter in this manual contains no information. How to disassemble and replace the HYDROTRAC GFT planetary gearbox is described in chapter 12 “Disassembly and replacement”. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe RE 79094, Issue 10.2019, Bosch Rexroth AG... -
Page 54: Disassembly And Replacement
Refer to the manufacturer’s operating instructions for more information on how to do this. f Protect the machine or vehicle against restarting. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe Bosch Rexroth AG, Issue 10.2019, RE 79094... -
Page 55: Disassembling The Planetary Gearbox From The Machine Or Chassis Frame
4. Let the planetary gearbox cool down until it can be disassembled without any risk. 5. Place a catch basin under the planetary gearbox in order to collect any leaking hydraulic fluid or lubricating oil. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe RE 79094, Issue 10.2019, Bosch Rexroth AG... -
Page 56: Draining The Lubricating Oil - T Model
Replace the damaged seals. 12. Seal bore 9 and bore 10 with the corresponding screw plugs. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe Bosch Rexroth AG, Issue 10.2019, RE 79094... - Page 57 27. Put the disassembled axial-piston motor down. For this, observe the operating instructions of the axial-piston motor. 28. Remove all means of attachment and lifting equipment from the axial-piston motor. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe RE 79094, Issue 10.2019, Bosch Rexroth AG...
- Page 58 37. Remove all means of attachment such as eye bolts, straps, chains, swivel hooks, shackles or devices which are still attached. 38. Assemble the axial-piston motor to the planetary gearbox again. Proceed as described in chapter 7 “Assembly”. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe Bosch Rexroth AG, Issue 10.2019, RE 79094...
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Page 59: Preparing The Planetary Gearbox For Storage Reuse
“Preservation” and the associated product data sheets and safety data sheets. 5. Store the planetary gearbox as described in chapter 6 “Transport and storage”. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe RE 79094, Issue 10.2019, Bosch Rexroth AG... -
Page 60: Disposal
Removal of the protective caps voids the warranty claims. If the setting has to be changed, contact the responsible Rexroth Service. For the address, please refer to chapter 10.6 “Spare parts”. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe Bosch Rexroth AG, Issue 10.2019, RE 79094... -
Page 61: Troubleshooting And Fault Correction
Gain a clear picture of what caused the malfunction. As necessary, ask the direct operator. f If appropriate, record the situation as you encountered it by taking digital photographs and send these to Rexroth Service. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe RE 79094, Issue 10.2019, Bosch Rexroth AG... - Page 62 If the malfunction occurrences cannot be eliminated, please contact one of the contact addresses indicated on www.boschrexroth.com or in the address directory in appendix A “Address directory” of the material number-specific operating instructions. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe Bosch Rexroth AG, Issue 10.2019, RE 79094...
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Page 63: Technical Data
The documents of chapter 17 “Appendix” are enclosed in the appendix of the material number-specific operating instructions. Also refer to chapter 1.2 “Required and supplementary documentations”. CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe RE 79094, Issue 10.2019, Bosch Rexroth AG... - Page 64 Bosch rexroth AG Gearbox Technology Nortkirchenstraße 53 44263 Dortmund Germany Phone +49 (0) 231 22819-5 info.gears@boschrexroth.de www.boschrexroth.com Additional information at: www.boschrexroth.com/gears CorreCtion Copy 1 |17.10.2019 | onLy For internAL USe Subject to change without notice Printed in Germany RE 79094...
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