Related Manuals for Bosch Rexroth Hyquip 10 Series
Summary of Contents for Bosch Rexroth Hyquip 10 Series
- Page 1 Axial Piston Variable Double Pump RE 93240-01-B/09.2012 Replaces: –.– A24VG English Series 10 Instruction manual...
- 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
RE 93240-01-B/09.2012 | A24VG Series 10 Bosch Rexroth AG 3/52 Contents Contents About this documentation ................5 Validity of the documentation ..............5 Required and supplementary documentation ..........5 Display of information .................. 6 1.3.1 Safety instructions ..................6 1.3.2 Symbols ......................7 1.3.3 Designations ....................7 1.3.4 Abbreviations ....................7... - Page 4 4/52 Bosch Rexroth AG A24VG Series 10 | RE 93240-01-B/09.2012 Contents Maintenance and repair ................40 10.1 Cleaning and care ..................40 10.2 Inspection ....................41 10.3 Maintenance ....................41 10.4 Repair ......................42 10.5 Spare parts ....................42 Removal and replacement ..............43 11.1 Required tools ...................43 11.2...
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Page 5: About This Documentation
RE 93240-01-B/09.2012 | A24VG Series 10 Bosch Rexroth AG 5/52 About this documentation About this documentation Validity of the documentation This documentation applies to the following products: • Axial piston variable double pump A24VG series 10 This documentation is intended for machine/system manufacturers, fitters and service technicians. -
Page 6: Display Of Information
6/52 Bosch Rexroth AG A24VG Series 10 | RE 93240-01-B/09.2012 About this documentation Display of information Standardized safety instructions, symbols, terms and abbreviations are used so that you can use this documentation to work quickly and safely with your axial piston unit. -
Page 7: Symbols
RE 93240-01-B/09.2012 | A24VG Series 10 Bosch Rexroth AG 7/52 About this documentation 1.3.2 Symbols The following symbols mark notes that are not safety-relevant but which increase the understanding of the documentation. Table 3: Meaning of the symbols Symbol Meaning If this information is disregarded, the product can not be used and/or operated to the optimum extent. -
Page 8: Safety Instructions
Any use other than that described as intended use shall be considered as improper and is therefore impermissible. Bosch Rexroth AG shall accept no liability whatsoever for damage resulting from improper use. The user shall bear all risks arising from improper use. -
Page 9: Personnel Qualifications
• having knowledge on the function and assembly of hydraulic components. Bosch Rexroth offers training support for special fields. An overview of the training contents can be found on the Internet at: http://www.boschrexroth.de/ didactic. -
Page 10: Product-Specific Safety Instructions
Operating the unit above the permissible maximum pressure can cause components to burst and hydraulic fluid to escape under high pressure. Changes to the factory settings must only be made by Bosch Rexroth specialist personnel. In addition, a pressure relief valve is needed as back-up in the hydraulic system. - Page 11 RE 93240-01-B/09.2012 | A24VG Series 10 Bosch Rexroth AG 11/52 Safety instructions wARNING Pressurized machine/system! Danger to life or risk of injury, serious injuries when working on machines/ systems not shutdown! Damage to equipment! Protect the complete system against being energized.
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Page 12: Personal Protective Equipment
12/52 Bosch Rexroth AG A24VG Series 10 | RE 93240-01-B/09.2012 Safety instructions CAUTION High noise development in operation! Danger of hearing damage, deafness! The noise emission of axial piston units depends on speed, operating pressure and installation conditions. The sound pressure level may rise above 70 dBA during normal application conditions. -
Page 13: General Instructions On Damage To Equipment And The Product
RE 93240-01-B/09.2012 | A24VG Series 10 Bosch Rexroth AG 13/52 General instructions on damage to equipment and the product General instructions on damage to equipment and the product The following notes apply for chapters 6 to 14. NOTE Danger from improper handling! Product can be damaged! Do not expose the product to an impermissible mechanical load. - Page 14 14/52 Bosch Rexroth AG A24VG Series 10 | RE 93240-01-B/09.2012 General instructions on damage to equipment and the product NOTE Contamination of the hydraulic fluid! The cleanliness of the hydraulic fluid has a considerable impact on the cleanliness and service life of the hydraulic system. Premature wear and...
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Page 15: Delivery Contents
RE 93240-01-B/09.2012 | A24VG Series 10 Bosch Rexroth AG 15/52 Delivery contents Delivery contents Fig. 1: Axial piston unit Included in the delivery contents are: • Axial piston unit as per order confirmation The following parts are also installed on delivery: •... -
Page 16: Product Description
16/52 Bosch Rexroth AG A24VG Series 10 | RE 93240-01-B/09.2012 Product description Product description Performance description The axial piston variable double pump generates, controls and regulates a hydraulic-fluid flow. It is designed for mobile applications such as construction machinery. Refer to data sheet RE 93240 and the order confirmation for the technical data, operating conditions and operating limits of the axial piston unit. -
Page 17: Functional Description
RE 93240-01-B/09.2012 | A24VG Series 10 Bosch Rexroth AG 17/52 Product description 5.2.2 Functional description Pump Torque and rotational speed are applied to the drive shaft (1) by an engine. The drive shaft is connected by splines to the cylinder (9) to set this in motion. With every revolution, the pistons (10) in the cylinder bores execute one stroke whose magnitude depends on the setting of the swashplate (12). -
Page 18: Product Identification
18/52 Bosch Rexroth AG A24VG Series 10 | RE 93240-01-B/09.2012 Product description Product identification The axial piston unit can be identified from the name plate. The following example shows an A24VG name plate: Rexroth DE - 89275 Elchingen CNR: X1234567890Y... -
Page 19: Transport And Storage
RE 93240-01-B/09.2012 | A24VG Series 10 Bosch Rexroth AG 19/52 Transport and storage Transport and storage Make sure you conform to the required ambient conditions during transportation and storage, see chapter 6.2 "Storing the axial piston unit". You can find unpacking notes in chapter 7.1 "Unpacking". -
Page 20: Storing The Axial Piston Unit
If the storage time exceeds 24 months, the shaft seal ring must be replaced. After expiry of the maximum storage time, we recommend that you have the axial piston unit inspected by your responsible Bosch Rexroth Service partner. In the event of questions regarding repair and spare parts, contact your responsible Bosch Rexroth Service partner or the service department of the manufacturer's plant for the axial piston unit, see chapter 10.5 "Spare parts"... - Page 21 Other hydraulic fluids require preservation methods that are specifically designed for them. In such a case, consult with Bosch Rexroth Service, see chapter 10.5 "Spare parts" for address. Bosch Rexroth recommends the following procedure: Clean the axial piston unit, see chapter 10.1 "Cleaning and care".
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Page 22: Installation
Prior to installation, the following documents must be ready at hand: • Installation drawing for axial piston unit (can be obtained from your responsible contact person at Bosch Rexroth) • Hydraulic circuit diagram for the axial piston unit (in the installation drawing) •... - Page 23 RE 93240-01-B/09.2012 | A24VG Series 10 Bosch Rexroth AG 23/52 Installation Make sure that the specified minimum boost pressure is present for the axial piston unit at port G in all installation locations and positions during operation and during cold start.
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Page 24: Installation Position
24/52 Bosch Rexroth AG A24VG Series 10 | RE 93240-01-B/09.2012 Installation Installation position The following installation positions are permissible. The shown piping layout illustrates the basic layout. Be certain to observe the notes in chapter 7.4.8 "Hydraulically connecting the axial piston unit". -
Page 25: Above-Reservoir Installation
RE 93240-01-B/09.2012 | A24VG Series 10 Bosch Rexroth AG 25/52 Installation 7.3.2 Above-reservoir installation Above-reservoir installation means that the axial piston unit is installed above the minimum fluid level of the reservoir. Recommended installation position: 5. t min t min... -
Page 26: Installing The Axial Piston Unit
If the material number for the axial piston unit does not correspond to the one in the order confirmation, contact Bosch Rexroth Service for clarification, see chapter 10.5 "Spare parts" for address. Before installing, completely empty the axial piston unit to prevent any mixing with the hydraulic fluid used in the machine/system. -
Page 27: General Instructions
RE 93240-01-B/09.2012 | A24VG Series 10 Bosch Rexroth AG 27/52 Installation 7.4.3 General instructions Please keep in mind the following general instructions for installation of the axial piston unit: • Note that you can expect certain installation positions to affect the control device. -
Page 28: Installation With Coupling
28/52 Bosch Rexroth AG A24VG Series 10 | RE 93240-01-B/09.2012 Installation 7.4.4 Installation with coupling The method for installing the axial piston unit with a coupling is described below: NOTE! Danger from improper handling! Product can be damaged! Do not install the coupling hub onto the drive shaft of the axial piston unit by striking it. -
Page 29: 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 responsible Bosch Rexroth Service partner or the service department of the manufacturer's plant for the axial piston unit. -
Page 30: Hydraulically Connecting The Axial Piston Unit
The setting screw are protected against unauthorized resetting by means of protective caps. Removing the protective caps will void the warranty. If you need to change the setting, please contact your responsible Bosch Rexroth Service partner (address as to chapter 10.5 "Spare parts"). - Page 31 RE 93240-01-B/09.2012 | A24VG Series 10 Bosch Rexroth AG 31/52 Installation Notes on routing Observe the following notes when routing the boost, pressure and reservoir lines. the lines • Lines and hoses must be installed without pre-charge pressure, so that no further mechanical forces are applied during operation that will reduce the service life of the axial piston unit and, if applicable, the entire machine/system.
- Page 32 32/52 Bosch Rexroth AG A24VG Series 10 | RE 93240-01-B/09.2012 Installation Reservoir line port Besides the actual case drain fluid, an additional cooling fluid flow is needed in (case drain) the housing for lubricating and cooling the rotary group in the housing.
- Page 33 RE 93240-01-B/09.2012 | A24VG Series 10 Bosch Rexroth AG 33/52 Installation Port overview Pump 2 Pump 1 Pump 2 Pump 1 The front pump (with mounting flange) is pump 1, the rear pump is pump 2. Fig. 9: Port overview A24VG, size 065-065, EP-EP control...
- Page 34 34/52 Bosch Rexroth AG A24VG Series 10 | RE 93240-01-B/09.2012 Installation Tightening torques The following tightening torques apply: • Female threads in the axial piston unit: The maximum permissible tightening torques M are maximum values for G max the female threads and must not be exceeded. For values, see the following table.
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Page 35: Electrically Connecting The Axial Piston Unit
Retighten the mounting nut. Tightening torque of the mounting nut: 5+1 Nm. Performing flushing cycle In order to remove foreign particles from the system, Bosch Rexroth recommends a flushing cycle for the entire system before the first commissioning. To avoid internal contamination, the axial piston unit must not be included in the flushing cycle. -
Page 36: Commissioning
36/52 Bosch Rexroth AG A24VG Series 10 | RE 93240-01-B/09.2012 Commissioning Commissioning wARNING Danger while working in the danger zone of a machine/system! Danger to life, risk of injury or serious injuries! Pay attention to and rectify potential danger sources before operating the axial piston unit. -
Page 37: Filling The Axial Piston Unit
Use only a hydraulic fluid that conforms to the following requirements: You can find details of the minimum requirements on hydraulic fluids in Bosch Rexroth data sheets RE 90220, RE 90221 and RE 90222. You can find the title of the data sheets in table 1 "Required and supplementary documentation". -
Page 38: Testing The Hydraulic Fluid Supply
38/52 Bosch Rexroth AG A24VG Series 10 | RE 93240-01-B/09.2012 Commissioning 8.1.2 Testing the hydraulic fluid supply The axial piston unit must always have a sufficient supply of hydraulic fluid. For this reason, the supply of hydraulic fluid must be ensured at the start of the commissioning process. -
Page 39: Running-In Phase
After the running-in phase, have a hydraulic fluid specimen analyzed for the required cleanliness level. Change the hydraulic fluid if the required cleanliness level is not reached. If a laboratory test is not carried out after the running-in phase, Bosch Rexroth recommends the hydraulic fluid be changed. Recommissioning after standstill Depending on the installation conditions and ambient conditions, changes may occur in the hydraulic system which make recommissioning necessary. -
Page 40: Operation
40/52 Bosch Rexroth AG A24VG Series 10 | RE 93240-01-B/09.2012 Operation Operation The product is a component which requires no settings or changes during 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 provided in the technical data. -
Page 41: Inspection
Maintenance and repair 10.2 Inspection In order to enable long and reliable operation of the axial piston unit, Bosch Rexroth recommends testing the hydraulic system and axial piston unit on a regular basis, and documenting and archiving the following operating conditions:... -
Page 42: Repair
A24VG Series 10 | RE 93240-01-B/09.2012 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 may only be performed by service centers certified by Bosch Rexroth. -
Page 43: Removal And Replacement
RE 93240-01-B/09.2012 | A24VG Series 10 Bosch Rexroth AG 43/52 Removal and replacement 11 Removal and replacement 11.1 Required tools Removal can be performed with standard tools. No special tools are necessary. 11.2 Preparing for removal Decommission the entire system as described in the instruction manual for the machine or system. -
Page 44: Disposal
Do not modify the axial piston unit. This also includes a modification of the setting screws. The Bosch Rexroth warranty only applies for the delivered configuration. In case of conversion or extension, the entitlement under warranty will be rendered void. -
Page 45: Troubleshooting
RE 93240-01-B/09.2012 | A24VG Series 10 Bosch Rexroth AG 45/52 Troubleshooting 14 Troubleshooting The following table may assist you in troubleshooting. The table makes no claim for completeness. In practical use, problems which are not listed here may also occur. -
Page 46: Malfunction Table
Air bleed the axial piston unit axial piston unit (pressure cut-off incorrectly Check viscosity of the hydraulic fluid set). Contact Bosch Rexroth Service. Malfunction of the pressure relief valves on the Air bleed the axial piston unit axial piston unit (boost pressure, high pressure, Check viscosity of the hydraulic fluid pressure cut-off incorrectly set). - Page 47 Check external control (machine/system manufacturer). Insufficient pilot pressure or control pressure. Check pilot pressure or control pressure, contact Bosch Rexroth Service. Malfunction of the control device or controller of Contact Bosch Rexroth Service. the axial piston unit. Wear of axial piston unit.
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Page 48: Technical Data
48/52 Bosch Rexroth AG A24VG Series 10 | RE 93240-01-B/09.2012 Technical data 15 Technical data The permissible values of the technical data of your axial piston unit can be found in data sheet RE 93240. The data sheet can be found on the Internet under www.boschrexroth.com/various/utilities/mediadirectory/index. -
Page 49: Alphabetical Index
RE 93240-01-B/09.2012 | A24VG Series 10 Bosch Rexroth AG 49/52 Alphabetical index Alphabetical index Abbreviations 7 Identification 18 Address directory 48 Inspection 41 Assembly 16 Installation 22 Completing 29 General instructions 27 On a gearbox 28 Below-reservoir installation 24 Preparation 26... - Page 50 50/52 Bosch Rexroth AG A24VG Series 10 | RE 93240-01-B/09.2012 Alphabetical index Recommissioning 39 after standstill 39 Removal 43 Performing 43 Preparing 43 Repair 42 Replacement 43 Required documentation 5 Retaining plate 16 Running-in phase 39 Safety instructions 8 General 9...
- Page 51 RE 93240-01-B/09.2012 | A24VG Series 10 Bosch Rexroth AG 51/52...
- Page 52 Bosch Rexroth AG Mobile Applications Glockeraustraße 4 89275 Elchingen Germany Tel. +49 73 08-82-0 Fax +49 73 08-72 74 info.brm@boschrexroth.de www.boschrexroth.com/axialkolbenpumpen Änderungen vorbehalten Printed in Germany RE 93240-01-B/09.2012...