Related Manuals for Bosch rexroth A10VG 60 Series
Summary of Contents for Bosch rexroth A10VG 60 Series
- Page 1 Operating instructions Axial piston variable pump A10VG series 60 RE 92760-01-B/2024-07-16, EN...
- Page 2 It must be remembered that our products are subject to a natural process of wear and aging. © Bosch Rexroth AG 2024. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
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Page 3: Table Of Contents
7.4.4 Installation with a coupling ................36 7.4.5 Installation on a gearbox ................37 7.4.6 Installation with cardan shaft ..............37 7.4.7 Completion of installation ................37 7.4.8 Hydraulically connecting the axial piston unit ..........39 7.4.9 Electrically connecting the axial piston unit ..........43 Performing flushing cycle ................44 RE 92760-01-B/2024-07-16, Bosch Rexroth AG... - Page 4 Preparing the components for storage or further use .........53 Disposal ....................54 Extension and conversion ............... 55 Troubleshooting ..................56 14.1 How to proceed for troubleshooting ............56 14.2 Malfunction table ..................57 Technical data ..................61 Alphabetical index ................. 62 Bosch Rexroth AG, RE 92760-01-B/2024-07-16...
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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 92760-01-B/2024-07-16, Bosch Rexroth AG... -
Page 6: Representation Of Information
BODAS hall effect angle and linear position sensor PAL, series 10 95161 Data sheet Contains the permissible technical data and dimensions. 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
Axial piston variable pump, closed circuit Threaded plug Metal screw, pressure-resistant Protective plug Made out of plastic, not pressure-resistant, only for transportation As generic term for "axial piston variable pump A10VG", the designation "axial piston unit" will be used in the following. RE 92760-01-B/2024-07-16, Bosch Rexroth AG... -
Page 8: Abbreviations
Electronic, direct acting control International Organization for Standardization Japan Industrial Standard Rexroth document in the English language VDI 2230 Guideline for the systematic calculation of heavy-duty threaded connections and cylindrical screw joints from the VDI (Verein Deutscher Ingenieure - Association of German Engineers) Bosch Rexroth AG, RE 92760-01-B/2024-07-16... -
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 damage 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
Persons with implanted cardiac pacemakers must take special precautions. Magnets may have a nickel coating, which can lead to allergic reactions. RE 92760-01-B/2024-07-16, 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. ▶ Pressure cut-off (hydraulic or electronic) is not a sufficient safeguard against pressure overload. - Page 13 ▶ Check whether or not your machine requires additional safety measures for your application to avoid unintentional actuation. If necessary, make sure these are appropriately implemented. ▶ Wear suitable protective clothing. RE 92760-01-B/2024-07-16, Bosch Rexroth AG...
- Page 14 ▶ Only ever connect connecting elements and lines that match the ports of the axial piston unit and can resist the intended application conditions (e.g. pressure level, flow, hydraulic fluid, temperature) with the necessary safety factors. Bosch Rexroth AG, RE 92760-01-B/2024-07-16...
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Page 15: Personal Protective Equipment
▶ Check how to safely get on top of the machine/system. 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 must be intact. RE 92760-01-B/2024-07-16, Bosch Rexroth AG... -
Page 16: General Instructions On Property Damage And Product Damage
▶ Make sure the suction line is always filled with hydraulic fluid during commissioning and operation. Mixing hydraulic fluids! Product can be damaged! ▶ Any mixture of hydraulic fluids of different manufacturers and/or different types of the same manufacturer is generally not permissible. Bosch Rexroth AG, RE 92760-01-B/2024-07-16... - Page 17 Leaks may lead to leakage of hydraulic fluid. ▶ Take appropriate measures to protect the axial piston unit from chemical or corrosive environmental conditions. RE 92760-01-B/2024-07-16, Bosch Rexroth AG...
- Page 18 The warranty only applies to the machine configuration 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, RE 92760-01-B/2024-07-16...
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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. fixing screws (4) RE 92760-01-B/2024-07-16, Bosch Rexroth AG... -
Page 20: About This Product
The swivel angle is controlled hydraulically by means of the stroking piston. 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. Bosch Rexroth AG, RE 92760-01-B/2024-07-16... - Page 21 (neutral position). ▶ Check whether remedial measures are needed on the machine for the application concerned in order to bring the driven consumer into a safe position (e.g. safe stop) and ensure any measures are properly implemented. RE 92760-01-B/2024-07-16, Bosch Rexroth AG...
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Page 22: Bypass Function (Optional)
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. 3. Re-tighten the lock nut (2), turning clockwise to a torque of 22 Nm. RE 92760-01-B/2024-07-16, Bosch Rexroth AG...
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Page 24: Product Identification
(viewed on drive shaft) – here: 11 Serial number clockwise 12 Material number of the axial 5 Bar code piston unit 6 Weight (optional) The inspection stamp is located next to the name plate on the axial piston unit. Bosch Rexroth AG, RE 92760-01-B/2024-07-16... -
Page 25: Transport And Storage
▶ Only manually transport the axial piston unit for a short period of time. Observe the national regulations in your country for manual transport. ▶ Always use appropriate lifting, lowering and moving techniques. ▶ Use your personal protective equipment (e.g. safety goggles, safety gloves, suitable working clothes, safety shoes). RE 92760-01-B/2024-07-16, Bosch Rexroth AG... -
Page 26: Transport With Lifting Devices
▶ Make sure that the eye bolt can bear the total weight of the axial piston unit angle detection) plus approx. 20%. You can hoist the axial piston unit as shown in Fig. 5 with the eye bolt (2) screwed into the housing. Remove the M10 grub screw (1) before using a size 5 hexagon socket wrench. Bosch Rexroth AG, RE 92760-01-B/2024-07-16... - 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, magnets, or piping) and that the axial piston unit is not suspended from assembled parts (see Fig. 6). Fig. 6: Transport with lifting strap RE 92760-01-B/2024-07-16, Bosch Rexroth AG...
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Page 28: 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"... - Page 29 In such a case, consult your local contact person; you can find their contact information at https://addresses.boschrexroth.com Bosch Rexroth recommends the following procedure: 1. Clean the axial piston unit; see chapter 10.1 "Cleaning and care" on page 50. 2. Drain the axial piston unit.
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Page 30: Installation
• Installation drawing for the axial piston unit (can be obtained from your contact person at Bosch Rexroth, if required) • Hydraulic circuit diagram for the axial piston unit (in the data sheet and on the installation drawing) •... - 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 92760-01-B/2024-07-16, Bosch Rexroth AG...
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Page 32: Installation Position
Air bleed port Suction port Drain port Control pressure port Boost pressure port inlet Baffle (baffle plate) Minimum required immersion depth (200 mm) t min Minimum required distance to reservoir bottom (100 mm) Maximum permissible suction height (800 mm) S max Bosch Rexroth AG, RE 92760-01-B/2024-07-16... -
Page 33: Below-Reservoir Installation (Standard)
, S, T t min t min Filling unit Filling unit Recommendation: Filling with filter/filling unit. When filling without filter/filling unit, the pump must be filled at the highest drain port. Port X top only permissible upon request. RE 92760-01-B/2024-07-16, Bosch Rexroth AG... -
Page 34: Above-Reservoir Installation
7.4 Installing the axial piston unit 7.4.1 Preparation 1. Check the specifications on the name plate to see you have the correct axial piston unit. 2. Compare the material number and designation (type code) with the parameters in the order confirmation. Bosch Rexroth AG, RE 92760-01-B/2024-07-16... -
Page 35: 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 92760-01-B/2024-07-16, Bosch Rexroth AG... -
Page 36: Installation With A Coupling
Make sure no excessive axial and radial forces are acting on the drive shaft. 8. Details on the required tools and tightening torques for the fixing screws are available from the machine/system manufacturer. Bosch Rexroth AG, RE 92760-01-B/2024-07-16... -
Page 37: Installation On A Gearbox
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. RE 92760-01-B/2024-07-16, Bosch Rexroth AG... - Page 38 3. For versions with through drive, install the auxiliary pump according to the pump manufacturer's manual. The protective cover (4) is not pressure-resistant and therefore not permissible during operation. For the design of the fixing screws, observe VDI 2230 with μ = 0.1 and screw quality 8.8. Bosch Rexroth AG, RE 92760-01-B/2024-07-16...
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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 92760 (see Table 8). RE 92760-01-B/2024-07-16, Bosch Rexroth AG... - Page 40 ▶ 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, RE 92760-01-B/2024-07-16...
- Page 41 For values, see Table 9. • Threaded plugs: For the metallic threaded plugs supplied with the axial piston unit, the required tightening torques of threaded plugs M apply. For values, see Table 9. RE 92760-01-B/2024-07-16, Bosch Rexroth AG...
- Page 42 70 Nm 5/16 in 7/8-14 UNF-2B 240 Nm 110 Nm 3/8 in 1 1/16-12 UN-2B 360 Nm 170 Nm 9/16 in 1 5/16-12 UN-2B 540 Nm 270 Nm 5/8 in 1 5/8-12 UN-2B 960 Nm 320 Nm 3/4 in 1 7/8-12 UN-2B 1200 Nm 390 Nm 3/4 in Bosch Rexroth AG, RE 92760-01-B/2024-07-16...
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Page 43: Electrically Connecting The Axial Piston Unit
(inside-reservoir installation). The machine/system manufacturer is responsible for electric control layout. Electrically controlled axial piston units must be connected in accordance with the electrical circuit diagram for the machine/system. RE 92760-01-B/2024-07-16, Bosch Rexroth AG... -
Page 44: Performing Flushing Cycle
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 45: Commissioning
▶ Make sure all electrical and hydraulic ports are connected or plugged. ▶ Commission only a fully installed, fully functioning product with original accessories from Bosch Rexroth. 8.1 Initial commissioning During all commissioning work on the axial piston unit, observe the general safety instructions and intended use detailed in chapter 2 "Safety instructions"... - Page 46 Bosch Rexroth evaluates hydraulic fluids on the basis of the Fluid Rating according to data sheet 90235. For hydraulic fluids which have been positively evaluated in the Fluid Rating, please refer to data sheet 90245 "Bosch Rexroth Fluid Rating List for Rexroth hydraulic components (pumps and motors)".
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Page 47: Testing The Hydraulic Fluid Supply
The axial piston unit is tested for functional capability and performance before delivery according to the technical data. During commissioning, make sure the axial piston unit was installed in the machine/system as intended. RE 92760-01-B/2024-07-16, Bosch Rexroth AG... -
Page 48: Running-In Phase
▶ After the running-in phase, have a hydraulic fluid sample 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 changing the hydraulic fluid. 8.3 Recommissioning after standstill Depending on the installation conditions and ambient conditions, changes may occur in the hydraulic system which make recommissioning necessary. -
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 92760-01-B/2024-07-16, Bosch Rexroth AG... -
Page 50: 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: Maintenance
Early detection of hydraulic fluid loss can help to find faults on the machine/system and rectify them. This is why Bosch Rexroth recommends always keeping the axial piston unit and system clean. Check axial piston unit for unusual noise development. -
Page 52: Repair
52/64 A10VG series 60 | 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
6. Remove the axial piston unit. Use a suitable lifting device. 7. Completely drain the axial piston unit. 8. 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 92760-01-B/2024-07-16, Bosch Rexroth AG... -
Page 54: Disposal
Also observe the applicable safety data sheet for the hydraulic fluid. 4. Disassemble the axial piston unit into its constituent parts for proper recycling. 5. For example, separate the parts into: – Castings – Steel – Aluminum – Non-ferrous metal – Electronic waste – Plastic – Seals Bosch Rexroth AG, RE 92760-01-B/2024-07-16... -
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. Any modification or upgrade voids the warranty. 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 contact addresses at: https://addresses.boschrexroth.com. Bosch Rexroth AG, RE 92760-01-B/2024-07-16... -
Page 57: Malfunction Table
Air bleed the axial piston unit and hydraulic control valves in the axial piston unit system (boost-pressure relief valve, high-pressure Contact Bosch Rexroth Service: relief valve, pressure reducing valve) 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) - Page 58 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...
- Page 59 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 Output unit defective (e.g. hydraulic motor or...
- Page 60 Oscillate pressure relief valves and pressure Air bleed the axial piston unit and hydraulic control valves in the axial piston unit system (boost-pressure relief valve, high-pressure Contact Bosch Rexroth Service relief valve, pressure reducing valve) Unstable control signal Contact machine/system manufacturer or Bosch Rexroth Service Malfunction in the control devices or the Contact Bosch Rexroth Service...
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Page 61: Technical Data
The data sheet can be found in the Download Center: www.boschrexroth.com/ics/ref/media/92760 Additional information can be found in the Rexroth store: www.boschrexroth.com/p-A10VG-60 Order-related technical data for your axial piston unit can be found in the order confirmation. RE 92760-01-B/2024-07-16, Bosch Rexroth AG... -
Page 62: Alphabetical Index
Identification ........ 24 Preparing ........53 Inspection ........50 Repair ........... 52 Installation ........30 Replacement ......... 53 Completion ........ 37 Required documentation ....5 General instructions ....35 Running-in phase ......48 On a gearbox ......37 Bosch Rexroth AG, RE 92760-01-B/2024-07-16... - Page 63 Tools..........53 Transport ........25 By hand ........25 With eye bolt ......26 With lifting strap ......27 Transporting ......... 25 Transport protection ..... 38 Troubleshooting ......56 Unpacking ........30 Warranty ......18 Weight .......... 25 RE 92760-01-B/2024-07-16, Bosch Rexroth AG...
- Page 64 Bosch Rexroth AG Glockeraustraße 2 89275 Elchingen Germany Phone +49 7308 82-0 info.ma@boschrexroth.de www.boschrexroth.com Your local contact person can be found at: https://addresses.boschrexroth.com Subject to change RE 92760-01-B/2024-07-16...
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