Related Manuals for Bosch A4VG A4VG 32 Series
Summary of Contents for Bosch A4VG A4VG 32 Series
- Page 1 Axial piston variable pump A4VG Series 32 Instruction manual Replaces: 04.2008 RE 92003-01-B/12.2015 English...
- Page 2 © Bosch Rexroth AG 2016. 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.
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Page 3: Table Of Contents
Installation position 7.3.1 Below-reservoir installation (standard) 7.3.2 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 coupling 7.4.5 Installation on a gearbox 7.4.6 Completing installation RE 92003-01-B/12.2015, A4VG Series 32, Bosch Rexroth AG... - Page 4 11.2 Preparing for removal 11.3 Performing removal 11.4 Preparing the components for storage or later use Disposal Extension and conversion Troubleshooting 14.1 How to proceed with troubleshooting 14.2 Malfunction table Technical data Alphabetical index Bosch Rexroth AG, A4VG Series 32, RE 92003-01-B/12.2015...
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Page 5: About This Documentation
Manual Contains additional information on the use of Rexroth axial piston units at low temperatures. Storage and preservation of axial piston units 90312 Data sheet Contains additional information on storage and preservation. RE 92003-01-B/12.2015, A4VG Series 32, Bosch Rexroth AG... -
Page 6: Display Of Information
• Type and source of danger: indicates the type and source of the danger • Consequences: describes what occurs if the safety instructions are not complied with • Precautions: states how the danger can be avoided Bosch Rexroth AG, A4VG Series 32, RE 92003-01-B/12.2015... -
Page 7: Symbols
Metal screw, pressure-resistant Protection plug Made out of plastic, not pressure-resistant, only for transportation As a generic term for “axial piston variable pump A4VG”, the designation “axial piston unit” will be used hereinafter. RE 92003-01-B/12.2015, A4VG Series 32, Bosch Rexroth AG... -
Page 8: Abbreviations
Rexroth document in the English language VDI 2230 Directive for the systematic calculation of high duty bolted joints and joints with one cylindrical bolt from the VDI (Verein Deutscher Ingenieure - Association of German Engineers) Bosch Rexroth AG, A4VG Series 32, RE 92003-01-B/12.2015... -
Page 9: Safety Instructions
Any use other than that described as intended use shall be considered as improper and is therefore impermissible. Bosch Rexroth AG is not liable for damages resulting from improper use. The user bears all risks from improper use. The following forms of forseeable use are also considered to be improper (this list does not claim to be exhaustive): •... -
Page 10: Personnel Qualifications
• Specifically, 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 92003-01-B/12.2015, A4VG Series 32, Bosch Rexroth AG... -
Page 12: Product-Specific Safety Instructions
▶ Changes to the factory settings must only be made by Bosch Rexroth specialists. ▶ In addition, a pressure relief valve is needed 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 92003-01-B/12.2015, A4VG Series 32, 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, A4VG Series 32, RE 92003-01-B/12.2015...
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Page 15: Personal Protective Equipment
Personal protective equipment is the responsibility of the user of the axial piston unit. Observe the safety regulations and provisions in your country. All pieces of personal protective equipment must be intact. RE 92003-01-B/12.2015, A4VG Series 32, Bosch Rexroth AG... -
Page 16: General Instructions On Damage To Property And The Product
Before installation, remove all fluids from the axial piston unit to prevent mixing with the hydraulic fluid used in the machine/system. ▶ Any mixing of hydraulic fluids from different manufacturers or different types from the same manufacturer is generally not permitted. Bosch Rexroth AG, A4VG Series 32, RE 92003-01-B/12.2015... - 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 92003-01-B/12.2015, A4VG Series 32, Bosch Rexroth AG...
- Page 18 The warranty only applies to the delivered configuration. The entitlement to warranty cover will be rendered void if the product is incorrectly installed, commissioned or operated, or if it is used or handled improperly. Bosch Rexroth AG, A4VG Series 32, RE 92003-01-B/12.2015...
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Page 19: Scope Of Delivery
• Axial piston unit as per order confirmation The following parts are also assembled prior to delivery: • Protective covers (1) • Protective plug/threaded plug (2) • For version with through drive, metallic protective cover and mounting bolts (3) RE 92003-01-B/12.2015, A4VG Series 32, Bosch Rexroth AG... -
Page 20: About This Product
2 Retainer plate (distributor plate) 10 Piston 3 Stroking piston 6 Low-pressure side 11 Slipper pad 4 Control unit 7 Boost pump 12 Cradle (using the EP as 8 High-pressure side an example here) Bosch Rexroth AG, A4VG Series 32, RE 92003-01-B/12.2015... -
Page 21: Functional Description
Use an appropriate emergency-off device to ensure that the drive can be brought to a safe position at any time. The machine or system manufacturer is responsible for the installation of a proper emergency-off device. RE 92003-01-B/12.2015, A4VG Series 32, 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 at both pressure relief valves (avoiding a function in only travel direction). -
Page 23: Bypass Function Size 28 To
▶ Wear heat-resistant protective clothing, e.g., gloves. ▶ Only tow the vehicle out of the immediate danger zone. The vehicle may only be towed out of the immediate danger zone. RE 92003-01-B/12.2015, A4VG Series 32, Bosch Rexroth AG... -
Page 24: Bypass Function Size
Remove the plastic tamper-proof cap (1) on the high-pressure relief valve with a suitable tool (e.g. gripper). Loosen the screw (2) by turning counter-clockwise two turns with a hexagon socket wrench (WAF 5). The plastic tamper-proof cap is destroyed when removing. Bosch Rexroth AG, A4VG Series 32, RE 92003-01-B/12.2015... - Page 25 (WAF 5) in a clockwise rotation with a torque of 10 ±1 Equip the screw (2) with a tamper-proof cap again to protect the pressure relief valve against unauthorized resetting. RE 92003-01-B/12.2015, A4VG Series 32, Bosch Rexroth AG...
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Page 26: Bypass Function Size 125 To 180
Immediately following towing, switch off the bypass function. Restore the function of the high-pressure relief valve. Tighten the screw (1) with a hexagon head screw (WAF 36) in a clockwise rotation with a torque of 200 ±10 Bosch Rexroth AG, A4VG Series 32, RE 92003-01-B/12.2015... -
Page 27: Product Identification
4 Direction of rotation (viewed on 11 Serial number drive shaft) – here: clockwise 12 Material number of the axial piston unit 5 Specified area for inspection stamp 13 Type code 6 Weight (optional) 7 Power RE 92003-01-B/12.2015, A4VG Series 32, Bosch Rexroth AG... -
Page 28: Transport And Storage
(pulling) axial forces are applied. ▶ For all female threads, use a stud end from the same system of units and of the correct size. Bosch Rexroth AG, A4VG Series 32, RE 92003-01-B/12.2015... - Page 29 Place the lifting strap around the axial piston unit in such a way that it does not pass over attachments (e.g., valves, piping) and that the axial piston unit is not suspended from attachments (see Fig. 8). Fig. 8: Transport with lifting strap RE 92003-01-B/12.2015, A4VG Series 32, Bosch Rexroth AG...
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Page 30: Storing The Axial Piston Unit
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” on page 56. - Page 31 The following instructions only refer to axial piston units which are operated with a mineral oil-based hydraulic fluid. Other hydraulic fluids require preservation methods that are specifically designed for them. In such cases, consult Bosch Rexroth Service, see Chapter 10.5 “Spare parts” on page 56 for the address. Bosch Rexroth recommends the following procedure: Clean the axial piston unit, see Chapter 10.1 “Cleaning and care”...
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Page 32: Installation
A check valve in the drain line (cracking pressure 0.5 bar) can prevent the system from draining through the drain line. Please note the correct flow direction. ▶ To keep noise down, decouple all connecting lines from all vibration-capable components (e.g., reservoir) using elastic elements. Bosch Rexroth AG, A4VG Series 32, RE 92003-01-B/12.2015... - Page 33 ▶ Use lint-free cloths for cleaning. ▶ Use suitable mild cleaning agents to remove lubricants and other difficult-to- remove contamination. Cleaning agents must not enter the hydraulic system. RE 92003-01-B/12.2015, A4VG Series 32, Bosch Rexroth AG...
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Page 34: Installation Position
2. To prevent unexpected actuation and damage, the stroking chambers must be air bled via the ports X , or X depending on the installation position. Bosch Rexroth AG, A4VG Series 32, RE 92003-01-B/12.2015... -
Page 35: Below-Reservoir Installation (Standard)
3 (drive shaft, vertically downward) – S + T 4 (drive shaft vertically upward) S + T 5 (drive shaft horizontal) – S + T 6 (drive shaft horizontal) – S + T RE 92003-01-B/12.2015, A4VG Series 32, Bosch Rexroth AG... -
Page 36: Above-Reservoir Installation
Baffle (baffle plate) Control pressure Stroking chamber pressure port Ports F and F are part of the external piping and must be provided on the customer side to make filling and air bleeding easier. Bosch Rexroth AG, A4VG Series 32, RE 92003-01-B/12.2015... -
Page 37: 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” on page 56. Before installing, completely empty the axial piston unit to prevent mixing with the hydraulic fluid used in the machine/system. -
Page 38: Dimensions
The type of installation to be used for the axial piston unit depends on the connecting elements to the drive side. The following descriptions explain the installation of the axial piston unit: • with a coupling • on a gearbox Bosch Rexroth AG, A4VG Series 32, RE 92003-01-B/12.2015... -
Page 39: Installation With Coupling
Details on the required tools and tightening torques for the mounting bolts are available from the machine/system manufacturer. When using flexible couplings, check that the drive is free of resonance after completing the installation. RE 92003-01-B/12.2015, A4VG Series 32, Bosch Rexroth AG... -
Page 40: 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 responsible Bosch Rexroth Service partner or the service department of the manufacturer's plant for the axial piston unit. - Page 41 Setting screws are protected against unauthorized resetting by means of tamper- proof caps. Removal of the tamper-proof caps will void the warranty. If you need to change the settings, contact your responsible Bosch Rexroth Service partner (for address, see Chapter 10.5 “Spare parts” on page 56).
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Page 42: Changing The Lever Position Of The Hw Control
(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, A4VG Series 32, RE 92003-01-B/12.2015... - Page 43 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. RE 92003-01-B/12.2015, A4VG Series 32, Bosch Rexroth AG...
- Page 44 44/68 Installation Port overview Fig. 15: Port overview A4VG, size 28 Fig. 16: Port overview A4VG size 40, 56 Fig. 17: Port overview A4VG, size 71 to 180 Bosch Rexroth AG, A4VG Series 32, RE 92003-01-B/12.2015...
- Page 45 • Mounting bolts: For mounting bolts with metric ISO thread according to DIN 13 or thread according to ASME B1.1, we recommend checking the tightening torque in individual cases in accordance with VDI 2230. RE 92003-01-B/12.2015, A4VG Series 32, Bosch Rexroth AG...
- Page 46 For relationship between direction of rotation and flow direction, please refer to data sheet 92003. Bosch Rexroth AG, A4VG Series 32, RE 92003-01-B/12.2015...
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Page 47: Electrically Connecting The Axial Piston Unit
Nm. 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 the first commissioning. To avoid internal contamination, the axial piston unit must not be included in the flushing cycle. -
Page 48: Commissioning
▶ During the commissioning process, monitor the temperature of the hydraulic fluid in the reservoir to ensure that it remains within the permissible viscosity limits. Bosch Rexroth AG, A4VG Series 32, RE 92003-01-B/12.2015... -
Page 49: 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 90220, 90221, 90222 or 90223. The titles of the data sheet can be found in Table 1 “Required and supplementary documentation”... -
Page 50: 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 designated threaded plugs. Bosch Rexroth AG, A4VG Series 32, RE 92003-01-B/12.2015... -
Page 51: Running-In Phase
10 operating hours. 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 52: Operation
Use the product only within the performance range specified in the technical data. The machine/system manufacturer is responsible for the proper project planning of the hydraulic system and its control. Bosch Rexroth AG, A4VG Series 32, RE 92003-01-B/12.2015... -
Page 53: 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 sensitive and important components, such as solenoids, valves and sensors, clean. RE 92003-01-B/12.2015, A4VG Series 32, Bosch Rexroth AG... -
Page 54: Inspection
54/68 Maintenance and repair 10.2 Inspection In order for the axial piston unit to be reliable and long-lasting, Bosch Rexroth recommends testing the hydraulic system and axial piston unit on a regular basis, and documenting and archiving the following operating conditions:... -
Page 55: Changing The Filter Element
Screw the filter housing (4) onto the filter head (1). Tighten the filter housing (4) with 45 Nm. 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 may only be performed by service centers certified by Bosch Rexroth. -
Page 56: Spare Parts
Address all questions regarding spare parts to your responsible Bosch Rexroth Service partner or the service department of the manufacturer's plant for the axial piston unit. -
Page 57: Removal And Replacement
Completely drain the axial piston unit of hydraulic fluid. Plug all openings. 11.4 Preparing the components for storage or later use ▶ Proceed as described in Chapter 6.2 “Storing the axial piston unit” on page 30. RE 92003-01-B/12.2015, A4VG Series 32, Bosch Rexroth AG... -
Page 58: Disposal
Disassemble the axial piston unit into its individual parts and properly recycle these parts. For example, separate the parts into: – Cast parts – Steel – Aluminum – Non-ferrous metal – Electronic waste – Plastic – Seals Bosch Rexroth AG, A4VG Series 32, RE 92003-01-B/12.2015... -
Page 59: Extension And Conversion
Changes to settings on the customer side should only be made using the product- specific setting instructions. The warranty by Bosch Rexroth only applies to the product as delivered. The warranty is void if the unit is modified or extended. Setting screws are protected against unauthorized resetting by means of tamper- proof caps. -
Page 60: 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, contact one of the contact addresses which can be found at: www.boschrexroth.com/addresses. Bosch Rexroth AG, A4VG Series 32, RE 92003-01-B/12.2015... -
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 92003-01-B/12.2015, A4VG Series 32, Bosch Rexroth AG... - Page 62 Control of the control device defective Check control (contact machine/system manufacturer or Bosch Rexroth Service) Wear or mechanical damage to the Replace axial piston unit axial piston unit Contact Bosch Rexroth Service Bosch Rexroth AG, A4VG Series 32, RE 92003-01-B/12.2015...
- Page 63 Check control (contact machine/system manufacturer or Bosch Rexroth Service) Wear or mechanical damage to the Replace axial piston unit axial piston unit Contact Bosch Rexroth Service Output unit defective Contact machine/system manufacturer (e.g. hydraulic motor or cylinder) RE 92003-01-B/12.2015, A4VG Series 32, Bosch Rexroth AG...
- Page 64 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 Bosch Rexroth AG, A4VG Series 32, RE 92003-01-B/12.2015...
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Page 65: Technical Data
The data sheet can be found on the Internet at www.boschrexroth.com/various/utilities/mediadirectory Additional information can be found in the online product catalog Mobile hydraulics: www.boschrexroth.com/axialkolbenpumpen The order-related technical data for your axial piston unit can be found in the order confirmation. RE 92003-01-B/12.2015, A4VG Series 32, Bosch Rexroth AG... -
Page 66: Alphabetical Index
▶ P Performance description ▶ F Piston Filling Port overview Filter 54, 55 Pressure side – changing Product description Flushing cycle Property damage Functional description – Control ▶ Q Functional test Qualifications Bosch Rexroth AG, A4VG Series 32, RE 92003-01-B/12.2015... - Page 67 ▶ T Technical data Tightening torques Tools Transportation – by hand – with eye bolt – with lifting strap Transporting Transport protection Troubleshooting ▶ U Unpacking ▶ w Warranty 18, 41, 59 Weight RE 92003-01-B/12.2015, A4VG Series 32, Bosch Rexroth AG...
- Page 68 Bosch Rexroth AG Mobile Applications Glockeraustraße 4 89275 Elchingen Germany Tel. +49 7308 82-0 [email protected] www.boschrexroth.com Your local contact can be found at: www.boschrexroth.com/addresses Subject to change Printed in Germany RE 92003-01-B/12.2015...