General Instruction Manual For Axial Piston Units
General Instruction Manualfor Axial Piston UnitsInstruction manualReplaces: 02.06RE 90300-B/06.2012English
The data specified above serve to describe theproduct. Should information be provided onuse, these are only examples of applicationsand suggestions. Information from the catalogare not assured properties. The informationgiven does not release the user from theobligation of own judgment and verification.Our products are subject to a natural wear andaging process. This document, as well as the data,specifications and other information set forth init, are the exclusive property of Bosch RexrothAG. It may not be reproduced or given to thirdparties without its consent.The original instruction manual was created inthe German language.
Contents3/52Contents1About this manual51.1Validity of the documentation51.2Required and supplementary documentation51.3Display of information61.3.1 Safety instructions61.3.2 Symbols71.3.3 Designations71.3.4 Abbreviations72Safety instructions82.1About this chapter82.2Intended use82.3Improper use92.4Personnel qualifications2.5General safety instructions102.6Product-specific safety instructions102.7Personal protective equipment123General instructions on damage to equipment and the product134Delivery contents165Product description165.1Performance description165.2Product description175.3Product identification176Transport and storage186.1Transporting the axial piston unit1896.1.1 Transporting by hand186.1.2 Transporting with lifting device186.2Storing the axial piston unit207Installation227.1Unpacking227.2Installation conditions227.3Installation position247.3.1 Below-reservoir installation (standard)247.3.2 Inside-reservoir installation247.3.3 Above-reservoir installation247.425Installing the axial piston unit7.4.1 Preparation257.4.2 Dimensions257.4.3 General instructions267.4.4 Installation with coupling267.4.5 Installation on a gearbox277.4.6 Installation with cardan shaft287.4.7 Completing installation287.4.8 Hydraulically connecting the axial piston unit297.4.9 Electrically connecting the axial piston unit327.533Peforming flushing cycleRE 90300-B/06.2012, General Instruction Manual for Axial Piston Units, Bosch Rexroth AG
4/52 Contents8Commissioning348.1First commissioning348.1.1 Filling the axial piston unit348.1.2 Testing the hydraulic fluid supply368.1.3 Performing functional test368.2Running-in phase378.3Recommissioning after standstill379Operation3810Maintenance and repair3810.1 Cleaning and care3810.2 Inspection3810.3 Maintenance3910.4 Repair4010.5 Spare parts401141Removal and replacement11.1 Required tools4111.2 Preparing for removal4111.3 Removing the axial piston unit4111.4 Preparing the components for storage or further use4112Disposal4213Extension and conversion4214Troubleshooting4314.1 How to proceed for troubleshooting4314.2 Malfunction table4415Technical data4716Alphabetical index48Bosch Rexroth AG, General Instruction Manual for Axial Piston Units, RE 90300-B/06.2012
About this manual5/521 About this manual1.1 Validity of the documentationThis documentation is valid for axial piston units supplied by Bosch Rexroth.This documentation is intended for machine/system manufacturers, fitters andservice technicians.This documentation contains important information on the safe and appropriateinstallation, transport, commissioning, operation maintenance, removal and simpletroubleshooting of the axial piston unit . Read this documentation completely and in particular the chapter 2 “Safetyinstructions” on page8 and chapter 3 “General instructions on damage toequipment and the product” on page13 before you start work with the axialpiston unit.1.2 Required and supplementary documentation Only commission the axial piston unit if the documentation marked with the booksymbolis available to you and you have understood and observed it.Table 1: Required and supplementary documentationTitleDocument numberDocument typeOrder confirmation–Contains the order-related technical data for your axial piston unit.Order confirmationInstallation drawingContains the outer dimensions, all connections and the hydrauliccircuit diagram for your axial piston unit.Please request the installationdrawing via your contact person atBosch Rexroth.Installation drawingProduct-Specific Operating InstructionsContains special information for the axial piston unit concerned.Ask your responsible contact personat Bosch Rexroth for a productspecific instruction manual for youraxial piston unit.Instruction manualProduct-specific data sheetContains the permissible technical data.The product-specific data sheetcan be found in the internet, seechapter 15 “Technical data” onpage 47.Data sheetGeneral circuit diagram of the machine or systemThe hydraulic and electrical circuit diagrams of the machine/system contain the information of the hydraulic or electrical ports.You will need these data to work with the axial piston unit as partof the machine/system.You will receive the documents fromyour machine/system manufacturer.Circuit diagramMineral-oil based hydraulic fluid and related hydrocarbonsDescribes the requirements on a mineral-oil based hydraulic fluidand related hydrocarbons for the operation with Rexroth hydrauliccomponents, and assists you in selecting a hydraulic fluid for yourhydraulic system.RE 90220Data sheetEnvironmentally acceptable hydraulic fluidsDescribes the requirements on an environmentally acceptablehydraulic fluid for operation with Rexroth hydraulic componentsand assists you in selecting a hydraulic fluid for your hydraulicsystem.RE 90221Data sheetFire-resistant, water-free hydraulic fluids (HFDU/HFDR)Describes the requirements on fire-resistant, water-free hydraulicfluids for operation with Rexroth hydraulic components andassists you in selecting a hydraulic fluid for your hydraulic system.RE 90222Data sheetRE 90300-B/06.2012, General Instruction Manual for Axial Piston Units, Bosch Rexroth AG
6/52About this manualTable 1: Required and supplementary documentationTitleDocument numberDocument typeInformation of the use of hydrostatic drives at low temperaturesContains additional information on the use of Rexroth axial pistonunits at low temperatures.RE 90300-03-BManualStorage and preservation of axial piston unitsContains additional information on storage and preservation.RE 90312Data sheet1.3 Display of informationStandardized safety instructions, symbols, terms and abbreviations are used so thatyou can use this documentation to work quickly and safely with your product. To giveyou a better understanding they are explained in the sections below.1.3.1 Safety instructionsThis documentation includes safety instructions in chapter 2.6 “Product-specificsafety instructions” on page 10 and in chapter 3 “General instructions on damageto equipment and the product” on page13 and before a sequence of actions or aninstruction for action involving a risk of personal injury or damage to equipment.The described danger prevention measures must be observed.Safety instructions are set out as follows:Signal wordType and source of danger!Consequences in case of noncompliance Measure for danger prevention List Safety sign: draws attention to the danger Signal word: identifies the degree of the danger Type and source of danger: identifies 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 avoidedTable 2: Danger classes in accordance with ANSI Z535.6-2006Safety sign, signal wordMeaningDANGERIdentifies a dangerous situation that will result in death orserious injuries if it is not avoided.WARNINGIdentifies a dangerous situation that may result in death orserious injuries if it is not avoided.CAUTIONNOTEIdentifies a dangerous situation that may result in minor tomoderate injuries if it is not avoided.Damage to equipment: the product or the environment maybe damaged.Bosch Rexroth AG, General Instruction Manual for Axial Piston Units, RE 90300-B/06.2012
About this manual7/521.3.2 SymbolsThe following symbols mark notes that are not safety-relevant but which increase theunderstanding of the documentation.Table 3: Meaning of the symbolsSymbolMeaningIf this information is disregarded, the product can not be usedand/or operated to the optimum extent. Single, independent step1.Numbered instruction:The numbers specify that the steps are completed one after the other.2.3.1.3.3 DesignationsThis documentation uses the following designations:Table 4: DesignationsDesignationMeaningThreaded plugMetal screw, pressure-resistantProtective plugMade out of plastic, not pressure-resistant, only for transportation1.3.4 AbbreviationsThis documentation uses the following abbreviations:Table 5: AbbreviationsAbbreviationMeaningATEXEU directive for explosion protection (Atmosphère explosible)DINDeutsche Industrie Norm (German Institute for Standardization)ISOInternational Organization for StandardizationJISJapan Industrial StandardRERexroth document in the English languageVDI 2230Directive for the systematic calculation of high duty bolted joints and jointswith one cylindrical bolt from the VDI (Verein Deutscher Ingenieure –Association of German Engineers)RE 90300-B/06.2012, General Instruction Manual for Axial Piston Units, Bosch Rexroth AG
8/52Safety instructions2 Safety instructions2.1 About this chapterThe axial piston unit has been manufactured according to the generally acceptedrules of current technology. There is, however, still a danger of personal injuryor damage to equipment if this chapter and the safety instructions in thisdocumentation are not complied with. Read this documentation completely and thoroughly before working with the axialpiston unit. Keep this documentation in a location where it is accessible to all users at alltimes. Always include the required documentation when you pass the axial piston uniton to third parties.2.2 Intended useAxial piston units are hydraulic components, meaning that in their application theyare classified neither as complete nor as incomplete machines in the sense of theEU machine directive 2006/42/EC. A component is exclusively intended to form anincomplete or a complete machine together with other components. The componentmay only be commissioned after it has been installed in the machine/system forwhich it is intended and the safety of the entire system has been established inaccordance with the machine directive.The product is intended for the following use:ProductUseAxial piston pump inopen circuitThe axial piston unit is only approved as a pump for hydrostatic drivesin open circuit.Axial piston pump inclosed circuitThe axial piston unit is only approved as a pump for hydrostatic drivesin closed circuit.Plastic feed pumpThe axial piston unit is only approved for pumping polyurethanecomponents (polyol and isocynate).Axial piston motorThe axial piston unit is only approved for use as a hydraulic motor inhydrostatic drives. Observe the technical data, application and operating conditions andperformance limits as specified in the product-specific data sheet and in theorder confirmation. Information about approved hydraulic fluids can be found inthe product-specific data sheet.The axial piston unit is only intended for professional use and not for private use.Intended use includes having read and understood the complete documentation,especially the chapter 2 “Safety instructions” on page 8.Bosch Rexroth AG, General Instruction Manual for Axial Piston Units, RE 90300-B/06.2012
Safety instructions9/522.3 Improper useAny use other than that described as intended use shall be considered as improperand is therefore impermissible.Bosch Rexroth AG shall accept no liability whatsoever for damage resulting fromimproper use. The user shall bear all risks arising from improper use.Similarly, the following foreseeable faulty usages are also considered to be improper: Using outside the operating parameters approved in the product-specific datasheet or in the order confirmation (unless customer-specific approval has beengranted) Use for non-approved fluids, e.g. water or polyurethane components (exception:plastic feed pump) Modification of factory settings by non-authorized persons Use of add/on parts (e.g. mountable filter, control unit, valves) that are notspecified Rexroth components Using the axial piston unit under water at a depth of more than 10 meters withoutnecessary additional measures, e.g. pressure equalization Using the axial piston unit when the exterior pressure is greater than the interiorpressure (case pressure) Using the axial piston unit in explosive environments unless the component ormachine/system has been certified as compliant with the ATEX directive 94/9/EC Using the axial piston unit in an aggressive atmosphere Using the axial piston unit in aircraft or space craft2.4 Personnel qualificationsThe activities described in this documentation require basic mechanical, electricaland hydraulic knowledge, as well as knowledge of the associated technical terms.For transporting and handling the product, additional knowledge is necessary withregard to working with a lifting device and the corresponding attachment equipment.In order to ensure safe use, these activities may therefore only be carried out byappropriate qualified personnel or an instructed person under the direction andsupervision of qualified personnel.Qualified personnel are those who can recognize possible hazards and institutethe appropriate safety measures due to their professional training, knowledge, andexperience, as well as their understanding of the relevant regulations pertainingto the work to be done. Qualified personnel must observe the rules relevant to thesubject area and have the necessary hydraulic knowledge.Hydraulic knowledge means, for instance: reading and fully understanding hydraulic plans, fully understanding in particular the interrelationships regarding safety devices, and having knowledge on the function and assembly of hydraulic components.Bosch Rexroth offers training support for special fields. You can find an overviewof the training contents on the internet at:http://www.boschrexroth.de/didactic.RE 90300-B/06.2012, General Instruction Manual for Axial Piston Units, Bosch Rexroth AG
10/52Safety instructions2.5 General safety instructions Observe the applicable accident prevention and environmental protectionregulations. Observe the safety regulations and provisions of the country in which the productis used/operated. Use Rexroth products only when they are in good technical order and condition. Observe all notes on the product. Persons who install, operate, remove or maintain Rexroth products must notconsume any alcohol, drugs or pharmaceuticals that may affect their ability torespond. Only use Rexroth original accessories and spare parts to ensure there is no risk topersons from unsuitable spare parts. Conform to the technical data and ambient conditions specified in the productdocumentation. If unsuitable products are installed or used in applications that are of relevanceto safety, unexpected operating conditions may occur in the application whichcould result in injury to persons or property damage. For this reason, only usethe product in a safety-relevant application if this use is expressly specified andpermitted in the product documentation, for example in ex-protection applicationsor in safety-related parts of a control system (functional safety). You may only commission the product if it has been determined that the endproduct (e.g. machinery or a system) into which the Rexroth products are installedcomplies with the country-specific provisions, safety regulations and standards ofthe application.2.6 Product-specific safety instructionsThe following safety instructions apply for chapters 6 to 14.WARNINGDanger from excessively high pressure!Danger to life or risk of injury, damage to equipment!Incorrectly changing the factory pressure setting can cause pressure to increasebeyond the permissible maximum pressure.Operating the unit above the permissible maximum pressure can causecomponents to burst and hydraulic fluid to escape under high pressure. Changes to the factory settings must only be made by Bosch Rexroth specialistpersonnel. In addition, a pressure-relief valve is needed as back-up in the hydraulic system.If the axial piston unit is equipped with a pressure cut-off and/or a pressurecontrol, this is not an adequate back-up against pressure overload.Bosch Rexroth AG, General Instruction Manual for Axial Piston Units, RE 90300-B/06.2012
Safety instructions11/52WARNINGDanger from suspended loads!Danger to life or risk of injury, damage to equipment!Improper transportation may cause the axial piston unit to fall down lead to injuriese.g. crushing or broken bones or damage to the product. Make certain that the forklift truck or lifting device has adequate lifting capacity. Never stand under or put you hands under suspended loads. Ensure your position is stable during transportation. Use your personal protective equipment (e.g. safety glasses, safety gloves,suitable working clothes, safety shoes). Use suitable lifting devices for transportation. Observe the prescribed position of the lifting strap. Observe the national laws and regulations on work and health protection andtransportation.Pressurized machine/system!Danger to life or risk of injury, serious injuries when working on machines/systemsnot shutdown! Damage to equipment! Protect the complete system against being energized. Make sure that the machine/system is depressurized. Please follow the machine/system manufacturer’s instructions. Do not disconnect any line connections, ports and components when themachine/system is pressurized. Switch off all power-transmitting components and connections (electric,pneumatic, hydraulic, mechanical) in accordance with the manufacturer'sinstruction and secure them against being switched back on.Escaping oil mist!Risk of explosion, fire, health hazard, environmental pollution! Depressurize the machine/system and repair the leak. Only perform welding work then the machine/system is depressurized. Keep open flames and ignition sources away from the axial piston unit. If axial piston units are to be situated in the vicinity of ignition sources orpowerful thermal radiators, a shield must be erected to ensure that any escapedhydraulic fluid can not ignite, and to protect hose lines from premature aging.Electrical voltage!Risk of injury due to electric shock or damage to equipment! Always set up the relevant part of the machine/system so that it is free ofelectrical voltage before you install the product or when connecting anddisconnecting plugs. Protect the machine/system against being energized.RE 90300-B/06.2012, General Instruction Manual for Axial Piston Units, Bosch Rexroth AG
12/52Safety instructionsCAUTIONHigh noise development in operation!Danger of hearing damage, deafness!The noise emission of axial piston units depends on speed, operating pressure andinstallation conditions. The sound pressure level may rise above 70 dBA duringnormal application conditions. Always wear hearing protection when in the vicinity of the operating axial pistonunit.Hot surfaces on the axial piston unit!Risk of burns! Allow the axial piston unit to cool down sufficiently before touching it. Wear heat-resistant protective clothing, e.g. gloves.Improper routing of cables and lines!Tripping hazard and damage to equipment! Lay cables and lines so that they can not be damaged and nobody can trip overthem.Contact with hydraulic fluid!Hazard to health/health impairment e.g. eye injuries, skin damage, toxication duringinhalation! Avoid contact with hydraulic fluids. When working with hydraulic fluids, strictly observe the safety instructionsprovided by the lubric
Bosch Rexroth AG, General Instruction Manual for Axial Piston Units, RE 90300-B/06.2012 8 Commissioning34 8.1 First commissioning 34 8.1.1 Filling the axial piston unit 34 8.1.2 Testing the hydraulic fluid supply 36 8.1.3 Performing functional test 36 8.2 Running-in phase
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Total Sevice Axial load 765 630 kN 1395 kN Ultimate axial load 1.2 765 1.6 630 1926 kN Column type (2): Axial 2unfactored Dead load 42.5 kN/m2 4 7 m 1190 kN Axial unfactored Live 2load 35 2kN/m 4 7 m 980 kN Total Sevice Axial load 1190 980 kN 2170 kN Ultimate axial load 1.2 1190 1.6 980 2996 kN
