Bosch rexroth HS5E User manual

Instruction manual
RE92076-01-B/2021-04-22, replaces: 10.2017, DE
Control system HS5E(V)(L)
for Axial piston variable pump
A4VSO, A4VBO, A4VSG and A4CSG

© BoschRexrothAG 2021. 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. Theinformation given does
notrelease the user from the obligation of own
judgment and verification. It must be remembered
that our products are subject to anatural process of
wear and aging.
The cover shows an example application. The
product delivered may differ from the image on the
cover.
The original operating instructions were created in
German.

RE92076-01-B/2021-04-22, BoschRexrothAG
Contents | A4... with HS5E(V)(L) control system Series 1x and 30 3/104
1 About this documentation ........................................................................ 6
1.1 Validity of the documentation ......................................................................6
1.2 Required and supplementary documentation...............................................6
1.3 Representation of information......................................................................7
1.3.1 Safety instructions .......................................................................................7
1.3.2 Symbols .......................................................................................................8
1.3.3 Designations ................................................................................................9
1.3.4 Abbreviations ...............................................................................................9
2 Safety instructions ................................................................................. 10
2.1 About this chapter......................................................................................10
2.2 Intended use ..............................................................................................10
2.3 Improper use..............................................................................................11
2.4 Personnel qualifications .............................................................................11
2.5 General safety instructions .......................................................................12
2.6 Product-specific safety instructions ..........................................................13
2.7 Personal protective equipment...................................................................17
3 General instructions on property damage and product damage.............. 18
4 Scope of delivery.................................................................................... 21
5 About this product ................................................................................. 22
5.1 Performance description............................................................................22
5.2 Product description ...................................................................................22
5.2.1 Axial piston unit layout...............................................................................22
5.2.2 Functional description HS5E(L) .................................................................23
5.2.3 Functional description HS5EV ....................................................................23
5.3 Parallel and cascade control of the HS5E(V)(L) control system.................24
5.3.1 Parallel control structure ...........................................................................25
5.3.2 Cascading control structure .......................................................................26
5.3.3 Controller parameters (parallel) ................................................................27
5.3.4 Control parameter sets ..............................................................................27
5.3.5 Special operating modes............................................................................27
5.3.6 Working pressure limits..............................................................................29
5.4 Ambient conditions ....................................................................................31
5.4.1 Oil-immersed applications .........................................................................31
5.4.2 Ambient temperature .................................................................................31
5.5 Notes on the selection of hydraulic fluids ..................................................31
5.6 Noise development ....................................................................................31
5.6.1 Noise development in the unit ...................................................................32
5.6.2 Pulsation damper .......................................................................................32
5.7 Master/slave operation..............................................................................32
5.7.1 Circuitry of HS5E(V)(L) ..............................................................................33
5.8 Description of the IndraWorks commissioning tool ....................................35
5.8.1 System requirements .................................................................................35
5.8.2 Firmware update ........................................................................................36
5.9 Switch-on sequence of electronics/hydraulics ...........................................36
5.10 Product identification.................................................................................37
6 Transport and storage ............................................................................ 38
Contents

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BoschRexrothAG, RE92076-01-B/2021-04-22
6.1 Transporting the axial piston unit...............................................................38
6.1.1 Transport with lifting devices .....................................................................38
6.2 Storing the axial piston unit .......................................................................40
7 Installation............................................................................................. 42
7.1 Unpacking ..................................................................................................42
7.2 Installation conditions................................................................................42
7.3 Installation position ...................................................................................44
7.3.1 Below-reservoir installation (standard)......................................................44
7.3.2 Above-reservoir installation........................................................................44
7.4 Installing the axial piston unit....................................................................45
7.4.1 Preparation ................................................................................................45
7.4.2 Dimensions ................................................................................................46
7.4.3 General instructions...................................................................................46
7.4.4 Installation with acoupling........................................................................47
7.4.5 Installation on agearbox............................................................................48
7.4.6 Installation with cardan shaft.....................................................................48
7.4.7 Completion of assembly.............................................................................48
7.4.8 Hydraulically connecting the axial piston unit............................................50
7.4.9 Electrically connecting the axial piston unit...............................................56
7.5 Performing flushing cycle...........................................................................57
7.6 Electrically connecting the HS5E(V)(L) control system ..............................57
7.6.1 Cable sets ..................................................................................................57
7.6.2 Wiring the electronic components..............................................................57
7.6.3 Connection to the swivel angle sensor .......................................................58
7.6.4 X2M1 and X2M2: Analog, configurable pressure sensor interface (coding A),
M12, 5-pin, socket......................................................................................58
7.6.5 X7E1 and X7E2: Plug-in connector assignment for Ethernet interface
(codingD), M12, 4-pin, socket ...................................................................59
7.6.6 LED status indicators .................................................................................59
7.6.7 Voltage supply of the HS5E pilot control valve ...........................................60
7.6.8 Selection, installation location, and installation direction of the pressure
transducer..................................................................................................61
8 Commissioning....................................................................................... 63
8.1 Initial commissioning .................................................................................65
8.1.1 Filling the axial piston unit.........................................................................65
8.1.2 Testing the hydraulic fluid supply...............................................................66
8.1.3 Performing afunctional test.......................................................................67
8.1.4 Connection to the control (IndraWorks).....................................................67
8.1.5 Making the basic setting on the control electronics ...................................68
8.1.6 Switching on the drive motor of the pump .................................................75
8.1.7 Setting controller parameters ....................................................................76
8.1.8 Calibrating the HS5E(V)(L) control system.................................................80
8.1.9 Saving parameters......................................................................................82
8.2 Running-in phase .......................................................................................82
8.3 Recommissioning after standstill ...............................................................83
9 Operation ............................................................................................... 84
10 Maintenance and repair.......................................................................... 85
10.1 Cleaning and care ......................................................................................85

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Contents | A4... with HS5E(V)(L) control system Series 1x and 30 5/104
10.2 Inspection ..................................................................................................86
10.3 Maintenance...............................................................................................86
10.4 Repair ........................................................................................................87
10.5 Spare parts ................................................................................................87
10.5.1 Replacement of components.....................................................................87
11 Removal and replacement ...................................................................... 90
11.1 Required tools............................................................................................90
11.2 Preparing for removal.................................................................................90
11.3 Performing the removal..............................................................................90
11.4 Preparing the components for storage or further use.................................90
12 Disposal ................................................................................................. 91
13 Extension and conversion....................................................................... 91
14 Troubleshooting ..................................................................................... 92
14.1 How to proceed for troubleshooting...........................................................92
14.2 Error/diagnosis memory.............................................................................93
14.2.1 Fault diagnosis ...........................................................................................93
14.3 Malfunction table .......................................................................................94
14.3.1 Swivel angle measurement check.............................................................100
15 Technical data ...................................................................................... 101
16 Alphabetical index ............................................................................... 102

6/104 A4... with HS5E(V)(L) control system Series 1x and 30 | About this documentation
BoschRexrothAG, RE92076-01-B/2021-04-22
1 About this documentation
1.1 Validity of the documentation
This documentation is valid for axial piston units with an HS5E(V)(L) control system:
• Axial piston variable pump A4VSO
• Axial piston variable pump A4VSG
• Axial piston variable pump A4CSG
• Axial piston variable pump A4VBO
This documentation is intended for project engineers, operators, machine/system
manufacturers, assemblers and service engineers.
This documentation contains important information on safe and proper
transportation, assembly, commissioning, operation, maintenance, removal,
and simple troubleshooting of the A4... with HS5E(V)(L) control system.
▶ Read this documentation completely, in particular the chapters entitled 2
"Safety instructions" page10 and 3 "General instructions on damage to
equipment and the product" on page18 before you start work with the
A4... with HS5E(V)(L) control system.
1.2 Required and supplementary documentation
▶ Only commission the axial piston unit if the documentation marked with the book
symbol is available to you and you have understood and observed it.
Table 1: Required and supplementary documentation
Title Document number Document type
Order confirmation
Contains the order-related technical data for your axial piston variable
pump A4... with HS5E(V)(L) control system.
– Order confirmation
Installation drawing
Contains the outer dimensions, all ports and the hydraulic
circuit diagram for your axial piston variable pump
A4... with HS5E(V)(L) control system.
Please request the installation
drawing from your contact at
Bosch Rexroth.
Installation drawing
Axial piston variable pump A4... with HS5E(V)(L) control system
Contains the permissible technical data, ports, main dimensions and
circuit diagrams of standard versions.
92076 Data sheet
Axial piston variable pump A4VSO
Axial piston variable pump A4VSG
Axial piston variable pump A4CSG
Axial piston variable pump A4VBO
Contains the permissible technical data, ports, main dimensions and
circuit diagrams of standard versions.
92050
92100
92105
92122
Data sheet
Axial piston variable pump A4VSO for HFC hydraulic fluids
Contains the permissible technical data.
92053 Data sheet
Swivel angle sensor typeVT-SWA-Lin-1x/G15
Contains the permissible technical data.
30263 Data sheet
Pressure transducer with integrated electronics type HM 20
Contains the permissible technical data.
30272 Data sheet

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Table 1: Required and supplementary documentation
Title Document number Document type
Hydraulic fluids based on mineral oils and related hydrocarbons
Describes the requirements for mineral oil-based hydraulic fluids and
related hydrocarbons for operation with Rexroth hydraulic components
and provides support for selection of suitable hydraulic fluids for the
hydraulic system.
90220 Data sheet
General Instruction Manual for Axial Piston Units
Contains additional information on the use of Rexroth axial piston units.
90300-B Instruction manual
Instruction Manual for Axial Piston Unit A4VSO
Instruction Manual for Axial Piston Unit A4VSG
Instruction Manual for Axial Piston Unit A4CSG
Instruction Manual for Axial Piston Unit A4VBO
Contains additional information on the use of Rexroth axial piston units.
92050-01-B
92100-01-B
92105-01-B
92122-01-B
Instruction manual
Information on the application of hydrostatic drives at low
temperatures
Contains additional information on the application of Rexroth axial
piston units at low temperatures.
90300-03-B Manual
Storage and preservation of axial piston units
Contains additional information on storage and preservation.
90312 Data sheet
Rexroth HydraulicDrive functions
(firmware and software descriptions)
30338-FK Functional
description
Rexroth HydraulicDrive functions
(firmware and software descriptions) Additional information
30237-Z Functional
description
Rexroth HydraulicDrive functions
(Parameter description)
30330-PA Parameter
description
Rexroth HydraulicDrive functions
(Description of diagnosis)
30330-WA Description of
diagnosis
Rexroth HydraulicDrive functions
(Firmware description)
30330-RN Firmware
description
Pressure transducer with integrated electronics, type HM 20 30272-MON Assembly
instructions
Installation, commissioning and maintenance of hydraulic systems 07900 Data sheet
Declaration of environmental compatibility 30030-U Environment data
sheet
1.3 Representation of information
Standardized safety instructions, symbols, terms and abbreviations are used
throughout this documentation so that you can work quickly and safely with your
product. For clarification, they are explained in the sections below.
1.3.1 Safety instructions
In this documentation, safety instructions appear in the chapter 2.6"Product-specific
safety instructions" on page13 and in the chapter 3"General instructions on
material damage and product damage" on page18 as well as before asequence of
actions or before action instructions in which there is adanger of personal injury or
property damage. Always follow the measures for danger prevention associated with
the use of this product.

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BoschRexrothAG, RE92076-01-B/2021-04-22
Safety instructions are set out as follows:
SIGNAL WORD
Type and source of danger!
Consequences of noncompliance
▶ Danger prevention measures
•Warning sign: draws attention to the danger
•Signal word: identifies the degree of the danger
•Type and source of danger: indicates the type and source of the danger
•Consequences: describes what occurs if safety instructions are disregarded
•Precautions: states how the danger can be avoided
Table 2: Hazard classes as defined in ANSI Z535.6
Warning sign, signal word Meaning
DANGER Identifies adangerous situation that will result in death or
serious injury if it is not avoided.
WARNING Identifies adangerous situation that may result in death or
serious injury if it is not avoided.
CAUTION Identifies adangerous situation that may result in minor to
moderate injury if it is not avoided.
NOTICE Property damage: The product or surrounding area may be
damaged.
1.3.2 Symbols
The following symbols indicate notices that are not safety-relevant but increase
understanding of the documentation.
Table 3: Meaning of symbols
Symbol Meaning
If this information is disregarded, the product cannot be used and/or
operated to its full extent.
▶ Single, independent action
1.
2.
3.
Numbered instruction:
The numbers indicate that the actions must be completed in order.

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1.3.3 Designations
This documentation uses the following designations:
Table 4: Designations
Designation Meaning
A4VSO Axial piston variable pump, open circuit
A4VSG Axial piston variable pump, closed circuit
A4CSG Axial piston variable pump, closed circuit
A4VBO Axial piston variable pump, open circuit, high-pressure unit
HS5E Control system with integrated On Board Electronics
and external control pressure supply
HS5EV, HS5EL Control system with integrated On Board Electronics
and internal control pressure supply
FWA-HYDRV-HDB-XXVXX Firmware for HydraulicDrive
HM20 Pressure transducer, Type HM20
IndraWorks Service tool for commissioning, parameterizing, and diagnosing the
HydraulicDrive
VT-SWA-Lin-1X/G15 Swivel angle sensor
As umbrella term for "Axial piston variable pump A4VSO, A4VBO and A4VSG,
A4CSG", the designation "Axial piston unit" will be used in the following.
1.3.4 Abbreviations
This documentation uses the following abbreviations:
Table 5: Abbreviations
Abbreviation Meaning
ATEX EC directive on explosion protection (Atmosphère explosible)
DB Pressure relief valve
PT Pressure Transducer
EMC Electromagnetic compatibility
GND Ground
n.c. not connected
p Pressure (character in formulas)
PC Personal Computer
PCV Precompression Volume
pdiff Control difference between the pressure command value and the actual
pressure value
PE Protective Earth
pactual Actual pressure value
Pset Pressure command value
SW Swivel angle
SWact Swivel angle actual value
SWset Swivel angle command value
URSupply voltage
DIN Deutsches Institut für Normung (German Institute for Standardization)
ISO International Organization for Standardization
JIS Japan Industrial Standard
RE 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)

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BoschRexrothAG, RE92076-01-B/2021-04-22
2 Safety instructions
2.1 About this chapter
The HS5E(V)(L) control system has been manufactured according to the generally
accepted rules of current technology. There is still, however, arisk of personal injury
or property damage if this chapterand the safety instructions in this documentation
are not observed.
▶ Read this documentation completely and thoroughly before working with the
HS5E(V)(L) control system.
▶ Keep this documentation in alocation where it is accessible to all users at all
times.
▶ Always include the required documentation when you pass the axial piston unit
on to third parties.
2.2 Intended use
The HS5E(V)(L) control system is ahydraulic component, which means that in
its field of application, it is classified neither as complete nor as partly complete
machinery in the sense of EC Machinery Directive 2006/42/EC. The component is
exclusively intended to form partly completed machinery or complete machinery
together with other components. The component should only be commissioned after
it has been installed in the machine/system for which it is intended, and the safety of
the entire system has been established in accordance with the Machinery Directive.
This product is intended for the following use:
The pressure flow control system is used for the electro-hydraulic pressure and
swivel angle control and torque limitation of an axial piston variable pump type
A4VSO, A4VBO, A4VSG or A4CSG.
▶ Observe the technical data, the application and operating conditions and the
performance limits according to the data sheets listed on page6 and the
order confirmations.
The HS5E(V)(L) control system is apiece of technical work equipment and it is not
intended for personal use.
Intended use includes having completely read and understood this documentation,
especially the chapter on 2 "Safety instructions".
Operation is only allowed if you comply with national EMC regulations for the
present application. If you need information about EMC-compliant installation,
refer to Bosch Rexroth’s EMC test documentation (seedata sheet 92076). Ensuring
compliance with the limit values required by national regulations is the responsibility
of the manufacturer of the system or machine.
• European countries: EC directive 2014/30/EU (EMC Directive)
• USA: See the national electrical system regulations (NEC), National organization
of the manufacturers of electrical systems (NEMA) as well as regional building
regulations.
▶ Observe the technical data, the application and operating conditions and the
performance limits as specified in the data sheet 92076 and in this document
and in the order confirmation. Information about approved hydraulic fluids can be
found in data sheet 92076.
The axial piston unit is only intended for commercial use and not for private use.

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2.3 Improper use
Any use other than that described as intended use is considered improper.
BoschRexrothAG is not liable for damages 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):
• Use outside the operating parameters approved in the data sheet and in the order
confirmation (unless specifically approved by the customer)
• Use of non-approved fluids, e.g.water or polyurethane components
• Changes to factory settings by unauthorized persons.
• Use of assembled parts (e.g.control unit, valves) not in combination with the
specified Rexroth components
• Use of the axial piston unit with assembled parts under water at adepth of more
than 10 meters without the necessary additional measures, for example pressure
equalization. Units with electrical components (e.g.sensors) generally cannot
come into contact with water.
• Use of the axial piston unit under acontinuous pressure differential between
housing and ambient pressure greater than 2bar, with the ambient pressure always
lower than the case pressure. Momentary (t< 0.1 s) pressure peaks of up to 4bar
are allowed. Beyond this, the maximum permissible case pressure specified in the
data sheet should not be exceeded.
• If you do not comply with the domestic EMC regulations for the present
application. If you need information about EMC-compliant installation, refer
to Bosch Rexroth’s EMC test documentation (seedata sheet 92076). Ensuring
compliance with the limit values required by national regulations is the
responsibility of the manufacturer of the system or machine (European countries:
EC directive 2014/30/EU (EMC Directive); USA: See the national electrical system
regulations (NEC), National organization of the manufacturers of electrical systems
(NEMA) as well as regional building regulations
• Use of the HS5E(V)(L) control system in an explosive environment unless the
component or machine/system has been certified as being compliant with ATEX
directive 2014/34/EU.
• Use of the axial piston unit in acorrosive atmosphere
• Use of the axial piston unit in aircraft or spacecraft
2.4 Personnel qualifications
The activities described in this documentation require abasic understanding of
mechanics, electricity and hydraulics, as well as familiarity with associated technical
terms. For transporting and handling the product, knowledge regarding the use of
lifting devices and lifting accessories is required. In order to ensure safe use, these
activities should only be performed by skilled personnel or an instructed person
under the direction and supervision of skilled personnel.
Skilled personnel refers to persons who possess the professional training,
knowledge and experience, as well as the understanding of the regulations relevant
to the work to be done that are necessary to recognize possible dangers and take
the appropriate safety measures. Skilled personnel must follow the rules relevant
to their field and have the necessary expert knowledge of hydraulics and electrical
systems.

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Hydraulic expert knowledge includes:
• Being able to read and fully understand hydraulic circuit diagrams
• In particular, fully understanding the relationships with regard to safety devices
• comprising of knowledge regarding the function and layout of hydraulic
components.
Expert knowledge of electrical systems includes:
• Reading and fully understanding electrical circuit diagrams,
• In particular, fully understanding the relationships with regard to safety devices
• and understanding how electrical components function and are put together.
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.
2.5 General safety instructions
• Observe applicable accident prevention and environmental protection regulations.
• Observe the safety regulations of the country in which the product is
used/operated.
• Use Rexroth products only when they are in good working order.
• Observe all notices on the product.
• Do not assemble, operate, remove or maintain Rexroth products if under the
influence of alcohol, drugs or medication that may affect your reaction time.
• Only use genuine Rexroth accessories and spare parts to ensure there is no hazard
to persons from unsuitable spare parts.
• Observe the technical data and ambient conditions specified in the product
documentation.
• If unsuitable products are installed or used in applications that are of relevance to
safety, unexpected operating conditions may occur in the application, which could
result in personal injury or property damage. For this reason, only use the product
in safety-relevant applications if this use is expressly indicated and approved in the
product documentation, e.g.in explosion protection areas or in safety-related parts
of acontrol system (functional safety).
• Only commission the product if it has been determined that the end product
(e.g.machinery/system) in which the Rexroth products are installed complies
with the country-specific provisions, safety regulations and standards for the
application.
• Use tools appropriate for the work being performed and wear appropriate
protective clothing to prevent punctures and cuts (e.g.when removing protective
covers, disassembly).
• There is arisk of entanglement when operating the axial piston unit with abare
shaft end. Check whether or not your machine requires additional safety measures
for your application. If necessary, make sure these are appropriately implemented.
•
• Depending on the type of control used, electromagnetic effects can be produced
when using solenoids. Applying adirect voltage signal (DC) to solenoids does not

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create electromagnetic interference (EMI) nor is the solenoid affected by EMI.
Potential electromagnetic interference (EMI) exists if the solenoid is energized
with amodulated direct current (e.g.PWM signal). The machine manufacturer
should conduct appropriate tests and take appropriate measures to ensure that
other components or operators (e.g.with apacemaker) are not affected by this
potentiality.
2.6 Product-specific safety instructions
The following safety instructions apply to chapters 3 to 11.
WARNING
Danger from excessive pressure!
Risk of death or injury, or property damage!
Improperly changing the factory pressure settings can result in apressure increase
beyond the maximum permissible pressure.
Operating the unit above the maximum permissible pressure can cause
components to burst and hydraulic fluid to escape under high pressure.
High pressures can result due to deactivation of pressure control, using apressure
sensor that is not parameterized in the electronic system, parameterizing the
electronics parameters incorrectly, or setting the wrong command values.
▶ Changes to the factory settings may only be made by Bosch Rexroth specialists.
▶ In addition, apressure relief valve is required in the hydraulic system as back-
up. If the axial piston unit is equipped with apressure cut-off and/or pressure
controller, this is not an adequate safeguard against pressure overload.
Danger due to suspended loads!
Risk of death or injury, or property damage!
Improper transportation may cause the axial piston unit to fall down and lead to
injury, e.g.crushing or fracture, or damage to the product.
▶ Make sure that the load bearing capacity of the lifting device is sufficient to
safely bear the weight of the axial piston unit.
▶ Never stand or reach under suspended loads.
▶ Ensure astabletransport position.
▶ Use your personal protective equipment (e.g.safety goggles, safety gloves,
suitableworking clothes, safety shoes).
▶ Use suitablelifting devices for transport.
▶ Observe the prescribed position of the lifting strap.
▶ Observe the national laws and regulations on occupational health and safety,
and transportation.

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WARNING
System/machine under pressure!
Risk of death or serious injury when working on unsecured machines/systems!
Property damage!
▶ Switch off the relevant machine/system part and secure these against
reactivation according to the parameters by the machine/system manufacturer.
▶ Ensure that all relevant components of the hydraulic system are depressurized.
For this purpose, observe the parameters indicated by the machine/system
manufacturer.
▶ When working at hydraulic systems with stored pressure energy
(e.g.accumulators), hydraulic components may even be pressurized after the
pressure supply has been switched off. During work, hydraulic fluid may escape
or hydraulic components may fly around and cause serious injuries. Before
starting work at the system, ensure that the hydraulic system is depressurized.
▶ Please note that the hydraulic system might still be pressurized even after
separation from the actual pressure supply.
▶ Do not disconnect any line connections, ports or components as long as the
hydraulic system is under pressure.
Escaping hydraulic fluid mist!
Risk of explosion and fire hazard, health hazard, risk of environmental pollution!
▶ Depressurize the relevant machine/system component and repair the leak.
▶ Only perform welding work when the machine/system is depressurized.
▶ Keep open flames and ignition sources away from the axial piston unit.
▶ If axial piston units are located in the vicinity of ignition sources or powerful
thermal radiators, ashield must be erected to ensure any escaping hydraulic
fluid cannot be ignited, and to protect hose lines from premature aging.
Hydraulic fluid will explode when making contact with water!
Risk of explosion and fire!
▶ Do not bring hot hydraulic fluids in contact with water.
Electrical voltage!
Danger to life or risk of injury due to electric shock or property damage!
▶ Always diskonnect the voltage supply to the relevant machine/system part
before assembling the product and/or connecting or diskonnecting the
connector. Protect the machine/system against being re-energized.

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WARNING
Danger from unexpected machine movement!
Danger to life or risk of injury! Unintentional or careless actuation of the manual
override of the solenoids can cause unexpected machine movements.
▶ Use the manual override only for functional testing or in the event of technical
malfunctions.
▶ Using the manual override on apermanent basis (e.g.by wedging, blocking) is
not permitted.
▶ The use of the manual override is only permitted with limited technical data
(e.g.0.25 ×maximum data).
▶ 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.
Restriction of control function!
Risk of injury or property damage!
Under certain circumstances, moving parts in control equipment (e.g.valve spools)
can get stuck in an undefined position due to contamination (e.g.impure hydraulic
fluid, abrasion or residual dirt from components). As aresult, the hydraulic fluid flow
and the build-up of torque in the axial piston unit can no longer respond correctly
to the operator’s specifications. Even the use of various filter elements (external or
internal flow filtration) will not rule out afault but merely reduce the risk.
▶ Check whether your application requires remedial measures on your machine in
order to bring the driven consumer to asafe position (e.g.safe stop).
▶ If necessary, make sure these are appropriately implemented.
Escaping hydraulic fluid due to leakage of machine/system components!
Risk of burning and risk of injury due to escaping hydraulic fluid jet!
▶ Depressurize the relevant machine/system component and repair the leak.
▶ Never attempt to block or seal the leak or hydraulic fluid jet with acloth.
CAUTION
High noise development during operation!
Risk of hearing damage or hearing loss!
The noise emission of axial piston units depends on rotational speed, working
pressure and installation conditions, among other factors. The sound pressure level
may rise above 70 dB (A) in certain application conditions.
▶ Always wear hearing protection near arunning axial piston unit.

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CAUTION
Hot surfaces on the axial piston unit and HS5E(V)(L) control system!
Risk of getting burnt!
▶ Allow the axial piston unit and the HS5E(V)(L) control system to cool down
sufficiently before touching them.
▶ Wear heat-resistant, protective clothing, e.g.gloves.
Improper cable and line routing!
Risk of stumbling and property damage! Due to incorrect routing of lines and
cables, both arisk of stumbling as well as damage to parts and components can
occur, e.g.due to lines and connectors being torn off.
▶ Always install cables and lines in away that nobody can fall over them, that
they are not bend or twisted, do not chafe on edges and are not guided through
ducts with sharp edges without sufficient protection.
Contact with hydraulic fluid!
Risk of adverse health effects, e.g.eye injury, skin irritation, toxication from
inhalation!
▶ Avoid any contact with hydraulic fluids.
▶ When handling hydraulic fluids, the safety instructions of the lubricant
manufacturer need to be observed at all times.
▶ Use your personal protective equipment (e.g.safety goggles, safety gloves,
suitableworking clothes, safety shoes).
▶ Immediately seek medical attention, however, if hydraulic fluid gets into your
eyes or blood circuit or if you swallow it accidentally.
Danger from improper handling!
Slip hazard! Risk of slipping on wet surfaces when climbing on the axial piston unit.
▶ Never grab or climb onto the axial piston unit.
▶ Check how to safely get on top of the machine/system.
Missing potential equalization on the hydraulic unit!
Uncontrolled function of the axial piston unit.
▶ Missing or incorrect potential equalization on the hydraulic unit can lead to
its functions being uncontrolled. Depending on the application, this can lead
to hazards to persons. This means that you must ensure proper potential
equalization by means of the existing pin assignment on the connector side.
Interference in case of energy fluctuations and/or energy failure with HS5E, open
circuit (A4VSO, A4VBO)!
Uncontrolled movements in the system:
▶ In case of energy fluctuations and/or energy failure, the axial piston unit will
return into the basic position Vg min if the control pressure supply is sufficient.
Limiting the minimum displacement can cause torque to be generated in the
application.
Check whether additional measures are necessary on your machine for the
application in order to guarantee that the torque is switched off. If necessary,
make sure these are appropriately implemented.

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Safety instructions | A4... with HS5E(V)(L) control system Series 1x and 30 17/104
CAUTION
Interference in case of energy fluctuations and/or energy failure with HS5E,
closed circuit (A4VSG, A4CSG)!
Uncontrolled movements in the system:
▶ In case of energy fluctuations and/or energy failure, the axial piston unit will
open if the control pressure supply is sufficient -Vg max or α = -100%.
Check whether additional measures are necessary on your machine for the
application in order to guarantee that the torque is switched off. If necessary,
make sure these are appropriately implemented.
Interference in case of energy fluctuations and/or energy failure with HS5EV,
open circuit (A4VSO, A4VBO)!
Uncontrolled movements in the system:
▶ In case of energy fluctuations and/or failure, the unit will move to different
swivel angles, depending on the available load pressure (system-related). If the
load pressure is missing, the axial piston unit will move in Vg max.
Check whether additional measures are necessary on your machine for the
application in order to guarantee that the torque is switched off. If necessary,
make sure these are appropriately implemented.
Interference in case of energy fluctuations and/or energy failure with HS5EL,
closed circuit (A4CSG)!
Uncontrolled movements in the system:
▶ In case of energy fluctuations and/or failure, the unit will move to -Vg max
(α=-100%) depending on the available and sufficient load pressure and boost
pressure (system-related).
Check whether additional measures are necessary on your machine for the
application in order to guarantee that the torque is switched off. If necessary,
make sure these are appropriately implemented.
NOTICE
Interference due to electromagnetic radiation!
Uncontrolled movements in the system.
▶ The hydraulic unit with its electronic components can interfere with other
electronics systems by emitting electromagnetic radiation. Apart from this,
hydraulic units with electronic components can be interfered with by the
electromagnetic radiation of other electronics systems and magnetic fields.
In both cases, this can lead to uncontrolled movements in the system.
▶ Pay attention to the limit values for electromagnetic radiation and, if necessary,
screen electronic components, connection and signal lines appropriately.
▶ Make sure that there is an adequate distance between the electronics, including
the connection and signal lines, and high-voltage current-conducting lines.
2.7 Personal protective equipment
Personal protective equipment is the responsibility of the user of the axial piston
unit with HS5E(V)(L) control system. Observe the safety regulations in your country.
All pieces of personal protective equipment should be intact.

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BoschRexrothAG, RE92076-01-B/2021-04-22
3 General instructions on property
damage and product damage
The following notes apply for chapters 3 to 14.
NOTICE
Danger from improper handling!
Product can be damaged!
▶ Do not subject the product to improper mechanical loads.
▶ Never use the product as handle or step.
▶ Do not put/place any objects on the product.
▶ Do not strike the drive shaft of the axial piston unit.
▶ Do not set/place the axial piston unit on the drive shaft or assembled parts.
▶ Do not strike assembled parts (e.g.sensors or valves).
▶ Do not hit sealing surfaces (e.g.on the working ports).
▶ Leave the protective covers on the axial piston unit until you connect the lines.
▶ Diskonnect all electrical connectors before arc welding and painting operations.
▶ Make sure the electronic components (e.g.sensors) do not build up
electrostatic charges (e.g.during painting).
Risk of property damage due to inadequate lubrication!
Product can be damaged or destroyed!
▶ Never operate the axial piston unit with insufficient hydraulic fluid. Specifically,
make sure that the rotary group has sufficient lubrication.
▶ When commissioning amachine/system, make sure that the housing area and
the working lines of the axial piston unit are filled with hydraulic fluid and
remain filled during operation. Avoid air inclusions in the forward drive shaft
bearing, especially with the axial piston unit installed with the drive shaft up.
▶ Check the hydraulic fluid level in the housing area regularly and recommission, if
necessary. With above-reservoir installation, the housing area may drain via the
drain line after longer standstill periods (air enters via the shaft seal) or via the
working line (gap leakage). This means the bearings are insufficiently lubricated
when the system is turned on.
▶ Make sure the suction line is always filled with hydraulic fluid during
commissioning and operation.
▶ With above-reservoir installation, an axial piston unit must be moved to full
swivel angle after no more than three seconds during commissioning and
recommissioning. Make sure that the axial piston unit really does suck in
hydraulic fluid and build up pressure.

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NOTICE
Mixing hydraulic fluids!
Product can be damaged!
▶ Before installation, remove all fluids from the axial piston unit to prevent mixing
with the hydraulic fluid used in the machine/system.
▶ Any mixture of hydraulic fluids of different manufacturers and/or different types
of the same manufacturer is generally not permissible.
Contamination of hydraulic fluid!
The cleanliness of the hydraulic fluid impacts the service life of the axial piston unit.
Contamination of the hydraulic fluid may lead to premature wear and malfunctions!
▶ Always ensure awork environment in the assembly location that is free from dust
and foreign particles to prevent foreign particles, e.g.welding beads or metal
cuttings, from entering the hydraulic lines and lead to wear and malfunctions in
the product. The axial piston unit should be clean when installed.
▶ Only use clean ports, hydraulic lines and assembled parts (e.g.measuring
devices).
▶ When plugging the ports, no contamination may ingress.
▶ Before commissioning, ensure that all hydraulic connections are tight and
that all seals and plugs of the plug-in connection are correctly installed and
undamaged to prevent fluids and foreign particles from entering the product.
▶ Filter the hydraulic fluid when filling the system with asuitablefilter system
to minimize the solid particle contamination and water in the hydraulic system
and to achieve the required cleanliness level.
Improper cleaning!
Product can be damaged!
▶ Plug all openings with appropriate protective covers in order to prevent cleaning
agents from entering the axial piston unit.
▶ Never use solvents or aggressive cleaning agents. Use only water and, if
necessary, amild cleaning agent to clean the axial piston unit.
▶ Do not point ahigh-pressure cleaner at sensitive components, e.g.shaft seal,
electrical connections and components.
▶ Use fiber-free cloths for cleaning.
Environmental pollution due to improper disposal!
Careless disposal of the axial piston unit and its assembled parts, the hydraulic
fluid and the packaging material can cause environmental pollution!
▶ Dispose of the axial piston unit, hydraulic fluid and packaging in accordance
with the regulations in your country.
▶ Dispose of the hydraulic fluid in accordance with the applicable safety data
sheet for the hydraulic fluid.

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NOTICE
Danger from chemical or corrosive environmental conditions!
Product can be damaged! If the axial piston unit is exposed to chemical or
corrosive environmental conditions, such as sea water, fertilizer or road salt, it can
result in corrosion or, in extreme cases, malfunction. Leaks may lead to aleakage of
hydraulic fluid.
▶ Take appropriate measures to protect the axial piston unit from chemical or
corrosive environmental conditions.
Leakage or spilling of hydraulic fluid!
Risk of environmental pollution and contamination of ground water!
▶ Always place adrip tray under the axial piston unit when filling and draining
hydraulic fluid.
▶ Use asuitable binding agent to collect any leaked hydraulic fluid.
▶ Observe the parameters in the safety data sheet for the hydraulic fluid and the
specifications provided by the machine/system manufacturer.
Danger from hot components!
Nearby products can be damaged! Due to aheat development in components
(e.g.solenoids), adjacent products may be damaged during assembly if no
sufficient safety distance is complied with.
▶ When installing the axial piston unit, check the safety distances to nearby
products to ensure that they are not damaged.
The warranty exclusively applies to the delivered configuration.
The warranty will be voided if the product is incorrectly installed, commissioned or
operated, or if it is used or handled improperly.