Bosch Rexroth 63 Series User manual

<Replace this illustration area with an
illustration of your product>
Instruction manual
RE 92202-01-B/08.2012
Replaces: –.–
English
Axial Piston Variable Pump
A7VO
Series 63

The data specified above serve to describe the
product. Should information be provided on
use, these are only examples of applications
and suggestions. Information from the catalog
are not assured properties. The information
given does not release the user from the
obligation of own judgment and verification.
Our products are subject to a natural wear and
aging process.
© This document, as well as the data, specifica-
tions and other information set forth in it, are
the exclusive property of Bosch Rexroth AG. It
may not be reproduced or given to third parties
without its consent.
The cover shows an example application. The
product delivered may differ from the image on
the cover.
The original instruction manual was created in
the German language.

RE 92202-01-B/08.2012, A7VO Series 63, Bosch Rexroth AG
3/60Contents
Contents
1 About this documentation 5
1.1 Validity of the documentation 5
1.2 Required and supplementary documentation 5
1.3 Display of information 6
1.3.1 Safety instructions 6
1.3.2 Symbols 7
1.3.3 Designations 7
1.3.4 Abbreviations 7
2 Safety instructions 8
2.1 About this chapter 8
2.2 Intended use 8
2.3 Improper use 8
2.4 Personnel qualifications 9
2.5 General safety instructions 9
2.6 Product-specific safety instructions 10
2.7 Personal protective equipment 12
3 General instructions on damage to equipment and the product 13
4 Delivery contents 16
5 About this product 17
5.1 Performance description 17
5.2 Product description 17
5.2.1 Assembly of the axial piston unit 17
5.2.2 Functional description 18
5.3 Product identification 19
6 Transport and storage 20
6.1 Transporting the axial piston unit 20
6.1.1 Transporting by hand 20
6.1.2 Transporting with lifting device 20
6.2 Storing the axial piston unit 22
7 Installation 24
7.1 Unpacking 24
7.2 Installation conditions 24
7.3 Installation position 25
7.3.1 Below-reservoir installation for sizes 28 to 160 26
7.3.2 Below-reservoir installation for sizes 250 to 500 27
7.3.3 Above-reservoir installation for sizes 250 to 500 28
7.4 Installing the axial piston unit 29
7.4.1 Preparation 29
7.4.2 Dimensions 29
7.4.3 General instructions 30
7.4.4 Installation with coupling 31
7.4.5 Installation on a gearbox 32
7.4.6 Installation with cardan shaft 32
7.4.7 Completing installation 32
7.4.8 Hydraulically connecting the axial piston unit 34
7.4.9 Electrically connecting the axial piston unit 41
7.5 Performing flushing cycle 42

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Bosch Rexroth AG, A7VO Series 63, RE 92202-01-B/08.2012
8 Commissioning 43
8.1 First commissioning 43
8.1.1 Filling the axial piston unit 43
8.1.2 Testing the hydraulic fluid supply 44
8.1.3 Performing functional test 45
8.2 Running-in phase 46
8.3 Recommissioning after standstill 46
9 Operation 47
10 Maintenance and repair 48
10.1 Cleaning and care 48
10.2 Inspection 49
10.3 Maintenance 49
10.4 Repair 50
10.5 Spare parts 50
11 Removal and replacement 51
11.1 Required tools 51
11.2 Preparing for removal 51
11.3 Removing the axial piston unit 51
11.4 Preparing the components for storage or further use 51
12 Disposal 52
13 Extension and conversion 52
14 Troubleshooting 53
14.1 How to proceed for troubleshooting 53
14.2 Malfunction table 54
15 Technical data 56
16 Alphabetical index 57
Contents

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RE 92202-01-B/08.2012, A7VO Series 63, Bosch Rexroth AG
1 About this documentation
1.1 Validity of the documentation
This documentation applies to the following products:
•Axial piston variable pump A7VO Series 63
This documentation is intended for machine/system manufacturers, fitters and
service technicians.
This documentation contains important information on the safe and appropriate
transport, installation, commissioning, operation, maintenance, removal and simple
troubleshooting of the axial piston unit.
▶ Read this documentation completely and in particular the chapter2 "Safety
instructions" on page 8 and chapter3 "General instructions on damage to
equipment and the product" on page 13 before you start work with the axial
piston unit.
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 of your axial piston variable pump A7VO.
– Order confirmation
Installation drawing
Contains the outer dimensions, all connections and the hydraulic schematic for
your axial piston variable pump A7VO.
Please request the
installation drawing
via your contact
person at Bosch
Rexroth.
Installation drawing
Axial piston variable pump A7VO
Contains the permissible technical data for the axial piston variable pump A7VO
series 63, sizes 28 to 160.
RE 92202 Data sheet
Axial piston variable pump A7VO
Contains the permissible technical data for the axial piston variable pump A7VO
series 63, sizes 250 to 500.
RE 92203 Data sheet
Mineral-oil based hydraulic fluids and related hydrocarbons
Describes the requirements on a mineral-oil based hydraulic fluid and related
hydrocarbons for the operation with Rexroth hydraulic components, and assists
you in selecting a hydraulic fluid for your hydraulic system.
RE 90220 Data sheet
Environmentally acceptable hydraulic fluids
Describes the requirements on an environmentally acceptable hydraulic fluid
for operation with Rexroth hydraulic components and assists you in selecting a
hydraulic fluid for your hydraulic system.
RE 90221 Data sheet
Fire-resistant, water-free hydraulic fluids (HFDU/HFDR)
Describes the requirements on fire-resistant, water-free hydraulic fluids for
operation with Rexroth hydraulic components and assists you in selecting a
hydraulic fluid for your hydraulic system.
RE 90222 Data sheet
Notes on the use of hydrostatic drives at low temperatures
Contains additional information on the use of Rexroth axial piston units at low
temperatures.
RE 90300-03-B Manual
Storage and preservation of axial piston units
Contains additional information on storage and preservation.
RE 90312 Data sheet

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Bosch Rexroth AG, A7VO Series 63, RE 92202-01-B/08.2012
1.3 Display of information
Standardized safety instructions, symbols, terms and abbreviations are used so that
you can use this documentation to work quickly and safely with your product. To give
you a better understanding they are explained in the sections below.
1.3.1 Safety instructions
This documentation includes safety instructions in chapter2.6 "Product-specific
safety instructions" on page36 and in chapter3 "General instructions on damage
to equipment and the product" on page 13 and before a sequence of actions or
an instruction 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 WORD
Type 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: names 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
Table 2: Danger classes in accordance with ANSI Z535.6-2006
Safety sign, signal word Meaning
DANGER Identifies a dangerous situation that will result in death or
serious injuries if it is not avoided.
WARNING Identifies a dangerous situation that may result in death or
serious injuries if it is not avoided.
CAUTION Identifies a dangerous situation that may result in minor to
moderate injuries if it is not avoided.
NOTE Damage to equipment: The product or the environment may
be damaged.

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1.3.2 Symbols
The following symbols mark notes that are not safety-relevant but which increase the
understanding of the documentation.
Table 3: Meaning of the symbols
Symbol Meaning
If this information is disregarded, the product can not be used and/or
operated to the optimum extent.
▶ Single, independent step
1.
2.
3.
Numbered instruction:
The numbers specify that the steps are completed one after the other.
1.3.3 Designations
This documentation uses the following designations:
Table 4: Designations
Designation Meaning
A7VO Axial piston variable pump, open circuit
Threaded plug Metal screw, pressure-resistant
Protective plug Made out of plastic, not pressure-resistant, only for transportation
As umbrella term for "axial piston variable pump A7VO" 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 EU directive for explosion protection (Atmosphère explosible)
DIN Deutsche Industrie Norm (German Institute for Standardization)
DR Pressure controller
EP Proportional control electric
HD Proportional hydraulic control
LR Power control
LRD Power control with pressure cut-off
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, A7VO Series 63, RE 92202-01-B/08.2012
2 Safety instructions
2.1 About this chapter
The axial piston unit has been manufactured according to the generally accepted
rules of current technology. There is, however, still a danger of personal injury
or damage to equipment if this chapter and the safety instructions in this
documentation are not complied with.
▶ Read this documentation completely and thoroughly before working with the
axialpiston unit.
▶ 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
Axial piston units are hydraulic components, meaning that in their application area
they are classified neither as complete nor as incomplete machines in the sense
of the EU machine directive 2006/42/EC. A component is exclusively intended to
form an incomplete or a complete machine together with other components. The
component may 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 machine directive.
The product is intended for the following use:
The axial piston unit is only approved as a pump for hydrostatic drives in open
circuit.
▶ Observe the technical data, application and operating conditions and
performance limits as specified in data sheets RE 92202 and RE 92203 and in the
order confirmation. Information about approved hydraulic fluids can be found in
data sheetRE 92202 and RE 92203.
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.
2.3 Improper use
Any use other than that described as intended use shall be considered as improper
and is therefore impermissible.
Bosch Rexroth AG shall accept no liability whatsoever for damage resulting from
improper use. The user shall bear all risks arising from improper use.
Similarly, the following foreseeable faulty usages are also considered to be improper:
•Use outside the operating parameters approved in the data sheet or in the order
confirmation (unless customer-specific approval has been granted)
•Use for non-approved fluids, e.g.water or polyurethane components
•Modification of factory settings by non-authorized persons
•Use of add/on parts (e.g. mountable filter, control unit, valves) that are not
specified Rexroth components
•Using the axial piston unit under water at a depth of more than 10 meters without
necessary additional measures, e.g. pressure equalization

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RE 92202-01-B/08.2012, A7VO Series 63, Bosch Rexroth AG
•Using the axial piston unit when the exterior pressure is greater than the interior
pressure (case pressure)
•Using the axial piston unit in explosive environments unless the component or
machine/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 craft
2.4 Personnel qualifications
The activities described in this documentation require basic mechanical, electrical
and hydraulic knowledge, as well as knowledge of the associated technical terms.
For transporting and handling the product, additional knowledge is necessary with
regard 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 by
appropriate qualified personnel or an instructed person under the direction and
supervision of qualified personnel.
Qualified personnel are those who can recognize possible hazards and institute
the appropriate safety measures due to their professional training, knowledge, and
experience, as well as their understanding of the relevant regulations pertaining
to the work to be done. Qualified personnel must observe the rules relevant to the
subject 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. An overview of the
training contents can be found on the Internet at:
http://www.boschrexroth.de/didactic.
2.5 General safety instructions
•Observe the applicable accident prevention and environmental protection
regulations.
•Observe the safety regulations and provisions of the country in which the product
is 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 not
consume any alcohol, drugs or pharmaceuticals that may affect their ability to
respond.
•Only use Rexroth original accessories and spare parts to ensure there is no risk to
persons from unsuitable spare parts.
•Conform to the technical data and ambient conditions specified in the product
documentation.

10/60 Safety instructions
Bosch Rexroth AG, A7VO Series 63, RE 92202-01-B/08.2012
•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 injury to persons or property damage. For this reason, only use
the product in a safety-relevant application if this use is expressly specified and
permitted in the product documentation, for example in ex-protection applications
or in safety-related parts of a control system (functional safety).
•You may only commission the product if it has been determined that the end
product (e.g. machinery or a system) into which the Rexroth products are installed
complies with the country-specific provisions, safety regulations and standards of
the application.
2.6 Product-specific safety instructions
The following safety instructions apply for chapters 6 to 14.
WARNING
Danger from excessively high pressure!
Danger to life or risk of injury, damage to equipment!
Incorrectly changing the factory pressure setting can cause pressure to increase
beyond the permissible maximum pressure.
Operating the unit above the permissible maximum pressure can cause
components to burst and hydraulic fluid to escape under high pressure.
▶ Changes to the factory settings must only be made by Bosch Rexroth specialist
personnel.
▶ In addition, a pressure relief valve is needed as back-up in the hydraulic system.
If the axial piston unit is equipped with a pressure cut-off and/or a pressure
control, this is not an adequate back-up against pressure overload.
Danger 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 injuries
e.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 and
transportation.