Bosch REXROTH A4 Series User manual

Instruction manual
RE 92076-01-B/10.2017
Replaces: –.–
English
Axial piston variable pump
A4... with HS5E pilot control
valve
Series 10, 11 and Series 3x

© Bosch Rexroth AG 2017. 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 instruction manual was created in
the German language.

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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 14
2.7 Personal protective equipment 18
3 General instructions on damage to property and theproduct 19
4 Scope of delivery 22
5 About this product 23
5.1 Performance description 23
5.2 Unit description 23
5.2.1 Layout of the axial piston unit 23
5.2.2 Functional description 23
5.3 Parallel and cascade control of the HS5E 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 28
5.4 Ambient conditions 29
5.4.1 Oil-immersed applications 29
5.4.2 Ambient temperature 29
5.5 Notes on selecting hydraulic fluids 29
5.6 Noise development 29
5.6.1 Noise development in the unit 30
5.6.2 Pulsation damper 30
5.7 Master/slave operation 30
5.7.1 Circuitry of HS5E 31
5.8 Description of the IndraWorks commissioning tool 32
5.8.1 System requirements 33
5.8.2 Firmware update 34
5.9 Switch-on sequence of electronics/hydraulics 34
5.10 Product identification 35
6 Transport and storage 36
6.1 Transporting the axial piston unit 36
Contents

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6.1.1 Transporting with a lifting device 36
6.2 Storing the axial piston unit 38
7 Installation 40
7.1 Unpacking 40
7.2 Installation conditions 40
7.3 Installation position 42
7.3.1 Below-reservoir installation (standard) 42
7.3.2 Above-reservoir installation 43
7.4 Installing the axial piston unit 44
7.4.1 Preparation 44
7.4.2 Dimensions 44
7.4.3 General instructions 44
7.4.4 Installation with coupling 45
7.4.5 Installation on a gearbox 46
7.4.6 Installation with cardan shaft 46
7.4.7 Completing installation 47
7.4.8 Hydraulically connecting the axial piston unit 49
7.4.9 Electrically connecting the axial piston unit 54
7.5 Performing flushing cycle 55
7.6 Connecting the HS5E control system electrically 55
7.6.1 Wiring the electronic components 55
7.6.2 Connection to the swivel angle sensor 56
7.6.3 X2M1 and X2M2: Analog, configurable pressure sensor interface (coding A),
M12, 5-pin, socket 56
7.6.4 X7E1 and X7E2: Plug-in connector assignment for Ethernet port (coding D),
M12, 4-pin, socket 56
7.6.5 LED status indicators 57
7.6.6 Voltage supply of the HS5E pilot control valve 57
7.6.7 Selection, installation location, and installation direction of the pressure
transducer 58
8 Commissioning 60
8.1 Initial commissioning 61
8.1.1 Filling the axial piston unit 62
8.1.2 Testing the hydraulic fluid supply 63
8.1.3 Performing a functional test 63
8.1.4 Connection to the control (IndraWorks) 64
8.1.5 Making the basic setting on the control electronics 65
8.1.6 Switching on the drive motor of the pump 70
8.1.7 Setting controller parameters 71
8.1.8 Calibrating the HS5E control system 75
8.1.9 Saving parameters 76
8.2 Running-in phase 77
8.3 Recommissioning after standstill 77
9 Operation 78
10 Maintenance and repair 79
10.1 Cleaning and care 79
10.2 Inspection 80

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10.3 Maintenance 80
10.4 Repair 81
10.5 Spare parts 81
10.5.1 Replacement of components 82
11 Removal and replacement 85
11.1 Required tools 85
11.2 Preparing for removal 85
11.3 Performing removal 85
11.4 Preparing the components for storage or further use 85
12 Disposal 86
13 Extension and conversion 86
14 Troubleshooting 87
14.1 How to proceed with troubleshooting 87
14.2 Error/diagnosis memory 88
14.2.1 Fault diagnosis 88
14.3 Malfunction table 89
14.3.1 Swivel angle measurement check 95
15 Technical data 96
15.1 Electrical connection of the pilot valve 96
15.2 Environmental compatibility for the areas EMC, clime and mechanical load 98
16 Alphabetical index 99

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1 About this documentation
1.1 Validity of the documentation
This documentation is valid for axial piston units with an HS5E pilot control valve:
•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 planning engineers, operators, machine/system
manufacturers, assemblers, and service engineers.
This documentation contains important information on safe and proper
transportation, installation, commissioning, operation, maintenance, removal, and
simple troubleshooting of the A4... with HS5E pilot control valve.
▶ Read this documentation completely, in particular, chapter2 “Safety
instructions” on page10 and chapter3 “General instructions on damage
to property and theproduct” on page19, before you start work on the
A4... with HS5E pilot control valve.
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 A4... with HS5E pilot control valve.
– Order confirmation
Installation drawing
Contains the outer dimensions, all ports and the hydraulic
circuit diagram for your axial piston variable pump
A4... with HS5E pilot control valve.
Please request the
installation drawing
from your contact at
Bosch Rexroth.
Installation drawing
Axial piston variable pump A4... with HS5E pilot control valve Series 3x
Contains the permissible technical data.
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.
92050
92100
92105
92122
Data sheet
Axial piston variable pump A4VSO For HF 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
Mineral oil-based hydraulic fluids and related hydrocarbons
Describes the requirements on a mineral oil-based hydraulic fluid and
related hydrocarbons for operation with Rexroth hydraulic components,
and assists you in selecting a hydraulic fluid for your 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
General Instruction Manual for Axial Piston Units
Contains additional information on the use of Rexroth axial piston units.
90300-B Instruction manual

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Table 1: Required and supplementary documentation
Title Document number Document type
Instruction Manual for Axial Piston Unit A4VSO
Contains additional information on the use of Rexroth axial piston units.
92050-01-B Instruction manual
Instruction Manual for Axial Piston Unit A4VSG
Contains additional information on the use of Rexroth axial piston units.
92100-01-B Instruction manual
Instruction Manual for Axial Piston Unit A4VBO
Contains additional information on the use of Rexroth axial piston units.
92122-01-B Instruction manual
Information on the use of hydrostatic drives at low temperatures
Contains additional information on the use 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
Installation, commissioning and maintenance of hydraulic systems 07900 Data sheet
Rexroth HydraulicDrive functions
(firmware and software descriptions)
30338-FK Functional 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. 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14 and in chapter3 “General instructions on damage
to property and theproduct” on page19 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.

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Safety instructions are set out as follows:
SIGNAL WORD
Type and source of danger!
Consequences of noncompliance
▶ Measures to prevent danger
•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 the safety instructions are not complied with
•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 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.
NOTICE Property damage: The product or the environment may get
damaged.
1.3.2 Symbols
The following symbols indicate information that is not safety-relevant but increases
understanding of the documentation.
Table 3: Meaning of the symbols
Symbol Meaning
If this information is disregarded, the product cannot be used and/or
operated to the optimum extent.
▶ Single, independent action
1.
2.
3.
Numbered instruction:
The numbers indicate that the actions must be completed one after
the other.

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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 Pilot control valve with on board electronics
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
The designation "axial piston unit" will be used below as the umbrella term for “axial
piston variable pump” A4... with HS5E pilot control valve.
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
UBSupply 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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2 Safety instructions
2.1 About this chapter
The HS5E control system has been manufactured according to the generally
accepted rules of current technology. There is, however, still a danger of personal
injury or property damage if this chapter and the safety instructions in this
documentation are not complied with.
▶ Read this documentation completely and thoroughly before working with the
HS5E 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 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 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 Machinery Directive.
This product is intended for the following use:
The pressure flow control system is for control of the electrohydraulic pressure and
swivel angle of an axial piston variable pump.
Observe the technical data, operating conditions and performance limits as specified
in the data sheet and order confirmation.
The HS5E control system is a piece of technical work equipment and it is not
intended for personal use.
Intended use includes having read and understood this documentation completely,
especially chapter2 “Safety instructions” on page10.
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 chapter “Electrical connection of
the pilot valve” on page96). Ensuring compliance with the limit values required
by national regulations is the responsibility of the manufacturer of the system or
machine.
• European countries: EU Directive 2014/30/EU (EMC Directive)
• USA: See the National Electrical Code (NEC), national organization
of the manufacturers of electrical systems (NEMA) as well as regional building
regulations.
▶ Comply with the technical data, the application and operating conditions,
and the performance limits as specified in data sheet92076 and in the order
confirmation. Information about approved hydraulic fluids can be found in data
sheet92076.

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The axial piston unit is only intended for professional use and not for private use.
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 is not liable for damages resulting from improper use. The user
shall bear all risks arising from improper use.
The following foreseeable faulty usages are also be considered to be improper (this
list does not claim to be exhaustive):
•Use outside the operating parameters approved in the data sheet or 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 add-ons (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 from case
pressure to ambient pressure of greater than 2bar, whereby the ambient pressure
must always be lower than the case pressure. Short-term pressure peaks (t<0.1s)
of up to 4bar are permitted. Beyond this, the maximum case pressure specified on
the data sheet cannot 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 chapter “Electrical connection of the pilot valve”
on page96
). Ensuring compliance with the limit values required by national
regulations is the responsibility of the manufacturer of the system or machine.
European countries: EU 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 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 basic mechanical, electrical
and hydraulics expertise, as well as knowledge of the associated technical terms.
For transporting and handling the product, additional knowledge is necessary with
regard to working with lifting devices and their slings. 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 persons are those who can recognize possible dangers and take the
appropriate safety measures due to their professional training, knowledge, and
experience, as well as their understanding of the relevant regulations pertaining to

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the work to be done. Skilled personnel must follow the rules relevant to their field
and have the necessary expert knowledge of hydraulics and electrical systems.
Hydraulic expert knowledgeincludes:
•Reading and fully understanding hydraulic circuit diagrams,
•especially fully understanding the relationships with regard to safety devices
•and understanding how hydraulic components work and are put together.
Expert knowledge of electrical systemsincludes:
•Reading and fully understanding electrical circuit diagrams,
•especially fully understanding the relationships with regard to safety devices
•and understanding how electrical 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.
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 working order.
•Observe all notices on the product.
•Persons who install, operate, remove or maintain Rexroth products may not be
under the influence of alcohol, drugs or medication that may affect their reaction
time.
•Only use genuine Rexroth accessories and spare parts to ensure there is no hazard
to persons due to 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 injury to personnel or property damage. For this reason, only use
the product in safety-relevant applications if this use is expressly specified and
permitted in the product documentation, for example in explosion 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 (for example, machinery or 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 that these are properly implemented.
•Depending on the type of control used, electromagnetic effects can be produced
when using solenoids. When a direct current is applied, solenoids do not cause
electromagnetic interference nor is their operation impaired by electromagnetic

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interference. 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.

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2.6 Product-specific safety instructions
The following safety instructions apply to chapters 3 to 11.
WARNING
Danger from excessively high pressure!
Risk of death or injury, or property damage!
Improperly changing the factory pressure settings can result in a pressure 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.
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 must only be made by Bosch Rexroth specialists.
▶ In addition, a pressure relief valve is required in the hydraulic system as a back-
up. If the axial piston unit is equipped with a pressure cut-off and/or a pressure
controller, this is not an adequate back-up against pressure overload.
Danger from suspended loads!
Risk of death or injury, or property damage!
Improper transportation may cause the axial piston unit to fall down and lead to
injuries e.g. crushing or broken bones 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 put your hands under a suspended load.
▶ Make sure the unit remains stable during transport.
▶ Wear your personal protective equipment (e.g.safety goggles, 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.
System/machine under pressure!
Danger to life or risk of injury, serious injuries when working on machines/systems
not secured! Risk of property damage!
▶ Switch off the entire system and secure it against reconnection according to the
parameters provided by the machine/system manufacturer.
▶ Make sure that all relevant components of the hydraulic system are
depressurized. Follow the parameters given by the machine/system
manufacturer.
▶ Note that the hydraulic system may still may be under pressure even after the
pressure supply itself has been disconnected.
▶ Do not disconnect any line connections, ports and components as long as the
hydraulic system is under pressure.

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WARNING
Escaping oil mist!
Risk of explosion and fire, 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 that any escaped hydraulic
fluid cannot be ignited, and to protect hose lines from premature aging.
Electrical voltage!
Risk of injury from electric shock or risk of property damage!
▶ Always set up the relevant part of the machine/system so that it is free
of electrical voltage before you install the product or when connecting and
disconnecting connectors. Protect the machine/system against being
re-energized.
Danger from unforeseen 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 additional protective measures are necessary for the application
on your machine in order to avoid unintentional actuation. If necessary, make
sure that these are properly implemented.
▶ Wear suitable protective clothing.
Restriction of the control function!
Risk of injury or property damage!
Moving parts in control equipment (e.g.valve spools) can, under certain
circumstances, get stuck in position as a result of 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 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.

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CAUTION
High noise development during operation!
Risk of hearing damage or hearing loss!
The noise emission of axial piston units depends on, among other factors,
rotational speed, working pressure and installation conditions. The sound pressure
level may rise above 70dB(A) in certain application conditions.
▶ Always wear hearing protection when in the vicinity of the operating axial piston
unit.
Hot surfaces on the axial piston unit and HS5E control system!
Risk of burning!
▶ Allow the axial piston unit and the HS5E control system to cool down sufficiently
before touching them.
▶ Wear heat-resistant protective clothing, e.g.gloves.
Improper routing of cables and lines!
Risk of stumbling and property damage! Improper routing of cables and lines can
cause a risk of stumbling as well as damage to equipment and components, for
example, tearing of lines and connectors.
▶ Always lay cables and lines in such a way that no one can trip over them, that
they do not become kinked or twisted, do not rub on edges and do not run
without adequate protection through sharp-edged ducts.
Contact with hydraulic fluid!
Risk of adverse health effects, e.g.eye injury, skin irritation, poisoning from
inhalation!
▶ Avoid contact with hydraulic fluids.
▶ When working with hydraulic fluids, strictly observe the safety instructions
provided by the lubricant manufacturer.
▶ 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.
Escaping hydraulic fluid due to machine/system leakage!
Risk of burns and risk of injury due to escaping oil jet!
▶ Depressurize the relevant machine/system component and repair the leak.
▶ Never attempt to block or seal the leak or oil jet with a cloth.
Danger from improper handling!
Risk of slipping! 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.

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CAUTION
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 people. This means that you must ensure proper potential
equalization by means of the existing pin assignment on the connector side.
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, connecting, and signal lines appropriately.
▶ Make sure that there is an adequate distance between the electronics, including
the connecting and signal lines, and high-voltage current-conducting lines.

18/104 Safety instructions
Bosch Rexroth AG, A4... with HS5E pilot control valve/Series 3x, RE 92076-01-B/10.2017
2.7 Personal protective equipment
Personal protective equipment is the responsibility of the user of the axial piston
unit with HS5E control system. Observe the safety regulations and provisions in your
country.
All pieces of personal protective equipment must be intact.

General instructions on damage to property and theproduct 19/104
RE 92076-01-B/10.2017, A4... with HS5E pilot control valve/Series 3x, Bosch Rexroth AG
3 General instructions on damage to
property and theproduct
The following notes apply to chapters 3 to 7.
NOTICE
Danger from improper handling!
Product can get damaged!
▶ Do not expose the product to excessive mechanical loads.
▶ Never grab or climb onto the product.
▶ Do not place/lay 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 strike sealing surfaces (e.g. working ports).
▶ Leave the protective covers on the axial piston unit until you connect the lines.
▶ Disconnect all electrical connectors before electro-welding or painting
operations.
▶ Make certain that the electronic components (e.g.sensors) do not become
electrostatically charged (e.g.during painting operations).
Risk of property damage due to inadequate lubrication!
Damage or destruction of product possible!
▶ 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. Air inclusions in the forward drive shaft bearing
are to be prevented, especially with the installation position “drive shaft
upwards”.
▶ Check the hydraulic fluid level in the housing area regularly; if necessary,
recommission. 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 that 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.

20/104 General instructions on damage to property and theproduct
Bosch Rexroth AG, A4... with HS5E pilot control valve/Series 3x, RE 92076-01-B/10.2017
NOTICE
Mixing of hydraulic fluids!
Product can get damaged!
▶ 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.
Contamination of the hydraulic fluid!
The cleanliness of the hydraulic fluid has a considerable impact on the cleanliness
and service life of the hydraulic system. Contamination of the hydraulic fluid can
cause premature wear and malfunctions.
▶ Make sure that the working environment at the installation site is fully free
of dust and foreign substances in order to prevent foreign particles, such
aswelding beads or metal cuttings, from getting into the hydraulic lines and
causing product wear or malfunctions. The axial piston unit must be installed
in a clean condition.
▶ Use only clean ports, hydraulic lines and assembled parts (e.g.measuring
devices).
▶ No contamination may enter the ports when they are plugged.
▶ Before commissioning, make sure that all hydraulic connections are tight and
that all of the seals and plug-in connections are installed correctly to ensure
that they are leak proof and fluids and foreign particles are prevented from
penetrating the product.
▶ Use a suitable filter system to filter hydraulic fluid during filling to minimize solid
particle contamination and water in the hydraulic system.
Improper cleaning!
Product can get damaged!
▶ Plug all openings with the appropriate protection equipment in order to prevent
cleaning agents from entering the hydraulic system.
▶ Never use solvents or corrosive 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 result in environmental pollution.
▶ Dispose of the axial piston unit, hydraulic fluid and packaging in accordance
with the national regulations in your country.
▶ Dispose of the hydraulic fluid in accordance with the applicable safety data
sheet for the hydraulic fluid.