Bosch Rexroth A4VG 35 Series User manual

Instruction manual
RE92035-01-B/2019-11-25
Replaces: 04.2018
English
Axial piston variable pump
A4VG
Series35

© BoschRexrothAG 2019. 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.

Contents 3/64
RE92035-01-B/2019-11-25, A4VG Series35, Bosch Rexroth AG
1 About this documentation 5
1.1 Validity of the documentation 5
1.2 Required and supplementary documentation 5
1.3 Representation of information 6
1.3.1 Safety instructions 6
1.3.2 Symbols 7
1.3.3 Designations 7
1.3.4 Abbreviations 8
2 Safety instructions 9
2.1 About this chapter 9
2.2 Intended use 9
2.3 Improper use 9
2.4 Personnel qualifications 10
2.5 General safety instructions 11
2.6 Product-specific safety instructions 12
2.7 Personal protective equipment 15
3 General instructions on property damage and product damage 16
4 Scope of delivery 19
5 About this product 20
5.1 Performance description 20
5.2 Product description 20
5.2.1 Axial piston unit layout 20
5.2.2 Functional description 21
5.3 Bypass function 22
5.3.1 Activating and deactivating the bypass function 22
5.4 Product identification 24
6 Transportand storage 25
6.1 Transporting the axial piston unit 25
6.1.1 Transportby hand 25
6.1.2 Transportwith lifting devices 25
6.2 Storing the axial piston unit 28
7 Installation 30
7.1 Unpacking 30
7.2 Installation conditions 30
7.3 Installation position 32
7.3.1 Below-reservoir installation (standard) 32
7.3.2 Above-reservoir installation 33
7.4 Installing the axial piston unit 34
Contents
7.4.1 Preparation 34
7.4.2 Dimensions 35
7.4.3 General instructions 35
7.4.4 Installation with a coupling 36
7.4.5 Installation on a gearbox 36
7.4.6 Installation with cardan shaft 37

4/64
Bosch Rexroth AG, A4VG Series35, RE92035-01-B/2019-11-25
7.4.7 Completion of assembly 37
7.4.8 Hydraulically connecting the axial piston unit 39
7.4.9 Electrically connecting the axial piston unit 43
7.5 Performing flushing cycle 43
8 Commissioning 44
8.1 Initial commissioning 44
8.1.1 Filling the axial piston unit 45
8.1.2 Testing the hydraulic fluid supply 46
8.1.3 Performing a functional test 47
8.2 Running-in phase 47
8.3 Recommissioning after standstill 48
9 Operation 49
10 Maintenance and repair 50
10.1 Cleaning and care 50
10.2 Inspection 51
10.3 Maintenance 51
10.4 Repair 52
10.5 Spare parts 52
11 Removal and replacement 53
11.1 Required tools 53
11.2 Preparing for removal 53
11.3 Performing the disassembly 53
11.4 Preparing the components for storage or further use 53
12 Disposal 54
13 Extension and conversion 55
14 Troubleshooting 56
14.1 How to proceed for troubleshooting 56
14.2 Malfunction table 57
15 Technical data 61
16 Alphabetical index 62
Contents

About this documentation 5/64
RE92035-01-B/2019-11-25, A4VG Series35, Bosch Rexroth AG
1 About this documentation
1.1 Validity of the documentation
This documentation is valid for the following products:
• Axial piston variable pump A4VG Series35
This documentation is intended for machine/system manufacturers, assemblers and
service engineers.
This documentation contains important information on the safe and proper
transport, installation, commissioning, operation, maintenance, removal and simple
troubleshooting of the axial piston unit.
▶ Read this documentation completely, in particular chapter 2 "Safety instructions"
on page 9 and chapter 3 "General instructions on property damage and
product damage" on page 16 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 for your axial piston variable
pump A4VG.
– Order confirmation
Installation drawing
Contains the outer dimensions, all ports and the hydraulic circuit diagram
for your axial piston variable pump A4VG.
Please request the
installation drawing
from your contact at
BoschRexroth.
Installation drawing
Axial piston variable pump A4VG
Contains the permissible technical data, ports, main dimensions and
circuit diagrams.
92035 Data sheet
Hydraulic fluids based on mineral oils and related hydrocarbons
Describes the requirements for hydraulic fluids on mineral oil basis 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
Environmentally acceptable hydraulic fluids
Describes the requirements for environmentally acceptable hydraulic
fluids on mineral oil basis and related hydrocarbons for operation with
Rexroth hydraulic components and provides supportfor selection of
suitable hydraulic fluids for the hydraulic system.
90221 Data sheet
Fire-resistant, water-free hydraulic fluids (HFDR/HFDU)
Describes the requirements on fire-resistant, water-free hydraulic fluids
(HFDR/HFDU) for operation with Rexroth hydraulic components and
assists you in selecting a hydraulic fluid for your hydraulic system.
90222 Data sheet

6/64 About this documentation
Bosch Rexroth AG, A4VG Series35, RE92035-01-B/2019-11-25
Table 1: Required and supplementary documentation
Title Document number Document type
Axial piston units for operation with fire-resistant
hydraulic fluids – water-free, water-containing
(HFDR, HFDU, HFA, HFB, HFC)
Describes the requirements on fire-resistant, water-free and
water-containing hydraulicfluids (HFDR, HFDU, HFA, HFB, HFC) and
contains the technical data for operation
with Rexroth hydraulic components.
90225 Data sheet
Component class: 92035-CC-0001_ETPump
The component class specification explains what data is available,
howthis data was obtained, and gives further notices to be observed.
92035-CC-0001_ETPump Component class
specification
BODAS-drive eDA application software
BODAS-drive eDA is a software solution integrated in the Rexroth
SRC-eDA1/31 control unit for controlling the hydrostatic drive train in
wheeled vehicles.
95315 Data sheet
BoschRexroth Fluid Rating List for Rexroth hydraulic components
(pumps and motors)
Contains the hydraulic fluids positively evaluated by BoschRexroth.
90245 Data sheet
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
1.3 Representation of information
Uniform safety instructions, symbols, terms and abbreviations are used throughout
this documentation to ensure safe and proper use of the product. For clarification,
they are explained in the sections below.
1.3.1 Safety instructions
This documentation contains safety instructions in chapter 2.6 "Product-specific
safety instructions" on page12 and in chapter 3 "General instructions on property
damage and product damage" on page16, as well as before a sequence of actions
or an instruction for action involving a risk of personal injury and property damage.
Always follow the measures for danger prevention associated with the use of this
product.
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

About this documentation 7/64
RE92035-01-B/2019-11-25, A4VG Series35, Bosch Rexroth AG
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.
1.3.3 Designations
This documentation uses the following designations:
Table 4: Designations
Designation Meaning
A4VG Axial piston variable pump and closed 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 A4VG" the designation
"axialpistonunit" will be used in the following.

8/64 About this documentation
Bosch Rexroth AG, A4VG Series35, RE92035-01-B/2019-11-25
1.3.4 Abbreviations
This documentation uses the following abbreviations:
Table 5: Abbreviations
Abbreviation Meaning
ATEX EC directive on explosion protection (Atmosphère explosible)
DIN Deutsches Institut für Normung (German Institute for Standardization)
ET Electric control, direct-operated with two pressure reducing valves
(PRV)
ISO International Organization for Standardization
RE Rexroth document in the English language
VDI2230 Directive for the systematic calculation of high duty screwed
joints and cylindrical screw joints from the VDI(Verein Deutscher
Ingenieure-Association of German Engineers)

Safety instructions 9/64
RE92035-01-B/2019-11-25, A4VG Series35, Bosch Rexroth AG
2 Safety instructions
2.1 About this chapter
The axial piston unit has been manufactured to generally accepted engineering
standards. 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 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 partly completed machinery as
defined in the 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 axial piston unit is only approved as a pump for hydrostatic drives in closed
circuit.
▶ Observe the technical data, the application and operating conditions and
the performance limits as specified in the datasheet 92035 and in the order
confirmation. Information about approved hydraulic fluids can be found in
datasheet92035.
The axial piston unit is only intended for commercial use and not for private use.
Intended use includes having fully read and understood this documentation,
especially chapter 2 "Safety instructions" on page9.
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)

10/64 Safety instructions
Bosch Rexroth AG, A4VG Series35, RE92035-01-B/2019-11-25
• 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, e.g.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 10bar are allowed, but no more than 1000 pressure peaks over the entire
service life. Beyond this, the maximum permissible case pressure specified in the
datasheetshould not be exceeded.
• Application of the axial piston unit in explosive environments unless the
componentor machine/system has been certified as compliant with the
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 hydraulic expert knowledge.
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
• Knowledge regarding the function and interaction of hydraulic components
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.