Bosch rexroth A4VSO 10 Series User manual

Axial piston variable pump
A4VSO Series 10, 11 and 30
for explosive areas
II 2G Ex h IIC T4-T1 Gb X and
II 3G Ex h IIC T4-T1 Gc X
Instruction manual according to
ATEX directive 2014/34/EU
RE 92050-01-X-B0/2019.08.23
Mat. no.: R902569828
Replaces: 01.2017
English

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What you need to know about this instruction manual
The full instruction manual in accordance with ATEX Directive 2014/34/EU of the A4VSO axial piston variable
pump
ATEX for explosive areas consists of the following two parts:
Part I Product-specific and general instructions RE92050-01-X-B1/2019.08.23 72pages
Part II Data sheet RE92050-01-X-B2/2019.08.23 48pages
The Declaration of Conformity can be found on the next-to-last page.
DE: Die Inbetriebnahme dieses Produkts darf erst dann erfolgen, wenn Sie diese Betriebsanleitung in einer für
Sie verständlichen Sprachversion vorliegen und den Inhalt verstanden haben. Ist dies nicht der Fall, wenden Sie
sich bitte an Ihren BoschRexroth Ansprechpartner oder die zuständige Servicestelle. Diese finden Sie auch unter
www.boschrexroth.com.
EN:
This product may only be commissioned if these operating instructions are available to you in a language
version that you can understand and if you have understood its content. If this is not the case, please contact your
BoschRexroth contact partner or the responsible service point. You can also find them under www.boschrexroth.com.
BG: Пускането в експлоатация на този продукт може да се извърши едва тогава, когато разполагате с това
упътване за употреба в разбираема за Вас версия на езика и сте разбрали неговото съдържание. Ако това
неетака, обърнете се към Вашия партньор BoschRexroth или към компетентен сервиз. Ще го намерите
вwww.boschrexroth.com.
CS: Tento výrobek smí být uveden do provozu jedině tehdy, máte-li k dispozici tento návod k obsluze v pro vás
srozumitelné jazykové verzi a rozumíte celému jeho obsahu. Pokud tomu tak není, obraťte se na svou kontaktní
osobu u firmy BoschRexroth nebo na příslušné servisní středisko. To naleznete také na internetové adrese
www.boschrexroth.com.
DA: Dette produkt må først tages i brug, når du har modtaget og læst driftsvejledningen på et for dig forståeligt
sprog og har forstået indholdet. Hvis det ikke er tilfældet, bedes du kontakte din kontaktperson hos BoschRexroth
eller den ansvarlige kundeserviceafdeling. Den kan du finde på hjemmesiden www.boschrexroth.com.
EL: Το προϊόν επιτρέπεται να τεθεί σε λειτουργία μόνο εάν διαθέτετε τις παρούσες οδηγίες χρήσης σε κατανοητή
γλώσσα και εφόσον έχετε κατανοήσει το περιεχόμενό τους. Εάν δεν πληρούνται αυτές οι προϋποθέσεις, απευθυνθείτε
στους κατά τόπους αντιπροσώπους της BoschRexroth ή σε κάποιο εξουσιοδοτημένο σέρβις. Για τα σχετικά στοιχεία
επισκεφτείτε την ιστοσελίδα www.boschrexroth.com.
ES: La puesta en servicio de este producto únicamente podrá realizarse cuando disponga de las instrucciones
de servicio en un idioma que entienda y haya entendido su contenido. En caso contrario, diríjase a su persona
de contacto de BoschRexroth o al servicio técnico competente, que podrá encontrar también en la dirección
www.boschrexroth.com.
ET: Toodet tohib kasutada ainult siis, kui teil on olemas teie jaoks arusaadavas keeles kasutusjuhend ja te saate
sellesisust aru. Kui see nii ei ole, pöörduge oma BoschRexrothi esindaja või vastava teeninduse poole. Nende
kontaktandmed leiate aadressilt www.boschrexroth.com.
FI: Älä ota tuotetta käyttöön ennen kuin olet saanut käyttöohjeen omalla kielelläsi ja ymmärrät sen sisällön. Ota
muussa tapauksessa yhteyttä BoschRexroth -yhteyshenkilöösi tai valtuutettuun huoltoliikkeeseen. Yhteystiedot
löydät osoitteesta www.boschrexroth.com.
FR: Ce produit ne doit être mis en service que lorsque vous disposez des présentes instructions de service en une
version linguistique que vous comprenez e que vous avez compris son contenu. Si cela n‘est pas le cas, veuillez vous
adresser à votre interlocuteur BoschRexroth ou au service compétent. Vous trouvez les coordonnées également sur
le site www.boschrexroth.com.

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HU: Ennek a terméknek az üzembe helyezése csak akkor történhet meg, ha ez a kezelési
útmutató rendelkezésre áll az Ön számára érthető egyik nyelven, és megértette annak
tartalmát. Egyéb esetben forduljon a BoschRexroth kapcsolattartójához vagy az
illetékes szervizhez. Ezeket is megtalálja az alábbi címen: www.boschrexroth.com.
IT: La messa in servizio di questo prodotto può essere eseguita solo se si dispone del
presente manuale d‘uso in una lingua conosciuta e se ne è stato compreso il contenuto.
In caso contrario rivolgersi al referente BoschRexroth o al punto di assistenza
competente. Questi sono anche riportati sul sito www.boschrexroth.com.
LT: Pradėti naudoti šį produktą leidžiama tik turint šią vartotojo instrukciją Jums
suprantama kalba ir jei supratote jos turinį. Jei instrukcijos nesuprantate, prašome
kreiptis į savo BoschRexroth konsultantą arba atsakingą aptarnavimo tarnybą.
Informaciją apie juos rasite adresu www.boschrexroth.com.
LV: Šīs ierīces ekspluatāciju drīkst sākt tikai tad, ja šī ekspluatācijas instrukcija Jums ir
pieejama kādā jums saprotamā valodā un Jūs esatizpratis tās saturu. Pretējā gadījumā
lūdzam vērsties pie attiecīgās "BoschRexroth" kontaktpersonas vai kompetentā
servisa dienestā. Nepieciešamā informācija ir pieejama arī mūsu mājas lapā internetā
www.boschrexroth.com
NL: U mag het product pas in bedrijf stellen, als deze bedieningshandleiding voor
ubeschikbaar is in een voor u begrijpelijke taal en als u de inhoud daarvan begrepen
heeft. Is dit niet het geval, neem dan a.u.b. contact op met uw BoschRexroth
contactpersoon of de servicepartner. Deze vindt u ook op www.boschrexroth.com.
NO: Dette produktet må ikke tas i bruk før du har mottatt denne bruksanvisningen på et
språk som du forstår, og du har forstått innholdet. Hvis dette ikke er tilfellet, ta kontakt
med din kontaktperson hos BoschRexroth eller den ansvarlige kundeserviceavdelingen.
Disse finner du også på www.boschrexroth.com.
PL: Przed uruchomieniem niniejszego produktu należy zapoznać się z instrukcją obsługi
w Państwa wersji językowej. Wprzypadku, gdy nie dołączono instrukcji wdanym
języku, należy zwrócić się z zapytaniem do osoby kontaktowej BoschRexroth lub
do odpowiedniego punktu obsługi. Listę takich punktów można znaleźć na stronie
www.boschrexroth.com.
PT: A colocação deste produto em funcionamento pode ser efetuada apenas se
omanual de instruções estiver disponível em um idioma compreensível para você
e se você tiver compreendido o conteúdo do mesmo. Se esse não for o caso, entre
em contato com o seu representante da BoschRexroth ou com a assistência técnica.
Encontre-os em www.boschrexroth.com
RO: Aveţi voie să puneţi în funcţiune acest produs, doar după ce aţi primit acest
manual de utilizare într-o versiune de limbă inteligibilă pentru dumneavoastră şi aţi
înţeles conţinutul său. Dacă aceste condiţii nu sunt îndeplinite, adresaţi-vă persoanei
dumneavoastră de contact de la BoschRexroth sau la service-ul BoschRexroth
competent. Găsiţi aceste service-uri la www.boschrexroth.com
RU: Ввод в эксплуатацию данного продукта разрешен только после того,
как руководство по эксплуатации будет получено Вами на русском языке
иполностью понято. Если у Вас нет руководства по эксплуатации, обратитесь,
пожалуйста, кответственному за Ваш регион представителю BoschRexroth
или в соответствующий сервисный центр. Оно также находится на сайте
www.boschrexroth.com.

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SK: Tento výrobok sa smie uviesť do prevádzky až vtedy, keď ste dostali tento
návod na prevádzku k dispozícii v pre vás zrozumiteľnej jazykovej mutácii aobsahu
ste porozumeli. V opačnom prípade sa, prosím, obráťte na vašu kontaktnú osobu
vBoschRexroth alebo na zodpovedné servisné miesto. Nájdete ich tiež na
www.boschrexroth.com.
SL: Z uporabo tega izdelka lahko pričnete šele, ko ste prebrali ta navodila za uporabo
vvam razumljivem jeziku in razumeli njihovo vsebino. Če navodila za uporabo niso
na voljo v vašem jeziku, vas prosimo, da se obrnete na kontaktno osebo podjetja
BoschRexroth oz. pooblaščeni servis. Te lahko najdete tudi na www.boschrexroth.com.
SV: Denna produkt får inte tas i drift förrän du har mottagit en bruksanvisning på ett
språk som du förstår och sedan har läst och förstått innehållet i. Om detta inte är fallet
ber vi dig kontakta din kontaktperson på BoschRexroth eller ansvarig kundservice.
Dessa hittar du också på www.boschrexroth.com.
ZH: 使用该产品前，请您确保已拥有一份您所熟悉语言版本的使用说明书并已理解其内容。如果
尚未拥有，请向博世力士乐合作伙伴或相关服务部门索取，也可登录 www.boschrexroth.com
下载

CORRECTION COPY | 2019-08-23 | FOR INTERNAL USE ONLY
Part I of instruction manual
according to ATEX directive
2014/34/EU Product-specific
and general instructions
RE 92050-01-X-B1/2019.08.23
Replaces: 01.2017
English
Axial piston variable pump
A4VSO Series 10, 11 and 30
for explosive areas
II 2G Ex h IIC T4-T1 Gb X and
II 3G Ex h IIC T4-T1 Gc X

© 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 manual was created inthe
Germanlanguage.

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3/72Contents
Contents
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 7
2 Safety instructions 8
2.1 About this chapter 8
2.2 Intended use 8
2.3 Improper use 9
2.4 Personnel qualifications 9
2.5 General safety instructions 10
2.6 Product-specific safety instructions 11
2.7 Personal protective equipment 16
3 General instructions onproperty damage and product damage 17
3.1 Operator's obligations 19
4 Scope ofdelivery 20
5 About this product 21
5.1 Performance description 21
5.2 Product description 21
5.2.1 Axial piston unit layout 21
5.2.2 Functional description 22
5.3 Product identification 23
5.3.1 Axial piston unit name plate 23
5.3.2 Explosion protection mark 24
6 Transport and storage 26
6.1 Transporting theaxial piston unit 26
6.1.1 Transport byhand 27
6.1.2 Transport with lifting devices 27
6.2 Storing theaxial piston unit 28
7 Installation 30
7.1 Unpacking 30
7.2 Installation conditions 31
7.3 Installation position 32
7.3.1 Below-reservoir installation (standard) 33
7.3.2 Inside-reservoir installation 33
7.3.3 Above-reservoir installation 34

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Contents
7.4 Installing theaxial piston unit 36
7.4.1 Preparation 36
7.4.2 Dimensions 37
7.4.3 General instructions 38
7.4.4 Installation with acoupling 38
7.4.5 Installation on a gearbox 39
7.4.6 Installation with cardan shaft 40
7.4.7 Completion of assembly 40
7.4.8 Hydraulically connecting theaxial piston unit 41
7.4.9 Electrically connecting theaxial piston unit 45
7.4.10 Connecting to the potential equalization 46
8 Commissioning 47
8.1 Initial commissioning 47
8.1.1 Comply with the limits for supply/leakage temperature 48
8.1.2 Functional test of shut-off chain
(Equipment Category II 2G Ex h IIC T4-T1 Gb X only) 48
8.1.3 Filling theaxial piston unit 48
8.1.4 Testing thehydraulic fluid supply 49
8.1.5 Performing afunctional test 50
8.1.6 Performing flushing cycle 51
8.2 Running-in phase 51
8.3 Recommissioning after standstill 52
9 Operation 53
9.1 Operating the optional auxiliary actuation device 54
10 Maintenance and repair 54
10.1 Cleaning and care 55
10.2 Inspection 56
10.3 Maintenance 57
10.4 Service life characteristics of NG 40 to 500 57
10.5 Repair 61
11 Removal and replacement 62
11.1 Required tools 62
11.2 Preparing for removal 62
11.3 Performing thedisassembly 62
11.4 Preparing thecomponents for storage orfurther use 63
12 Disposal 64
13 Extension and conversion 65
14 Troubleshooting 66
14.1 How toproceed for troubleshooting 66
14.2 Malfunction table 67
15 Technical data 71

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1 About this documentation
1.1 Validity ofthedocumentation
This documentation isvalid for thefollowing products:
• Axial piston variable pump A4VSO ATEX (series 1x and 30).
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 8 and chapter 3 "General instructions onproperty damage and
product damage" onpage 17 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 technical data relevant tothe Axial piston variable pump A4VSO
ATEXseries 1x and 30 ordered.
– Order confirmation
Installation drawing
Contains the outer dimensions, all ports and the hydraulic circuit diagram foryour
Axial piston variable pump A4VSO ATEX.
Please request
theinstallation
drawing from
your contact
atBoschRexroth.
Installation drawing
Axial piston variable pump A4VSO for explosive areas
II 2G Ex h IIC T4-T1 Gb X and II 3G Ex h IIC T4-T1 Gc X
Contains the permissible technical data.
92050-01-X-B2 Data sheet
Control devices DR, DRG, DP, FR and DFR
Contains information on pressure and flow controllers
92060 Data sheet
Power controllers LR2 and LR3
Contains information on power controllers
92064 Data sheet
Hydraulic control, pilot-pressure related HD
Contains information on pilot-pressure related controllers
92080 Data sheet
Hydraulic fluids based onmineral oils and related hydrocarbons
Describes the requirements on a hydraulic fluid based on mineral oil and related
hydrocarbons for operation with Rexroth hydraulic components, and assists you in
selecting a hydraulic fluid for your hydraulic system.
90220 Data sheet
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

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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
This documentation contains safety instructions inchapter 2.6 "Product-specific
safety instructions" onpage 11 and inchapter 3 "General instructions onproperty
damage and product damage" onpage 17, 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
▶ Measures toprevent danger
▶ <List>
•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Z535.6-2006
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.

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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
A4VSO ATEX Axial piston variable pump, open circuit for explosive areas
II 2G Ex h IIC T4-T1 Gb X and II 3G Ex h IIC T4-T1 Gc X
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 A4VSO ATEX" 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)
DIN Deutsche Industrie Norm (German Institute for Standardization)
A4VSO Axial piston variable pump, open circuit
DFR Pressure flow controller
DP Pressure controller for parallel operation
DR Pressure controller
DRG Pressure controller, remote-controlled
FR Flow controller
HD Hydraulic control, pressure-dependent
LR2 Power controller with hyperbolic characteristic curve
LR3 Power control with remotely controllable power characteristic
OV Without control
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 screwed joints and
cylindrical screw joints from theVDI (VereinDeutscherIngenieure -
Association ofGerman Engineers)

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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anopen
circuit.
▶ Adhere to the technical data, the application and operating conditions, and
the performance limits as specified in the data sheet (Part II) and in the order
confirmation. Information about approved hydraulic fluids can be found in the
data sheet(Part II).
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 8.
The axial piston units in explosion-protected design satisfy the requirements of the
EU ATEX Directive (2014/34/EU).
Information on the equipment group and category as defined in the ATEX Directive
(2014/34/EU) can be found on the data sheet (Part II) under application in
accordance with EC directive 2014/34/EU and on the name plate of the axial piston
unit.
Under EC directive 1999/92/EC, the user/operator is required to divide explosive
areas into zones. Chapter 5.3.2 "Explosion protection mark" on page 24 compares
the zones with the equipment groups and categories.
The axial piston unit should only be used in applications specified for the equipment
group and category in Directive 2014/34/EU and according to the areas specified in
the type of protection or in areas (explosion group, temperature class) with lower
requirements. It should be operated in accordance with the technical data and
ambient conditions specified in this directive and in this instruction manual.

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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 misuses are also considered improper:
• Use outside the operating parameters approved in the data sheet (Part II) or in the
order confirmation (unless customer-specific approval has been granted)
• Use ofnon-approved fluids, e.g. water orpolyurethane components
• Changes tofactory settings byunauthorized persons.
• Use of assembled parts (e.g., attachment filter, control unit, valves) other than
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
• Use of the axial piston unit when ambient pressure is greater than internal pressure
(case pressure)
• Use oftheaxial piston unit inpotentially explosive areas 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
• Use of the axial piston unit in areas where propagating brush discharge could occur
(as per ENISO80079-36)
2.4 Personnel qualifications
The activities described in this documentation require basic knowledge of
mechanics, electricity, hydraulics and ATEX, 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
• Comprising ofknowledge regarding thefunction and layout 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:
http://www.boschrexroth.de/didactic.

10/72 Safety instructions
BoschRexrothAG, axial piston variable pump A4VSO, RE 92050-01-X-B1/2019.08.23
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 install, operate, remove ormaintain Rexroth products ifunder theinfluence
ofalcohol, drugs ormedication that may affect your reaction time.
• Adhere to all applicable legal regulations, rules and directives regarding explosion
protection.
• 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 applications
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.

Safety instructions 11/72
RE 92050-01-X-B1/2019.08.23, Axial piston variable pump A4VSO, BoschRexrothAG
2.6 Product-specific safety instructions
The following safety instructions apply tochapters 6 to14.
DANGER
Risk of explosion and/or fire due to ignition of an explosive atmosphere or of
combustible dust!
Serious injury caused by blast pressure and fire may result.
▶ Take care to remove dust in a timely manner in order to reduce the risk of
ignition.
▶ The case leakage temperature on the drain port, or the inlet temperature on the
suction port, must not exceed the specified limit values. The system operator
must ensure that the case leakage temperature does not exceed the limit value
under any operating conditions. This can be done by adhering to a maximum
inlet temperature. The readings are checked on a daily basis. Observe the
relevant information on the data sheet (Part II).
▶ The reservoir level should also be monitored.
▶ Make sure parts (e.g., coupling components) that are able to move relative to
each other do not touch, as this could create sparks and/or heat and explosion
protection would no longer be guaranteed.
Also observe the following for ATEX category II 2G Ex h IIC T4-T1 Gb X:
▶ The axial piston unit should only be operated if the hydraulic system is equipped
with a leakage temperature monitor that, in the event the maximum leakage
temperature is exceeded (see data sheet, Part II), deactivates the system so the
temperature cannot continue to rise. This must be provided by the operator.
Risk of explosion and/or fire due to ignition of an explosive atmosphere or
of combustible dust on a hot surface caused by overheating due to faults or
defects, or actuation of high-pressure relief valves!
Serious injury caused by blast pressure and fire may result.
▶ Regardless of the control, the system should be safeguarded against pressure
overload.
▶ Set the external pressure relief valve so the maximum permissible pressure
cannot be exceeded; see data sheet (Part II).
▶ Set the opening pressure of the high pressure relief valve to a value of at least
30 bar above the value set at the pressure controller.

12/72 Safety instructions
BoschRexrothAG, axial piston variable pump A4VSO, RE 92050-01-X-B1/2019.08.23
DANGER
Risk of explosion and/or fire due to ignition of an explosive atmosphere or of
combustible dust on a hot surface caused by friction due to lack of lubricant!
Serious injury caused by blast pressure and fire may result.
▶ Ensure lubrication by means of case drain fluid. Always use the highest case
drain port to ensure internal lubrication through circulating case drain fluid,
seechapter 7.3 "Installation position" on page 32.
▶ With above-reservoir installation, only operate the axial piston unit with bearing
flushing.
▶ With above-reservoir installation, prevent idling.
▶ Fill the axial piston unit with hydraulic fluid prior to commissioning.
Risk of explosion and/or fire due to ignition of an explosive atmosphere or of
combustible dust on a hot surface caused by overloading and damage to shaft
key or splines causing coupling to turn on shaft!
Serious injury caused by blast pressure and fire may result.
▶ Make sure the permissible shaft load indicated on the data sheet (Part II) is not
exceeded under any operating conditions.
▶ Make sure the shaft and coupling are correctly aligned; see chapter7.4.4
"Installation with acoupling" on page38.
Risk of explosion and/or fire due to ignition of an explosive atmosphere or of
combustible dust on a hot surface caused by overheating!
Serious injury caused by blast pressure and fire may result.
▶ Make sure the permissible case pressure according to the data sheet (Part
II) is never exceeded, excessive case pressure or pressure peaks can cause
inadmissibly high temperature on the shaft seal and, with it, a risk of ignition.
▶ Bearing damage or damage to rotary groups within the axial piston unit result
in an increase in the case leakage temperature caused by heat released through
mechanical friction losses. A gradual increase in the case leakage temperature
can, thus, indicate the start of bearing damage. If this occurs, check whether
there is an increase in mechanical loading. Contact BoschRexrothService for
maintenance if you cannot trace the increase in temperature to an increase in
the loading of the axial piston unit.
▶ A sudden increase in the case leakage temperature indicates severe damage
with extreme friction. If this occurs, shut down the axial piston unit immediately
and contact BoschRexrothService for maintenance.

Safety instructions 13/72
RE 92050-01-X-B1/2019.08.23, Axial piston variable pump A4VSO, BoschRexrothAG
DANGER
Risk of explosion and/or fire due to ignition of an explosive atmosphere or
of combustible dust on a hot surface caused by overheating due to excessive
speed!
Serious injury caused by blast pressure and fire may result.
▶ Make sure the maximum permissible rotational speed as specified on the data
sheet (Part II) is not exceeded.
▶ If necessary, take measures to ensure rotational speed is limited.
Risk of explosion and/or fire due to ignition of an explosive atmosphere or of
combustible dust caused by mechanically generated sparks!
Serious injury caused by blast pressure and fire may result.
To prevent mechanically generated sparks due to foreign particles made
of aluminum with ferric oxide and/or particles of rust on the surface
(seeDINENISO80079-36, 6.4.2.1), the pump comes with an anticorrosive paint.
▶ Make sure the paint is not damaged.
▶ Do not transport or store the axial piston unit in potentially explosive areas.
▶ Do not load the axial piston unit in potentially explosive areas.
▶ Do not unpack or pack the axial piston unit in potentially explosive areas.
Risk of explosion and/or fire due to ignition of an explosive atmosphere or of
combustible dust due to sparks caused by electrostatic discharge!
Serious injury caused by blast pressure and fire may result.
The axial piston unit has been painted as specified in Section 6.7 (Static Electricity)
of DINENISO80079-36.
▶ Additional coats of paint should only be applied as specified in Section 6.7
of DINENISO80079-36, otherwise explosion protection cannot is no longer
guaranteed. The ground terminal must not be painted.
▶ Include the axial piston unit in the potential equalization connection.
▶ The axial piston unit is only approved for use in areas where no propagating
brush discharge can occur.
▶ Do not transport or store the axial piston unit in potentially explosive areas.
▶ Do not load the axial piston unit in potentially explosive areas.
▶ Do not unpack or pack the axial piston unit in potentially explosive areas.

14/72 Safety instructions
BoschRexrothAG, axial piston variable pump A4VSO, RE 92050-01-X-B1/2019.08.23
WARNING
Danger from excessive pressure!
Danger tolife, risk of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.
▶ Changes tothe factory settings may only bemade byBoschRexroth specialists.
▶ 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.
▶ Set the external pressure relief valve so the maximum permissible pressure
cannot be exceeded; see data sheet (PartII).
▶ Set the opening pressure of the high pressure relief valve to a value of at least
30 bar above the value set at the pressure controller.
Danger due tosuspended loads!
Danger tolife, risk of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 fork lift truck or lifting device has adequate lifting capacity.
▶ Never step orgrip 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 specifications ofoccupational safety and health
and transport.
System/machine under pressure!
Danger to life or risk of injury, serious injuries when working on machines/systems
that are not shut down! Property damage!
▶ Secure theentire system against being re-energized.
▶ Make sure that the machine/system is depressurized. For this purpose, observe
theparameters indicated bythemachine/system manufacturer.
▶ Do not disconnect any line connections, ports and components as long as the
machine/system is under pressure.
▶ Switch off all power-transmitting components and connections
(electric,pneumatic, hydraulic, mechanical) in line with the manufacturer's
specifications and secure them against being turned back on.

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RE 92050-01-X-B1/2019.08.23, Axial piston variable pump A4VSO, BoschRexrothAG
WARNING
Escaping oil mist!
Risk ofexplosion and fire hazard, health hazard, risk ofenvironmental pollution!
▶ Depressurize the machine/system 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.
▶ Only use a hydraulic fluid that complies the requirements on the
datasheet(Part II) (in accordance with DINENISO80079-36, chapter4.5).
▶ 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.
Electrical voltage!
Risk ofinjury from electric shock orrisk ofproperty damage!
▶ Always disconnect thevoltage supply tothe relevant machine/system part
before installing theproduct and/or connecting ordisconnecting theconnector.
Protect themachine/system against being re-energized.

16/72 Safety instructions
BoschRexrothAG, axial piston variable pump A4VSO, RE 92050-01-X-B1/2019.08.23
CAUTION
High noise development during operation!
Danger ofhearing damage, 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) under normal application conditions.
▶ Always wear hearing protection near arunning axial piston unit.
Hot surfaces onaxial piston unit!
Risk ofburning!
▶ Allow theaxial piston unit tocool down sufficiently before touching it.
▶ Protect yourself with heat-resistant protective clothing, e.g. gloves.
Inappropriate routing ofcables and lines!
Risk ofstumbling and property damage!
▶ Lay cables and lines so that they cannot be damaged and nobody can trip over
them.
Contact with hydraulic fluid!
Danger tohealth / damage tohealth, e.g. eye injury, skin damage, toxication inthe
event of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.
Escaping hydraulic fluid due tomachine/system leakage!
Risk ofburning and risk ofinjury due toescaping hydraulic fluid jet!
▶ Depressurize the machine/system and repair the leak.
▶ Never attempt toblock orseal the leak orhydraulic fluid jet with acloth.
2.7 Personal protective equipment
Personal protective equipment istheresponsibility oftheuser oftheaxial piston
unit. Observe thesafety regulations inyour country.
All pieces ofpersonal protective equipment should beintact.