Electric Drives Linear Motion and

and Controls Hydraulics Assembly Technologies Pneumatics Service

General Operating Instructions RE 90 300-B/02.06

Replaces 05.05
for Axial Piston Units

General Operating Instructions

B
2/44 Bosch Rexroth AG General operating instructions for axial piston units RE 90 300-B/02.06

Manufacturer Contents
1 About these instructions ............................................................3
Bosch Rexroth AG 1.1 Structure and requirements ....................................................3
Hydraulics 1.2 Staff requirements ....................................................................5
Product Segment Axial Piston Units 1.3 Hazard markings and pictograms .........................................6
Elchingen plant
Glockeraustrasse 2 2 Safety ...................................................................................................7
89275 Elchingen, Germany 2.1 Basic safety instructions .........................................................7
2.2 Operating company’s and operator’s obligations
Telephone +49 (0) 73 08 82-0
to exercise due care .................................................................9
Fax +49 (0) 73 08 72 74
2.3 Responsibility of machine or system manufacturer .........10

3 Product description.................................................................... 11
Bosch Rexroth AG 3.1 Identification of axial piston unit...........................................11
Hydraulics 3.2 Functional description............................................................12
Product Segment Axial Piston Units 3.3 Scope of supply ......................................................................12
Horb plant 3.4 Technical data ..........................................................................12
An den Kelterwiesen 14 3.5 Conventional use ....................................................................13
72160 Horb am Neckar, Germany
Telephone +49 (0)74 51 - 92 0 4 Installation ...................................................................................... 15
Fax +49 (0)74 51 - 82 21 4.1 General installation instructions ..........................................16
4.2 Unpacking instructions .......................................................... 17
[email protected] 4.3 Preparing axial piston unit for assembly ............................ 17
www.boschrexroth.com/addresses 4.4 Transporting the axial piston unit to the installation
location ...............................................................................................18
This website also provides information about contact persons 4.5 Assembling axial piston unit .................................................18
in other countries. 4.6 Connecting lines .....................................................................21
4.7 Connecting electric controller ........................................... 22
4.8 Disassembling axial piston unit ........................................... 23
Manufacturer details are available on the axial piston unit name 4.9 Preparing axial piston unit for storage............................... 23
plate. 4.10 Disposing of axial piston unit............................................... 24

5 Commissioning ............................................................................25
5.1 Preparations ............................................................................ 26
5.2 Filling axial piston unit .......................................................... 26
5.3 Testing the direction of rotation of the engine ................. 28
5.4 Testing hydraulic fluid supply .............................................. 28
5.5 Performing functional test .................................................... 29
5.6 Performing flushing cycle ..................................................... 29

6 Troubleshooting ........................................................................... 31

7 Servicing ..........................................................................................35
7.1 Maintenance ............................................................................ 35
7.2 Inspection ................................................................................ 35
7.3 Repair ....................................................................................... 36

Appendix A: Project planning notes .............................................37

Index .............................................................................................................. 41
RE 90 300-B/02.06 General operating instructions for axial piston units Bosch Rexroth AG 3/44

Avoiding hazards

! DANGER! To ensure reliable operation and to avoid damage when performing an installation,
commissioning or repair work, study these operating instructions carefully and thoroughly!
Bosch Rexroth AG can not be held liable for any personal injuries or machine damage arising
from non-adherence to these operating instructions. In case of damage induced by disregard
of these operating instructions, any warranty provided by Bosch Rexroth AG will be rendered
null and void and liability placed with the operator.

1 About these instructions

1.1 Structure and requirements

Documents Operating instructions for Rexroth axial piston units consist of three part documents:
• General operating instructions for axial piston units
These general operating instructions for axial piston units will assist you during installation,
commissioning and operation of Rexroth axial piston units. These include axial piston
pumps and motors for use in open or closed hydraulic circuits.
Unless stated differently, the information in these operating instructions applies to all
Rexroth axial piston units. Information, which only applies to specific pumps or motors or
hydraulic concepts, is marked in the text accordingly.
• Product-specific operating instructions
The product-specific operating instructions for the individual Rexroth axial piston units
contain additional, specific information on installation, commissioning and operation.
Not every Rexroth axial piston unit is supplied with its own product-specific operating
instructions.
Always observe both the details in the product-specific operating instructions and the
details in the general operating instructions RE 90 300-B.
• Technical data sheet
The technical data sheets for the individual Rexroth axial piston units contain the complete
technical data.
Please contact Rexroth to request the missing parts of the documentation, if you are not in
possession of the whole set of documents. Safe operation of Rexroth axial piston units can
only be guaranteed if you observe the details in all the part documents.

General operating These general operating instructions will assist you during installation, commissioning and
instructions operation of Rexroth axial piston units. You will require the individual chapters of these
instructions for the different phases of working with the axial piston unit:
• "2 Safety" on page 7 explains how the instructions in this document are to be understood
and contains several basic safety instructions on handling axial piston units.
• "3 Product description" on page 11 provides you with information on the identification of
axial piston units as well as its proper and intended use.
• "4 Installation" on page15 provides you with information on the installation, and on the
disassembly and storage of axial piston units.
• "5 Commissioning" on page 25 explains what you have to observe during the
commissioning of the axial piston unit and machine or the system.
• The overview in "6 Troubleshooting" on page 31 assists you in searching and tracing faults
on the axial piston unit and the general machine or system.
4/44 Bosch Rexroth AG General operating instructions for axial piston units RE 90 300-B/02.06

• "7 Servicing" on page 35 provides you with information on maintenance, inspection and
repairs to the axial piston unit.
• The Annex starting on page 37 contains project-planning notes for selection of the
hydraulic fluid, and design of the tank, filter and heat exchanger as well as the correct
piping of the hydraulic system.

Area of validity for These operating instructions are valid for Rexroth axial piston units for operation with
these instructions permissible hydraulic fluids. Information on permissible hydraulic fluids is available in the
technical data sheet.
These operating instructions are for the:
• machine or system manufacturer,
• operating company,
• operator.
Each particular installation drawing, technical data sheet and order confirmation of the Bosch
Rexroth AG is also binding for the machine or system manufacturer.

Important Before starting with the tasks described in this instruction manual, make sure that the
documents following documents are already available:
• Product-specific operating instructions
The product-specific operating instructions contain special information valid for each
particular axial piston unit. Please ask Rexroth if there is a product-specific instruction
manual for your axial piston unit.
• Order confirmation
The order confirmation contains the preset technical data. The axial piston unit may only be
operated using the values and conditions specified in the order confirmation.
• Installation drawing
The installation drawing for the axial piston unit contains the outer dimensions, all
connections and the hydraulic plan for the axial piston unit.
• Technical data sheet
The technical data sheet contains among other things the permissible technical data for
the axial piston unit.
• General connection plan of the machine or system
The hydraulic and electrical connection plan of the machine or system contain the
information of the hydraulic or electrical connections. You need this data to work with the
axial piston unit as part of the machine or system. You will get the documentation from the
machine or system manufacturer.
The following Rexroth publications give further information about installation and operation of
the axial piston unit:
• RE 90 220: Mineral-oil based hydraulic fluids
Describes the requirements on a mineral-oil based hydraulic fluid for the operation of a
Rexroth axial piston unit and assists you in selecting a hydraulic fluid for your system.
• RE 90 221: Environmentally acceptable hydraulic fluids HEES, HEPG, HETG for axial
piston units
Describes the requirements on an environmentally acceptable hydraulic fluid for the
operation of a Rexroth axial piston unit and assists you in selecting a hydraulic fluid for your
system.
• RE 90 223: Axial piston unit for the operation with HF hydraulic fluids
Contains additional information on the use of Rexroth axial piston units with HF hydraulic
fluids.
• RE 90 300-03-B: Information on using hydraulic drives at low temperatures
Contains additional information on the use of Rexroth axial piston units at low
temperatures.
RE 90 300-B/02.06 General operating instructions for axial piston units Bosch Rexroth AG 5/44

1.2 Staff requirements

General Axial piston units may only be installed and operated by qualified personnel.
requirements,
Qualified personnel is someone who is able to evaluate his tasks, to recognize dangers, and
qualification
to take necessary measures to provide risks of accidents on the basis of his professional
education, his knowledge and experience as well as the knowledge of relevant regulations.
Persons who are currently being instructed, trainees, or supervised persons under 18 may
not work on Rexroth hydraulic products.
This does not apply for adolescents with a minimum age of 16, if
• the work with Rexroth hydraulic products is necessary for reaching the training goal,
• the protection of the adolescent is guaranteed by an experienced supervisior and if they
use only work equipment, tools and protection means which exclude injuries.
Persons, who are alcoholized, or under the influence of drugs or medicaments, which affect
the reactivity may generally not operate or maintain Rexroth hydraulic products.

Requirements Maintenance measures can be necessary to obtain the operability of the axial piston unit.
on maintenance Details are available in chapter "7 Servicing" (page 35).
staff
Maintenance measures include inspection, service and maintenance of hydraulic and
electrical components. For these different activities different levels of minimum qualifications
of the staff are required.
To perform inspections on the outermost parts of the axial piston unit the staff has to fulfill
the following requirements:
• he/she has to be instructed in the task.
To perform service tasks on hydraulic parts of the axial piston unit personnel must fulfill the
following requirements:
• he/she has to introduced in the task,
• he/she has have specific hydraulic knowledge,
• he/she has be able of reading and fully understanding hydraulic plans,
• he/she has fully understand the relations regarding the installed security devices and,
• he/she has fully understand the function and configuration of the hydraulic components.
Repair work on axial piston units may only be made by repair shops who are authorized by
Rexroth. Rexroth offers a complete range of services for the repair of Rexroth axial piston
units.
For electric work generally applies the following:
• Work on electric equipment may only be done by an authorized and trained electrician
or by instructed persons under the direction and supervision of an authorized trained
electrician according to the electro-technical regulations.
6/44 Bosch Rexroth AG General operating instructions for axial piston units RE 90 300-B/02.06

1.3 Hazard markings and pictograms

This instruction differentiate between categories of hazards as per ISO Guide 37:

! DANGER! This hazard marking warns of high risk, lethal dangers and severe injuries.

! WARNING This hazard marking warns of medium risk, injuries and severe property damage.

! This hazard marking warns of low risk and property damage.

Note This marking refers to information, which helps to better understand the machine processes,
or which refers to special or important circumstances.

Tip This marking refers to information which helps to work more efficient.
RE 90 300-B/02.06 General operating instructions for axial piston units Bosch Rexroth AG 7/44

2 Safety
Read this chapter carefully before starting to work with the axial piston unit.
Rexroth axial piston units are to be installed as components in machines or systems. The
safety regulations in this instruction relate to axial piston units only. Please note additionally
the manufacturer’s safety regulations for the machine or system.

2.1 Basic safety instructions

Please observe strictly the following safety instructions as well as the safety instructions of
the machine or system manufacturer, to avoid any injuries and health damages as well as
material damage and environmental pollution.

! DANGER! Danger of life

Working on operational machines or systems forms a danger to life or physical condition.

The works described in this document may only be performed on disconnected machines or
systems. Before starting to work please ensure that:
• the engine cannot be switched on.
• all power transmitting components and connections (electric, pneumatic, hydraulic) are
switched off according to the manufacturers instructions and cannot be switched on
again. If possible, remove the main fuse on the machine or system.
• the machine or system is completely hydraulically relieved (depressurized). Please follow
the instructions of the machine or system manufacturer.

! WARNING Risk of injury

To avoid any injuries, please observe the following recommendations regarding safety wear:
• While working on the machine or system always wear safety shoes with steel caps.
• While working with dangerous substances (for example hydraulic fluids) always wear
safety gloves, safety glasses and suitable working clothes.

! DANGER! Risk of toxication and injury

Contact with hydraulic fluids may damage your health (e.g. eye injuries, skin and tissue
damage, toxication at inhalation).
• Please check the lines for wear or damage before each inital operation.
• Please wear thereby protective gloves, safety glasses and suitable working clothes.
• If however hydraulic fluid contacts the eyes or penetrates your skin please consult a
doctor immediately.
• When dealing with hydraulic fluids absolutely observe the safety instructions of the
hydraulic fluid manufacturer.
8/44 Bosch Rexroth AG General operating instructions for axial piston units RE 90 300-B/02.06

! WARNING Risk of burns!

The axial piston unit heats up during operation. Also the solenoids on the axial piston unit
heat up during operation. Touching the axial piston unit or solenoids could result in severe
burn injuries.
• Always allow the axial piston unit to cool down before touching it.
• Protect yourself by wearing heat-resistant gloves and protective clothing.

! DANGER! Risk of toxication and injury

While searching for leakages escaping hydraulic fluid can penetrate the skin and cause
severe poisoning and injuries.
• Only search for leakages when the machine is switched off and depressurized.

! WARNING Risk of injury and damage

Incorrectly connected components can cause severe malfunctions.

• Ensure that pipes are connected according to the connection plan.
• Perform component-oriented functional tests.

! DANGER! Fire hazard

Hydraulic pressure fluid is flammable.

• Please obstruct a naked flame and ignition sources from the axial piston unit.

! WARNING Hearing damage

The noise emission of axial piston units depends on speed, operating pressure and
installation conditions. You can count on the fact that the sound pressure level rises above
70 dBA on normal operating conditions. This may cause hearing damage.
• Always wear hearing protection while working next to the operating axial piston.
RE 90 300-B/02.06 General operating instructions for axial piston units Bosch Rexroth AG 9/44

! WARNING Environmental pollution

Hydraulic fluids are water-endangering fluids. Leaking hydraulic fluid can cause toxication of
the groundwater and ground contamination.
• Place a collector vessel under the axial piston unit.
• Remedy the leakage immediately.
• National laws and regulations must be observed at all times. In Germany hydraulic
machines or systems are classified as "systems for handling water-polluting substances
for the purpose of the Federal Water Act (WHG)". In this context please note especially
§1 and §19 of the WHG (§19g, 19i, 19l).
• Further information is available in the Rexroth publications "Mineral-oil based hydraulic
fluids", RE 90 220. "Environmentally acceptable, rapid biologically degradable hydraulic
fluids HEPG, HEES for axial piston units", RE 90 221 and "Axial piston units for operation
with HF hydraulic fluids, RE 90 223.

2.2 Due diligence of the operating company and the

operator
The operating company and the operator has to ensure that
• the axial piston unit is only used conventionally (see "3.5 Conventional use" on page 13).
• the axial piston unit is stored, operated and repaired according to the operating and
environmental conditions defined in the technical data, and especially that the limits given
in the technical data will not be exceeded.
• the axial piston unit after being repaired may only be operated if in proper and fully
functional condition.
• required personal protective equipment is available to the staff and that it will be worn.
• while working on the axial piston unit the engine has been securely switched off and the
system has to be depressurized.
• the operating instructions (general and product-specific) are always available in a legible
and complete status at the location of the axial piston unit.
• only qualified and authorized staff will be deployed for the maintenance of the axial piston
unit.

Note For storing, installation, commissioning or operation of the axial piston unit at low
temperatures (lower than –25 °C) the instructions in the Rexroth publication "Instructions on
using hydrostatic drives at low temperatures", RE 90 300-03-B must be observed.

Note In addition to the instruction manual please observe generally valid, statutory and other
binding regulations of the national legislation for accident prevention and environmental
protection.
10/44 Bosch Rexroth AG General operating instructions for axial piston units RE 90 300-B/02.06

2.3 Responsibility of the machine or system manufacturer

Rexroth axial piston units are components for the purpose of the Machine Directive 98/37/
EG (sub units), which are used for the installation in a machine or a system. Rexroth axial
piston units are no ready-to-use machines for the purpose of the EU Machine Directive.
Bosch Rexroth AG indicates that the scope of supply is exclusively intended for the
installation in a machine or system or to be connected with other components to a whole
new machine or system.
This instruction serves as a basis for the general system instructions to be issued by the
machine or system manufacturer.
Commissioning is prohibited until it is secured that the machine or system, in which
these products are installed, comply with the regulation of the EU Directives and all
other guidelines regarding the machine or system.
In addition to the machine guidelines, additional guidelines such as, e.g. pressure vessel
directive and explosion protection directive, are also valid. The interaction of the hydraulic
product with the machine or system, in which the hydraulic product is installed, can cause
various dangers. For this reason make sure that the hydraulic product is unreservedly
applicable for its intended use at its installation point.
The interfaces to the general machine and the operating conditions are of major significance.
We recommend that the result of the danger analysis (risk assessment) for the general
machine has also to be involved in the planning for the hydraulic product.

Note For storing, installation, commissioning or operation of the axial piston unit at low
temperatures (lower than –25 °C) the instructions in the Rexroth publication "Instructions on
using hydrostatic drives at low temperatures", RE 90 300-03-B must be observed.
RE 90 300-B/02.06 General operating instructions for axial piston units Bosch Rexroth AG 11/44

3 Product description
This chapter explains how to identify an axial piston unit using the name plate. In addition you
will get information how to use the axial piston unit properly.

3.1 Identification of the axial piston unit

The axial piston unit can be identified with the name plate. The following example shows the
name plate of a variable pump A4VG:

1 3FYSPUI
D-89275 Elchingen

2 TYP: A4VG125DA2D2/32R-NZF02F001SP
MNR: R90XXXXXXX 7
3
7202 8
4 SN: 12345678
5 FD: 05W28 Rotation:
-1 9
6 n = 1800 min p = 216 kW

Made in Germany 10

The name plate contains the following information:

1 Manufacturer
2 Ordering code
3 Material number of axial piston unit
4 Serial number
5 Production date
6 Speed 1)
7 Internal plant designation
8 Direction of rotation (looking on to shaft, here: clockwise)
9 Designated area for test stamp
10 Power 1)
1): Positions 6 and 10 vary depending on the product.
12/44 Bosch Rexroth AG General operating instructions for axial piston units RE 90 300-B/02.06

3.2 Functional description

The product spectrum of Rexroth axial piston units covers the following categories:
• Type of function: pump or motor
• Type of circuit: open or closed hydraulic circuit
• Design: bent axis or swashplate
• Displacement: fixed or variable
The pressure range of Rexroth axial piston unit is available in the technical data sheet.
Axial piston pumps are designed and built for the generation, the control and the regulation
of a hydraulic flow and are product-specific in the open or closed circuit. Thereby they are
powered by an "engine".

Note In these operating instructions the term "engine" is used as a generic term for diesel, petrol,
gas and electric engines.

Axial piston units are designed and built to convert the hydraulic flow into rotation and
torque.
Axial piston units are used to build hydrostatic transmissions for the insertion in static or
mobile operation. Such transmissions are suitable for the transmission of outputs for moving,
turning, lifting and for all kinds of motion involving large forces.
A detailed functional description is available in the product-specific operating instructions for
your axial piston unit.

3.3 Scope of supply

The following components are part of scope of supply of axial piston units:
• Axial piston unit with transport protection
• Protective caps
• Flange covers
• Label with commissioning information

3.4 Technical data

Details on technical data of your axial piston unit are available in the technical data sheet.
The set technical data of your axial piston unit are available in the order confirmation.
RE 90 300-B/02.06 General operating instructions for axial piston units Bosch Rexroth AG 13/44

3.5 Conventional use

Observe the following while operating the axial piston unit:
• The axial piston unit may only be stored in a dry and dust-free atmosphere, which is free of
corrosives and vapors.
The factory corrosion protection is sufficient when stored under the specified conditions,
unless condensate or leakage water penetrates the axial piston unit.
• The axial piston unit may only be operated using the following hydraulic fluids:
– Mineral oils according to the "Mineral-oil based hydraulic fluids" data sheet (RE 90 220)
– Environmentally acceptable hydraulic fluids according to the "Environmentally
acceptable hydraulic fluids HEES, HEPG, HETG for axial piston units" data sheet
(RE 90 221)
– Fire resistant HF hydraulic fluids according to the "Axial piston units for operation with
HF hydraulic fluids" data sheet (RE 90 223)
You can get information about using the product combined with other hydraulic fluids on
request.
When using non mineral-oil based hydraulic fluids observe the restrictions in the
"Environmentally acceptable hydraulic fluids HEES, HEPG, HETG for axial piston units"
(RE 90 221) and "Axial piston units for operation with HF hydraulic fluids" (RE 90 223).
• The axial piston unit may only be operated under the specified operating conditions.
The axial piston unit may only be operated when technically in perfect working order and
further it may only be stored, operated and repaired according to the technical data,
operating and environmental conditions mentioned in the order confirmation. Particularly
the limits specified in the technical data may not be exceeded.
For storing, installation, commissioning or operation of the axial piston unit at low
temperatures (lower than –25 °C) the instructions in the Rexroth publication "Instructions
on using hydrostatic drives at low temperatures", RE 90 300-03-B must be observed.
• The axial piston unit may only be operated with the specified output data.
The operation with other connection, application or output data, than those specified in
the general and product-specific operating instructions and the technical data sheet, is
only permitted with a written agreement of Bosch Rexroth AG. Additionally, the technical
details specified in the respective order confirmation of Bosch Rexroth AG apply related to
a system. The order confirmation is available for the machine or system manufacturer and
is binding.
• The axial piston unit may only be used for the specified purpose.
The axial piston unit may not be used for other purposes than the specified one, unless
Bosch Rexroth AG agreed the other purpose in written form. The operating instructions of
the machine or system manufacturer and if necessary any technical data must be strictly
observed.
• The axial piston unit may not be used in explosive environments.
Ignition sources are not allowed in immediate vicinity of the axial piston unit, because
hydraulic fluid escaping may be flammable or even explosive.
• General use and predictable fault usage has to be considered (Device and Product Safety
Act GPSG, Product Liability Act PHG).

Note Any deviations from the intended usage or specifications contained in these instructions,
technical modifications and conversions of the axial piston unit, and the operation of indivi-
dual parts or the installation of individual parts into other products will affect the safety and
exclude any warranty.
14/44 Bosch Rexroth AG General operating instructions for axial piston units RE 90 300-B/02.06
RE 90 300-B/02.06 General operating instructions for axial piston units Bosch Rexroth AG 15/44

4 Installation
This chapter describes the essential, generally valid steps for the installation of Rexroth axial
piston units. Read this chapter if you:
• wish to install an axial piston unit into a static or mobile hydraulic system or
• wish to disassemble or dispose an axial piston unit.
Also observe the details of the installation in the product-specific operating instructions of
your axial piston unit.

Note Observe the underlying safety instructions on page 7 of these operating instructions for all
work performed for installation of the axial piston unit.

The following warning is corresponding to all variable pumps influencing with an external
signal the volume flow resp. the flow direction (e.g. with HD or EP control unit):

! CAUTION The spring centering in the pilot control unit is not a safety device

Through contamination in the control unit – e.g. in hydraulic fluid, wear particles, or particles
out of a system –the valve spool can get stuck in an undefined position. In this case, the
pump flow does not follow the command inputs of the machine operator anymore .
• Make sure that a proper emergency shut down function can bring the driven machine
movements to a safe position immediately (e.g. stop).
• Adhere to the specified cleanliness level 20/18/15 (< 90 °C) or 19/17/14 ( > 90 °C) to
ISO 4406.

You will find all information about the selection of the hydraulic fluid and the design of the
tank, the filter and the heat exchanger as well as for correct piping of the hydraulic system in
the Annex as from page 37.
Structure of
chapter This chapter is structured as follows:

• "4.1 General installation instructions" on page 16 contains information that must be

observed before and after the installation.
• Information on unpacking the axial piston unit is available on page 17.
• As from "4.3 Preparing axial piston unit for assembly" on page 17 you will be informed
about the steps for the installation.
The following sections describe the necessary steps.
– Unpacking of the axial piston unit.
– Assembly of the axial piston unit at the scheduled installation location.
– Connection of the hydraulic lines.
– Connection of an electrical controller (optional).
• "4.8 Disassembling the axial piston unit" on page 23 and the following sections contain
information about disassembling, storing or disposing the axial piston unit.
16/44 Bosch Rexroth AG General operating instructions for axial piston units RE 90 300-B/02.06

4.1 General installation instructions

The installation location and position for an axial piston unit essentially determine the process
of installation and commissioning (as when filling the axial piston unit).
Information about permitted installation locations and positions is available in the product-
specific operating instructions or in the technical data sheet.

Note Please count on an influence of the control device while operating with variable axial piston
units which are assemblied in certain installation locations. Because of gravity, dead weight
and housing internal pressure minor curve displacements and actuating time changes may
occur.

Valid for all installation positions:

• The housing of the axial piston unit must be filled and air bled with hydraulic fluid at com-
missioning and during operation.
• To achieve favorable noise values, decouple all connecting lines (suction, pressure and
leakage fluid connections) from the tank using flexible elements.
Suction pressure Generally in all installation positions and locations a minimum suction pressure at con-
for pumps nection "S" is prescribed for all pumps : Minimum suction pressure ≥ 0.8 bar abs (additional
values see technical data sheet).

. -0,2
0,8 abs

1 2 0
-1 1
Absolute 0 3 Standard
2
pressure pressure
gauge gauge

! CAUTION Risk of damage for to axial piston unit

The axial piston unit must always be filled with hydraulic fluid.
• During commissioning make sure that the axial piston unit is supplied with sufficient hy-
draulic fluid.
• Ensure that the entire hydraulic system is tight.
• In the case of unusual noise or vibration development switch off the machine or system
immediately and check whether the axial piston unit has been filled with hydraulic fluid.

Cleanliness Cleanliness must be observed:

• Absolute cleanliness is required. The axial piston unit must be installed in a clean condi-
tion. Contamination of the hydraulic fluid may severely impair the service life of the axial
piston unit.
• Do not use any cotton waste or fibrous cloths for cleaning. Use suitable fluid cleaning
agents to remove lubricants and other major contamination. Cleaning agent must not
penetrate the hydraulic system.
RE 90 300-B/02.06 General operating instructions for axial piston units Bosch Rexroth AG 17/44

4.2 Unpacking instructions

While unpacking the axial piston unit please observe the following instructions:

! CAUTION Risk of parts falling down

If the packaging is not opened correctly parts may fall out and damage the parts or result in
injury.
• Place the packaging on a flat and sustainable underground.
• Open the packaging from the top only.

Note The axial piston unit will be delivered in a corrosion protection film. The film can be disposed
of with other polyethylene materials.
When disposing of the packaging always observe the national laws.

4.3 Preparing axial piston unit for assembly

To prepare the axial piston unit for assembly:
1 Remove the packaging material and dispose it according to the valid regulations.
2 Check the scope of supply regarding transportation damages.
3 Compare the material number and designation (ordering code) with the details in the
order confirmation.
If the material number for the axial piston unit does not correspond with the one in the
order confirmation. Please contact the Rexroth-Service for clarification.
4 Check the rotational direction of the axial piston unit (on the name plate) and make sure
that this corresponds to the directional rotation of the engine or power take-off drive.

Anti-
clockwise
Clockwise

Note Please note that the direction of rotation as specified on the name plate determines the
direction of rotation of the axial piston unit with regard to the drive shaft. The engine direction
of rotation is described in the engine manufacturer’s operating instructions.
18/44 Bosch Rexroth AG General operating instructions for axial piston units RE 90 300-B/02.06

4.4 Transporting the axial piston unit to the installation location

Depending on size and local conditions axial piston units can be transported – e.g. using a
fork lift truck or hoisting gear.
The drive shaft can be used to transport the axial piston unit as long as only outward axial
forces occur. Thus you can hook the axial piston unit onto the drive shaft.
Therefore turn an eyebolt into the drive shaft. Make sure that each eyebolt can bear the total
weight of the axial piston unit plus approx. 20 %.

! CAUTION Risk of damage

Prompt or impulsive forces on the drive shaft can damage the axial piston unit.
While transporting make sure that the axial piston unit’s drive shaft is not subjected to
prompt or impulsive forces. That means precisely:
• Do not hit the coupling or drive shaft of the axial piston unit.
• Do not set/place the axial piston unit on the drive shaft.
• Details about the permissible axial and radial loading are available in the technical data
sheet.

To transport the axial piston unit to the installation location:

1 Turn the eyebolt into the drive shaft as shown. The size of the thread is stated in the instal-
lation drawing.
You can hoist the axial piston unit as shown using the eyebolt screwed into the drive shaft
without any risk of damaging it.

4.5 Assembling the axial piston unit

How to assemble the axial piston unit depends on the connecting elements to the drive or the
output side. The following descriptions explain the installation of the axial piston unit:
• via coupling
• via a gearbox
• via a cardan shaft
Tool You will require the following tool:
required
The installation drawing contains the dimensions for all connections on the axial piston unit.
Please observe also the instructions of the manufacturers for the other hydraulic compon-
ents when selecting the required tool.
RE 90 300-B/02.06 General operating instructions for axial piston units Bosch Rexroth AG 19/44

General During assembly (and disassembly) of the axial piston unit observe the following general
information instructions:

• The axial piston unit has to be fixed so that the expected forces and torques can be trans-
ferred without any danger.
• The permissible axial and radial loading of the drive shaft, the permissible torsional vib-
rations, optimum direction of load force, as well as the limit speeds are available in the
respective technical data sheet.
• When driving a pump or the output of a motor with the aid of a cardan shaft vibrations
may occur, which may result in temporary leaks on the shaft seal ring of the axial piston
unit depending on the frequency and temperature.
• After a short running time toothed belts lose a major portion of their pre-tension and thus
cause fluctuations in speed or torsional vibrations.
Torsional vibrations may result in leakages on the shaft sealing ring of the driven axial
piston unit. Particularly at risk are diesel drives with a small number of cylinders and low
flywheel mass.
Rexroth recommends to avoid this type of toothed belt drive or to equip it with an
automatic tensioning device.
• V-belt drives without automatic tensioning device are also critical in terms of speed fluctu-
ations or torsional vibrations. These can also lead to leakages on the shaft sealing ring.
An automatic tensioning device can lessen the speed fluctuations and vibrations and thus
avoid consequential damage.
Rexroth recommends the use of V-belt drives only with an automatic tensioning device.
• In both types of belt drive the permissible radial loading on the shaft must be observed. If
necessary, the belt pulley can be separately mounted.
• The drive and output elements are to be assembled by pulling it onto the drive shaft with
the aid of the threaded hole in the drive shaft end.

! CAUTION Risk of damage

Prompt or impulsive forces on the drive shaft can damage the axial piston unit.
During installation make sure that the axial piston unit’s drive shaft is not subjected to prompt
or impulsive forces. That means precisely:
• Do not hit the coupler or drive shaft of the axial piston unit.
• Do not set/place the axial piston unit on the drive shaft.
• Details about the permissible axial and radial loading are available in the technical data
sheet.

Coupling To assemble the axial piston unit with a coupling:

1 Assemble the specified coupling half to the drive or output shaft of the axial piston unit
according to the coupling manufacturer’s specifications.
The shaft of the axial piston unit is equipped with a threaded hole. The size of thread is
stated in the installation drawing. This threaded hole can be used for assembling the
coupling.
2 Make sure that the installation location is clean and free from contaminants.
3 Brace the coupling hub onto the drive shaft or ensure a permanent lubrication of the drive
shaft. This avoids any formation of frictional corrosion and thus the attendant wear.
4 Transport the axial piston unit to the installation location and assemble the coupling onto
the drive or output according to the coupling manufacturer’s specifications.
Please note that the axial piston unit should not be tightened until the coupling has been
correctly assemblied.
20/44 Bosch Rexroth AG General operating instructions for axial piston units RE 90 300-B/02.06

5 Fix the axial piston unit at the installation location. If necessary, details on the tools re-
quired and tightening torques for the fixing screws can be procured from the machine or
system manufacturer.
a) For installation of the bell housing check the axial play of the coupling through the
bell window according to the manufacturer’s specifications.
b) For installation of the flange align the axial piston unit carrier to the drive or output.

Note Please note the following:

• Frictional corrosion on the coupling parts is to be avoided either by clamping the coupling
hub onto the drive shaft or through constant lubrication.
• When using flexible couplings and after completing the installation check the drive has to
be free of resonance.

Installation on a Drive shaft connections are to be protected against frictional corrosion (constant lubricati-
gearbox on).

The concealed installation means that it is not longer possible to inspect whether the axial
piston unit’s centering diameter actually centers the axial piston unit (observe tolerances),
or whether axial or acts on the drive shaft of the axial piston unit (installation length). The
control must therefore take place during the assembly procedure.
Completing the
assembly To complete the assembly:

1 Remove any assemblied eyebolts.

2 Remove transport protection.
The axial piston unit is delivered with protective caps and plastic plugs. They have to be
removed before the connection. Which actual transport protection has to be removed at
your axial piston unit can be read in the product-specific operating instructions.
Generally the caps and plugs can be removed by hand. If necessary a gripper can also be
used.
The protective caps of the adjustment screws may not be removed.

Note Sealing rings and surfaces may be damaged if the transport protection is not removed cor-
rectly.
Please note the following:
• Do not damage the sealing surfaces!
• All ports must have pipes or hoses connected according to the hydraulic connection plan
or the ports must be sealed with screw plugs.
• The operating and function connections are designed exclusively for connecting hydraulic
lines (see under "4.6 Connecting lines").

3 For axial piston pumps with drive-through:

If a drive through element is used (auxiliary pump, PTO), remove the flange cover and
assemble the auxiliary pump as shown in the pump manufacturer’s instructions.
RE 90 300-B/02.06 General operating instructions for axial piston units Bosch Rexroth AG 21/44

4.6 Connecting lines

The machine or system manufacturer is responsible to dimension the lines. The axial piston
unit must be connected in line with the hydraulic connection plan of the machine or system
manufacturer to the remaining hydraulic system.
Observe the following safety instructions.

! CAUTION Risk of damage

Hydraulic lines and hoses that are installed under tension, generate additional mechanical
forces during operation and thus reduce the service life of the axial piston unit and the overall
system.
• Install all lines and hoses free of tension.

! CAUTION Risk of damage

Generally a minimum permissible suction pressure at port "S" is prescribed for axial piston
pumps in all installation locations. If the pressure at port "S" drops under the specified va-
lues, damage may occur, which may lead to destruction of the pump.
• Make sure that the required suction pressure is reached by using corresponding piping
(suction cross-section, pipe diameter, tank position) and appropriate viscosity .

Note The operating and function connections are designed exclusively for connecting hydraulic
lines.

! WARNING Risk of wear and malfunctions

The cleanliness of the hydraulic fluid determines the cleanliness and the service life of the
hydraulic system. Contamination of the hydraulic fluid leads to wear and malfunctions.
In particular, solid contaminants in the hydraulic lines such as welding beads and metal
shavings may damage the axial piston unit.
• Absolute cleanliness is required. The axial piston unit must be installed in a clean
condition. Contaminants in the hydraulic fluid could considerably impact the function and
service life of the axial piston unit.
• Pay particular attention during installation to ensure that ports, hydraulic lines and
attachment parts (e.g. measuring device) are clean. Thoroughly clean these items before
opening ports. Make certain than no contaminants enter the system when closing the
ports.
• Use suitable liquid cleaning agents to remove lubricants and other difficult-to-remove
contaminants.Cleaning agent must not penetrate the hydraulic system.
• Do not use any cotton waste or fibrous cloths for cleaning.
• Do not use hemp or mastic as sealant.
22/44 Bosch Rexroth AG General operating instructions for axial piston units RE 90 300-B/02.06

Notes on Observe the following instructions when routing the suction, pressure and leakage fluid
routing lines lines. Observe also the project planning instructions in the Annex (see page 37).

The suction line (pipe or hose) must be as short and straight as possible.
The line cross section is to be measured so that the minimum permitted pressure at the suc-
tion port is not dropped below and the maximum permitted pressure is not exceeded. Obser-
ve the air tightness of the junctions and the pressure strength of the hose compared with the
external air pressure.
Sufficient burst resistance of the pipes, hoses and connecting elements must be observed
for pressure lines.
Route leakage fluid lines so that the housing is constantly filled with hydraulic fluid and to
ensure that no air gets through the shaft sealing ring even for extended down times. The hou-
sing internal pressure may not exceed the limits listed for the axial piston unit in the technical
data sheet under any operating conditions. The junction of the leakage fluid line must always
be mounted under the minimum fluid level in the tank.
Procedure To connect the axial piston unit to the hydraulic system:

1 Remove the transport protection (if not already removed).

2 Clean the lines.
3 Connect the lines according to the hydraulic connection plan.
All ports must be connected either to pipes or hoses according to the installation drawing
and machine or system connection plan or the ports plugged using suitable locking
screws.
The following tightening torques apply:
— Internal threads of the axial piston unit: The maximum permissible tightening torques
MG max are the maximum values of the internal threads and must not be exceeded.
Values see in product-specific operating instructions.
— Fittings: Observe the manufacturer's instruction regarding tightening torques of the
used fittings.
— Fixing screws: For fixing screws according to DIN 13/ISO 68, we recommend
checking the tightening torque in individual cases as per VDI 2230
— Locking screws: For the locking screws supplied with the axial piston unit, the required
tightening torques of locking screws MV apply. Values see in product-specific operating
instructions.
4 Make sure:
– that the union nuts are correctly tightened on the screwed connections and flanges
(Observe tightening torques!). Mark all checked screwed connections using, e.g. a
permanent marker.
– that pipe and hose lines and any combination of connecting pieces, couplings or
connecting points with hoses or pipes are checked by an expert to ensure that they are
safe to operate.

4.7 Connecting electric controller

The machine or system manufacturer is responsible for dimensioning the electrical control.
For electrically controlled axial piston units, the electric controller must be connected accord-
ing to the electric connection plan of the machine or system manufacturer.

Note To prevent malfunctions or incorrect direction of rotation or flow, make certain that all
connections are correct.