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Bosch Rexroth RE 90300-B Instruction Manual
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Bosch Rexroth RE 90300-B Instruction Manual

Bosch Rexroth RE 90300-B Instruction Manual

Axial piston units
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Instruction manual
General
Instruction Manual for
Axial Piston Units
RE 90300-B/2021-01-19, replaces: 06.2012, EN

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Summary of Contents for Bosch Rexroth RE 90300-B

  • Page 1 Instruction manual General Instruction Manual for Axial Piston Units RE 90300-B/2021-01-19, replaces: 06.2012, EN...
  • Page 2 © Bosch Rexroth AG 2021. 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...
  • Page 3 EN: This product may only be used 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.
  • Page 4 SV: Denna produkt får inte användas 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.

  • Page 5: Table Of Contents

    7.4.5 Installation on a gearbox ................34 7.4.6 Installation with cardan shaft ..............34 7.4.7 Completion of assembly ................35 7.4.8 Hydraulically connecting the axial piston unit ..........36 7.4.9 Electrically connecting the axial piston unit ..........40 Performing flushing cycle ................41 RE 90300-B/2021-01-19, Bosch Rexroth AG...
  • Page 6 Troubleshooting ..................52 14.1 How to proceed for troubleshooting ............52 14.2 Axial piston pump malfunction table ............53 14.3 Axial piston motor malfunction table ............57 Technical data ..................59 Product-specific instruction manuals ............. 60 Alphabetical index ................. 62 Bosch Rexroth AG, RE 90300-B/2021-01-19...

  • Page 7: About This Documentation

    1 About this documentation 1.1 Validity of the documentation This documentation is valid for the following products: Axial piston units from Bosch Rexroth, which include: • Axial piston pumps • Axial piston motors This documentation is intended for machine/system manufacturers, assemblers and service engineers.

  • Page 8: Representation Of Information

    Describes the requirements on fire-resistant, water-free and water-containing hydraulic fluids (HFDR, HFDU, HFA, HFB, HFC) and contains the technical data for operation with Rexroth hydraulic components. Bosch Rexroth Fluid Rating List for Rexroth hydraulic 90245 Data sheet components (pumps and motors) Contains the hydraulic fluids positively evaluated by Bosch Rexroth.

  • Page 9: Symbols

    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 Threaded plug Metal screw, pressure-resistant Protective plug Made out of plastic, not pressure-resistant, only for transportation RE 90300-B/2021-01-19, Bosch Rexroth AG...

  • Page 10: Abbreviations

    Deutsches Institut für Normung (German Institute for Standardization) International Organization for Standardization Japan Industrial Standard Rexroth document in the English language VDI 2230 Standard for the systematic calculation of heavy-duty threaded connections and cylindrical screw joints from the VDI (Verein Deutscher Ingenieure - Association of German Engineers) Bosch Rexroth AG, RE 90300-B/2021-01-19...

  • Page 11: Safety Instructions

    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 11. RE 90300-B/2021-01-19, Bosch Rexroth AG...

  • Page 12: Improper Use

    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):...

  • Page 13: General Safety Instructions

    Potential electromagnetic interference (EMI) exists if the solenoid is energized with a modulated direct current (e.g. PWM signal). The machine manufacturer should conduct appropriate tests and take appropriate measures to ensure that other components or operators (e.g. with a pacemaker) are not affected by this potentiality. RE 90300-B/2021-01-19, Bosch Rexroth AG...

  • Page 14: Product-Specific Safety Instructions

    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. ▶ In addition, a pressure relief valve is required in the hydraulic system as back-up.
  • Page 15 ▶ The use of the manual override is only permitted with limited technical data (e.g. 0.25 × maximum data). ▶ Check whether or not your machine requires additional safety measures for your application to avoid unintentional actuation. If necessary, make sure these are appropriately implemented. ▶ Wear suitable protective clothing. RE 90300-B/2021-01-19, Bosch Rexroth AG...
  • Page 16 This can result in restriction or loss of load-holding functions in lifting winches. ▶ Check whether the application on your machine requires additional safety measures in order to keep the load in a safe position. ▶ If necessary, make sure these are appropriately implemented. Bosch Rexroth AG, RE 90300-B/2021-01-19...
  • Page 17 ▶ 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. RE 90300-B/2021-01-19, Bosch Rexroth AG...

  • Page 18: Personal Protective Equipment

    ▶ Check how to safely get on top of the machine/system. 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. Bosch Rexroth AG, RE 90300-B/2021-01-19...

  • Page 19: General Instructions On Property Damage And Product Damage

    Make sure that the axial piston unit really does draw in hydraulic fluid and build up pressure (for axial piston variable pumps in open circuits). RE 90300-B/2021-01-19, Bosch Rexroth AG...
  • Page 20 ▶ Dispose of the axial piston unit, hydraulic fluid and packaging in accordance with the regulations in your country. ▶ Dispose of the hydraulic fluid in accordance with the applicable safety data sheet for the hydraulic fluid. Bosch Rexroth AG, RE 90300-B/2021-01-19...
  • Page 21 The warranty only applies to the machine configuration as delivered. The warranty will be voided if the product is incorrectly installed, commissioned or operated, or if it is used or handled improperly. RE 90300-B/2021-01-19, Bosch Rexroth AG...

  • Page 22: Scope Of Delivery

    • Axial piston unit as per order confirmation The following parts may also be installed on delivery: • Protective covers • Protective plugs/threaded plugs • Connector protective covers • for version with through drive, protective cover and mounting bolts Bosch Rexroth AG, RE 90300-B/2021-01-19...

  • Page 23: About This Product

    5.2 Product description The product range of Bosch Rexroth axial piston units covers the following categories: • Function type: Pump or motor • Type of circuit: Open or closed hydraulic circuit •...

  • Page 24: Transport And Storage

    ▶ Use your personal protective equipment (e.g. safety goggles, safety gloves, suitable working clothes, safety shoes). ▶ Do not transport the axial piston unit by sensitive assembled parts (e.g. sensors or valves). ▶ Carefully place the axial piston unit on the seating to prevent it from being damaged. Bosch Rexroth AG, RE 90300-B/2021-01-19...

  • Page 25: Transport With Lifting Devices

    ▶ Make sure that the eye bolts can bear the total weight of the axial piston unit plus approx. 20%. You can hoist the axial piston unit as shown in Fig. 3 with the eye bolts screwed into the housing. Fig. 3: Mounting eye bolts in housing RE 90300-B/2021-01-19, Bosch Rexroth AG...

  • Page 26: Storing The Axial Piston Unit

    • Do not store the axial piston unit on the drive shaft or assembled parts, e.g. sensors or valves. • For further storage conditions, see Table 6. ▶ Check the axial piston unit monthly to ensure professional storage. Bosch Rexroth AG, RE 90300-B/2021-01-19...
  • Page 27 Once the max. storage time has elapsed, we recommend that you have the axial piston unit checked by your Bosch Rexroth service partner. For questions regarding repair and spare parts, contact your proper Bosch Rexroth service partner or the service department of the manufacturer's plant of the axial piston unit, see chapter 10.5 "Spare parts"...
  • Page 28 28/64 Axial piston units | Transport and storage Bosch Rexroth recommends the following procedure: 1. Clean the axial piston unit; see chapter 10.1 "Cleaning and care" on page 47. 2. Drain the axial piston unit. 3. For storage times up to 12 months: Moisten the inside of the axial piston unit with mineral oil and fill with approx.

  • Page 29: Installation

    • Product-specific instruction manual (contains product-specific parameters) • Installation drawing for the axial piston unit (can be obtained from your contact person at Bosch Rexroth, if required) • Hydraulic circuit diagram for the axial piston unit (in the product-specific data sheet and on the installation drawing) •...
  • Page 30 ▶ Use fibre-free cleaning cloths for cleaning. ▶ Use suitable, mild cleaning agents to remove lubricants and other heavy contamination. Do not allow cleaning agents to enter into the hydraulic system. Bosch Rexroth AG, RE 90300-B/2021-01-19...

  • Page 31: Installation Position

    Above-reservoir installation means that the axial piston unit is installed above the minimum fluid level of the reservoir. Observe for axial piston pumps the maximum permissible suction height h  = 800 mm. The permissible suction height h is derived from the S max total pressure loss. RE 90300-B/2021-01-19, Bosch Rexroth AG...

  • Page 32: Installing The Axial Piston Unit

    Follow these general notices when installing the axial piston unit: • Note that certain installation positions will affect the control system. Gravity, dead weight and case pressure can cause minor characteristic shifts and changes in response time. Bosch Rexroth AG, RE 90300-B/2021-01-19...

  • Page 33: Installation With A Coupling

    2. Make sure that the installation location is clean and free from dirt and foreign particles. 3. Clamp the coupling hub onto the drive shaft or ensure permanent lubrication of the drive shaft. This prevents the formation of frictional corrosion and the associated wear. RE 90300-B/2021-01-19, Bosch Rexroth AG...

  • Page 34: Installation On A Gearbox

    1. Position the axial piston unit near the intended installation location. Allow enough space for the cardan shaft to fit through on both sides. 2. Place the cardan shaft on the output shaft of the drive motor. Bosch Rexroth AG, RE 90300-B/2021-01-19...

  • Page 35: Completion Of Assembly

    Use a suitable tool for this to prevent damage to the sealing and functional surfaces. If sealing or functional surfaces are damaged, contact your Bosch Rexroth service partner or the service department of the manufacturer's plant of the axial piston unit. Ports intended for connecting lines come with protective plugs and/or threaded plugs, which serve as transport protection.

  • Page 36: Hydraulically Connecting The Axial Piston Unit

    – The hose must be pressure-resistant, also to external air pressure. • Pressure line – For the pressure lines, use only pipes, hoses and connecting elements rated for the working pressure range specified in the product-specific data sheet. Bosch Rexroth AG, RE 90300-B/2021-01-19...
  • Page 37 ▶ Use the drawings (installation drawing) to determine the required stud end for each fitting. ▶ Make sure the right fittings, mounting bolts and threaded plugs are installed. ▶ For all female threads, use a stud end from the same system of units and of the correct size. RE 90300-B/2021-01-19, Bosch Rexroth AG...
  • Page 38 These plugs must not be opened on the customer side! If you have opened the threaded plug accidentally, please contact your local contact person to ensure safe re-closing of the plug. You can find the address at www.boschrexroth.com/addresses Bosch Rexroth AG, RE 90300-B/2021-01-19...
  • Page 39 The tightening torques for the threaded plugs are valid for the condition "dry" and "lightly oiled". The tightening torques for the threaded plugs are valid for the condition "dry" – in the condition "lightly oiled", the tightening torques for M10 × 1 are reduced to 10 Nm and for M12 × 1.5 to 17 Nm. RE 90300-B/2021-01-19, Bosch Rexroth AG...

  • Page 40: Electrically Connecting The Axial Piston Unit

    1. Switch off the power supply to the relevant machine/system component. 2. Electrically connect the axial piston unit (12 or 24 V). Before establishing the connection, check whether the connector protective covers have been removed and the connector and all seals are intact. Bosch Rexroth AG, RE 90300-B/2021-01-19...

  • Page 41: Performing Flushing Cycle

    Fig. 7: Tightening torque for HIRSCHMANN connector 7.5 Performing flushing cycle In order to remove foreign particles from the system, Bosch Rexroth recommends a flushing cycle for the hydraulic system before the first commissioning. To avoid internal contamination, do not include the axial piston unit in the flushing cycle.

  • Page 42: Commissioning

    Usually, the cleanliness level of commercial hydraulic fluids is insufficient for the requirements of our components. These hydraulic fluids must be filtered during filling using an appropriate filter system to minimize solid particle contamination and water in the system. Bosch Rexroth AG, RE 90300-B/2021-01-19...
  • Page 43 Table 1 "Required and supplementary documentation" on page 7. Bosch Rexroth evaluates hydraulic fluids on the basis of the Fluid Rating according to data sheet 90235. For hydraulic fluids which have been positively evaluated in the Fluid Rating, please refer to data sheet 90245 "Bosch Rexroth fluid rating list for Rexroth hydraulic components (pumps...

  • Page 44: Testing The Hydraulic Fluid Supply

    ▶ After starting the drive motor, check in particular the specified pressures, e.g. working pressure, boost pressure and case pressure. ▶ Perform a leak test without and with load prior to normal operation. ▶ If necessary, remove the pressure gauge and plug the ports with the specified threaded plugs. Bosch Rexroth AG, RE 90300-B/2021-01-19...

  • Page 45: Running-In Phase

    To ensure that contamination in the hydraulic system does not damage the axial piston unit, Bosch Rexroth recommends the following procedure after the running-in phase: ▶ After the running-in phase, have a hydraulic fluid sample analyzed for the required cleanliness level.

  • Page 46: Operation

    Use the product only within the performance range specified in the technical data. The machine/system manufacturer is responsible for proper project planning of the hydraulic system and its control. Discrepancies are explained as necessary in the product-specific instruction manual. Bosch Rexroth AG, RE 90300-B/2021-01-19...

  • Page 47: Maintenance And Repair

    ▶ Use only water and, if necessary, a mild cleaning agent to clean the axial piston unit. Never use solvents or aggressive cleaning agents. ▶ Remove major external contamination and keep clean sensitive and important components, such as solenoids, valves, indicators and sensors. RE 90300-B/2021-01-19, Bosch Rexroth AG...

  • Page 48: Inspection

    Axial piston units | Maintenance and repair 10.2 Inspection In order for the axial piston unit to be reliable and long-lasting, Bosch Rexroth recommends inspecting the hydraulic system and axial piston unit on a regular basis, and documenting and archiving the following operating conditions:...

  • Page 49: Repair

    Maintenance and repair | Axial piston units 49/64 10.4 Repair Bosch Rexroth offers a comprehensive range of services for the repair of Rexroth axial piston units. Repairs on the axial piston unit and its assembled parts should only be performed by service centers certified by Bosch Rexroth.

  • Page 50: Removal And Replacement

    6. Remove the axial piston unit. Use a suitable lifting device. 7. Completely drain the axial piston unit. 8. Plug all openings. 11.4 Preparing the components for storage or further use ▶ Proceed as described in chapter 6.2 "Storing the axial piston unit" on page 26. Bosch Rexroth AG, RE 90300-B/2021-01-19...

  • Page 51: Disposal

    Changes to settings on the customer side should only be made using the product-specific setting instructions. The warranty from Bosch Rexroth only applies to the configuration as delivered. Entitlement to warranty cover will be rendered void in case of conversion, extension or a software modification.

  • Page 52: Troubleshooting

    ▶ Try to get a clear idea of the cause of the fault. Directly ask the (machine) operator. ▶ Document the work carried out. ▶ If the fault cannot be corrected, please refer to one of the contract addresses at: www.boschrexroth.com/addresses. Bosch Rexroth AG, RE 90300-B/2021-01-19...

  • Page 53: Axial Piston Pump Malfunction Table

    Contact Bosch Rexroth Service: Optimize the setting of the pressure limitation and pressure control valve Mechanical damage to the axial piston unit Replace axial piston unit (e.g. bearing damage) Contact Bosch Rexroth Service Increased, unusual vibration Bearings worn Contact Bosch Rexroth Service RE 90300-B/2021-01-19, Bosch Rexroth AG...
  • Page 54 Malfunction of the control device or Contact Bosch Rexroth Service controller of the axial piston unit Control of the control device defective Check control (contact machine/system manufacturer or Bosch Rexroth Service) Wear or mechanical damage to the axial Replace axial piston unit piston unit Contact Bosch Rexroth Service...
  • Page 55 Malfunction of the control device or Contact Bosch Rexroth Service controller of the axial piston unit Control of the control device defective Check control (contact machine/system manufacturer or Bosch Rexroth Service) Wear or mechanical damage to the axial Replace axial piston unit piston unit Contact Bosch Rexroth Service Output unit defective (e.g. hydraulic motor...
  • Page 56 Contact Bosch Rexroth Service Contact machine/system manufacturer Flushing flow of the flushing valve too low Contact Bosch Rexroth Service (relevant for axial piston units with flushing valve) Axial piston unit worn Replace axial piston unit; contact Bosch Rexroth Service Bosch Rexroth AG, RE 90300-B/2021-01-19...

  • Page 57: Axial Piston Motor Malfunction Table

    Malfunction of the control device or controller Contact Bosch Rexroth Service of the axial piston unit Control of the control device defective Check control (contact machine/system manufacturer or Bosch Rexroth Service) Wear or mechanical damage to the axial piston Replace axial piston unit unit Contact Bosch Rexroth Service Drive unit defective (e.g. hydraulic pump)
  • Page 58 Contact Bosch Rexroth Service Contact machine/system manufacturer Output speed too high Contact machine/system manufacturer Flushing flow of the flushing valve too low Contact Bosch Rexroth Service Axial piston unit worn Replace axial piston unit; contact Bosch Rexroth Service Bosch Rexroth AG, RE 90300-B/2021-01-19...

  • Page 59: Technical Data

    The permissible values of the technical data of your axial piston unit can be found in the product-specific data sheet. The product-specific data sheet can be found in the online product catalog at www.boschrexroth.com/axial-piston-pumps www.boschrexroth.com/axial-piston-motors Order-related technical data for your axial piston unit can be found in the order confirmation. RE 90300-B/2021-01-19, Bosch Rexroth AG...

  • Page 60: Product-Specific Instruction Manuals

    Fixed motor A2FMT/70 www.boschrexroth.com/p-A4FM Fixed motor A4FM www.boschrexroth.com/p-A10FM Fixed motor A10FM www.boschrexroth.com/p-A10FE Fixed motor A10FE www.boschrexroth.com/p-A6VM-6x Variable motor A6VM/63 www.boschrexroth.com/p-A6VM-6x Variable motor A6VM/65 www.boschrexroth.com/p-A6VM-71 Variable motor A6VM/71 www.boschrexroth.com/p-A6VE-6x Variable motor A6VE/63 www.boschrexroth.com/p-A6VE-6x Variable motor A6VE/65 Bosch Rexroth AG, RE 90300-B/2021-01-19...
  • Page 61 Variable motor A10VER www.boschrexroth.com/p-DSA BODAS speed sensor www.boschrexroth.com/p-DSM BODAS speed sensor www.boschrexroth.com/p-HDD BODAS speed sensor If there are no product-specific instruction manuals for your axial piston unit, please consult your responsible contact person at Bosch Rexroth. RE 90300-B/2021-01-19, Bosch Rexroth AG...

  • Page 62: Alphabetical Index

    Malfunction table ....53, 57 Performing ......... 50 Preparing ........50 Disposal ........51 Name plate ........23 Notes General ........32 Eye bolt ........25 Operation ........46 Filling ........... 42 Flushing cycle ....... 41 Functional test ......44 Bosch Rexroth AG, RE 90300-B/2021-01-19...
  • Page 63 Weight .......... 24 Safety instructions ....... 11 General ........13 Product-specific ......14 Signal word ........9 Scope of delivery ......22 Spare parts ........49 Storage ........24, 26 Storage time ......... 27 Symbols ......... 9 RE 90300-B/2021-01-19, Bosch Rexroth AG...
  • Page 64 Bosch Rexroth AG Glockeraustraße 4 89275 Elchingen Germany Tel. +49 (0) 7308 82-0 info.ma@boschrexroth.de www.boschrexroth.com Bosch Rexroth AG An den Kelterwiesen 14 72160 Horb a.N. Germany Tel. +49 (0) 7451 92-0 info.ma@boschrexroth.de www.boschrexroth.com Your local contact person can be found at: www.boschrexroth.com/addresses...

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