Rexroth 28-250 Pump and Service Manual
Contents
1. RT 12151 MAX Ps alal le Mp E E 8525 i B pg fa s l lt lt NA 6 1 b 14 1 ES de L A k k k il Xx G MH S FM Data Table AA4VG DA Direction of rotation Control Output flow direction Control Direction Operating Size Solenoid Pressure of Flow Pressure oe a X2 B to A Ma 83 40 56 b Xi Ato B Ma s 8 a X2 Ato B Ms Oo 71 90 125 180 b Xi BtoA Ma So a X2 AtoB Mg do 3 5 40 56 Xi BtoA Ma 88 a Xo BtoA Ma 71 90 125 180 b Xi Ato B Ms al B I Mg oj Je el MA A Solenoid a Ki Counter Ya Clockwise B 1 A e A Clockwise 5 fi X2 Solenoid b Rotary Inching Valve This valve is used to provide vehicle inching function and is used in conjunction with the DA Regulating Cartridge with fixed adjustment It permits the pilot pressure speed dependent to be reduced as necessary independently of the pump drive speed controlled by rotation of the inching lever Maximum angle of lever operation is 90 The position of the lever is optional inching operation clockwise or counter clockwi2. Dimensions D Ports Fe 8 Fa View W e Charge Pressure Filtration K with cold start valve Similar to option D except with cold start valve providing filter bypass function and charge pump protection Bypass valve Bypass setting Ap2 3 5 bar 50 psi Bypass flow To charge pump inlet POR Ba To line mounted filter Poit G From line mounted filter The filter should be fitted with a AP indicator and or switch set at lt 3 bar 43 5 psid Circuit Diagram K with cold start valve View W K2 Size K1 K2 Fe Size K1 K2 40 112 198 7 9 16 UNF 2B 15 deep 40 122 5 198 7 0 4 16 UNF 2B 15 deep 56 115 215 4 5416 UNF 2B 15 deep 56 125 5 215 4 0 54 16 UNF 2B 15 deep 71 134 239 0 1146 12
3. 3 bar abs 43 5 psia Charge pump Nominal pressure Psp 20 bar 290 psi Peak pressure PH max e eee eee eee 40 bar 580 psi Min pressure at charge pump inlet port S at V 141 SUS 30 cSt p gt 0 8 bar abs 6 3 in Hg at cold start p20 5 bar abs 15 2 in Hg 6 Fmannesmann Rexroth 92003 5 04 97 Variable Displacement Pump AA4VG Series 3 Technical Data AAAVG Specifications Theoretical values rounded Size 40 56 71 90 125 180 Displacement Variable pump Va max cm3 rev 40 56 71 90 125 180 inS rev 2 44 3 42 4 33 5 49 7 63 10 98 Charge pump Vox cm3 rev 8 4 11 1 18 7 18 7 25 7 36 9 in3 rev 0 51 0 68 1 14 1 14 1 56 2 25 Speed max rpm at Vy max Mmax cont rpm 4000 3600 3300 3050 2750 2400 limited max rpm O Miras imit rpm 4200 3900 3600 3300 3100 2900 intermittent max rpm O Mmax mem rpm 5000 4500 4100 3800 3450 3000 minimum rpm rpm 500 500 500 500 500 500 Flow at max cont ANA Vo max Cis L min 160 202 234 275 344 432 gpm 42 3 53 4 61 8 72 7 90 9 114 1 Power at Nmax cont Ap 400 bar Prax kW 107 134 156 183 229 288 Ap 5800 psi hp 144 180 209 245 307 386 Torque at V max Ap 400 bar Mas Nm 254 356 451 572 795 1144 without charge pump 5800 psi lb ft 187 263 333 423 586 844 Ap 100 bar M Nm 63 5 89 112 8 143 198 8 286 Ap 1450 psi lb ft 46 8 65 6 83 2 105
4. 14 32 pa AAAAAAAA Axial Piston Unit Operation Displacement Control amp Options Regulating Cartridge Design Series Index Direction of Rotation Seals NBR P NBR FPM shaft seal N Shaft Type For maximum permissible shaft torque refer to page 33 40 56 71 90 125 180 Spline SAE Standard for single pump 0 0 0 S Spline SAE Standard for tandem pump 15t pump e e e e T Spline SAE Only for tandem pump 2nd pump e U Spline DIN 5480 For tandem pump 2nd pump Z Mounting Flange 40 56 71 90 125 180 SAE 2 bolt C 4 bolt e D 2 4 bolt e 0 e F Port Connections 40 56 71 90 125 180 Ports A amp B SAE 4 bolt flange on top and bottom e e e e e e 52 Charge Pump 40 56 71 90 125 180 With Charge Pump amp without Through Drive e e F00 Without Charge Pump amp without Through Drive 0 e N00 With Charge Pump amp with Through Drive e e e e F Without Charge Pump with Through Drive 31 1 13 3 Through Drive 40 56 71 90 125 180 Shaft Flange SAE 9T 16 32P SAE A 2 bolt 19 9 01 SAE 8 13T 16 32P SAE B 2 bolt 0 0 0 0 02 SAE B B 1 15T 16 32P SAE 8 2 bolt 0 0 04 SAE B B 1 15T 16 32P SAE C 2 bolt
5. Hydraulic Control Speed Dependent DA mechanically adjustable with control lever with hydraulic inching valve DA1D5 DA2D5 with throttle valve Sizes 40 71 24 21 piece eo ee ee ee ee KL i RT Diea ti Pe Ey Fa F Ms NA Ti FTA 1 B nal lr Ir 1 KAL ai r 1 LV TT 0 Do JAN 4 2 12 ET E with pressure reducing valve Sizes 90 180 Hydraulic Control Speed Dependent DA fixed setting with separately installed master controller TH7 as inching valve DA1D7 DA2D7 Master controller TH7 p 1 see RE 64558 Ae A A E AL 111125 Dia B la Tal re Mp TI l pos H wo L 2 2 J B pj Pea U MA ee EM i i 4 meh mb Fmannesmann Rexroth 1 5 92003 S 04 97 Variable Displacement Pump AA4VG Series 3 Electrical Control Non Proportional EZ By energizing either solenoid a or b internal control pressure is connected directly to the stroking piston and the pump swivels to maximum displacement W
6. Pump Size Allen Wrench 28 125 180 250 10 Remove charge pump housing and inspect for wear or damage to gear set and O ring seals Grease O rings prior to reassem bly Make sure O rings are completely seated in their grooves Withdraw pinion shaft and inspect gear teeth and bearing sur faces for abnormal wear When reassembling make sure chamfer on outer edge of driven gear and drive gear is installed into housing per illustra tion Torque value for bolts when replacing charge pump Pump Size Torque 28 125 18 ft lbs 24 Nm 180 250 62 ft lbs 24 Nm Chamfer Note If serious wear or damage has occurred to one compo nent the complete charge pump assembly must be replaced because they are matched components Fmannesmann Rexroth 29 92003 S 04 97 Variable Displacement Pump AA4VG Series 3 Removal and Installation of Shaft Seal Remove the retaining ring with snap ring pliers NG 4 D f Screw in sheet metal screw into the holes fitted with rubber Pull out shaft seal with pliers Press in shaft seal with bushing to the stop Then replace snap ring 30 T mannesmann Rexroth 92003 5 04 97 Variable Displacement Pump AA4VG Series 3 Changing Charge Filter Remove charge filter turn counter clockwise with filter wrench Apply a small amount of oil to seal Screw on new filter C
7. Variable Displacement Pump AA4VG Series 3 Troubleshooting Procedure 3 Transmission Drives in One Direction Only 3 1 With control lines lines No Proceed to step 3 2 3 4 Check flushing valve No Not installed Proceed switched does pump Yes Control signal from one If Installed Is shuttle to step 3 5 drive in opposite direc side does not work spool stuck in one posi Yes Remove flushing valve tion only properly Repair as nec tion and clean or replace essary 3 5 Switch relief valves No Proceed to step 3 6 3 2 With control lines still No proceed to step 3 3 does transmission drive Yes Repair or replace relief switched does pump Yes Problem is one side of in other direction only valve on nondriving drive in initial direction control module or the side only pump Proceed to step 3 3 3 6 Replace control mod No Replace or repair pump ule and reconnect Yes Operate transmission 3 3 15 there control pres No Correct control signal control lines Does sure or current from problem pump operate properly both control lines Yes Proceed to step 3 4 4 Transmission Drives in the Wrong Direction 4 1 Pump with HD control Switch control lines on 4 3 Pump with HW Control Rework linkage or cable ports V4 and Yo to give correct drive direction 4 2 Pump with EP Control Switch electrical con nectors on solenoids A 6 8 5 Pump Does Not Find or Hold Neutral Also refer to pages 24 amp 25 5 1 Does pump return t
8. The adjustment screw is an eccentric therefore turning more than 90 in either direction will have no further centering effect and could cause damage to the eccentric pin Pump Size Allen Wrench Wrench 28 71 Screw Driver 10mm 90 250 4mm 13 Centering the HD Control Module With Yy and Yo ports vented to atmosphere neutral position of the HD control is correctly adjusted when any or all of the fol lowing conditions exist 1 Approximately when equal control pressures are obtained at control pressure ports Xy and Xo 2 The hydraulic motor does not turn when the brake is released 3 Charge pressure is registered equally at ports Ma and Mp when flow output of the pump is deadheaded against a locked motor or a valve Centering the HW Control Module With the control lever allowed to freely spring to its center posi tion the HW control module is correctly adjusted when any or all of the following conditions exist 1 Approximately when equal control pressures are obtained at control pressure ports X4 and Xo 2 The hydraulic motor does not turn when the brake is released 3 Charge pressure is registers equally at ports Ma and Mp when flow output of the pump is deadheaded against a locked motor or a valve Centering the EP Control Module With no electrical signal to solenoids A and B remove both plug in connectors the EP control module is correctly adjusted when any or all of the
9. Variable Displacement Pump AA4VG Series 3 Index Name Tag Information a y oo 8 8 Asio a oh de a Page 2 INDE Code o oe a 2 e A SO oe Oe Se we 4 5 Technical Data a amp iy 98 2 Heche ten we 9 9 e OH 0 AAA 6 7 Filtration Options 2 4 8 om Sok rod a Gee 90 a e i od ho 7 9 High Pressure Relief Valve a 10 Pump Controls 4 2s 8 wd be ok a a a 11 16 Pump Installation 85 38 55 ra oa Boe ee a 17 18 Start up Procedure 0 00 19 Trouble Shooting Procedure a a 20 23 Charge Pressure Relief Adjustments a 24 Mechanical Centering of Pump 6 6 kom 5 8 As B ee ee 5 24 Hydraulic Centering of Control Modules a 25 Adjustments of Pressure Override Valve 1 000 26 Adjustment of High Pressure Relief Valves 2 27 Tow Option Engagement 2 2 6 5 4 wes eae A we 4 4 AA a 28 Removal an Inspection of Charge Pump 29 Removal and Installation of Shaft Seal 30 Filter Replacement 5 5 5 5 8 59 99 8 6 4 9 we 48 b 8 8 ew 9 8 31 Routine Maintenance 4 8 4 9
10. Green Red window Indicator switching pressure Ap 3 bar 43 5 psi Circuit Diagram P mounted filter l EA ta ahi RT To ALED RE 3 Mg E AT a A i Charge Pressure Filtration L mounted filter With electrical contamination indicator Similar to option F except model L includes electrical contami nation indicator Indication Electrical Indicator switching pressure Ap 3 bar 43 5 psi Max switching power at24VDC 60 W 2 5 A Max switching power at12 WDC _ 30 W 2 5 A 31 2 PE Circuit Diagram L mounted filter Hej l 4 t IE 1 ea rT n SE Eh a Hen oe tea Charge Pressure Filtration M mounted filter With visual and electrical contamination indicator Similar to option F except model M includes visual and electrical contamination indicator Indication ep and visual by lamp Indicator switching pressure Ap 3 bar 43 5 psi Max switching power at24VDC 60 W 2 5 A Max switching power at12VDC 30 W 2 5 A Circuit Diagram M mounted filter RT 72 2 RE Ma a oo 1 View A rotated
11. HU00156494 1 2 mm DIA M6 HU00156495 1 4 mm DIA M6 HU00156496 1 6 mm DIA M6 HU00156497 1 8 mm DIA M6 Stroking Time Orifices for Sizes 90 250 Part Number Orifice Size Thread Size HU00426701 0 8 mm DIA M 10 HU00426702 0 9 mm DIA M 10 HU00426700 1 0 mm DIA M 10 HU00426703 1 2 mm DIA M 10 HU00426704 1 4 DIA 10 HU00426705 1 6 mm DIA M 10 HU00426706 1 8 mm DIA M10 HU00426707 2 0 mm DIA M 10 HU00426708 2 2 mm DIA M 10 HU00439372 2 4mm DIA M 10 HU00426709 2 5 mm DIA M 10 Connectors Stroking Time Orifices Ammeter Fmannesmann Rexroth 35 92003 S 11 97 Variable Displacement Pump AA4VG Series 3 Replacement Subassemblies and Parts Charge Pumps and Through Drives Type Code AA4VG28 AA4VG40 AA4VG56 AA4VG71 FOO A HU00606688 HU00606382 HU00606657 FO1 A HU00606691 HU00606386 HU00606655 FO2 A 00606694 HU00606390 HU00606661 FO4 A HU00606700 HU00606393 HU00606658 FO9 A HU00606687 O O 07 00606379 00606660 F69 A O O O F73 A O O O Type Code AA4VG90 AA4VG125 AA4VG180 AA4VG250 FOO HU00606811 HU00606320 HU00606233 A F01 HU00606803 HU00606309 HU00606225 FO2 HU00606809 HU00606312 HU00606228 A F04 HU00606807 HU00606314 HU00606226 A F09 O
12. of single and combination pumps Combination pump of same size Single pump ist Pump 2nd Pump Size Mtg flange 1 2 A3 4 5 A6 A8 Through drive A9 40 SAEC 2 Bolt 181 18 0127 15 12 7 S SAE 1 S SAE 114 FO9 KO9 U SAE 1 56 SAE 0 2 Bolt 181 18 0127 18 12 7 S SAE 1 T SAE 134 FO7 KO7 5 SAE 114 71 JSAEC 2 4 Bolt 181 114 6 18 14 127 15 15 12 7 S SAE 114 T SAE 134 7 7 S SAE 114 90 SAE 2 4 Bolt 228 6 161 4 22 21 152 4 17 20 12 7 S SAE 134 S SAE 134 F73 K73 W35 125 SAED 2 4 Bolt 228 6 161 4 22 21 152 4 20 20 12 7 S SAE 134 T SAE 2 F69 K69 S SAE 1 180 SAE E 4 Bolt 224 5 21 165 1 22 15 9 5 SAE 134 T SAE 214 F72 K72 5 SAE 134 Mounting Flange 1 8 Fmannesmann Rexroth 92003 5 04 97 Variable Displacement Pump AA4VG Series 3 Start Up Procedure The following procedure has been developed based on experi ence with most types of applications however certain applications may require a departure from or variation to this procedure For the start up of new or overhauled installations 1 10 11 12 13 14 15 16 If the prime mover is Internal combustion engine Diesel gasoline or
13. 2 to 5 ft Ibs 7 Nm Install relief valve assembly into pump tighten cover ref item 1 to 66 ft lbs 90 Nm Note All high pressure relief valve adjustments on size 40 and 56 to be done with a 3 mm allen wrench and a 5 mm box wrench Note Perform steps 4 amp 5 as quickly as possible to prevent overheating of the pump Flow should not be permitted to spill over the high pressure relief valves for longer than 10 seconds especially at higher pressures Note High pressure relief valve adjustments on size 71 and 90 to be done with a 11 mm box wrench and a 19 mm box wrench 125 and 180 to be done with a 5 mm allen wrench and a 17 mm box wrench Y Aa High pressure relief valve with tow option used in AA4VG40 and AA4VG56 Fmannesmann Rexroth 27 92003 S 11 97 Variable Displacement Pump AA4VG Series 3 Engagement of Relief Valve Tow Option Tow Option Engagement for AA4VG40 and AA4VG56 To actuate tow option loosen lock nut ref item 2 Turn tow option engagement screw ref item 3 in six turns and tighten lock nut To disengage tow option loosen lock nut and turn tow option screw all the way out until it stops Note Use a 4 mm allen wrench and a 13 mm box wrench to adjust Relief valve for AA4VG40 and AA4VG56 1 Nut used to torque relief valve into port block 2 Lock nut for tow option engagement 3 Tow option engagement screw Tow Option Engagement for AA4VG
14. 2 Pressure Cut Off With Pressure Cut Off ejejejejejej D Neutral Position Switch HW control oniv Without Neutral Position Switch no code e 6 e e e Omit With Neutral Position Switch e e e e L Mechanical Stroke Limiter Without Stroke Limiter e e e o e Omit With Stroke Limiter e e 6 e e M Ports Ks X4 for Stroking Pressure Without Ports Xs Xa no code ojo 0 o 19 Omit With Ports Xs Ka o e e e e e T Regulating DA Cartridge NV EZ DG EP HWHD DA 40 56 71 90 125 180 Without DA Cartridge 00000000 1 0 9 0 0 0 1 With DA Cartridge fixed adjustment Jejeojo o o 0 0 O 9 0 0 2 With DA Cartridge mech adjustable w lever Jejeje 19 9 o 19 0 0 3 With DA Cartridge fixed adjustment and Hydraulic Inching Valve built on 0 O e 4 4 With DA Cartridge mech adjust w lever and Hydraulic Inching Valve built on gt e e e o 5 With DA Cartridge fixed adjustment and connection for TH7 master controller e e e e e o e e 7 Series 3 Index 2 Direction of Rotation As viewed from drive shaft clockwise R counter clockwise L Shaft Option S is standard for the front pump of tandem units Available O See Page 6 With Cold Start bypass valve See page 7 O On Request Consult Factory Not Available 4 Fmannesmann Rexroth 92003 5 04 97 Variable Displacement Pump AA4VG Series 3
15. 2 put is used to operate Yes Proceed to step 2 7 HW Control sticking auxiliary functions do cable or linkage these other functions EP Control fluctuating cause fluctuations in control current charge pressure 2 2 Are the brakes fully No Check brake release 2 7 Isolate the auxiliary No Proceed to step 2 8 released circuit or mechanism function and run the Yes Operate transmission Yes Proceed to step 2 3 transmission Are the and return to step 2 1 charge pressure fluctu 2 3 Are the stroking time No Remove the plugs in ations reduced or orifices correctly sized ports Xy and Ko and eliminated for the application remove control orifices with 3mm allen wrench 2 8 Are there system pres No Proceed to step 2 9 for size 71 and a 5mm sure fluctuations which Yes Determine the cause of allen wrench for size are synchronous with system pressure fluctu 250 Try various sizes the charge pressure ations until desired pump fluctuations stroking rate is attained Yes Proceed to step 2 4 2 9 If variable displacement No Add motor stroking time motor is used is the adjustment valve or ori 2 4 With HD control is the No Change spring to suit motor stroking time cor fice to the variable control curve of the Yes Proceed to step 2 5 rect for the application motor or modify the remote pilot valve cor rectly matched to the pump control circuit to provide desired stroking time Fmannesmann Rexroth 21 92003 S 04 97
16. 5 146 6 210 9 Moment of inertia about drive axis J kgm2 0 003 0 0051 0 0072 0 0106 0 0164 0 0323 Ib ft2 0 0712 0 1210 0 1709 0 2515 0 3892 0 7665 Weight standard model without through drive m kg 31 38 50 66 80 104 lbs 68 84 110 145 176 229 O Limited maximum rpm O Intermittent maximum rpm at high idle speed during engine overspeed Ap 70 150 bar 1015 2176 psi and V max Ap lt 300 bar 4350 psi and 1 lt 5 seconds with reversing loads V Displacement cm8 or in3 per revolution Ap Differential pressure n Speed rpm Input Drive Permissible axial and radial loading on drive shaft Distance of F from shaft shoulder Max permissible radial load at distance Max permissible axial load Filtration Options Many factors influence the selection of a filter to achieve the desired cleanliness level including dirt ingression rate required cleanliness level and system complexity We have found the following filter Beta 6 ratios ISO 4572 to be satisfactory Suction Filtration 5959955995 Bjo 2 0 8 B302 100 Charge Pressure Filtration B10 gt 10 0 8 Boy gt 100 Machine testing is necessary to confirm the ability of the selected filter to maintain the desired fluid cleanliness levels at half corner power e g at Vg max and 40 56 6300 8000 11000 16000 5242 7051 10150 1
17. 90 125180 X 58 Ms S 5 a Ki BtoA Ma 23 40 56 b X2 AtoB MB a 88 a Xi Ato B Me 71 90 125 180 b X2 Bto Ma Solenoid a Ki Counter L Clockwise E B Clockwise 7 g E A Solenoid Model with DA control valve IK gt gt gt Mi mannesmann Rexroth 13 92003 S 04 97 Variable Displacement Pump AA4VG Series 3 D A Hydraulic Control Speed Dependent Pilot pressure from the DA regulating cartridge is directed to the stroking piston of the pump by a 4 3 way directional valve Pump displacement is infinitely variable in each direction of flow pro portional to both pump drive speed and discharge pressure Flow direction i e Machine forward or reverse is controlled by energizing solenoid a or b refer to flow direction data table at right Increasing pump drive speed generates a higher pilot pressure from the DA cartridge with a subsequent increase in pump flow and or pressure Dependent on the pump operating curve increasing system pressure causes the pump to swivel back towards a smaller dis placement A relatively constant torque input to the pump is achieved by this combination of de stroking the pu
18. LP Remove the coil wire close the injector rack or leave the gas turned off and turn the engine over until the charge pressure reaches 50 psi or more Electric Motor Jog the starting circuit until the charge pres sure reaches 50 psi or more Start the prime mover and if possible maintain a pump speed of approximately 750 rpm for 5 minutes This will allow the system to be filled Listen for any abnormal noises Check for oil leaks Run prime mover to 1800 rpm Adjust to the design speed if less than 1800 rpm Set charge and pilot pressure as required for the applica tion Refer to circuit schematic For the HD control bleed the pilot lines by loosening the connections at Y1 and Y2 and then actuate the remote con trol unit in both directions until oil seeps from the connections Retighten all connections Operate the control to work the hydrostatic transmission at approximately 20 of maximum speed Deaerate system by venting a bleed valve or by cracking the highest connection until fluid seeps out without bubbles Check fluid level and add fluid if necessary Continue operating transmission and gradually increase to full speed still with no load With controls neutralized check for creep in neutral If evi dent center the control in accordance with the instructions in the pump service manual Check that the controls are connected so that the transmis sion operates in the correct direction related to t
19. Switch Adjustment Procedure Note Before adjusting neutral start switch pump should be cen tered 1 To adjust neutral safety switch disconnect linkage from control handle and connect an ohm meter across the to leads from the neutral safety switch adjust the ohm meter to read continuity 2 Then loosen the jam nut with wrench A and turn the switch wrench B in until you lose Continuity 3 Then back the switch out until you complete the circuit and tighten jam nut 4 Block vehicle to prevent movement Return HW control to neutral Install gages in Ma and Mp and start engine Slowly bring pump on stroke switch must open before pressure is developed in Ma or Mp port Note All adjustments require a 23 mm box wrench and a 30 mm box wrench Adjustment of P O R valve on pumps with remote hydraulic pilot control type HD manual rotary servo type HW and proportional electric control type EP Wrench A Wrench B 26 Mimannesmann Rexroth 92003 S 11 97 Variable Displacement Pump AA4VG Series 3 High Pressure Relief Valve Adjustments High Pressure Relief Valve Adjustment Procedure AA4VG40 amp AA4VG56 1 2 3 4 5 Remove relief valve cover from pump ref item 1 Loosen jam screw ref item 2 Holding spring loading nut ref item 4 adjust valve spindle ref item 3 One turn equals approx 630 psi 44 bar After adjustment is completed tighten jam screw ref item
20. UN 20 deep 71 145 5 239 0 8 111512 UN 20 deep 90 128 248 5 1146 12 UN 20 deep 90 139 5 248 5 24 1 As 12 UN 20 deep 125 147 267 9 1546 12 UN 2B 20 deep 125 172 0 267 9 20 154512 UN 2B 20 deep 180 148 311 9 15812 UN 2B 20 deep 180 173 0 311 9 3 151612 UN 2B 20 deep External Charge Supply E without charge pump On units supplied without an integrated charge pump NOO or K the suction port S is plugged and the external charge supply is connected at port Fy Please note that the externally supplied charge flow must be maintained at the cleanliness levels indicated on page 4 Circuit Diagram E without charge pump ae 1 RTT gt 1 Ps 5 For M A ti 5 a A aS B I rt tse TA ii l nd f Wo 1 LY Ti ut SOE Em 3 e E Abma E A 28 ke l id x X gt G MH SFM 8 Fmannesmann Rexroth 92003 5 04 97 Variable Displacement Pump AA4VG Series 3 Filtration Options Charge Pressure Filtration F mounted filter Without contamination indicator Filter type coria Filter without bypass Integral bypass valve Bypass setting AP 23 5 bar 50 psi Bypass flow To charge pump inlet Filter element pressure drop mounted filter at V 141 SU
21. e 09 SAE 1 14T 12 24P SAE C 2 bolt eee 0 0 07 DIN N35x2x30x16x9H DIN 5480 SAE D 2 4 bolt e cont l SAE D 1 13T 8 16P SAE D 2 4 bolt e e 69 SAE 1 13T 8 16P SAE E 4 bolt O 72 Relief Valves Adjustment Range 40 56 71 90 125 180 W high press relief valves pilot oper 1450 6100 psi with bypass e e 1 With high pressure relief valves 4000 6100 psi without bypass e 3 Direct operated fixed setting with bvpass e e 5 1450 3600 psi without bypass e 4 with bvpass e e 6 Filtration 40 56 71 90 125 180 Filtration in Charge Pump suction line e e e 5 Charge Pressure Filtration Ports Fe and Fa 6 Cold start valve and ports for external charge circuit filter Ports Fe and Fa OOJO OJ OJ O K Mounted Filter Without contamination indicator F Filter with visual contamination indicator P Filter with electrical contamination indicator e e e e e L Filter with visual and electrical contamination indicator 9 6 M External Charge Supply Units without charge pump NO0 or K e e e e e e E Fmannesmann Rexroth 5 92003 S 04 97 Variable Displacement Pump AA4VG Series 3 Technical Data Description The AA4VG is a swashplate design variable displacement over center axial piston pump It has been designed exclusivel
22. pressure only Flow is negligible as the pilot signal is only acting on the spool of the control valve This spool then directs control oil into and out of the stroking cylinder to adjust pump displacement as required A feedback lever connected to the stroking piston maintains the pump flow for any given pilot signal A Pst Ps bar pal 18 16 14 12 61 203 100 80 60 40 e e o 12 16 18 Pilot pressure pg Begin of regulation End of regulation If the pump is also fitted with a DA control valve automotive y 7 Ps 10 6 18 bar 87 261 psi at ports Y4 Yo 6 bar 87 psi 18 bar 261 psi control of the vehicle transmission is possible For DA control valve see page 12 13 28 amp 29 Standard model RGI Data Table AA4VG HD Direction of rotation Control Output flow direction Pilot Control Direction Operating Size Pressure Pressure of Flow Pressure a Y Xi AtoB MB 2 3 40 56 Y2 X2 Bto A Ma 8 Y Xi BtoA Ma __ 71 90
23. swashplate angle as required to limit the maximum pressure at port A or B RT TABAH FIX A id PsFaFat Fe MB TE Bu e 5 E ea The pressure cut off valve prevents continuous dumping of f x H B excessive flow at load pressure through the cross port relief i valves in the pump This eliminates unnecessary heating of the i ee 868188 8 1 oil and protects the pump and motor during rapid acceleration or ji pa Y i deceleration or when the drive stalls causing the pump to dead i EEES nead TE The pressure peaks that occur with rapid swivel angle changes 7j A and also the maximum system pressure are further protected by i AAA a G ME S Fs Ma the high pressure relief valves The pressure cut off valve should be set 20 30 bar 290 435 psi less than the high pressure relief valve settings Standard Adjustment Range 2175 6500 psi 150 450 bar Electrical Control Non Proportional EZ1D EZ2D with Pressure Cut Off 10 Mimannesmann Rexroth 92003 5 04 97 Variable Displacement Pump AA4VG Series 3 HD Hydraulic Pilot Control The flow output of the pump is infinitely varied between 0 and 100 proportional to the difference in pilot pressure applied to the two control ports Y and Yo in the range of 6 to 18 bar 87 to 261 psi The pilot signal which originates from an external remote source is
24. 000 operating hours or annually irre spective of operating hours achieved The oil change should be carried out with the system in warm running condition Before re filling the reservoir should be cleaned to remove any sludge Caution Rags or other threading material must not be used Note The recommended interval between oil changes is based on various factors and should be carried out according to the type of fluid the degree of aging and contamination of the fluid The water content is also a contributory factor Under application conditions with a heavy occurrence of dust or severe temperature fluctuations the intervals between oil changes should be shortened accordingly Caution Practical experience shows that most maintenance errors occur during an oil change due to Use of an unsuitable hydraulic oil Use of oil contaminated due to faulty storage Failure to clean reservoir Inadequate cleanliness when filling dirty drums or con tainers Loop 3 Leakage Inspection a After commissioning b The complete transmission pump motor and all pipelines filters valves etc should be checked for leak age at regular intervals Caution Leaking joints and connections must only be tighened in pressure less conditions 4 Cleanliness Inspection The oil tank breather should be regularly cleaned of dirt and dust to prevent clogging The cooling surfaces should be cleaned at the same time Caution If hose coup
25. 08 HWD HU00608524 A HD HU00602245 A ER HU00602248 HU02007246 EP2 HU00602247 HU02007245 521 HU00437191 HU00437191 EZ2 HU00437190 HU00437190 Note To add neutral start switch to an existing HW control add kit 5400 635 009 A Partnumbers not released at time of printing Control Module Size Control module housing for sizes AA4VG28 AA4VG71 and AA4VG90 AA4VG250 are the same To determine size of con trol module feedback lever length dimension A can be measured To convert control modules within a housing size feed back levers can be changed Reference page 33 Pump Size Dimension 28 40 See page 33 56 1 45 in 36 8 mm 71 See page 33 90 1 36 in 34 5 mm 125 1 55 in 39 4 mm 180 2 15 in 54 6 mm 250 2 88 in 73 2 mm Pm Ref Control Module Fmannesmann Rexroth 33 92003 S 04 97 Variable Displacement Pump AA4VG Series 3 Replacement Subassemblies and Parts Control Module Size Control module housing for sizes AA4VG28 AA4VG40 AA4VG56 and AA4VG71 are the same To determine size of control module feedback lever length dimension A or B can be measured To convert control modules within a housing size feedback levers can be changed Reference page 33 Pump Size A Dimension B Dimension 28 40 2 27 in 57 7 mm 2 62 in 66 5 mm
26. 125 180 Ye X 58 Ms S je Yi 810 Ma 85 40 56 Ya X2 AtoB Ms 88 1 Xi Ato B Ms 71 90 125 180 Yo X2 Bto A Ma Ruel Counter Clockwise Clockwise Model with DA control valve ATF gt MH SLF M Fmannesmann Rexroth 11 92003 S 04 97 Variable Displacement Pump AA4VG Series 3 HW rotary Manual Servo Control The flow output of the pump is infinitely varied in the range of 0 to 100 proportional to the rotation of the control lever between 0 and 35 from the spring centered zero flow position A feedback lever connected to the stroking piston maintains the pump flow for any given position of the control lever between 0 and 35 0 100 80 60 40 20 50 20 40 60 80 100 x 8E Swivel angle of the control lever from 0 to Vg max or B 0 to 35 mechanical stop size 40 71 size 90 180 40 35 Required lever torque 85 210 Ncm 7 5 19 Ib in Maximum lever torque 250 Ncm 22 Ib in If the pump is also fitted with a DA valve automotive control of the vehicle transmission is also possible For DA cont
27. 178 1585 2282 787 1079 1348 Charge Flow Suction Filtration standard model S Filter ype nessies Filter without bypass Filter element pressure drop at V 141 SUS 30 cSt n nmax Ap lt 0 1 bar 1 5 psi at V 4635 SUS 1000 cSt n 1000 rpm Ap lt 0 3 bar 4 5 psi Min pressure at charge pump inlet port S at V 141 SUS 30 cSt p20 8 bar abs 6 3 in Hg at cold start p gt 0 5 bar abs 15 2 in Hg The filter should be fitted with a AP indicator and or switch Fmannesmann Rexroth 7 92003 S 04 97 Variable Displacement Pump AA4VG Series 3 Filtration Options Charge Pressure Filtration D Ports Fe amp Fa 18 66 Filter without bypass Filter element pressure drop line mounted filter at V 141 SUS 30 cSt Ap lt 1 bar 14 5 psi at cold start APmax 3 bar 43 5 psi valid for entire speed range Nmin Nmax Please note e With Direct Operated Hydraulic Control Tvpe DG control pressure should be supplied from the Ps port e The filter should be fitted with a AP indicator and or switch set at lt 3 bar 43 5 psid Circuit Diagram D Ports Fe amp Fa ea E ara Ab j IT Ps Fel Fay Fe t E SE
28. 25 Is it possible to adjust No Replace high pressure less than 2 bar abs or drain line so that case high pressure relief relief valve cartridges 30 psia pressure at port R is valves using the and return to step 1 21 less than 8 bar abs or 0 10 000 psi gages at Yes Adjust high pressure 30 psia Return to step MA and MB to monitor relief valves to required 1 21 pressure Refer to or design pressure Yes Proceed to step 1 24 relief valve adjustment Proceed to step 1 26 1 24 Stroke pump in both No Verify that loading of 1 26 Actuate Control in both No Check if motor sizing is directions Does any the pump will cause directions Does trans adequate for applica pressure greater than system pressure to mission run tion Check for 350 psi alternate increase above charge mechanical faults in the between parts Ma and pressure Proceed to drive beyond the motor Mg step 1 19 shaft Ves Proceed to step 1 25 Ves operate the transmis sion 2 Transmission Drive is Sluggish or Erratic 2 1 Is the control medium in No Rectifv the control fault 2 5 Does the charge pres No Proceed to step 2 9 good condition For HD Bleed pilot lines sure fluctuate more Yes Proceed to step 2 6 example control me HW Lubricate or free than 30 psi when dium is not in good the cable or linkage stroking the pump condition if EP Check control cur HD control air in pilot rent 2 6 If the charge pump out No Proceed to step 2 8 lines Yes Proceed to step 2
29. 30 cSt Absolute minimum viscosity 60 SUS 10 c St When the fluid viscosity is greater than 1000 SUS 216 c St the transmission should be operated at reduced speed until the oil has been warmed to a temperature of 40 F 4 5 C For applications that will operate near the extremes of viscosity and or temperature the fluid manufacturer should be consulted for assistance in selection of the most suitable type and grade of fluid for your application Rexroth strongly recommends the selection and use of fluids from reputable and established suppliers 32 Fmannesmann Rexroth 92003 S 04 97 Variable Displacement Pump AA4VG Series 3 Replacement Subassemblies and Parts Control Modules Control Size Module 28 40 56 HW HU00606886 HU00606886 HU00606888 HWD HU00607224 HU00607224 HU00607226 HD HU00601717 HU00601717 HU00433487 EPI HU00601622 HU00601622 HU00429169 EP2 HU00601621 HU00601621 HU00429168 EZ HU00600074 HU00600074 HU00600074 EZ2 HU00600076 HU00600076 HU00600076 Control Size Module 71 90 125 HW HU00606891 HU00608523 HU00608522 HWD HU00607228 HU00608526 HU00608525 HD HU00429114 HU00602225 HU00602238 EP1 HU00428139 HU00602227 HU00602236 EP2 HU00428138 HU00602226 HU00602237 EZ1 HU00600074 HU00437191 HU00437191 EZ2 HU00600076 HU00437190 HU00437190 Control Size Module 180 250 HW HU00608521 HU020080
30. 34636 and shims 1 Adjustable Charge relief for sizes 71 thru 180 2 Shim charge relief for sizes 40 and 56 only 1 mm equals 56 psi 3 9 bar 34 Fmannesmann Rexroth 92003 S 11 97 Variable Displacement Pump AA4VG Series 3 Replacement Subassemblies and Parts High Pressure Relief Valve Part Numbers Pump Part Pressure Type of Size Number Range Relief Valve 40 HU00447133 3600 6000 psi Direct acting without tow option HU00447134 3600 6000 psi Direct acting with tow option 56 HU00429458 3600 6000 psi Direct acting without tow option HU00434301 3600 6000 psi Direct acting with tow option 71 90 HU02600466 1450 6000 psi Pilot operated with tow option 125 180 HU00832121 1450 6000 psi Pilot operated with tow option 250 A A A A Part number not released at time of printing EP Solenoids Proportional Pump Size 24 Volts DC 12 Volts DC All HU00441692 HU00441691 EZ Solenoids Non Proportional Pump Size 24 Volts DC 12 Volts DC All HU00428266 HU00428265 Plug in Connectors Pump Size Gray Black All HU00152503 HU0085290 Ammeter with Sandwich Plug Part Number Pump Size All EP Controls 5956 001 018 Stroking Time Orifices for Sizes 28 71 Part Number Orifice Size Thread Size HU00156492 0 8 mm DIA M6 HU00156493 1 0 mm DIA M6
31. 4 97 Variable Displacement Pump AA4VG Series 3 Troubleshooting Procedure 7 Transmission Operates at a Higher Than Normal Temperature 7 1 15 the operating temper No 195 F is the upper limit 7 4 Check differential pres No Proceed to step 7 5 ature above 195 If temperature is close sure across oil cooler Yes Check piping from oil to 195 F the oil cooler as compared to the cooler to reservoir may need to be manufacturer s specs at Check for plugged or cleaned charge pump flow Is damaged oil cooler Yes Proceed to step 7 3 AP higher than it should be 7 2 15 the hydraulic motor No Proceed to 7 3 stalling intermittently Yes Hydraulic oil is being Note See page 7 for case heated through system pressure rating relief valves Shut down system and rectify 7 5 Disconnect pump case No Refer to charge pump cause of the motor stall drain from oil cooler and removed and inspection check flow from charge procedure 7 3 Does temperature No Operate transmission pump 15 flow normal Yes Check oil cooler loca remain above 195 F Check oil cooler more tion after cleaning oil often cooler Yes Proceed to step 7 4 8 Pump Does Not Develop Maximum Horsepower Flow amp Pressure 6 1 Does charge pressure No Return to step 1 9 8 3 Are high pressure relief No Adjust or replace relief meet specification Yes Proceed to 8 2 valves adjusted to the valve cartridge required pressure so Yes Replace the pump 8 2 15 the case pres
32. 5 6 4 4 32 ee a 32 Replacement Subassemblies and Parts 33 36 Filtration Configuration 6 21 2 ac oy RA a 37 Fmannesmann Rexroth 3 92003 S 04 97 Variable Displacement Pump AA4VG Series 3 Ordering Code Hydraulic Fluid Petroleum Oil For operation with other fluids consult a Rexroth Application Engineer je Axial Piston Unit gt Variable swashplate design Nominal pressure 5800 psi peak pressure 6500 psi AA4V gt Mode of Operation a Pump in closed circuit G Size gt Displacement Vg max CM3 28 40 56 71 90 125 180 250 Size 28 see RA 92002 A Size 250 see RA 92000 Control Options 40 56 71 90 125 180 None NV e o e e e NV Hvdraulic Control Direct Operated 19 DG Electrical Control Proportional EP 0 e e o EP Electrical Control Non Proportional EZ e e e EZ Rotarv Manual Servo Control HW e HW Hydraulic Control Pilot Operated HD e HD Hydraulic Control Speed Dependent DA 0 e e e e DA Solenoid Voltage EP EZ or DA oniv 12 Volt DC e e e e 1 24 Volt DC e e e e e e
33. 71 and AA4VG90 To actuate tow option turn tow option engagement screw ref item 4 out three turns To disengage tow option turn tow option engagement screw in until it stops SS AN NGA A f Note Use a 4 mm allen wrench to adjust 1 E Wh UNMET laa Tow option Engagement for AA4VG125 and AA4VG180 To actuate tow option turn relief valve ref item 1 out two turns To disengage tow option tighten relief valve Note Use a 36 mm box wrench to adjust Note Tow options are meant to be used for a short time period only Tow options are not to be used for extended tows Torque Specs for Relief Valves into Port Block Relief valve for AA4VG125 and AA4VG180 Pump Size Wrench Size Torque 1 Nut used to torque relief valve into port block and engage tow option mm ERC 2 Lock nut for high pressure relief adjustment a mm Ib 150 Nm 3 Adjustment Screw for high pressure relief adjustment 125 180 36 mm 147 ft lb 200 Nm Warning Tow option bypasses high pressure relief valves Catastrophic motor damage can occur if hydraulic circuit empties or overheats 28 Fmannesmann Rexroth 92003 5 04 97 Variable Displacement Pump AA4VG Series 3 Removal and Inspection of Charge Pump Before removing cap screws mark the position of the charge pump housing and separator plate in relation to the port block Loosen screws with metric allen wrench
34. 90 Option P Option L Option M L 1 5 5 Fmannesmann Rexroth 9 92003 S 04 97 Variable Displacement Pump AA4VG Series 3 High Pressure Relief Valve Adjustment diagram with Pressure Cut Off Safety Margin i Set value Pressure Cut Off Fl gt System AP Design Max Differential Pressure AP Relief Valve Setting At port A or B Operating Pressure pag 2300 psi ay Charge Press A Omax Note Relief valves are adjusted at a flow rate of 01 6 10 l min 1 6 2 6 gpm depending on size Example Charge pressure Operating pressure Pressure cut off setting Safety margin 30 bar 435 psi 410 bar 5945 psi 20 bar 290 psi Operating press pa Charge press psp Safety Margin Differential press Ap 30 bar 435 psi 410 bar 5945 psi 400 bar 5800 psi 20 bar 290 psi High pressure relief valve Pilot Operated size 71 180 Differential pressure settings ApHD High pressure relief valve Direct Operated size 40 56 Differential pressure settings ApHp Setting range valve 1 Ap 100 420 bar Ap 1450 6090 psi see model code 420 bar 6090 psi 400 bar 5800 psi 350 bar 5075 psi 320 bar 4640
35. Feedback Control Levers 71 2 31 in 58 7 mm 2 66 in 67 5 1 Feedback lever for HW control 2 Feedback lever for HD and EP controls Feedback Levers Pump Feedback lever Feedback lever Size HW Control HD amp EP Control 28 40 HU00432448 HU00432509 56 HU00432489 HU00430310 71 HU00432256 HU00430319 90 HU02008032 HU00436442 125 HU02008033 HU00445730 180 HU02008034 HU02008036 250 HU02008006 HU02006296 Feedback Control Levers 1 Feedback lever for HW control 2 Feedback lever for HD and EP controls Pressure Override Valve Part Numbers Pump Size Pressure Override Valve 28 HU00447281 40 HU00447281 56 HU00446763 71 HU00437084 90 HU00437363 125 HU00433834 180 HU00433834 250 A A Part numbers not released at time of printing Pressure Override Valve Charge Pressure Relief Valves Pump Size Pressure Range Part Number i 28 215 435 psi 15 30 bar 5400 635 0070 40 215 435 psi 15 30 bar 5400 635 0070 0 DO 56 215 435 psi 15 30 bar 5400 635 0070 CE 71 215 435 psi 15 30 bar 00434856 Wo 1 90 215 435 psi 15 30 ban HU00434856 125 215 435 psi 15 30 bar HU00434856 a 180 215 435 psi 15 30 bar HU00437151 CEH 2 250 215 435 psi 15 30 bar HU00437151 Adjustment kit 5400 635 007 consists of charge pressure relief Charge Pressure Relief Valves valve HU004
36. HU02006412 HU02006413 HU02006413 A 36 Fmannesmann Rexroth 92003 S 11 97 Variable Displacement Pump AA4VG Series 3 Filtration Configurations for AA4VG Series 32 Filtration Port AA4VG40 AA4VG71 AA4VG125 Configuration Configuration AA4VG56 AA4VG90 AA4VG180 Port Size Part Number Port Size Part Number Port Size Part Number 1 Plugged M18 x 1 5 76116 010 M22 x 1 5 76116 009 M33 x 2 76116 008 Suction 2 Plugged M18 x 1 5 76116 010 M22 x 1 5 76116 009 M33 x 2 76116 008 Filtration 3 Plugged M18 x 1 5 76116 010 M22 x 1 5 76116 009 M33 x 2 76116 008 4 Plugged 3 4 16 UN 76107 008 1 1 16 12 UN 76107 012 1 5 16 12 UN 76107 016 5 Open M14 x 1 5 M18 x 1 5 M20 x 1 5 6 Open 1 5 16 12 UN 1 5 8 12 UN 1 7 8 12 UN 1 Plugged M18 x 1 5 76116 010 M22 x 1 5 76116 009 M33 x 2 76116 008 Charge 2 Open 3 4 16 UN HU00607033 11 16 12 UN HU004488249 1 5 16 12 UN HU00442847 Pressure 3 Plugged M18 x 1 5 76116 010 M22 x 1 5 76116 009 M33 x 2 76116 008 Filtration 4 Open 3 4 16 UN 1 1 16 12 UN 1 5 16 12 UN D 5 Plugged M14x 1 5 76117 001 M18 x 1 5 76117 007 M20 x 1 5 76117 008 6 Open 15 16 12 UN 1 5 8 12 UN 1 7 8 12 UN 1 Open M18 x 1 5 Filter Port M22 x 1 5 Filter Port M33 x 2 Filter Port Mounted 2 Open M18 x 1 5 Filter Port M22 x 1 5 Filter Port M33 x 2 Filter Port Filter F or 3 Open M18 x 1 5 Filter Port M22 x 1 5 Filter Port M33 x 2 Filter P
37. MB B O ol SINMA A Ki Counter y Ta 9 Clockwise m Le o Clockwise H A crit x Neutral Position E Switch Technical data for neutral position switch Load performance 20A continuous Switch performance 15A 32V DC 4A 32V AC inductive Model with DA control valve and neutral position switch iro E RTT ll 1 Psh a fe Mp lt lt a T hy e si L q B ell dde a pake RAAT at E dl 14 du 4 pl ak sl A a A i k Xi X gt G MH 5 Lead NZ 12 Fmannesmann Rexroth 92003 5 04 97 Variable Displacement Pump AA4VG Series 3 E P proportional Electrical Control The flow output of the pump is infinitely varied in the range of 0 to 100 proportional to an electrical current in the range of 200 600 mA at 24 volts DC supplied to solenoid a or b A cur rent of 400 to 1200 mA is reguired for the 12 volt solenoids The electrical energy is converted to a force acting on the con trol spool The spool then directs control oil in and out of the stroking piston to stroke the pump as reguired A feedback lever connected to the stroking piston maintains the pump flow f
38. O O FO7 HU00606801 HU00606317 HU00606214 A Charge Pump F69 HU00606330 HU00606245 A F73 HU00606805 Not Available A Part numbers not released at time of printing Seal Kits and Shaft Seals for AA4VG 32 Size 28 250 Seal Kits Shaft Seal Pump AA4VG 32 P AA4VG 32 V AA4VG 32 N Buna FPM Size Buna FPM FPM Shaft Seal with Buna Seals 28 5470 635 023 5470 635 024 5470 635 025 HU00830425 HU00830742 40 5410 635 033 5410 635 035 5410 635 034 HU00831285 HU00831284 56 5420 635 028 5420 635 031 5420 635 029 HU00830970 HU00830976 71 5430 635 025 5430 635 027 5430 635 026 HU00830971 HU00830977 90 5440 635 033 5440 635 040 5440 635 038 HU00830972 HU00830978 125 5450 635 031 5450 635 033 5450 635 032 HU00830974 HU00830980 180 5480 635 007 5480 635 009 5480 635 008 HU00830973 HU00830979 250 O 5460 635 022 5460 635 023 O HU02600118 Not Available Charge Pressure Filtration Kits and Filter Elements Pump SPZ P Visual L Electrical M Visual amp Filter Size Standard Indicator Indicator Electrical Element Indicator Only 28 40 56 HU00434508 HU00441717 HU00606914 HU00606305 HU00830024 71 90 HU00434509 HU00446438 HU00434984 N A HU00157926 125 HU00434510 HU00447605 HU00601330 HU00602557 HU00157926 180 HU00434511 HU00600111 HU00447472 HU00606008 HU00157956 250 A A A A A A Part numbers not released at time of printing Cold Starting Valve A HU02007002
39. Proceed to step 1 21 screw if so equipped selected If not done automatically Note If flushing valve is used in circuit it should set at 25 psi less than charge pump relief Refer to data sheet on 1 21 Actuate the control in No Refer to the pump ser flushing valve for information and setting procedure both directions Does vice manual and then pump stroke Does it proceed to step 1 22 1 10 Is the suction line shut No Open valve go to full stroke Yes Operate the transmis off Yes Proceed to step 1 11 sion 1 11 15 the charge pump suc No Proceed to step 1 12 1 22 Remove stroking ori No Remove control module tion pressure within the Yes Proceed to step 1 16 fices in Ki and X2 and replace it with a recommended limits Stroke the pump in both new unit Repeat step 0 8 bar abs or 6 3 in directions Do the pres 1 21 Hg sures at X1 and X2 Yes Proceed to step 1 23 Alternate between 30 1 12 Is the suction filter ele No Proceed to step 1 13 and 250 psi during ment plugged Yes Replace filter element cycle 1 13 Does the reservoir de No Correct the reservoir sign ensure that suction design pipe is always covered Yes Proceed to step 1 14 with oil 20 Fmannesmann Rexroth 92003 5 04 97 Variable Displacement Pump AA4VG Series 3 Troubleshooting Procedure 1 Transmission does not Drive with the Prime Mover Running Continued from page 20 1 23 15 the pressure at port R No Repipe pump case 1
40. S 30 cSt N max Ap lt 1 bar 14 5 psi atcoldstart APmax 3 bar 43 5 psi valid for entire speed range Nmin Nmax Please note e Max perm charge pressure for sizes 40 and 56 Psp max 510 psi 35 bar e With Direct Operated Hydraulic Control Tvpe DG control pressure should be supplied from the Ps port e The filter should be fitted with a AP indicator and or switch set at lt 3 bar 43 5 psid Circuit Diagram F with filter assembly ma Die 1 11 Kul RITA IEX RE Is E TO 1 7 it it B se ml Gwe OLD 4 i L I ws Qee OCHO 1 us A k as k de Xx X G MH S Ma Dimensions F P L M with filter assembly Size FI F2 F3 Fs F5 F6 F7 F8 F9 F10 40 198 7 46 7 160 175 135 0 42 78 5 122 125 56 215 4 63 4 163 178 138 0 42 78 5 122 125 71 239 50 185 203 5 155 16 29 65 5 109 112 90 248 5 59 4 179 197 5 149 0 53 89 5 133 136 125 267 9 62 8 201 219 5 171 0 53 895 133 136 180 311 9 37 9 202 220 4 171 9 17 36 72 5 116 119 Option L M F1 Y Option F Charge Pressure Filtration P mounted filter With visual contamination indicator Similar to option F except model P includes visual contamina tion indicator Indication
41. ase Example At an ambient temperature of X F the closed circuit fluid temperature is 140 F 60 C Within the optimum operat ing viscosity range V shaded area this corresponds to ISO viscosity grades VG 46 or VG 68 VG 68 should be selected Important The leakage oil case drain oil temperature is influ enced by pressure and pump speed and is typically higher than the circuit temperature However maximum temperature at any point in the system must be limited to 239 F 115 C If itis not possible to comply with the above conditions because of extreme operating parameters or high ambient temperatures please consult Rexroth Fluid Cleanliness Levels In order to ensure proper and reliable operation the hydraulic fluid must be maintained at a minimum cleanliness level of 18 15 ISO DIS 4406 SAE J1165 Axial piston pump component life is directly affected by the cleanliness of the fluid in the system Temperature Range 40 195 F 195 240 F 40 90 C 90 115 C Cleanliness Recommendations Class Class ISO DIS 4406 SAE J1165 18 15 17 14 NAS 1638 9 8 SAE ASTM AIA 6 5 Operating Pressures Ranges Main pump Nominal charge pressure psp 20 bar 290 psi Nominal pressure port A or B pn 400 bar 5800 psi Peak pressure port A or B Pmax 450 bar 6525 psi Maximum case drain pressure 1 2 3 and Ta Die Arc A A one 220 E 2 bar abs 30 psia short term cold start
42. cessary follow the steps listed below To ensure there is equal pressure on both sides of the control module during the centering operation it is necessary to connect the Xy and Ko ports together by means of hose or tubing No less than a 1 4 inch ID The port sizes are as follows Size 28 90 7 16 20 UNF Size 125 amp 250 9 16 18 UNF Pump Size Allen Wrench Wrench 28 56 6mm 19mm 71 90 6mm 24 mm 125 250 8 mm 24 mm With pressure gages installed at Ma and Mp and with A and B ports blocked or motor stalled and with the pump running loosen the jam nut Turn the mechanical centering adjusting screw until 1000 psi is read on Ma or Mp then turn screw oppo site direction until 1000 psi is read on other pressure port Turn the screw back splitting the distance between the previous two positions This should be the neutral position Pressure on Ma and Mg should be equal Tighten jam nut stop the pump drive remove the hose connect ing ports X4 and Xo 24 Fmannesmann Rexroth 92003 5 04 97 Variable Displacement Pump AA4VG Series 3 Hydraulic Centering of Control Modules Preparation for Adjustment When control modules are exchanged or replaced it is generally necessary to center the new module This is done by running the pump with gauges installed at ports Ki X2 Ma and Mg Release the jam nut and turn the adjustment screw on top of the control module valve body
43. engineering mannesmann Rexroth Application amp Service Manual AA4VG Series 3 2 Size 28 250 RA 92003 S 11 97 92003 S 04 97 Variable Displacement Pump AA4VG Series 3 engineering mannesmann Rexroth Ordering of Parts For Rexroth to supply the correct parts for your unit please include all of the following information along with your parts order Model Code Serial Number Unit Number Part Name Part Number Due to modifications and improvements to our products minor changes can occur to the parts even though the type code may not necessarily reflect these changes The type number and serial number will guarantee that the correct parts for your unit are supplied THE REXROTH corp y PISTON PUMP DIVISION FOUNTAIN INN ROR OF AA4VG125NVD1 32L 06 95 PSF52N001S 5454 005 002 CCW PART NO MINERAL OIL ROTATION 111111 1 e MADE IN USA Ordering Example To order a replacement rotary group for an AA4VG variable displacement pump having the above nameplate the following information would be required Model Code AA4VG125NVD1 32LPSFN001S Serial Number G2014680 Unit Number 5454 005 002 Part Name Charge Pressure Relief Valve Part Number HU00434856 This information is taken from the nameplate on the pump This information is taken from the Application and Service Manual 2 Fmannesmann Rexroth 92003 5 04 97
44. fe we recom mend that the operating viscosity at normal loop operating temperature be selected from within the range Optimum Viscosity Vopt 80 170 SUS 16 36 mm2 S Viscosity Limits Max Viscosity at startup Vma 7273 SUS 1600 mm2 S Min Viscosity for short duration Vin 42 SUS 5 mm2 S Operating Temperature Limits Min operating temperature 13 25 C Absolute min temperature 40 40 C Max operating temperature for short duration 239 F 115 C Selection Diagram 7000 1600 1600 7425 5000 1000 3000 _ 600 2000 400 1000 200 500 7100 300 760 200 7 40 36 Y 150 4 170 100 20 ont 80 4 70 4 60 _10 48 a 80 Viscosity v mm s SUS 50 40 7 5 42 a 49 0 20 40 60 80 100 120 140 160 180 200 220240 40 30 29 edo do 20 do 9 20 60 do 9997 JE Temperature tin F C Notes on hydraulic fluid selection In order to select the correct fluid it is necessary to know the normal operating temperature in the circuit closed loop when the system is operated at the design ambient temperature The hydraulic fluid should be selected so that within the operat ing temperature range the fluid viscosity is within the optimum range Vo see shaded area of the selection diagram We rec ommend that the higher viscosity grade is selected in each c
45. following conditions exist 1 Approximately when equal control pressures are obtained at control pressure ports X4 and Xo 2 The hydraulic motor does not turn when the brake is released 3 Charge pressure is registered equally at ports Ma and Mp when the flow output of the pump is deadheaded against a locked motor or a valve If difficulties are encountered in obtaining neutral position of the HD or EP control modules check that the ends of the control spring are correctly located in the grooves near the end of the feedback lever arms Feedback Spring Lever Arm Fmannesmann Rexroth 25 92003 S 04 97 Variable Displacement Pump AA4VG Series 3 Pressure Override Valve Adjustment Function of Pressure Override The pressure override valve varies the swashplate angle as required to limit the maximum pressure at port A or B The over ride valve prevents continuous dumping of excessive flow at load pressure through the cross port relief valves contained in the pump This eliminates unnecessary heating of the oil and protects the pump and motor from heavy handed operators or if the the drive stalls causing the pump to deadhead The pres sure override valve should be adjusted to a pressure at least 500 psi less than the setting of the main relief valves Note One turn of screw equals 1200 psi Note All adjustments require a 4 mm allen wrench and a 13 mm box wrench Neutral Start
46. he control input Continue to monitor all pressure gauges and correct any irregularities Apply brakes and set high pressure relief valves and pres sure override if installed to levels required for the application by stroking the pump to approximately 20 of maximum displacement 17 18 19 20 21 22 23 24 Check security of high pressure connections Check oil level and temperature Remove and inspect high pressure filter elements if so equipped Replace with new elements Operate transmission under no load conditions for about 15 minutes to stabilize the temperature and remove any resid ual air from the fluid Again remove and inspect high pressure filter elements if so equipped If clean the high pressure bi direction filters may be removed from the circuit If contamination is still evi dent fit new elements and continue flushing until the system is clean Replace the elements in the charge pump suction or pres sure filter whichever is installed Operate the transmission under full and normal load condi tions Erratic operation may indicate there is still air trapped in the system By working the pump control to one or both sides the remaining air can be eliminated The system is free of air when all functions can be operated smoothly and when the oil in the reservoir is no longer aerated Usually less than 1 hour of operation Note If after following the Pre Start and Start
47. hown herein were as accurate as known at the time this publication was printed Rexroth reserves the right to discontinue models or options at any time or to change specifications materials or designs without notice and without incurring obligation Optional equipment and accessories may add cost to the basic unit and some options are available only in combination with certain models or other options DISTRIBUTED BY e Mobile Hydraulics Division 1700 Old Mansfield Road Wooster OH 44691 0394 Tel 330 263 3400 Fax 330 263 3329 Industrial Hydraulics Division 2315 City Line Road Bethlehem PA 18017 2131 Tel 610 694 8300 Fax 610 694 8467 The Rexroth Corporation 40 Fmannesmann Rexroth All rights reserved Subject to revision Printed in U S A
48. ith the EZ control pump flow is switchable from zero flow nei ther solenoid energized to maximum flow Flow direction is determined by which solenoid is energized please refer to the data table at the top of page 12 O A 12 vdc solenoids TENNANT e ee a add 24 vdc solenoids Pressure Cut Off Refer to page 8 Standard model Hydraulic Control Direct Operated D Pumps supplied with the DG control have no control module The module is replaced by a cover plate Pump output is controlled by hydraulic control pressure Px typ ically supplied by a remote pilot controller applied directly to the stroking piston through either the X or Ko port The DG control is not a positive displacement control as there is no control feedback device While pump displacement is infinitely variable between and 100 a given swashplate position can be affected by system pressure and or pump drive speed as well as the stroking piston centering springs Flow direction is determined by which pilot port is pressurized please refer to the data table at the top of page 9 Control Pressure column X Xo Nominal characteristics Begin of regulation Ps min 5 8 bar 73 116 psi End of regulation full stroke Pst max 22 25 bar 320 363 psi Applicatio
49. lings are used in the high pressure lines it is imperative that the utmost care be taken that no foreign bod ies infiltrate the oil circuit when coupling and uncoupling danger of damage to rotary group and even possibility of total break down 5 Oil level Inspection Inspect oil level in reservoir after commissioning thereafter daily Caution Top up only with specified oil type Do not mix fluids Hydraulic Fluid Most good quality mineral oil based hydraulic fluids exhibiting the following characteristics are suitable for use in a Rexroth hydrostatic transmission Good antiwear performance Resistant to oxidation depredation Protection against rust and corrosion Resistance to foaming Ability to separate water rapidly Suitable for widely varying temperature conditions good low temperature flow properties Retains viscosity temperature characteristics in service Universally available The prime consideration in the selection of hydraulic fluid is the expected oil temperature extremes that will be experienced in service The extremes should be considered when selecting a fluid so that the most suitable temperature viscosity characteris tics are obtained The fluid chosen should permit the system to operate within the following viscosity ranges Maximum viscosity at start up 4600 SUS 1000 cSt Normal operating viscosity range 66 464 SUS 12 100 cSt Optimum viscosity range 81 141 SUS 16
50. lockwise until seal touches housing Turn charge filter 30 degrees clockwise to tighten Fmannesmann Rexroth 31 92003 S 04 97 Variable Displacement Pump AA4VG Series 3 Routine Maintenance The AA4VG variable pumps are relatively maintenance free Maintenance work is confined to the system by way of oil changes and renewal of filter elements Both of these mea sures promote system cleanliness Monitoring and periodic maintenance of the system can prevent premature break downs and repairs Under normal application conditions the following maintenance intervals are suggested 1 Renewal of Filter Elements a After commissioning b At every 500 operating hours or when filter indicator shows a dirty element c With suction filtration the filter element should be renewed as soon as a Charge pump inlet pressure of less than 3 2 psi 0 8 bar absolute becomes evident with the transmission in warm running condition indicates con tamination d With charge flow filtration watch for high pressure differ ential across the filter element Refer to filter manufacturer s specifications Caution Only filter elements capable of meeting or exceeding the fluid cleanliness level requirements reference page 9 should be used Note Paper inserts cannot be cleaned use throwaway catridges maintain a stock 2 Hydraulic Oil Change a After 2000 operating hours 1st oil change b Thereafter every 2
51. mp as the operating pressure increases and the response to the pull down of the prime mover reduced pilot pressure Any additional power requirements such as implement hydraulics may result in engine pull down This leads to a reduction in pilot pressure and therefore pump displacement i e power The power thus released is then available to supply that demanded by the implement hydraulics Automatic power divi sion and full utilization of available power is thus achieved for both the vehicle transmission and the implement hydraulics Minimizing the engine pull down provides optimum usage of the available drive power This can be achieved by partial inching using the adjustable regulating cartridge with lever catalog code options 3 and 5 With partial inching the DA cartridge is mechanically coupled to the accelerator pedal This means that when a certain engine speed is reached movement of the accelerator pedal the control curve is offset parallel to the engine speed curve Application of the DA Control is only appropriate on certain types of vehicle drive systems and requires a careful review of the engine and vehicle parameters to ensure that the pump is set up correctly All DA applications must therefore be reviewed by a Rexroth Application Engineer Hydraulic Control Speed Dependent DA control valve mech adjustable with control lever DA1D3 DA2D3
52. n of the DG Control is only appropriate on certain types of vehicle drive systems and reguires a careful review of the engine and vehicle parameters to ensure that the pump is set up correctly All DG applications should be reviewed by a Rexroth Application Engineer Standard model 11112 Ps fo Fat F Ma 4 T 5 m E Ze B es ae anes AAI AR i CYY MA EEEE ji A 4 pean sj E ACEH CA ai A 20 ca Ki X gt 6 MH 5 Ps Pla LIN Standard model with DA control valve R 1112 5 a Tal e Mg AAA TI t A18 L gt lt Tt a a 5 2 wd ia ANAN el bi 1 1 NG 1 e 444 1 El rat O E E A AECE EA M Pi Xy X gt G MH 5 PS Pla lt gt 1 6 Fmannesmann Rexroth 92003 5 04 97 Variable Displacement Pump AA4VG Series 3 Installation Situation for Coupling Assembly In order to assure that rotating parts coupling hub and fixed parts housing circlip do not contact each other the installation situations are described in this data sheet have to be observed The installation situation depend upon the sizes and the spline For SAE spline shaft shaf
53. o No Proceed to step 5 2 5 2 Check mechanical cen No Repair or replace pump neutral with control lines Yes Check control for elec tering of pump and Yes Replace control module removed trical signal problem control per pages 24 amp if needed Operate EP control or back 25 Does pump return transmission pressure in the pilot to neutral with control lines HD Control lines removed 6 Transmission Drives at a High Noise Level 6 1 Are the drive gearboxes No Fill gearbox with correct 6 4 Is the suction pressure No Return to step 1 7 filled with correct grade grade of oil to the pre at the charge pump inlet Yes Proceed to step 6 5 of oil scribed level within recommended Yes Proceed to step 6 2 limits 6 2 15 the drive coupling No Install coupling per 6 5 Is there air in the No Proceed to step 6 6 correctly installed and manufacturer s instruc hydraulic oil This may Yes Deaerate the oil and aligned tions and tolerances be indicated by foaming inspect system for Yes Proceed to step 6 3 or milky colored oil cause of air induction 6 3 Is rigid piping con No Proceed to step 6 4 nected to the pump and Yes Install short length of 6 6 Is the hydraulic motor Yes Check motor sizing in motor hose between pressure ports and the system piping operating at excessive speed relation to available oil flow from the pump Check motor minimum displacement See page 20 22 Fmannesmann Rexroth 92003 5 0
54. operation of the control lever inching function Maximum angle of lever operation is 70 The position of the lever is optional inching operation clockwise or counter clockwise Hydraulic inching valve 4 5 This valve is used to provide vehicle inching function and is used in conjunction with the DA Regulating Cartridge either with fixed adjustment or mechanically adjustable with lever Model with throttle valve used on Size 40 56 amp 71 Model with pressure reducing valve used on size 90 125 amp 180 It permits the pilot pressure speed dependent to be reduced as necessary independently of the pump drive speed by applying a hydraulic pressure at Port Z This is normally supplied from the vehicle braking system using the brake fluid of the power brakes Master controller TH7 as inching valve 7 This valve is used to provide vehicle inching function and is used in conjunction with the DA control valve fixed setting Any reduction of control pressure independent from the input speed through the mechanical operation of the master controller TH7 The master controller is installed separately from the pump con nected with the pump by 2 hydraulic control lines at ports P and Y The master controller is to be ordered separately see data sheet RE 64558 Hydraulic Control Speed Dependent DA fixed setting DA1D2 DA2D2 gt R T Talbr TE
55. or any given current within the control range Proportional amplifiers MDSD PVR PVRS and special function amplifier EDA are available to control the proportional solenoids As well electronic control of the solenoids can be achieved by using a microcontroller with software that is programmed to per form special functions for custom applications A 800 700 600 500 400 300 200 190 100 80 60 40 20 0 20 40 60 80 100 T 2001 300 400 500 600 700 800 x 1 mA Control current 24 vdc EP2 1 200 600 mA Begin of control l 200 mA V40 End of control 1 600 mA Vg max Control current 12 vdc EP1 1 400 1200 mA Begin of control 1 400 mA V40 End of control l 1200 mA Vo max If the pump is also fitted with a DA control valve automotive control of the vehicle transmission is possible For DA control valve see page 12 13 28 8 29 Standard model Direction of rotation Control Output flow direction Data Table AA4VG EP Control Direction Operating Size Solenoid Pressure ofFlow Pressure sa a X1 AtoB MB 2 3 40 56 b X2 Bto A Ma 3 a Xi BtoA Ma 71
56. ort Cold Start 4 Plugged 3 4 16 UN 76107 008 1 1 16 12 UN 76107 012 1 5 16 12 UN 76107 016 Valve K 5 Plugged M14 x 1 5 76117 001 M18 x 1 5 76117 007 M20 x 1 5 76117 008 6 Open 1 5 16 12 UN 1 5 8 12 UN 1 7 8 12 UN 1 Plugged M18 x 1 5 76116 010 M22 x 1 5 76116 009 M33 x 2 76116 008 External 2 Plugged M18 x 1 5 76116 010 M22 x 1 5 76116 009 M33 x 2 76116 008 Charge 3 Plugged M18 x 1 5 76116 010 M22 x 1 5 76116 009 M33 x 2 76116 008 Supply 4 Open 3 4 16 UN 1 1 16 12 UN 1 5 16 12 UN E 5 Open M14x1 5 M18x1 5 M20 x 1 5 6 Plugged 1 5 16 12 UN 76107 016 1 5 8 12 UN 76107 020 1 7 8 12 UN 76107 024 Adapts metric Fe port to SAE size indicated NI Charge Pressure S amp F Return from filter D Charge source E Charge Pressure S amp D Filtered Oil Return F Charge Pressure S Charge Pump Discharge D amp F Mo Charge Pressure Inlet all Filter bvpass flow F 37 Fmannesmann Rexroth 92003 S 04 97 Variable Displacement Pump AA4VG Series 3 Note Page 38 Fmannesmann Rexroth 92003 S 04 97 Variable Displacement Pump AA4VG Series 3 Note Page Fmannesmann Rexroth 39 92003 S 04 97 Variable Displacement Pump AA4VG Series 3 Specifications descriptions and illustrative material s
57. ove and inspect No Proceed to step 1 18 1 5 Is there a broken pipe No Proceed to step 1 6 charge pump assembly Yes Repair or replace dam loose fitting or burst Yes Repair the fault Is it damaged aged components and hose return to step 1 7 1 6 Are the brakes re No Check brake release 1 18 Is the charge pump No Refit charge pump leased circuit or mechanism installed for correct Return to step 1 7 Yes Proceed to step 1 7 direction of rotation Yes With proper charge pressure and transmis Charge Pump amp Relief Valve sion still does not operate proceed to 1 7 Is there any charge No Proceed to step 1 10 step 1 19 pressure at port G Yes Proceed to step 1 8 Pump Control 1 6 15 the charge pressure No Proceed to step 1 9 at least 300 psi while Yes Proceed to step 1 19 1 19 Is control medium con No Connect appropriate the pump is running at nected to pump control medium and check that normal operating HD pilot pressure control signal is actually speed HW mechanical cable being applied to the or linkage pump control valve 1 9 Can charge pressure be No Proceed to step 1 10 EP 12 or 24 volts dc Yes Proceed to step 1 20 adjusted by adding or Yes Adjust charge pressure electrical current removing relief valve to 300 psi and proceed spring shims or by to step 1 19 1 20 If variable displacement No Select maximum dis adjusting charge pres motors are installed is placement sure relief valve setting maximum displacement Yes
58. psi 300 bar 4350 psi 270 bar 3915 psi 250 bar 3625 psi 230 bar 3335 psi 200 bar 2900 psi 150 bar 2175 psi 100 bar 1450 psi Setting range valve 3 5 Ap 270 420 bar Ap 3915 6090 psi see model code 420 bar 6090 psi 400 bar 5800 psi 350 bar 5075 psi 320 bar 4640 psi 300 bar 4350 psi Setting range valve 4 6 Ap 60 250 bar Ap 870 3625 psi see model code 230 bar 3335 psi 200 bar 2900 psi 150 bar 2175 psi 270 bar 3915 psi 100 bar 1450 psi 250 bar 3625 psi Standard setting if not specified otherwise Bypass Function Please state in clear text when ordering Size 40 56 HD valves direct operated 3 4 without bypass High pressure relief valve A Size 40 56 HD valves direct operated 5 6 with bypass Differential pressure setting ApHp 88 Size 71 180 HD valves pilot operated 1 with bypass Pressure value of the HD valve at Q4 Pmax PSi Pmax APHD Psp Simplification The bypass function is not shown in the circuit diagrams High pressure relief valve B The pilot operated HD valves sizes 71 180 are Differential pressure setting Apyp psi not shown in the circuit diagrams Pressure value of the HD valve at Q4 Pmax PSi Pressure Cut Off The pressure cut off valve varies the
59. rol valve see page 12 13 28 amp 29 For pressure cut off see page 8 Option Neutral position switch HWDL When the HW control lever is in the neutral position the neutral position switch is closed The switch opens if the control lever is moved out of neutral in either direction The neutral position switch provides a safety function for sys tems that require zero flow under certain operating conditions e g engine start Standard model RT HITA Da ti Psh Far RM AA Tr Pome T T al B taka 170 LET ij A 1 Fi i E e ae EE lt XX G MH S 68 Data Table AA4VG HW Direction of rotation Control Output flow direction Lever Control Direction Operating Size Direction Pressure of Flow Pressure 8 X2 B to A Ma 83 40 56 b Xi AtoB Ma 5 a X AtoB Ms 71 90 125 180 Xi Bto A Ma S a X2 Ato B MB Jo 3 5 40 56 b Xi Bto A MA 38 a X2 BtoA Ma 71 90 125 180 b Xi AtoB
60. se The valve is mounted separately from the pump and connected to the Ps port Maximum line length should be limited to approxi mately 2 meters 79 Hydraulic Control Speed Dependent DA with separate rotary inching valve Rotary inching valve see ordering code 14 Fmannesmann Rexroth 92003 5 04 97 Variable Displacement Pump AA4VG Series 3 D A Hydraulic Control Speed Dependent Function and control of DA valves Rotary Inching Valve The rotary inch valve is to be ordered separately Size Ordering Code 40 56 71 90 438 553 470 05 31 01 125 438 554 470 05 31 02 180 438 555 470 05 31 03 Please state your requirements in clear text Inching clockwise or counter clockwise operation of the lever this is determined on assembly Attention The rotary inch valve can be used independently from the control device DA regulating cartridge fixed adjustment 2 Pilot pressure is generated in relation to drive speed There are no provisions for inching with this cartridge The pump is factory preset as determined by engine vehicle requirements DA regulating cartridge mechanically adjustable w lever 3 Pilot pressure is generated in relation to drive speed The pump is factory preset as determined by engine vehicle requirements Pilot pressure may be reduced independently of drive speed as required by
61. sure No Check sizing of return that they do not by less than 2 bar abs or line from T port of pump pass 30 psia and cooler sizing related to flow Note lf pressure override Yes Proceed to 8 3 valve is fitted to pump check that pressure set ting is sufficient for the application Fmannesmann Rexroth 23 92003 S 04 97 Variable Displacement Pump AA4VG Series 3 Charge Pressure Relief Valve Adjustment For AA4VG28 AA4VG56 With pressure gauge installed at G port run pump at normal operating speed and temperature If pressure is low remove relief valve and add shim s If pressure is high remove relief valve and take shim s out Note 1mm 56 5 psi 3 9 bar For AA4VG71 AA4VG250 With pressure gage installed at G port run pump at normal oper ating speed and temperature If pressure is low loosen jam nut and turn set screw clockwise If pressure is high loosen jam nut and turn set screw counterclockwise Note 1 turn 55 psi 3 8 bar for sizes 71 thru 125 Note 1 turn 43 5 psi 3 0 bar for sizes 180 thru 250 Pump Allen Box Wrench Size Wrench Wrench To Remove 28 56 N A N A 27mm 71 125 5 17 27mm 180 250 5mm 17mm 32 mm Mechanical Centering of Pump Preparation for Adjustment The control piston has strong centering springs to ensure that once the pump is adjusted for the neutral position it will always return to neutral If an adjustment is ne
62. t S or T the outer diameter of the cou pling hub must be smaller than the inner diameter of the circlip dg at the zone of the drive shaft shoulder measure Ko X3 SAE Spline A A A O 383 3283 Sizes 56 180 Size 40 only Size edi 942 min ed3 eda XI X2 X3 40 40 51 4 630 1 127 4 3 0 2 12 7 05 56 40 54 4 68 0 1 127 7 0 0 2 12 7 05 71 45 66 5 8120 1 127 7 0 0 2 12 705 8 09 90 50 66 5 8140 1 152 4 6 8 0 2 12 7 05 k i 125 55 76 3 91 0 1 152 4 7 0 0 2 12 7 05 180 60 88 107 0 1 165 1 7 4 02 15 9 05 Fmannesmann Rexroth 17 92003 S 04 97 Variable Displacement Pump AA4VG Series 3 Combination Pump Combination pumps provide two independent closed circuits without the need for splitter gear boxes When ordering combination pumps the individual model codes should be connected by a sign Code Pump 1 front pump Code Pump 2 rear pump Code example AA4VG 56 EP1D1 32 R PTC 52 F073S AA4VG 56 EP1D1 32 R PSC 52 F003S External support for combination pumps of the same frame size is not required if the dynamic acceleration does not exceed 10g 98 1 m s2 The 4 bolt mounting flange is recommended for size 71 and larger pumps Combination pump of the same size 2nd pump without through drive and with auxiliary pump F00 Size 40 56 71 90 125 180 A10 475 5 521 2 5964 6088 669 1 764 Mounting flanges amp shaft options
63. up procedures the transmission does not perform correctly refer to the rele vant sections of the trouble shooting procedures on pages 20 23 19 Fmannesmann Rexroth 92003 S 04 97 Variable Displacement Pump AA4VG Series 3 Troubleshooting Procedure To aid in troubleshooting refer also to the diagnostic port con nections for test gauge installation information Procedure as sumes gauges are installed This procedure was written to aid the troubleshooter in following a logical approach to a system fault 1 Transmission does not Drive with the Prime Mover Running 1 1 Is there oil in the reser No Fill reservoir 1 14 Is the suction pipe size No Run at lower speed and voir Yes Proceed to step1 2 adequate for the flow return to point 1 7 or rework suction piping 1 2 Is engine clutch en No Engage clutch Yes Proceed to step 1 15 gaged Yes Proceed to step 1 3 1 15 Is the reservoir air No Proceed to step 1 16 1 3 Is the hydraulic piping in No Correct the piping breather blocked or Yes Clean or Replace air accordance with the Yes Proceed to step 1 4 undersized breather hydraulic circuit 1 16 Remove charge pres No Refit cartridge and pro 1 4 Is the pump direction of No Fit pump having the sure relief valve ceed to step 1 17 rotation correct correct direction of rota cartridge and inspect Yes Fit a new cartridge and tion Is it damaged return to step 1 7 Yes Proceed to step 1 5 1 17 Rem
64. y for closed circuit hydrostatic transmissions where a self contained pump package is required The pump design incorporates a charge pump a charge pressure relief valve two combination high pressure relief and make up check valves and an inte grated pressure cut off valve Installation The AA4VG pump may be mounted in any position around the horizontal drive shaft axis Other mounting orientations e g drive shaft vertical are possible but should be reviewed with a Rexroth Application Engineer prior to finalizing the design The case drain line should be connected to the highest case drain port T or T2 so that the pump case always remains full of oil The case drain piping or hose should be sized to accept the full flow of the charge pump at the maximum anticipated drive speed with minimal pressure drop Fluid Recommendations The AA4VG pumps are supplied as standard for use with good quality petroleum oil based anti wear hydraulic fluids More detailed information regarding the selection of hydraulic fluids and their application limits can be found in our Data Sheets RA 90220 Petroleum Oil RE 90221 Biodegradable Fluids and RA 90223 Type HF Fire Resistant Synthetic Fluids For applications with biodegradable or Type HF fluids possible reduction of the operating specifications may be required Please consult Rexroth and your oil supplier Operating Viscosity Range In order to obtain optimum efficiency and service li
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