Fixed Axial Piston Motor Bosch Rexroth A2FE 1422357561 PDF

Fixed Plug-In Motor RE 91008-01-B/08.
2011
Replaces: 02.09
A2FE English
Series 6
Instruction manual
The data specified above serve to describe the
product. Should information be provided on use,
these are only examples of applications and
suggestions. Information from the catalog are not
assured properties. The information given does
not release the user from the obligation of own
judgment and verification. Our products are subject
to a natural wear and aging process.
© This document, as well as the data, specifications

and other information set forth in it, are the exclusive
property of Bosch Rexroth AG.
It may not be reproduced or given to third parties
without its consent.
The cover shows an example application. The

product delivered may differ from the image on the
cover.
The original instruction manual was created in the

German language.
RE 91008-01-B/08.2011 | A2FE Series 6 Bosch Rexroth AG 3/48
Contents
Contents
1 About this manual......................................................................................5
1.1 Validity of the documentation.......................................................................5
1.2 Required and supplementary documentation..............................................5
1.3 Display of information...................................................................................6
1.3.1 Safety instructions........................................................................................6
1.3.2 Symbols.......................................................................................................7
1.3.3 Designations................................................................................................7
1.3.4 Abbreviations...............................................................................................7
2 Safety instructions.....................................................................................8
2.1 About this chapter........................................................................................8
2.2 Intended use................................................................................................8
2.3 Improper use................................................................................................8
2.4 Personnel qualifications...............................................................................9
2.5 General safety instructions...........................................................................9
2.6 Product-specific safety instructions............................................................10
2.7 Personal protective equipment...................................................................11
3 General instructions on damage to equipment and the product........ 12
4 Delivery contents.....................................................................................14
5 Product description.................................................................................15
5.1 Performance description............................................................................15
5.2 Product description....................................................................................15
5.2.1 Assembly of the axial piston unit................................................................15
5.2.2 Functional description................................................................................16
5.3 Product identification..................................................................................16
6 Transport and storage.............................................................................17
6.1 Transporting the axial piston unit...............................................................17
6.1.1 Transporting by hand.................................................................................17
6.1.2 Transporting with lifting device...................................................................17
6.2 Storing the axial piston unit........................................................................19
7 Installation................................................................................................21
7.1 Unpacking..................................................................................................21
7.2 Installation conditions.................................................................................21
7.3 Installation position.....................................................................................23
7.3.1 Below-reservoir installation (standard).......................................................23
7.3.2 Above-reservoir installation........................................................................24
7.4 Installing the axial piston unit.....................................................................25
7.4.1 Preparation.................................................................................................25
7.4.2 Dimensions................................................................................................25
7.4.3 General instructions...................................................................................25
7.4.4 Installation with coupling............................................................................26
7.4.5 Installation on a gearbox............................................................................27
7.4.6 Installation with cardan shaft......................................................................27
7.4.7 Completing installation...............................................................................28
7.4.8 Hydraulically connecting the axial piston unit.............................................29
7.5 Performing flushing cycle...........................................................................34
8 Commissioning........................................................................................35
8.1 First commissioning...................................................................................35
8.1.1 Filling the axial piston unit..........................................................................35
8.1.2 Testing the hydraulic fluid supply...............................................................36
8.1.3 Performing functional test..........................................................................36
8.2 Running-in phase.......................................................................................37
8.3 Recommissioning after standstill................................................................37
9 Operation..................................................................................................38
4/48 Bosch Rexroth AG A2FE Series 6 | RE 91008-01-B/08.2011
Contents
10 Maintenance and repair...........................................................................38

10.1 Cleaning and care......................................................................................38
10.2 Inspection...................................................................................................39
10.3 Maintenance...............................................................................................39
10.4 Repair.........................................................................................................39
10.5 Spare parts.................................................................................................40
11 Removal and replacement.......................................................................41
11.1 Required tools............................................................................................41
11.2 Preparing for removal.................................................................................41
11.3 Removing the axial piston unit...................................................................41
11.4 Preparing the components for storage or further use................................41
12 Disposal....................................................................................................42
13 Extension and conversion......................................................................42
14 Troubleshooting.......................................................................................43
14.1 How to proceed for troubleshooting...........................................................43
14.2 Malfunction table........................................................................................44
15 Technical data..........................................................................................45
16 Appendix...................................................................................................45
16.1 Address directory.......................................................................................45
17 Alphabetical index...................................................................................46
About this manual
1 About this manual
1.1 Validity of the documentation

This documentation is valid for the following product:
•• Fixed plug-in motor A2FE Series 6
This documentation is intended for machine/system manufacturers, fitters and

service technicians.
This documentation contains important information on the safe and appropriate
installation, transport, commissioning, operation maintenance, removal and
simple troubleshooting of the axial piston unit.
ff Read this documentation completely and in particular chapter 2 “Safety
instructions” and chapter 3 “General instructions on damage to equipment and
the product”, before working with the axial piston unit.
1.2 Required and supplementary documentation

ff Only commission the axial piston unit if the documentation marked with the
book symbol is available to you and you have understood and observed it.
Table 1: Required and supplementary documentation

Title Document number Document type
Order confirmation – Order confirmation
Contains the order-related technical data of your fixed plug-in motor A2FE.
Installation drawing Please request the Installation drawing
Contains the outer dimensions, all connections and the hydraulic circuit diagram installation drawing
for your A2FE fixed plug-in motor. via your contact
person at Bosch
Rexroth.
Fixed plug-in motor A2FE RE 91008 Data sheet
Contains the permissible technical data.
Pressure and boost valves for mobile applications, model MHDB RE 64642 Data sheet
BVD counterbalance valve RE 95522 Data sheet
Speed sensor (DSA) RE 95133 Data sheet
Mineral-oil based hydraulic fluid and related hydrocarbons RE 90220 Data sheet
Describes the requirements on a mineral-oil based hydraulic fluid and related
hydrocarbons for the operation with Rexroth hydraulic components, and assists
you in selecting a hydraulic fluid for your hydraulic system.
Environmentally acceptable hydraulic fluids RE 90221 Data sheet
Describes the requirements on an environmentally acceptable hydraulic fluid
for operation with Rexroth hydraulic components and assists you in selecting a
hydraulic fluid for your hydraulic system.
Axial piston units for operation with HF hydraulic fluids RE 90223 Data sheet
Contains additional information on the use of Rexroth axial piston units with HF
hydraulic fluids.
Information of the use of hydrostatic drives at low temperatures RE 90300-03-B Manual
Contains additional information on the use of Rexroth axial piston units at low
temperatures.
Storage and preservation of axial piston units RE 90312 Data sheet
Contains additional information on storage and preservation.
About this manual
1.3 Display of information

Standardized safety instructions, symbols, terms and abbreviations are used so
that you can use this documentation to work quickly and safely with your axial
piston unit. To give you a better understanding they are explained in the sections
below.
1.3.1 Safety instructions

Safety instructions are contained in this documentation in chapter 2.6 “Product-
specific safety instructions” and chapter 3 “General instructions on damage to
equipment and the product” as well as before a sequence or instruction whenever
there is a risk of injury to persons or damage to equipment. The described danger
prevention measures must be observed.
Safety instructions are set out as follows:
Signal word
Type and source of danger
Consequences with noncompliance
ff Measure for danger prevention
ff <List>
•• Safety sign: draws attention to the danger

•• Signal word: identifies the degree of the danger
•• Type and source of danger:identifies the type and source of the danger
•• Consequences: describes what occurs if the safety instructions are not
complied with
•• Precautions: states how the danger can be avoided
Table 2: Danger classes in accordance with ANSI Z535.6-2006
Safety sign, signal word Meaning

Identifies a dangerous situation that will result in death
DANGER or serious injuries if it is not avoided.
Identifies a dangerous situation that may result in death
WARNING or serious injuries if it is not avoided.
Identifies a dangerous situation that may result in minor
CAUTION to moderate injuries if it is not avoided.
NOTE Damage to equipment: the product or the environment

may be damaged.
About this manual
1.3.2 Symbols
The following symbols mark notes that are not safety-relevant but which increase
the understanding of the documentation.
Table 3: Meaning of the symbols
Symbol Meaning
If this information is disregarded, the product can not be used
and/or operated to the optimum extent.
ff Single, independent step

1. Numbered instruction:
The numbers specify that the steps are completed one after the other.
2.
3.
1.3.3 Designations
This documentation uses the following designations:
Table 4: Designations
Designation Meaning
A2FE Fixed plug-in motor Axial piston variable motor, open and closed
circuits
Screw plug Metal screw, pressure-resistant
Protective plug Made out of plastic, not pressure-resistant, only for transportation
As umbrella term for “Fixed plug-in motor A2FE”, the designation “axial piston
unit” will be used in the following.
1.3.4 Abbreviations
This documentation uses the following abbreviations:
Table 5: Abbreviations
Abbreviation Meaning
DIN Deutsche Industrie Norm (German Institute for Standardization)
ISO International Organization for Standardization
RE Rexroth document in the English language
VDI 2230 Directive for the systematic calculation of high duty bolted
joints and joints with one cylindrical bolt from the VDI
(Verein Deutscher Ingenieure – Association of German Engineers)
Safety instructions
2 Safety instructions
2.1 About this chapter

The axial piston unit has been manufactured according to the generally accepted
rules of current technology. There is, however, still a danger of personal injury
or damage to equipment if this chapter and the safety instructions in this
documentation are not complied with.
ff Read this documentation completely and thoroughly before working with the
axial piston unit.
ff Keep this documentation in a location where it is accessible to all users at all
times.
ff Always include the required documentation when you pass the axial piston
unit on to third parties.
2.2 Intended use

Axial piston units are hydraulic components, meaning that in their application
they are classified neither as complete nor as incomplete machines in the sense
of the EU machine directive 2006/42/EC. A component is exclusively intended to
form an incomplete or a complete machine together with other components. The
component may only be commissioned after it has been installed in the machine/
system for which it is intended and the safety of the entire system has been
established in accordance with the machine directive.
The product is intended for the following use:
The axial piston unit is only approved for use as a hydraulic motor in hydrostatic
drives.
ff Observe the technical data, application and operating conditions and
performance limits as specified in data sheet RE 91008 and in the order
confirmation. Information about approved hydraulic fluids can be found in data
sheet RE 91008.
The axial piston unit is only intended for professional use and not for private use.
Intended use includes having completely read and understood this
documentation, especially chapter 2 “Safety instructions”.
2.3 Improper use

Any use other than that described as intended use shall be considered as
improper and is therefore impermissible.
Bosch Rexroth AG shall accept no liability whatsoever for damage resulting from
improper use. The user shall bear all risks arising from improper use.
Similarly, the following foreseeable faulty usages are also considered to be not as
intended:
•• Using outside the operating parameters approved in the data sheet (unless
customer-specific approval has been granted)
•• Use for non-approved fluids, e.g. water or polyurethane components
•• Modification of factory settings by non-authorized persons
•• Use of add/on parts (e.g. mountable filter, control unit, valves) that are not
specified Rexroth components
•• Using the axial piston unit under water at a depth of more than 10 meters
without necessary additional measures, e.g. pressure equalization
Safety instructions
•• Using the axial piston unit when the exterior pressure is greater than the interior
pressure (case pressure)
•• Using the axial piston unit in explosive environments unless the
component or machine/system has been certified as compliant with the
ATEX directive 94/9/EC
•• Using the axial piston unit in an aggressive atmosphere
•• Using the axial piston unit in aircraft or space craft
2.4 Personnel qualifications

The activities described in this documentation require basic mechanical, electrical
and hydraulic knowledge, as well as knowledge of the associated technical terms.
For transporting and handling the product, additional knowledge is necessary
with regard to working with a lifting device and the corresponding attachment
equipment. In order to ensure safe use, these activities may therefore only be
carried out by appropriate qualified personnel or an instructed person under the
direction and supervision of qualified personnel.
Qualified personnel are those who can recognize possible hazards and institute
the appropriate safety measures due to their professional training, knowledge,
and experience, as well as their understanding of the relevant regulations
pertaining to the work to be done. Qualified personnel must observe the rules
relevant to the subject area and have the necessary hydraulic knowledge.
Hydraulic knowledge means, for instance:
•• reading and fully understanding hydraulic plans,
•• fully understanding in particular the interrelationships regarding safety devices,
and
•• having knowledge on the function and assembly of hydraulic components.
Bosch Rexroth offers training support for special fields. You can find an
overview of the training contents on the Internet at: http://www.boschrexroth.de/
didactic.
2.5 General safety instructions

•• Observe the applicable accident prevention and environmental protection
regulations.
•• Observe the safety regulations and provisions of the country in which the
product is used/operated.
•• Use Rexroth products only when they are in good technical order and condition.
•• Observe all notes on the product.
•• Persons who install, operate, remove or maintain Rexroth products must not
consume any alcohol, drugs or pharmaceuticals that may affect their ability to
respond.
•• Only use Rexroth original accessories and spare parts to ensure there is no risk
to persons from unsuitable spare parts.
•• Conform to the technical data and ambient conditions specified in the product
documentation.
•• If unsuitable products are installed or used in applications that are of relevance
to safety, unexpected operating conditions may occur in the application which
could result in injury to persons or property damage. For this reason, only use
the product in a safety-relevant application if this use is expressly specified
and permitted in the product documentation, for example in ex-protection
applications or in safety-related parts of a control system (functional safety).
Safety instructions
•• You may only commission the product if it has been determined that the end
product (e.g. machinery or a system) into which the Rexroth products are
installed complies with the country-specific provisions, safety regulations and
standards of the application.
2.6 Product-specific safety instructions

The following safety instructions apply for chapters 6 to 14.
WARNING
Danger from suspended loads!
Danger to life or risk of injury, damage to equipment!
Improper transportation may cause the axial piston unit to fall down lead to
injuries e.g. crushing or broken bones or damage to the product.
ff Make certain that the forklift truck or lifting device has adequate lifting
capacity.
ff Never stand under or put you hands under suspended loads.
ff Ensure your position is stable during transportation.
ff Use your personal protective equipment (e.g. safety glasses, safety gloves,
suitable working clothes, safety shoes).
ff Use suitable lifting devices for transportation.
ff Observe the prescribed position of the lifting strap.
ff Observe the national laws and regulations on work and health protection and
transportation.
Pressurized machine/system!
Danger to life or risk of injury, serious injuries when working on machines/
systems not shutdown! Damage to equipment!
ff Protect the complete system against being energized.
ff Make sure that the machine/system is depressurized. Please follow the
machine/system manufacturer’s instructions.
ff Do not disconnect any line connections, connections and components when
the machine/system is pressurized.
ff Switch off all power-transmitting components and connections (electric,
pneumatic, hydraulic) in accordance with the manufacturer’s instruction and
secure them against being switched back on.
Escaping oil mist!

Danger of explosion, danger of fire, allergic reactions, environmental pollution!
ff Depressurize the machine/system and repair the leak.
ff Only perform welding work then the machine/system is depressurized.
ff Keep open flames and ignition sources away from the axial piston unit.
ff If axial piston units are to be situated in the vicinity of ignition sources or
powerful thermal radiators, a shield must be erected to ensure that any
escaped hydraulic fluid can not ignite, and to protect hose lines from
premature aging.
Electrical voltage!
Risk of injury due to electric shock or damage to equipment!
ff Always set up the relevant part of the machine/system so that it is free of
electrical voltage before you install the product or when connecting and
disconnecting plugs. Protect the machine/system against being energized.
Safety instructions
CAUTION
High noise development in operation!
Danger of hearing damage, deafness!
The noise emission of axial piston units depends on speed, operating pressure
and installation conditions. The sound pressure level may rise above 70 dBA
during normal application conditions.
ff Always wear hearing protection when in the vicinity of the operating axial
piston unit.
Hot surfaces on the axial piston unit!

Risk of burns!
ff Allow the axial piston unit to cool down sufficiently before touching it.
ff Wear heat-resistant protective clothing, e.g. gloves.
Improper routing of cables and lines!

Tripping hazard and damage to equipment!
ff Lay cables and lines so that they can not be damaged and nobody can trip
over them.
Contact with hydraulic fluid!

Hazard to health/health impairment e.g. eye injuries, skin damage, toxication
during inhalation!
ff Avoid contact with hydraulic fluids.
ff When working with hydraulic fluids, strictly observe the safety instructions
provided by the lubricant manufacturer.
ff If hydraulic fluid should, nevertheless, come into contact with your eyes or
bloodstream or is swallowed, consult a doctor immediately.
Escaping hydraulic fluid due to machine/system leakage!

Risk of burns and risk of injury due to escaping oil jet!
ff Depressurize the machine/system and repair the leak.
ff Never attempt to block or seal the leak or oil jet with a cloth.
2.7 Personal protective equipment

The personal protective equipment is the responsibility of the user of the axial
piston unit. Observe the safety regulations and provisions of your country.
All components of the personal protective equipment must be intact.
General instructions on damage to equipment and the product
3 General instructions on damage

to equipment and the product
The following notes apply for chapters 6 to 14.
NOTE
Danger from improper handling!
Product can be damaged!
ff Do not expose the product to an impermissible mechanical load.
ff Never use the product as a handle or step.
ff Do not place/lay any objects on the product.
ff Do not strike the drive shaft of the axial piston unit.
ff Do not set/place the axial piston unit on the drive shaft.
ff Do not strike sensitive fittings (e.g. sensors or valves).
ff Do not strike sealing surfaces (e.g. service line ports).
ff Leave the protective covers on the axial piston unit until shortly before the
lines are connected.
Damage to equipment due to improper lubrication!

Product can be damaged or destroyed!
ff Never operate the axial piston unit with insufficient hydraulic fluid. Make sure
in particular that the rotary group has sufficient lubrication.
ff When commissioning a machine/system, make sure that the case interior
and the service lines of the axial piston unit are filled with hydraulic fluid and
remain filled during operation.
ff Check the hydraulic fluid level in the case interior regularly; if necessary,
recommission. With above-reservoir installation, the case interior may
drain via the reservoir line after longer standstill periods (air enters via the
shaft seal) or via the service line (gap leakage). The bearings are thus
insufficiently lubricated at switch on.
Mixing of hydraulic fluids!

ff Before installation, remove all fluids from the axial piston unit to prevent
mixing with the hydraulic fluid used in the machine/system.
ff Any mixing of hydraulic fluids of different manufacturers or different types
of the same manufacturer is not permissible in general.
General instructions on damage to equipment and the product
NOTE
Contamination of the hydraulic fluid!
The cleanliness of the hydraulic fluid has a considerable impact on the
cleanliness and service life of the hydraulic system. Premature wear and
malfunctions!
ff Make sure that the working environment at the installation site is fully free
of dust and foreign substances in order to prevent contaminants, such as
welding beads or metal cuttings, from getting into the hydraulic lines and
causing product wear or malfunctions. The axial piston unit must be installed
in a clean condition.
ff Use only clean connections, hydraulic lines and attachments (e.g. measuring
equipment).
ff No contaminants may enter the connections when they are plugged.
ff Before commissioning, make certain that all hydraulic connections are
tight and that all of the connection seals and plugs are installed correctly to
ensure that they are leakproof and fluids and contaminants are prevented
from penetrating the product.
ff Use a suitable filter system to filter hydraulic fluids during filling to minimize
solid impurities and water in the hydraulic system.
Improper cleaning!
ff Plug all openings with the appropriate protective equipment in order to
prevent detergents from entering the hydraulic system.
ff Never use solvents or aggressive detergents. Use only water and, if
necessary, a mild detergent to clean the axial piston unit.
ff Do not point the power washer at sensitive components, e.g. shaft seal,
electrical connections and components.
ff Use lint-free cloths for cleaning.
Environmental pollution due to incorrect disposal!

Careless disposal of the axial piston unit, the hydraulic fluid and the packaging
material could lead to pollution of the environment!
ff Dispose of the axial piston unit, hydraulic fluid and packaging in accordance
with the national regulations in your country.
ff Dispose of the hydraulic fluid in accordance with the applicable safety data
sheet for the hydraulic fluid.
Escaping or spilling hydraulic fluid!

Environmental pollution and contamination of the ground water!
ff When filling and draining the hydraulic fluid, always place a drip tray under
the axial piston unit.
ff Use an oil binding agent if hydraulic fluid is spilt.
ff Observe the information in the safety data sheet for the hydraulic fluid and
the specifications provided by the system manufacturer.
•• The warranty only applies to the delivered configuration.

•• The entitlement under warranty is rendered void if the product is incorrectly
installed, commissioned or operated, as well as in the case of improper use
and/or handling.
Delivery contents
4 Delivery contents
2
Fig. 1: Axial piston unit with service line ports at bottom
Included in the delivery contents are:

•• Axial piston unit as per order confirmation
The following parts are also installed on delivery:

•• Protective covers made of plastic (1) (metal protective covers are used
for painted axial piston units)
•• Protective plug/threaded plug (2)
Product description
5 Product description
5.1 Performance description

A fixed plug-in motor converts hydrostatic flow into mechanical rotation. It is
designed primarily for installation in mechanical gearboxes, e.g. track drive
gearboxes.
Refer to data sheet RE 91008 and the order confirmation for the technical data,
operating conditions and operating limits of the axial piston unit.
5.2 Product description

The A2FE is an fixed plug-in motor with axial tapered piston rotary group of bent-
axis design for hydrostatic drives in open and closed circuits. For axial piston
units with bent-axis design, the pistons are arranged diagonally with respect to
the drive shaft. The pistons rest directly on the drive shaft where they generate a
pressure-dependent torque.
Open circuit In the open circuit, the hydraulic fluid flows from the reservoir to the hydraulic
pump from where it is transported via a directional valve to the hydraulic motor.
From the hydraulic motor, the hydraulic fluid flows back to the reservoir via the
directional valve. The output direction of rotation of the hydraulic motor can be
changed by the directional valve.
Closed circuit In the closed circuit, the hydraulic fluid returning from the hydraulic motor flows
directly to the hydraulic pump. The output direction of rotation of the hydraulic
motor is changed by reversing the flow direction in the hydraulic pump.
5.2.1 Assembly of the axial piston unit
1 2
3
Fig. 2: Assembly of the A2FE
1 Drive shaft 4 Control plate

2 Piston 5 Port plate
3 Cylinder
Product description
5.2.2 Functional description

Motor function A hydraulic motor converts hydrostatic energy into mechanical energy. Hydraulic
fluid is directed via the port plate (5) and the control plate (4) to the cylinder bores.
The pistons (2) in the cylinder bores execute a stroke which is converted into
rotation by the piston at the drive shaft flange. During this process, the pistons
move the cylinder (3) and generate an output torque at the drive shaft. The output
torque increases with the pressure difference between the high- and low-pressure
sides. The output speed is proportional to the inward flow and inversely
proportional to the displacement of the hydraulic motor.
5.3 Product identification

The axial piston unit can be identified from the name plate. The following example
shows an A6VM name plate A2FE:
11
12
Rexroth
DE - 89275 Elchingen
CNR: X1234567890Y
Typ: A2FE28/61W-VAL100
10 MNR: R90XXXXXXX SC: X 2
9 SN: 12345678 7202 3
FD: 2011W30 4
Rotation:
8 m XXX kg
5
Made in Germany 6
Fig. 3: A4VSO name plate A2FE
1 Manufacturer 7 Bar code

2 Sample category (optional) 8 Production date
3 Internal plant designation 9 Serial number
4 Specified area for test stamp 10 Material number of
5 Direction of rotation (viewed on the axial piston unit
drive shaft) – here: bi-directional 11 Ordering code
6 Ground (optional) 12 Customer material number
Transport and storage
6 Transport and storage

ff Make sure you conform to the required ambient conditions during
transportation and storage, see chapter 6.2 “Storing the axial piston unit”.
You can find unpacking notes in chapter 7.1 “Unpacking”.
6.1 Transporting the axial piston unit

The transportation options below exist depending on the weight and duration of
the transport:
•• Transporting by hand
•• Transporting with lifting device (ring screw or lifting strap)
Dimensions and weights Table 6: Dimensions and weights

Size 28 32 45 56 63 80 90
Ground kg 10.5 10.5 15 18 19 23 25
Width mm The dimensions vary with the unit type. The values applicable
for your axial piston unit can be found in the installation drawing
Height mm
(request if necessary).
Depth mm
Size 107 125 160 180 250 355

Ground kg 34 36 47 48 82 110
Width mm The dimensions vary with the unit type. The values applicable
for your axial piston unit can be found in the installation drawing
Height mm
(request if necessary).
Depth mm
The weight specifications may vary depending on the unit type.
6.1.1 Transporting by hand

Axial piston units with a weight of up to 15 kg can be transported manually for a
short time if necessary.
Caution! Danger from heavy loads!
There is a danger of health damage when carrying axial piston units.
ff Use suitable lifting, placement and relocation equipment.
ff Do not transport the axial piston unit at sensitive attachment parts (e.g.
sensors or valves).
ff Carefully place the axial piston unit on the seating to prevent it from being
damaged.
6.1.2 Transporting with lifting device

For transporting, the axial piston unit can be connected to a lifting device via a
ring screw or a lifting strap.
Transport with ring screw
The axial piston unit can be transported suspended from a ring screw screwed
into the drive shaft as long as only outward (pulling) axial forces are applied.
ff For all female threads, use a threaded plug from the same system of units and
of the correct size.
ff To do this, screw a ring screw completely into the thread on the drive shaft.
The thread sizes is stated in the installation drawing.
ff Make sure that the ring screw can bear the total weight of the axial piston unit
plus 20%.
You can hoist the axial piston unit as shown in Fig. 4 with the ring screw screwed
into the drive shaft.
Fig. 4: Fixing the ring screw
Transport with lifting strap WARNING! Danger from suspended loads!

During transport with a lifting device, the axial piston unit can fall out of the lifting
strap and cause injuries.
ff Use the widest possible lifting strap.
ff Make sure that the axial piston unit is securely fixated with the lifting strap.
ff Only guide the axial piston unit by hand for fine positioning and to avoid
oscillations.
ff Never stand under or put you hands under suspended loads.
ff Place the lifting strap around the axial piston unit in such a way that it passes
over neither the attachment parts (e.g. valves) nor such that the axial piston
unit is hung from attachment parts (see Fig. 5).
Fig. 5: Transport with lifting strap

6.2 Storing the axial piston unit

Requirement •• The storage areas must be free from corrosive materials and gases.
•• To prevent damage to the seals, ozone-forming equipment (e.g. mercury-vapor
lamps, high voltage equipment, electric motors, sources of electrical sparks or
electrical discharges) must not be operated in storage areas.
•• The storage areas must be dry.
•• Ideal storage temperature: +5 °C to +20 °C.
•• Minimum storage temperature: -50 °C.
•• Maximum storage temperature: +60 °C.
•• Avoid high light irradiation (e.g. bright windows or direct fluorescent lighting).
•• Do not stack axial piston units and store them shock-proof.
•• Do not store the axial piston unit on sensitive attachment parts, e.g. speed
sensors.
•• For other storage conditions, see table 7.
ff Check the axial piston unit monthly to ensure proper storage.
After delivery The axial piston units are provided ex-works with corrosion protection packaging
(corrosion protection film).
The following table lists the maximum permissible storage times for an originally
packed axial piston unit as per data sheet RE 90312.
Table 7: Storage time with factory corrosion protection
Standard Long-term
Storage conditions
corrosion protection corrosion protection
Closed, dry room, uniform Maximum 12 months Maximum 24 months
temperature between +5 °C
and +20 °C. Undamaged
and closed corrosion
protection film.
The entitlement under warranty is rendered void if the requirements and

storage conditions are not adhered to or after expiration of the maximum
storage time (see table 7).
Procedure after expiration of the maximum storage time:

1. Check the entire axial piston unit for damage and corrosion prior to
installation.
2. Check the axial piston unit for proper function and leaks during a test run.
3. If the storage time exceeds 24 months, the shaft seal ring must be replaced.
After expiry of the maximum storage time, we recommend that you have the
axial piston unit inspected by your responsible Bosch Rexroth Service partner.
In the event of questions regarding repair and spare parts, contact your
responsible Bosch Rexroth Service partner or the service department of the
manufacture’s plant for the axial piston unit, see chapter “10.5 Spare parts” for
further information.
After removal If a dismounted axial piston unit is to be stored, it must be preserved against
corrosion for the duration of the storage.
The following instructions only refer to axial piston units which are operated
with a mineral-oil based hydraulic fluid. Other hydraulic fluids require
preservation methods that are specifically designed for them. In such a case,
consult with Bosch Rexroth Service, see chapter 10.5 “Spare parts” for
address.
Bosch Rexroth recommends the following procedure:

1. Clean the axial piston unit, see chapter 10.1 “Cleaning and care”.
2. Empty the axial piston unit.
3. For storage time up to 12 months: Moisten the inside of the axial piston unit
with mineral oil and fill with approx. 100 ml mineral oil.
For storage time up to 24 months: Fill the axial piston unit with corrosion
protection medium VCI 329 (20 ml).
Fill via reservoir port T (size 28 to 180) or T1 or T2 (size 250 to 355), see
chapter 7.4 “Installing axial piston unit”, Fig. 12 to 15.
4. Seal all ports airproof.
5. Moisten the unpainted surfaces of the axial piston unit with mineral oil or a
suitable, easily removed corrosion protection agent, e.g. acid-free grease.
6. Package the axial piston unit airproof together with desiccant in corrosion
protection film.
7. Store the axial piston unit so that it is protected against jolts, see
“Requirement” in this chapter.
Installation
7 Installation
Prior to installation, the following documents must be available:
•• Installation drawing for axial piston unit (can be obtained from your responsible
contact person at Bosch Rexroth)
•• Hydraulic circuit diagram for the axial piston unit (in the installation drawing)
•• Hydraulic circuit diagram for the machine/system (available from the machine/
system manufacturer)
•• Order confirmation (contains the order-related technical data for your axial
piston unit)
•• Data sheet of the axial piston unit (contains the permissible values of technical
data)
7.1 Unpacking
The axial piston unit is delivered in a corrosion protection film made of
polyethylene material (PE).
Caution! Danger from parts falling out!
If the packaging is not opened correctly, parts may fall out and damage the parts
or even cause injuries!
ff Place the packaging on a flat and solid surface.
ff Only open the packaging from the top.
ff Remove the packaging from the axial piston unit.

ff Check the axial piston unit for transport damage and completeness,
see chapter 4 “Delivery contents”.
ff Dispose of the packaging according to the environmental regulations of your
country.
7.2 Installation conditions

The installation location and position of the axial piston unit essentially determine
the procedures during installation and commissioning (such as when filling and air
bleeding the axial piston unit).
ff Fix the axial piston unit so that the expected forces and torques can be
transferred without any danger. The machine/system manufacturer is
responsible for dimensioning the fasteners.
ff Observe the permissible radial forces on the drive shaft when transferring
output drive with radial loading (belt drives). If necessary, the belt pulley must
be separately mounted.
ff Make certain that the axial piston unit is air bled and filled with hydraulic fluid
during commissioning and operation. This is also to be observed following
relatively long standstill periods as the axial piston unit may empty via the
hydraulic lines.
ff The case drain fluid in the case interior must be directed to the reservoir via
the highest case drain port. Use the line size which is appropriate for the port.
ff Avoid using a check valve in the reservoir line.
Exception: above-reservoir installation, shaft upward.
A check valve in the reservoir line (cracking pressure 0.5 bar) can prevent
draining via the reservoir line. Note the correct flow direction.
ff To achieve favorable noise values, decouple all connecting lines from all
vibration-capable components (e.g. reservoir) using elastic elements.
Installation
ff Make sure that the reservoir and return lines lead into the reservoir below the
minimum fluid level in all operating conditions. You prevent foam formation by
doing this.
ff Make sure that the working environment at the installation site is fully free of
dust and foreign substances. The axial piston unit must be installed in a clean
condition. Dirt contamination in the hydraulic fluid can seriously impair the
function and service life of the axial piston unit.
ff Use lint-free cloths for cleaning.
ff Use suitable mild detergents to remove lubricants and other difficult-to-remove
contamination. Cleaning agents must not enter the hydraulic system.
Installation
7.3 Installation position

The following installation positions are permissible. The shown piping layout
illustrates the basic layout.
7.3.1 Below-reservoir installation (standard)

Below-reservoir installation is when the axial piston unit is installed outside of the
reservoir below the minimum fluid level.
1 2a2)
ht min ht min
T21)
hmin hmin
T1
T1
T2 1)
3 2b3)
ht min ht min
hmin hmin
T21)
T21)
T1
T1
1) Standard for sizes 250 to 355, optional for sizes 28 to 180.

2) Piping suggestion without port T2 (standard for size 28 to 180).
3) Piping suggestion without port T2 (standard for size 250 to 355, optional for size 28 to 180).
Fig. 6: Below-reservoir installation with installation position 1–3
T1, T2 Highest reservoir port hmin Minimum required distance to

reservoir base (100 mm)
ht min Minimum necessary immersion
depth (200 mm)
Table 8: Below-reservoir installation

Installation position Air bleed Filling
1 (drive shaft, horizontal) – T1
2 (drive shaft, horizontal) – T1 (size 28 to 180), T2 (size 250 to 355)
3 (drive shaft, vertically downward) – T1
With installation position 2a, the case can no longer be sufficiently filled with
hydraulic fluid following installation. The case must therefore be filled with
hydraulic fluid prior to installation (applies to versions without port T2).
Installation
7.3.2 Above-reservoir installation

Above-reservoir installation is when the axial piston unit is installed above the
minimum fluid level of the reservoir.
4 52)
T1 T21)
T1
T21)
ht min ht min
hmin hmin
T1
T21)
ht min
hmin
1) Standard for sizes 250 to 355, optional for sizes 28 to 180.

2) Installation position only permissible if port T2 is fitted (standard for size 250 to 355, optional for size 28
to 180).
Fig. 7: Above-reservoir installation with installation position 4–6
T1, T2 Highest reservoir port hmin Minimum required distance to

reservoir base (100 mm)
ht min Minimum necessary immersion
depth (200 mm)
Table 9: Above-reservoir installation

Installation position Air bleed Filling
6 (drive shaft, vertically downward) – T1
Installation
7.4 Installing the axial piston unit
7.4.1 Preparation
1. Compare the material number and designation (ordering code) with the details
in the order confirmation.
If the material number for the axial piston unit does not correspond to the one
in the order confirmation, contact Bosch Rexroth Service for clarification, see
chapter “10.5 Spare parts” for address.
2. Before installing, completely empty the axial piston unit to prevent mixing with
the hydraulic fluid used in the machine/system.
L
W R
Fig. 8: Direction of rotation
W Bi-directional (counter-clockwise and clockwise rotation permissible)

L Counter-clockwise
R Clockwise
The direction of rotation as specified on the name plate, see chapter 5.3
“Identification of the product”, is the direction of rotation of the axial piston unit
as viewed to the drive shaft.
7.4.2 Dimensions
The installation drawing contains the dimensions for all connections and ports on
the axial piston unit. Also observe the manuals provided by the manufacturers of
the other hydraulic components when selecting the required tools.
7.4.3 General instructions

Please keep in mind the following general instructions for installation of the axial
piston unit:
•• Note that you can expect certain installation positions to affect the control
device. Because of gravity, dead weight and case pressure, minor characteristic
displacements and actuating time changes may occur.
•• After a short operating time, toothed belts lose a major portion of their pre-tension
and thus cause speed variations and torsional vibrations.
Torsional vibrations may cause leakages on the shaft seal or increased rotary
angle accelerations of the rotary group of the axial piston unit.
•• V-belt drives without automatic clamper are also critical with regard to speed
variations and torsional vibrations. These can also lead to leakages on the shaft
seal ring.
Installation
An automatic clamper can lessen the speed variations and vibrations and thus
avoid consequential damage.
–– When using toothed belts or v-belts to transfer the input or output drive,
always use an automatic tensioning device.
•• On the input or output drive of an axial piston unit, a cardan shaft may cause
vibrations and impermissible rotary angle accelerations. Depending on the
frequency and temperature, they may result in leakage on the shaft seal and
damage to the rotary group.
•• When multiple units are combined, make sure that the case pressure of
each unit is not exceeded. If there are pressure differences at the reservoir
ports of the units, the complete reservoir line must be changed so that the
lowest permissible case pressure of all connected units is not exceeded in
any situation. If this is not possible, separate reservoir lines must be laid as
required.
The installation method for the axial piston unit depends on the connecting
elements to the output side. The following descriptions explain the installation
of the axial piston unit:
•• with a coupling
•• on a gearbox
7.4.4 Installation with coupling

The method for installing the axial piston unit with a coupling is described below:
Note! Danger from improper handling!
ff Do not install the coupling hub onto the drive shaft of the axial piston unit by
striking it.
1. Install the specified coupling half onto the drive shaft of the axial piston unit
according to the instructions of the coupling manufacturer.
The drive shaft of the axial piston unit is equipped with a threaded bore. Use
this threaded bore to pull the coupling element onto the drive shaft. The size
of the threaded bore can be seen in the installation drawing.
2. Remove dirt and contaminants from the installation location.

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.
4. Transport the axial piston unit to the installation location.
5. Install the coupling on the drive shaft of the machine/system in accordance
with the specifications provided by the coupling manufacturer.
The axial piston unit may not be bolted down until the coupling has been
correctly installed.
6. Fix the axial piston unit at the installation location.

7. Align the drive shaft of the axial piston unit and the drive shaft of the machine
or system so that there is no angular deviation.
8. Make certain that no impermissible axial and radial forces act on the drive shaft.
9. Details on the required tools and tightening torques for the fixing screws are
available from the machine/system manufacturer.
Installation
10. When using flexible couplings, check that the output drive is free of resonance
after completing the installation.
7.4.5 Installation on a gearbox

The installation layout for the axial piston unit on a gearbox is described below.
After installing on a gearbox, the axial piston unit is covered and is difficult to
access:
ff Therefore, before installing, make sure that the centering spigot centers the
axial piston unit (observe tolerances) and that no impermissible axial or radial
forces act on the drive shaft of the axial piston unit (installation length).
ff Protect the drive shaft against frictional corrosion by providing permanent
lubrication.
ff Fix the axial piston unit at the installation location.
For attachment via gear wheel or No gearing forces higher than the permissible axial and radial forces are to act
helically-toothed shaft on the shaft, if necessary the gear wheel must be supported separately at the
gearbox output.
7.4.6 Installation with cardan shaft

To connect the axial piston unit to the engine via a cardan shaft:
1. Position the axial piston unit close to the specified installation location. It
should allow enough space for the cardan shaft to fit through on both sides.
2. Position the cardan shaft on the output shaft of the engine.
3. Push the axial piston unit to the cardan shaft and join the cardan shaft to the
drive shaft of the axial piston unit.
4. Bring the axial piston unit to the installation position and secure. Details on the
required tools and breakaway torques for the fixing screws can be obtained
from the system manufacturer if required.
Installation
7.4.7 Completing installation

1. Remove any mounted transport screws.
Caution! Operation with protective plug!

Operating the axial piston unit with protective plugs may result in injuries or
damage to the axial piston unit.
ff Before commissioning, remove all protective plugs and replace them with
suitable, pressure-proof, metal threaded plugs.
2. Remove the transport protection.

The axial piston unit is delivered with protective covers (1) and protective
plug (2). They are not pressure-resistant, therefore they have to be removed
prior to connection. Use a suitable tool for this to prevent damage to the
sealing and functional surfaces. If sealing or functional surfaces are damaged,
contact your responsible Bosch Rexroth Service partner or the service
department of the manufacture’s plant for the axial piston unit.
Fig. 9: Removing transport protection
1 Protective covers made of plastic 2 Protective plug/threaded plug

(metallic protective covers are
used for painted axial piston units)
Ports intended for connecting lines are covered by protective plugs or

threaded plugs, which serve as transport protection. All ports required for
functional operation must be connected (see table 12 “Ports A2FE/Series 6”).
If this requirement is disregarded, malfunction or damage may result. If a port
is not connected, it must be plugged with a threaded plug because protective
plugs are not pressure-resistant.
The following information only applies to fixed motors with pressure-relief valve.
The adjusting screws are protected against unauthorized resetting by means
of protective caps. Removal of the protective caps will void the warranty.
If you need a modification of the setting, please contact your responsible
Bosch Rexroth Service (address as to chapter “10.5 Spare parts”).
Installation
7.4.8 Hydraulically connecting the axial piston unit

The machine/system manufacturer is responsible for dimensioning the lines.
The axial piston unit must be connected to the rest of the hydraulic system
in accordance with the hydraulic circuit diagram of the machine/system
manufacturer.
The ports and fixing threads are designed for the maximum pressure specified
in the data sheet. The machine/system manufacturer must ensure that the
connecting elements and lines correspond to the specified application conditions
(pressure, flow, hydraulic fluid, temperature) with the necessary safety factors.
Connect only hydraulic lines that are appropriate for the axial piston unit port
(pressure level, size, system of units).
Notes on routing the lines Observe the following notes when routing the pressure and reservoir lines.
•• Lines and hoses must be installed without pre-charge pressure, so that no
further mechanical forces are applied during operation that will reduce the
service life of the axial piston unit and, if applicable, the entire machine/system.
•• Use suitable seals as sealing material.
•• Pressure line
–– For the pressure lines, use only pipes, hoses and connecting elements
rated for the operating pressure range specified in data sheet RE 91008
(see table 12).
•• Reservoir line
–– Always route the reservoir lines so that the case is constantly filled with
hydraulic fluid and to ensure that no air gets through the shaft seal even
during extended standstill periods.
–– The case internal pressure must not exceed the limit values listed for the axial
piston unit in the data sheet under any operating conditions.
–– The reservoir line joint in the reservoir must always be below the minimum
fluid level under all conditions (see chapter “7.3 Installation position”).
Risk of mix-ups with The axial piston units are used in application areas with metric as well as with the
threaded connections Anglo-American (inch) system of units.
Both the system of units as well as the size of female threade and threaded plug
(e.g. locking screw) must match.
Due to the limited options for visually detecting differences, there is a risk of
mix‑ups.
Warning! Leaking or popped-out threaded plugs!
If a threaded plug which is of a different measurement system and size with
respect to the female thread is pressurized, the threaded plug may loosen itself
or even be ejected from the hole in a projectile-like manner. This can result in
serious injury and damage to equipment. Hydraulic fluid can be discharged from
this leakage point.
ff Use the drawings (installation drawing/data sheet) to determine the required
threaded plug for each fitting.
ff Make certain that there are no mix-ups when installing fittings, fixing screws
and threaded plugs.
ff For all female threads, use a threaded plug from the same system of units and
of the correct size.
Installation
Connecting line to pressure-relief Please note the following information concerning the version with port plate 192.
valve with pressure cut-in stage
ff When screwing in and tightening the connection line to port PSt, the nut (1) on
the pressure-relief valve with pressure cut-in stage (2) must be braced with
WAF 24. Observe the manufacturer’s instructions regarding tightening torques
for the used connection line. The maximum permissible tightening torque at
the female thread (40 Nm) must not be exceeded.
PSt
1
Fig. 10: Brace nut at pressure-relief valve
The adjustment of the pressure-relief valve must not be changed. Changing

the setting of the adjusting screw on the pressure-relief valve will render the
warranty void.
Installation
Fixing the counterbalance valve Observe the following notes concerning the version with counterbalance valve
(port plate 181).
When delivered, the counterbalance valve is attached to the motor using tacking
screws (transport protection). The tacking screws must not be removed while
fixing the service lines! If the counterbalance valve and motor are delivered
separately, the counterbalance valve must first be attached to the motor port plate
using the provided tacking screws. The final fastening of the counterbalance valve
on the motor is performed by bolting the SAE flange with the following screws:
6 screws (1, 2, 3, 4, 5, 8) length B1+B2+B3
2 screws (6, 7) length B3+B4
Tighten the screws in two steps in the specified sequence from 1 to 8 (see
following diagram).
ff In the first step, tighten the screws with half the tightening torque; in the
second step, tighten with the maximum tightening torque (see table 10).
Table 10: Tightening torques of the fixing screws

Thread Strength class Tightening torque
M6 x 1 (tacking screw) 10.9 15.5 Nm
M10 x 1.5 10.9 75 Nm
M12 x 1.75 10.9 130 Nm
M14 x 2 10.9 205 Nm
2 4
B1
2)
6 8
7 5
B2
2)
3 1
B4
1)
B3
Y
1) SAE flange
2) Tacking screw (M6 x 1, length = B1 + B2, DIN 912)
Fig. 11: Fixing the counterbalance valve
The SAE flange and corresponding fixing screws are not included in the
delivery contents.
Table 11: Threaded sizes and dimensions

Size 28, 32, 45 56, 63 80, 90 107, 125, 160, 180
Dimension B11) M10 x 1.5 M10 x 1.5 M12 x 1.75 M14 x 2
17 deep 17 deep 18 deep 19 deep
Dimension B2 782) mm 68 mm 68 mm 85 mm
Dimension B3 customer-specific (flange-dependent)
Dimension B4 M10 x 1.5 M10 x 1.5 M12 x 1.75 M14 x 2
15 deep 15 deep 16 deep 19 deep
Fixing thread acc. to DIN 13. – For DIN 13 fixing screws, we recommend checking the tightening torque
on a case-by-case basis according to VDI 2230 Edition 2003.
1) Minimum required thread reach 1 x Ø thread
2) Including intermediate plate
Installation
Port overview
T1
T1
B
A
Fig. 12: Port overview A2FE, sizes 28 to 180, port plate 10, service line ports at bottom
S1 PSt
PSt
T1
T1
B
A
MA
MB
Fig. 13: Port overview A2FE, sizes 28 to 180, port plate 192 with pressure-relief
valves, service line ports at bottom
MA
T1
T1
B
MB
Fig. 14: Port overview A2FE, sizes 28 to 180, port plate 181 with mounted
counterbalance valve, service line ports at bottom
Installation
T1
B
A
T2
Fig. 15: Port overview A2FE, sizes 250 to 355, port plate 01, service line ports at rear
Table 12: Ports A2FE Series 6

Designation Port for Standard Maximum State
pressure [bar]1)
A, B Service line SAE J5182) 4503) O
Fixing thread A/B DIN 13
T1 Reservoir line (case drain fluid) DIN 38524) 10 O5)
T2 6) Reservoir line (case drain fluid) DIN 38524) 10 X5)
MA7) Measuring, pressure A DIN 38524) 4503) X
MB7) Measuring, pressure B DIN 38524) 4503) X
S1 Supply DIN 38524) 40 X
(only with port plate 191/192)
PSt Control port DIN ISO 2284) 30 O
(only with port plate 192)
1) Short
term pressure spikes may occur depending on the application. Keep this in mind when selecting
measuring equipment and fittings.
2) Only dimensions in accordance with SAE J518, metric fixing thread deviating from the standard.
3) For sizes 250 to 355, maximum pressure 400 bar.
4) The countersink may be deeper that specified in the standard.
5) Depending on installation position, either T1 or T2 must be connected (see chapter 7.3 “Installation
position”)
6) Port T2 Optional for size 28 to 180.
7) Available for size 355 and sizes 18 to 180 with port plate 181, 191 or 192.
O = Must be connected (plugged on delivery)
X = Plugged (in normal operation)
Tightening torques The following tightening torques apply:

•• Threaded hole of the axial piston unit:
The maximum permissible tightening torques MG max are maximum values of the
female thread and must not be exceeded. For values, see the following table.
•• Fittings:
Observe the manufacturer’s instructions regarding the tightening torques of the
fittings used.
•• Fixing screws:
For fixing screws with metric ISO thread according to DIN 13 or thread
according to ASME B1.1, we recommend checking the tightening torque
individually according to VDI 2230.
•• Threaded plugs:
For the metallic threaded plugs supplied with the axial piston unit, the required
tightening torques of threaded plugs MV apply. For values, see the following
table.
Installation
Table 13: Tightening torques of the female threads and threaded plugs
Ports Maximum permissible
Required tightening torque WAF hexagon socket for
tightening torque of the
Standard Thread size of the threaded plugs MV the threaded plugs
female threads MG max
DIN 3852 M10 x 1 30 Nm 12 Nm 5 mm
M12 x 1.5 50 Nm 25 Nm 6 mm
M14 x 1.5 80 Nm 35 Nm 6 mm
M16 x 1.5 100 Nm 50 Nm 8 mm
M18 x 1.5 140 Nm 60 Nm 8 mm
M22 x 1.5 210 Nm 80 Nm 10 mm
M26 x 1.5 230 Nm 120 Nm 12 mm
M27 x 2 330 Nm 135 Nm 12 mm
M33 x 2 540 Nm 225 Nm 17 mm
M42 x 2 720 Nm 360 Nm 22 mm
DIN ISO 228 G1/41) 40 Nm – –
1) Connecting thread on pressure relief valve, see chapter 7.4.8 “Hydraulically connecting the axial piston unit”.
Procedure To connect the axial piston unit to the hydraulic system:

1. Remove the threaded plugs at the ports at which the connections are to be
made according to the hydraulic circuit diagram.
2. Make certain that the sealing surfaces of the hydraulic ports and functional
surfaces are not damaged.
3. Use only clean hydraulic lines or flush them before installation. (Observe
chapter 7.5 “Perform flushing cycle” when you flush the entire system.)
4. Connect the lines in accordance with the installation drawing and the machine
or system circuit diagram. Check whether all ports are piped up or plugged
with threaded plugs.
5. Correctly tighten the union nuts for the fittings and flanges (observe tightening
torques!). Mark all correctly tightened fittings, e.g. with a permanent marker.
6. Check all pipes and hose lines and every combination of connecting pieces,
couplings or connecting points with hoses or pipes to ensure they are in
condition for safe working.
Relationship between direction of rotation and flow direction:

clockwise rotation: A to B
counter-clockwise rotation: B to A
7.5 Performing flushing cycle

In order to remove foreign particles from the system, Bosch Rexroth recommends
a flushing cycle for the entire system. To avoid internal contamination, the axial
piston unit must not be included in the flushing cycle.
The flushing cycle must be performed with an additional flushing unit. Follow
the instructions of the flushing unit’s manufacturer for the exact procedure
during the flushing cycle.
Commissioning
8 Commissioning
WARNING
Danger while working in the danger zone of a machine/system!
Danger to life, risk of injury or serious injuries!
ff Pay attention to and rectify potential danger sources before operating the
axial piston unit.
ff Nobody may stand in the danger zone of the machine/system.
ff The emergency stop button for the machine/system must be within the
operator’s reach.
ff Always follow the instructions of the machine/system manufacturer during
commissioning.
CAUTION
Commissioning of an incorrectly installed product!
Risk of injury and damage to equipment!
You can injure yourself on incorrectly installed products or damage the product.
ff Make sure that all electrical and hydraulic ports are connected or plugged.
ff Only commission a completely installed product.
8.1 First commissioning

During all work for commissioning the axial piston unit, observe the general
safety instructions and intended use in chapter 2 “Safety instructions”.
ff Connect the gauge for the operating pressure and case pressure to the
specified measuring points on the axial piston unit or in the hydraulic system,
to check the technical data at first operation.
ff During the commissioning process, monitor the temperature of the hydraulic
fluid in the reservoir to ensure that it lies within the permissible viscosity limits.
8.1.1 Filling the axial piston unit

Professional filling and air bleeding is necessary to prevent damage to the axial
piston unit and to maintain correct function.
The axial piston unit should be filled with a filling unit (10 µm filter grade). The
axial piston unit must not be operated while it is being filled by the filling unit.
Use only a hydraulic fluid that conforms to the following requirements:

You can find details of the minimum requirements on hydraulic fluids in Bosch
Rexroth data sheets RE 90220, RE 90221 and RE 90223. You can find the title of
the data sheets in table 1 “Required and supplementary documentation”. You can
find details of permissible and optimal viscosity in data sheet RE 91008.
To ensure the functional reliability of the axial piston unit, cleanliness level 20/18/15
according to at least ISO 4406 is necessary for the hydraulic fluid. At very
high hydraulic fluid temperatures (+90 °C to maximum +115 °C), cleanliness
level 19/17/14 according to at least ISO 4406 is necessary. For permissible
temperatures, see data sheet RE 91008.
Commissioning
1. Place a drip tray under the axial piston unit to collect any hydraulic fluid that
may escape.
Note! Contaminated hydraulic fluid!

The cleanliness levels of hydraulic fluids on delivery do not normally conform to
the requirements for our components.
ff Use a suitable filter system to filter hydraulic fluids during filling to minimize
solid impurities and water in the hydraulic system.
2. Fill and air bleed the axial piston unit via the appropriate ports, see chapter
“7.3 Installation position”. The hydraulic lines of the system must also be filled.
Note! Damage to equipment due to improper lubrication!

Product can be damaged or destroyed!
ff When using a shut-off valve in the reservoir line, make sure that the input of
the axial piston unit can only be started when the shut-off valves are open.
3. When using a shut-off valve in the reservoir line, only operate the axial piston
unit when the shut-off valves are open.
8.1.2 Testing the hydraulic fluid supply

The axial piston unit must always have a sufficient supply of hydraulic fluid.
For this reason, the supply of hydraulic fluid must be ensured at the start of the
commissioning process.
When you test the hydraulic fluid supply, constantly monitor the noise
development and check the hydraulic fluid level in the reservoir. If the axial piston
unit becomes louder (cavitation) or the case drain fluid is discharged with bubbles,
this is an indication that the axial piston unit is not being sufficiently supplied with
hydraulic fluid.
Notes on troubleshooting can be found in chapter “14 Troubleshooting”.
To test the hydraulic fluid supply:
1. Allow the axial piston unit to run at low speed and without load. Pay attention
to leakage and noise.
2. Check the axial piston unit’s reservoir line during the test. The case drain fluid
should not contain any bubbles.
3. Increase the load and check whether the operating pressure rises as
expected.
4. Carry out a leak test to ensure that the hydraulic system is sealed and can
withstand the maximum pressure.
5. At maximum pressure, check the case drain pressure at port T, T1 or T2.
Refer to data sheet RE 91008 for the permissible value.
8.1.3 Performing functional test
WARNING
Incorrectly connected axial piston unit!
Mixing up the ports will lead to malfunctions (e.g. lift instead of lower) and thus
to corresponding danger to persons and equipment!
ff Before the functional test, check whether the piping specified in the hydraulic
circuit diagram has been installed.
Commissioning
Once you have tested the hydraulic fluid supply, you must perform a functional
test on the machine/system. The functional test should be performed according to
the instructions of the machine/system manufacturer.
The axial piston unit is checked for functional capability before delivery according
to the technical data. During commissioning, it must be ensured that the axial
piston unit was installed properly in the machine/system.
ff After starting the engine, check in particular the specified pressures, e.g.
system pressure, boost pressure and case pressure.
ff If necessary, disconnect the gauge and plug the ports with threaded plugs.
8.2 Running-in phase
NOTE
Damage to equipment by insufficient viscosity!
An increased hydraulic fluid temperature may reduce the viscosity values by too
much and damage the product!
ff Monitor the operating temperature during the running-in phase, e.g. by
measuring the case drain temperature.
ff Reduce the loading (pressure, rpm) of the axial piston unit if impermissible
operating temperatures and/or viscosities occur.
ff Operating temperatures that are too high indicate faults that have to be
analyzed and cleared.
The bearings and sliding surfaces are subject to a running-in phase. The
increased friction at the start of the running-in phase results in increased heat
development which decreases with increasing operating hours. The volumetric
and mechanical-hydraulic efficiency increases as well through the conclusion of
the running-in phase of approx. 10 operating hours.
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:
ff After the running-in phase, have a hydraulic fluid specimen analyzed for the
required cleanliness level.
ff Change the hydraulic fluid if the required cleanliness level is not reached. If
a laboratory test is not carried out after the running-in phase, Bosch Rexroth
recommends the hydraulic fluid be changed.
8.3 Recommissioning after standstill

Depending on the installation conditions and ambient conditions, changes may
occur in the hydraulic system which make recommissioning necessary.
Among others, the following criteria may make recommissioning necessary:
•• Air and/or water in the hydraulic system
•• Old hydraulic fluid
•• Other contamination
ff Before recommissioning, proceed as described in chapter 8.1 “First

commissioning”.
Operation
9 Operation
The product is a component which requires no settings or changes during
operation. For this reason, this chapter of the manual does not contain any
information on adjustment options. Use the product only within the performance
range provided in the technical data. The machine/system manufacturer is
responsible for the proper project planning of the hydraulic system and its control.
10 Maintenance and repair
NOTE
Inspection and maintenance work carried out too late!
Damage to equipment!
ff Carry out the specified inspection and maintenance work at the intervals
described in this manual.
10.1 Cleaning and care
NOTE
Damage to seals and electrical system by mechanical effects!
The water jet of a power washer may damage the seals and electrical system
of the axial piston unit!
ff Do not point the power washer at sensitive components, e.g. shaft seal,
electrical connections and components.
For cleaning and care of the axial piston unit, observe the following:
ff Check whether all seals and fittings on the connections are securely seated
to ensure that no moisture can penetrate into the axial piston unit during
cleaning.
ff Use only water and, if necessary, a mild detergent to clean the axial piston
unit. Never use solvents or aggressive detergents.
ff Remove external coarse dirt and keep sensitive and important components,
such as solenoids, valves, indicators and sensors, clean.
Maintenance and repair
10.2 Inspection
In order to enable long and reliable operation of the axial piston unit, Bosch
Rexroth recommends testing the hydraulic system and axial piston unit on a
regular basis, and documenting and archiving the following operating conditions:
Table 14: Inspection schedule
Task to be carried out Interval
Hydraulic Check level of hydraulic fluid in the reservoir. Daily
system
Check the operating temperature at a Weekly
comparable load condition at the reservoir
port and in the reservoir.
Conduct analysis of hydraulic fluid: viscosity, Yearly or every 2000
aging and dirt contamination operating hours
(whichever occurs
first)
Axial piston unit Check axial piston unit for leakage. Daily
Early detection of hydraulic fluid loss can help
to find errors on the machine/system and to
rectify them. For this reason, Bosch Rexroth
recommends that the axial piston unit and
system are always kept in a clean condition.
Check axial piston unit for unusual noise Daily
development.
Check fasteners for tight seating. Monthly
All fasteners have to be checked when the
hydraulic system is switched off, depressurized
and cooled down.
10.3 Maintenance
The axial piston unit is low maintenance when used properly.
The service life of the axial piston unit is heavily dependent on the quality of the
hydraulic fluid. For this reason, we recommend changing the hydraulic fluid at
least once per year or every 2000 operating hours (which ever occurs first) or
having it analyzed by the hydraulic fluid manufacturer or a laboratory to determine
its suitability for further use.
The service life of the axial piston unit is limited by the service life of the bearings
fitted. The service life based on the load cycle can be requested from the
responsible Bosch Rexroth Service partner, see chapter 10.5 “Spare parts” for
address. Based on these details, a maintenance period is to be determined by
the system manufacturer for the replacement of the bearings and included in the
maintenance schedule of the hydraulic system.
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 may only be performed by service centers certified
by Bosch Rexroth.
ff Use exclusively original spare parts from Rexroth to repair the Rexroth axial
piston units, otherwise the functional reliability of the axial piston unit can not
be assured and you lose your entitlement under warranty.
In the event of questions regarding repair, contact your responsible Bosch

Rexroth Service partner or the service department of the manufacture’s plant
for the axial piston unit, see chapter “10.5 Spare parts” for further information.
Maintenance and repair
10.5 Spare parts
CAUTION
Use of unsuitable spare parts!
Spare parts that do not meet the technical requirements specified by Bosch
Rexroth may cause personal injury or property damage!
ff Use exclusively original spare parts from Rexroth to repair the Rexroth axial
piston units, otherwise the functional reliability of the axial piston unit can not
be assured and you lose your entitlement under warranty.
The spare parts lists for axial piston units are order specific. When ordering spare
parts, quote the material and serial number of the axial piston unit as well as the
material numbers of the spare parts.
Address all questions regarding spare parts to your responsible Bosch Rexroth
Service partner or the service department of the manufacture’s plant for the axial
piston unit.
Details on the manufacture’s plant are available on the axial piston unit’s name
plate.
Bosch Rexroth AG
Glockeraustraße 4
D-89275 Elchingen, Germany
Tel. +49-7308-82-0
Fax +49-711-811-513-9382
[email protected]
Bosch Rexroth AG
An den Kelterwiesen 14
72160 Horb a.N., Germany
Tel. +49 (0) 74 51-92-0
Fax +49 (0) 711-811-513-93 82
[email protected]
For the addresses of foreign subsidiaries, please refer to

www.boschrexroth.com/addresses
Removal and replacement
11 Removal and replacement
11.1 Required tools

Removal can be performed using standard tools. No special tools are necessary.
11.2 Preparing for removal

1. Decommission the entire system as described in the instruction manual for the
machine or system.
–– Relieve pressure in the hydraulic system according to the instructions of the
machine or system manufacturer.
–– Make certain that the relevant system components are not under pressure
or voltage.
2. Protect the complete system against being energized.
11.3 Removing the axial piston unit

Proceed as follows to remove the axial piston unit:
1. Check whether the hydraulic system is depressurized.
2. Allow the axial piston unit to cool down until it can be removed without danger.
3. For below-reservoir installation, before removing the axial piston unit from the
complete system, seal the connection to the reservoir or drain the reservoir.
4. Place a drip tray under the axial piston unit to collect any hydraulic fluid that
may escape.
5. Loosen the lines and collect the escaping hydraulic fluid in the drip tray.
6. Remove the axial piston unit. Use a suitable lifting device.
7. Completely empty the axial piston unit.
8. Plug all openings.
11.4 Preparing the components for storage or further use

ff Proceed as described in chapter “6.2 Storing the axial piston unit”.
Disposal
12 Disposal
Careless disposal of the axial piston unit, the hydraulic fluid and the packaging
material could lead to pollution of the environment.
Observe the following points when disposing of the axial piston unit:
1. Completely empty the axial piston unit.
2. Dispose of the axial piston unit and packaging material in accordance with
the national regulations in your country.
3. Dispose of the hydraulic fluid according to the national regulations of your
country. Also observe the applicable safety data sheet for the hydraulic fluid.
4. Remove the axial piston unit into its individual parts and properly recycle
these parts.
5. Separate according to, for instance:
–– Cast parts
–– Steel
–– Aluminum
–– Non-ferrous metal
–– Electronic waste
–– Plastic
–– Seals
13 Extension and conversion

Do not modify the axial piston unit.
The Bosch Rexroth warranty only applies for the delivered configuration.
In case of conversion or extension, the entitlement under warranty will be
rendered void.
Troubleshooting
14 Troubleshooting
The following table may assist you in troubleshooting. The table makes no claim
for completeness.
In practical use, problems which are not listed here may also occur.
14.1 How to proceed for troubleshooting

ff Always act systematically and targeted, even under pressure of time. Random
and imprudent removal and a readjustment of settings could result in the
inability to ascertain the original failure cause.
ff First obtain a general overview of how your product works in conjunction with
the entire system.
ff Try to determine whether the product worked properly in conjunction with the
entire system before the error occurred.
ff Try to determine any changes of the entire system in which the product is
integrated
–– Were there any changes to the product’s application conditions or operating
range?
–– Has maintenance work recently been carried out? Is there an inspection or
maintenance log?
–– Were changes (e.g. conversions) or repairs made to the complete system
(machine/system, electrics, control) or on the product? If yes, which?
–– Has the hydraulic fluid been changed?
–– Was the product or machine operated as intended?
–– How did the malfunction appear?
ff Try to get a clear idea of the error cause. Directly ask the (machine) operator.
ff Document the work carried out.
ff If you cannot rectify the error, contact one of the contact addresses which can
be found under:
www.boschrexroth.com/addresses.
Troubleshooting
14.2 Malfunction table

Table 15: Axial piston unit malfunction table
Fault Possible cause Remedy
Unusual noises Output speed too high. Machine/system manufacturer.
Improper fixing of the axial piston unit. Check the fixing of the axial piston unit
according to the specifications of the
machine/system manufacturer. Observe
tightening torques.
Improper fixing of the attachment parts, Fix attachment parts according to the
e.g. coupling and hydraulic lines. information provided by the coupling or
fitting manufacturer.
Mechanical damage to the axial piston unit Exchange axial piston unit,
(e.g. bearing damage). contact Bosch Rexroth Service.
Pressure/flow fluctuations Axial piston unit not or insufficiently air bled. Completely air bleed axial piston unit.
Operational data not achieved Insufficient flow at hydraulic pump. Check function of the hydraulic pump.
Hydraulic fluid not in optimum viscosity Use suitable hydraulic fluid

range. (machine/system manufacturer).
Wear of axial piston unit. Exchange axial piston unit,
contact Bosch Rexroth Service.
Mechanical damage to the axial piston unit Exchange axial piston unit,
(e.g. bearing damage). contact Bosch Rexroth Service.
Excessive hydraulic fluid temperature and Excessive inlet temperature at the axial Machine or system manufacturer: inspect
case temperature piston unit. system, e.g malfunction of the cooler,
insufficient hydraulic fluid in the reservoir.
Malfunction of the pressure control valves Contact Bosch Rexroth Service.
(e.g. high-pressure relief valve, pressure
cut-off, pressure controller).
Output speed too high. Machine/system manufacturer.
Malfunction of the flushing valve. Contact Bosch Rexroth Service.
Wear of axial piston unit. Exchange axial piston unit,

contact Bosch Rexroth Service.
Instability/vibrations Target value not stable. Machine/system manufacturer.
Resonance in the reservoir line. Machine/system manufacturer.
Malfunction of the control devices Contact Bosch Rexroth Service.

or the controller.
Technical data
15 Technical data
The permissible values of the technical data of your axial piston unit can be found
in data sheet RE 91008.
The data sheet can be found on the internet at
www.boschrexroth.com/axial-piston-motors
The order-related technical data of your axial piston unit can be found in the order
confirmation.
16 Appendix
16.1 Address directory

For the addresses of foreign subsidiaries, please refer to
www.boschrexroth.com/addresses
Alphabetical index
17 Alphabetical index
A L
Abbreviations 7 Lifting device 17
Address directory 45 Lifting strap 18
Assembly 15
M
B Maintenance 38, 39
Below-reservoir installation 23 Malfunction table 44
C N
Care 38 Name plate 16
Circuit
closed 15
O
open 15
Cleaning 38 Operation 38
Commissioning 35
First 35 P
Connecting
Performance description 15
Hydraulic 29
Piston 15
Conversion 42
Port overview 32
Corrosion protection 19
Port plate 15
Corrosion protection film 19
Product description 15
Cylinder 15
Q
D
Qualifications 9
Damage to equipment 12
Delivery contents 14
Designations 7 R
Dimensions 17, 25 Recommissioning 37
Direction of rotation 25 After standstill 37
Disposal 42 Removal 41
Drive shaft 15 Performing 41
Preparing 41
F Repair 39
Replacement 41
Filling 35
Required documentation 5
Flushing cycle 34
Ring screw 17
Functional description
Running-in phase 37
Motor function 16
Functional test 36
S
I Safety instructions 8
General 9
Identification 16
Product-specific 10
Inspection 39
Signal word 6
Installation 21
Spare parts 40
Completing 28
Storage 17
General instructions 25
Storage time 19
On a gearbox 27
Storing 19
Preparation 25
Symbols 7
With coupling 26
Installation conditions 21
Installation Position
Below-reservoir installation 23
Installing 25
Instructions
General 25
Intended use 8
Alphabetical index
T
Technical data 45
Tightening torques 33
Tools 41
Transport 17
With lifting strap 18
With ring screw 17
Transporting 17
Transport protection 28
Troubleshooting 43
U
Unpacking 21
W
Warranty 19, 35, 42
Warranty rights 28
Weights 17
Bosch Rexroth AG
Axial piston units
Glockeraustrasse 4
89275 Elchingen
Germany
Tel. +49 (0) 73 08-82-0
Fax +49 (0) 73 08-72 74
[email protected]
Bosch Rexroth AG
Axial piston units
An den Kelterwiesen 14
72160 Horb a.N.
Germany
Tel. +49 (0) 74 51-92-0
Fax +49 (0) 74 51-82 21
[email protected]
Subject to change
Printed in Germany
RE 91008-01-B/08.2011

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What is the purpose of the manual?

What is the purpose of the manual?

What components does the manual describe?

What components does the manual describe?

Fixed Plug-In Motor RE 91008-01-B/08.

© This document, as well as the data, specifications

The cover shows an example application. The

The original instruction manual was created in the

10 Maintenance and repair...........................................................................38

About this manual

1 About this manual

1.1 Validity of the documentation

This documentation is intended for machine/system manufacturers, fitters and

1.2 Required and supplementary documentation

Table 1: Required and supplementary documentation

About this manual

1.3 Display of information

1.3.1 Safety instructions

•• Safety sign: draws attention to the danger

Table 2: Danger classes in accordance with ANSI Z535.6-2006

Safety sign, signal word Meaning

NOTE Damage to equipment: the product or the environment

About this manual

ff Single, independent step

2.1 About this chapter

2.2 Intended use

2.3 Improper use

2.4 Personnel qualifications

2.5 General safety instructions

2.6 Product-specific safety instructions

Escaping oil mist!

Hot surfaces on the axial piston unit!

Improper routing of cables and lines!

Contact with hydraulic fluid!

Escaping hydraulic fluid due to machine/system leakage!

2.7 Personal protective equipment

General instructions on damage to equipment and the product

3 General instructions on damage

Damage to equipment due to improper lubrication!

Mixing of hydraulic fluids!

General instructions on damage to equipment and the product

Environmental pollution due to incorrect disposal!

Escaping or spilling hydraulic fluid!

•• The warranty only applies to the delivered configuration.

Fig. 1: Axial piston unit with service line ports at bottom

Included in the delivery contents are:

The following parts are also installed on delivery:

5.1 Performance description

5.2 Product description

5.2.1 Assembly of the axial piston unit

Fig. 2: Assembly of the A2FE

1 Drive shaft 4 Control plate

5.2.2 Functional description

5.3 Product identification

Fig. 3: A4VSO name plate A2FE

1 Manufacturer 7 Bar code

Transport and storage

6 Transport and storage

You can find unpacking notes in chapter 7.1 “Unpacking”.