REXROTH WORLDWIDE HYDRAULICS Applications and Service Manual AAAV SERIES 1 Hydrostatic Transmission Pump RA 06710/08.88 Replaces: 01.86INTRODUCTION This manual is intended to provide the information required to successfully start up, adjust, troubleshoot and service the Rexroth hydrostatic transmis- sion pump, type AA4V Series 1 The adjustment and disassembly procedures described herein may be per- formed in clean conditions without affecting the warranty. Dismantling the units beyond the stages described in the manual without the express permission of Rexroth may void the warranty. When performing any type of service or conversion to these pumps, the ut- most cleanliness of work area, tools, cleaning rags, and the components is required. Dirt and contamination introduced during assembly and service is a major cause of failure in high pressure piston equipment. Therefore, the im- portance of cleanliness cannot be over emphasized. For dimensions and detailed descriptions of the function of the various con- trols, please refer to the relevant “RA” engineering data sheet. ‘©Copyright 1958 Rexroth Corporation, Mobile Hycraues Dision Spocicalons, descriptions and ilutraive material shown hecaln were as accurate as known athe tne this pubscation ws approved fr prising, Faxon eserves ty ig fo cscotinuernodle er ontons st sy tne or change Specilcalions, materials, of designs witout nalice and without incurring obligation. Optional equipment and accessories may add additigna cost to the basic unt, and some options are avaliable only in'combination wih certain mogete er aner options, For the avalablo combinaiionsrtor othe relovant data sheots for the baste unt and the desirad option. Information contained herein should be confirmed before pacing orders ROTH REE 2Index ‘Type Code General Specifications Controt Descriptions Optional Features Filtration Recommendation Pre-Start Procedure Start-Up Procedure Diagnostic Ports with Port Sizes Troubleshooting Procedure 1, Transmission Does Not Drive with Prime Mover Operating Properly 2. Transmission Drive is Sluggish or Erratic. 3, Transmission Drives in One Direction Only 4, Transmission Drives in the Wrong Direction 5. Transmission Does Not Find or Hold Neutral 6. Transmission Operates at a High Noise Level 7. Transmission Operates at a Higher than Normal ‘Temperature 8, Pump Does Not Develop Maximum Horsepower Mechanical Centering of Pump Hydraulic Centering of Control Modules HD, HW, EL . Removal and Adjustment of Relief Valves Adjustment of Pressure Override Removal and Inspection of Charge Pump Replacement of Shaft Seal Routine Maintenance Hydraulic Fluids Replacement Subassemblies and Parts Ordering of Subassemblies and Parts Page 4 10 10 it 13 14 4 14 14 18 18 16 7 18 19 20 2 22 22 23 28 REXROTHType Code AAAV a a 0 | 14 [0 /12vbc-P-cv| let|1[R[s[o Model axial Psion, {Variable Displacement Pimp a Size Baa iow ao emirev ‘342 insrow ‘56 omsnov 549 insrov 80 emakev 753 inov 125 cov Control Romote hydraulic pot Manuel rotary serve Préportional electric Non-proportional slate Watnout conti! module without contol module with POR, FEE) BEBE & al Design Series No. Sizes, 40, 88, 80, & 105 Cy rection of Rotation Fight hand (clockwise) Lett hand (counterclockwise) (is viowod at shatt ond) Mounting Contiguration Sizes 40 and 66, SAE “C Pbom Flange, Mf, 12/24 Pitch, 30° Tnvoluta, Tal, CLS. Spin ‘Shatt ANSI 892.10 ‘Size 90 SAE ‘D’ 2-olt Flange, Hat, 12124 Pitch, 30° Iovate, TOLGLS, Spline Shatt ANS! BS2:18 Sizo 125, SAE “0° 2bot Flange, ‘at fi@ Phen, 30° votre. LS] Tel, L5, Spline Shalt ANSI B28 “Foor to the rlovent data shoot fr torque lniations and ‘dnensional deta of through rho. Model Number Example—ARAVSGEL 1R302010/12VDC-TP.CV Variable digplacement hysrasialic transmission pump, ype AAV, ‘ize 56, remota proprational eect con! ({2VOC), sees gh hand etation, SAE’ c* mounting lange, ta toa —'2/24 pln span hall, porling fox external enarge flow iter, ree! valve aston ange t 2600 fe 6400 psi, without pressure override, tampa rool ape.on adjustment sevens and with high prossure shut chock ‘Aaaito (lear text) er conto, ase equited contol vo ‘Standard = 24 VOC Volts DC Gpttonat = 12 VOC Volis DC. 2) For tamperproo! caps on adjustment screws show TP 3)For POLA, checks but without the POR: show cv. 4) For noutal start smtch (GW conto! any) show NSS, 5) For lager charge puny (size 40 ony) show UCI {For viton shalt soal show W. 7) For auxitary Y-Port for remote Inching show ¥. Pressure Override (.0.R.) Option Without pressure overdo ea] With prassure verida {presdure oversde o standard with {ie conron High Pressure Rolie Valves With plo operated reli valves alate range of 20000 £5000 pst standard design) With pilot operated cate values Edustabio range of eet C2] 2800 ps. Speed Sensing Horsepower Limiter Information For use wit er gasoline engi only. Not available with OV contel aout S81. con catidae (hard ei i) For SSHLL. ooo brochure RA06202 Filter Port Options With porting tor ution ter only (Stanaara) th porting for external charge Now titer {eternal charge tow fiation fs rogutad wih SSHL., contact Frat Yor details) ‘wath diroet mounted itor gute wh a) ‘onact Fexroih far deals and avalabity ‘Through Drive For Auxiliary Pur ‘Without Trough dive for auxliany pump itnout charge pump & ‘without through dee with charge pump & SAE A, 2ibol through ive \Witn charge pump & SAE B, 2ibol through dive \Watn charge pump & SAE 6-8, Bot through ive Wit charge pump & SAE C, Beat ihrough deve. Size 90 & 185 only, @ CI [e] Ce] HE REXROTHTechnical Details General Specifications AA4V Pump Secor a ‘Tho AAV transmission pump is usually face-mounted to a drive gear box with tho shat engaging @ maing female splined gear ub, — ier ‘espling adaptor The largo dv shalt Barings permit fe pump ! tobe avon by vo or tothad belt aves. The ease drain ne souls be connected tothe highest case drain pod (ToT) so thatthe emia tow = Bump anaysromaie fl oo Theaba dan ti NG e Brhavo, shouldbe sized to accep the fl ew ofthe charge ars ae al the maximum antcpated dive speed Maxima pss For mobile appications, th ol servic capacity aqulod (in US " Salone) Ts generally 75 01 times ine charge pump ow (r US — Puen el Ballons per minut} fora one pump. one moter Wansm'sion. Tho qe const vs Frat exchanger shouldbe located between the pump ease drain yb a and the eso and io 19 accapt ho tl wo th charge Mima ainsi [om Baump atthe maximum antcpated deve pa a 1} ef aL Rt={ Me To sccommodaa sh sal misalignment anda dampen vera shat reve Tn fA) P| METH] thon so ofa floxie eoupling le recomme skews tie aed] — Should workeusay iit cupng manure a ma_| aa | aan | 20 | 00 | applying 2 sulable coupling. Whan fox coupings ium spent rom | sm [so | soo | soo | bels'ortcathedtinngbots are to be used tne counting hal gor, ‘or pulley, should be secured fo the drive shaft vsing a spacer be: awe as __| # | 7 | we |__| eon the coupiing and the shoulder onthe rive shaft, and locke | wat onto pe to [oes | asf st] om ing the coupling to ho shat by using a set ser a halen the ond ofthe shalt. this fs nel passibie, az when mount Maen tea Iter | sore | 206) | 8872 | M24) ing tho motor to a drive gearbox, Optimoly Pasie White T mull " __| ome [ese [coos [ears | aad} purpose tubrcating past or equivalent MUST be applied fo tho mr | a Ta] a [a] Shalt avoid trang corrosion of the spine, axiom cae pes Flushing Cieul... When one variable pump and one moor fs us eda flushing valv isnot narmaty requed unas continuous high Speed andior high pressure fs aneipalec. nis ease, ashing lay be required through the motor case as wellas the pump case (coo note Beton Whenever any ype of valves, such as drectlonal control vahes or Now diviger vates, are used inthe closed loop cireut, a sysiom Hsing valve s recommended. NOTE: All charge pump flow must pass through the pump case ‘en the tamsmiseion fen neulral and the pump ts roating. It Maximum permissble esta eg the cies Charge Pump ‘reuit lushing valve (hot ol shistle vaio) fused, the outlet port Nominal aw a lth valve must be conected to the ower case drain port of the pump, | ‘wo 9 Filtration... There are throe options available forthe fitration of the hydraulic us used nthe AAA puma ‘See Page 9 for detalled descriptions, Moninunpese Fluid Recommendations...the AMY pumps are supplied as sia ard for use with good quay, petoteurrbased, nyerallo ds. ‘Soo Page 23 fot lid chatactersties and fluid visosiy ranges, ima tess | — pig | a2 | a2 (sua peg 9) ua Instalation,.tbe AAAY pump may be mouried in any postion Operating Temperature. ~19% to +1954" (-25% 0 90°). The round tne fozonal xe, Te heal sas (ve shal may empertre velo pur sy enema tres Be tilted to 15° in ener direction Irom the horizon the pump or motor case drain. This omporaturo i then Used (© | ‘establish tha cooling requlcamants forthe system Design Features AA4V Pump @ ssokng ine ores (2 per pump) @ conte piston © Heavy-duty rotor bearings Q Rocker cam swashplate Hrctned pistons © Spherical contro plate @ Cone! module © spline coupiing © inernat goar charge pump REXROTH 5 WORDDE HORTLE,Control Descriptions Remote Hydraulic Pilot Control, Type HD ‘The flow output ofthe pump is intintoly varia inthe range of 0 4 100%, proportional alow pressure pilot signal, in tho range ‘f 85 to 260 psl, applied at port Vi or ¥2. ‘The pilot signal, which rginatos rom an external, moto source, 's prssure only. Flow is negligible asthe plat signals only acting fn the spcol of tho contal vale This spool then dlrects contol iin and out of the contol elinder to stoke the pump as required. ‘feedback over connected to tho contol plston maintins the pup flow for any given pit signal ‘itn no command signal at Yer Ya, the conto isin the neutral (2ore fow) position preventing transmission output ‘The Rexroth TH7 remote conta, lever, and foot pedal-operated pilot valves, may bo used dlrety with this pump contr Flow a 96 of max, deihery ae Flow as % of ‘max. delivery r Pilot pressure ator Pilet pressure Alport Ys STANDARD STRORNG YES oo [aa Zero max. depl._——_(c) ta [ta Mr fp 10 210 ee) ta [2 ice seo tm) 1a [10 | Fastor or slower stroking times are possible by changing the size ofthe stroking time ociices, Manual Rotary Servo Control, Type HW “The flow output ofthe pump is infinitely vaviad in the range of 0 to 100%, proportional tothe contrat lever between O° and 92 low from the pump is reversed by moving the lover from position ‘to poston bt ‘feedback aver connected tothe corr piston mainain the pump flo or any given position af the control over betwoer 0° and 31% “The. "HWW contol is suitable for use with push-pull cables and ‘mechanical nkagos; hones, over movenont must be mechanics: Iy limited to prevent control damage. The torque required to activate the control is 198 in bs, (22 Nem), onto tver _ ‘movement STANDARO STAOKING TEST 40 [56 [90 | 105 recon a Zoro max. deol. (see) | 1.0 | 4.0 12 12. Max, dp. to zoo (see)| 10 [1.0 | 12 | 42 Orifice size (nm) Contra ever (em [08 [08 [10 [10 Movement decion 3 Faster or slower stroking times are possibi by changing the size othe stroking timo odicas, REARQTH 6 yy y r 4Control Descriptions Proportional Electric Control, Type EL. “Th flow output of tho pump is itintely vara in tho range of 0 {0 400%, proportional to an eloctical euro, in tho range of 200 + 10% fo 600 4. 104 millamps al 24 VDC, supplied to solenoid {orb (A currntof 400 + 1086 to 1200 +108 mA is roquied for tho favo soleneds) The elactcal energy is converted a free acting on the canttot p00 The spool then drets conto olin and out ofthe cont finder to stoke the pump as required. feedback lever connected {@the contro piston mairain tho pump low for any given current vthin the control ange. Even though this & proportional on: Urol, the titration requirement is tho same as the tlal pump ascomby SoveralFexroth amplifiers maybe use to provide the contol cu ‘ent o solonold aor b. The amplifier requires an external power ‘Supply of 120" 24 VDC and can be romatoly operated by moans OF pane eesti porte: "SAD STAORIG THES [0B BOS fee Sohel, — teatee! [aac max doo [10 ue ae | ta “ ian dp to ano fee) | 0 1a | 42 ta - 1» | Orifice size (mm | 08 | 08 | 10 | 10 ontol current at olen" SEEREER ‘contol current solenoid 24 ve FFastor or slower stroking times are possible by changing the size Othe stroking time orees. Also, stoking times may be varied by adjusting the ramp times on the ampli Coil Resistance Pump Size Voltage oC 40, 58,90 & 125 | _12. OC i 2a vor 26 Cols require a 100 Hz, dither Frequency with an amplitude of + {300 mA Tor 12 VDC or + 150 mA for 24 VDC. Pump Without Control Module, Type OV Pumps with dering code OV have no contol madule. The module is raplaced by a cover plate. ‘When a hycraulc pressure which i typleally supped by a remote hydraulic iit control or pressure reducing valve s applied to the Xt of Xe por, the pump will come an soko to produce a flow of ‘il out af either tha Aor B port. Pump displaement is determined by tho rasistance ofthe centring springs in the pump, the hyaraulc pressure supplied at port Xr of Xe, and tho hydrostatie contering force ofthe rotary pump which is proportional to system pressure ‘This pump canta snl a posivecsplacement conto, sins thers leno foedback botweon te stroking piso and the coniol module ‘Wpical applications for an OV conto are: a drive transmission in 4 vehicle where speed is continuously contoled by the operator ‘and smooth acceleration and deceleration is a necessity, oF fo a ‘ving conta on a crane or excavaee. Some examples of those ap plications are skidsteer leaders, industrial sweepers, municipal ‘woopors, raload equipment, fw Wactors, ar Il Tucks, Control Characteris 1. Contr piston displacement from neutral fo maximum swash angle of 15° In elther erection, Pump Sie, | 6 [0 | 1 Neutral to 15° coe ese esa era ‘wash angle 15° owash angle Bo cuted cates | trae eva enh etc Oriice sizo (mm) | 08 | o8 | 10 | 10 Faster or slower soking times are possibe by changing the sizo fol the stroking time oriices in ports Xi and Xe 28, Control pressure required at port Xs oF Xo begin stroking the pump against the centering springs wih anly charge pressure fat port A and B =87 psi (5 ba) 4. Control pressure required al port Xo Xe to aly stroke the pump against the centering springs and hydrostatic centering forces 18800 pst (400 bars) wil bo in tho 220 pel (22 bar) t0 400 psi {26 bay range depending on pump size and dive speed. NOTE: The pump swash angle for any given contro pressure bbotwoon 87 psi (6 bar) and 350 psi (24 bar) will be in yoneed by Ghanges in systom posse a port ar B GRE a 0.685 | o.987 | 1.885 | 2.22 (11.29 | 06.18) | 25.97 | 6.5) 2, Standard stroking times whon using ports X+ and Xs. REXROTHControl! Descriptions Pump Without Control Module With P.O.R., Type HM 2. Conta pressure requ a pont Xe 0X to bog stoking tho Se eeaae arene Bump ages! n cantoring Springs wih oly charge pressure “Te Hl pup conte provides the same typ of dsplacementcon- un agalns he catering spr {rol aeart OV but alo faorporos a presse sverige vate When , fhyaraulo pressure, won £8. Conol pressure requted at pot Xo Xt fy soko the pump ile pil conto rs Saint the conorng springs and Nyarostalc catering fxcos or Yap the Pam 5000 pt (00 ba wl be the 320 pa (28 bar 0400 pal Ghautl ae hd Acre pon Purp dsplacenetisdeermined (28 ba) Fange depending on pump size and drive speed, Syteresisiane ofthe catering gpangsin the pump, the hyraule NOTE: Tho pump swash angle for ary given contol pressure osu supped apt anh hyn ting ‘betwen 8 pat ( ba) and 850 pot (24 bar wl bo force of the rotary group which is proportional to system pressure. fluenced by changes in system pressure al port A or 8. ‘The pressure owrice lve (PO. vrs the svaahple angi, a8 requ iit the maximum syste prossure at port Aor 8 ‘ihoovonde ve prevents contnucs dumping ol excoesvo ow aood pressure tivaugh the cross pot ell vawes conan i tho purip, This pump cartels no pasitve displacement cone tal eeinee ne eedbck eee he oting pion an the enol made. “Hpical applications oan HM conto are: a civ transmission in 2 fencie where speed contnoauslyeonolog bythe operator find smoot acceleration sn deceleration sm neeaeshy. sft Swing conto on a rane or excavate: Some examples of these ap. Bleatons sre shieteet adr, nut swoapors, municipal Sneepers,rlroes equipment, tow actors, and it Wks. A Control Characteristics 4, Standard sicoking times when using ports X+ or Xo u Baap Ss [a0 | 66 [00 [8 iH ‘Neutr Be 70) 10 42 12) mil aa Oe : SMNMye| wo | so | a2 | isso | t) ‘Orifice size ~ ans os | ov | 10 | 10 —— Fesor or slower stoking tines ae posible by changing the size ofthe Suckag tino ones n pores ane 8 Optional Features Through Drive for Auxiliary Pump charge Purmp and Through Drive wable tment of free (Mas) + Standard SAE A, B, 8-8, and C ‘Atonble trough cre Txaue Ge) 2-bolt mounting flanges oD w + Convenient location for additional alee pump +4 + Compact dimensions * Rexroth steering pumps can be mounted to provide complete drive and steering package * Through drive can be retrofitted in 7 fx» the field charge pump // Tandem pump Length of through dive adapter: ("b" dimension) Variable pump Ana Through drive adapter Through drive | Sie | 40 [58 | 90 [125 | L, (inchos) _Distanco to contr of gravity of tandom pump ‘SAE A (Code C] 190 [224 [2.17 | ast 7 ae Jo | Bet 27 ET] tnchos) Length of though dive adapter SAE BLE (Code J) 3:76 | 402 [3.94 | 3.07 | wr (pounds) Weight of tandom pump ‘SAE C (Code Ni 495 | 524 1 Ma WH + toy Maximum Allowable Through Drive Torque: Tom (bt) ough drive | Sie | a0] 6 | 90 | 195 Allowable Moment of Force: Mou (tit) [SAE A (Code Ta | M4] 74 | ra] | Through drive "Size [ao [56 “90 | 125 SHE B (ove C Fa [ aie | tie _| ie] [SAE A (Code Cy 3¢_| 96 | 38] 70 ‘SAE 6: (Code J) jie] 118] 118_[-2aa | | SAEB Code G) a7_|-ar[s7_| 76 ‘SAE C (Code Mj) Tee [ie] [SAEBB (Code J) a7 |-s7_|_37_ [76 'SAE-C (Code M) 162_| 120 Rfor to RA06204 for more information REXROTH Snot 8Optional Features vm | eIUTRATION Fiter Connection Pot Sles - ‘The fluid should be filtered prior to system start-up and continuous ‘ets prints scion’ ond nahi aeeatnogs elt 63 ‘arts conesponde appotintey eG ess Casa Pump Sas 10 8 6 0 8 Srminmom, as beter cesniness\ewis wit syniicaniyincoaco | POTFE B14 UNF__ 7/84 UNF__-/16"12 UN ‘component life, Port Fa(G) —7/8"-14 UNF 1-1/16"-12 UNF 1-1/16"-42 UNF eLlrr—C— a ‘of Fazio, nei nea ‘the required ae IMPORTANT ea a coun go a igo HOM Neer pag F won te aap soe td a te Seraning cnr erdguo copy Sine om” Nat unger whan ne ates oy pe sharpeateiterels aie eaelsreobevae at a rr ea sua oe ee =Y" (Customer supplied) 1 Ordering Code Option Number 1 ‘With poring Yor Scion filer only (etandarc! design). Fluid cleanlinoss level 180 code 10/15, Pressure drop at fier coment fat V = 141 SBU (80 cSt) ad p Fel fi sped 15001 ba) at V = 4600 88U (1060 681) | a in 44 pi (09 ba | su a a a hs a “avs at S80 (oo eS -3 psig (08 ban) HX i theta Sa =F Fa 5 Ba, Auton fer wie! bps ad wi cpg deer CIRCUIT SCHEMATIC, OPTION NUMBER 2 eee Recommendations For External Charge Flow Filter | Owering cove Option Number 2° pcommandations ‘ee | ipl elaine Kaw ts, he option actives Set emt a 80 cove tts Sytonng te pag gur o sropacgt mh aa soapy Pn Li — sloove, This azeper seve allows allo he ad rom the charge Co tar “8 pol (3 bal burp io be passed voueh a customer supplied, exaral low Cai or apd ang Nin Yo Ns) me Fressure filer prior to being delivered Ito te closed oop ici ia port Fa () ‘A charge fw titer with bypass and wth clogging incisors recon eee ‘monded HUTES ELEMENT HUST BE CABRBLE OF WITHSIAN. SING FULL CHARGE PRESSURE WITHOUT COLLAPSING “NOTE: Ordering code option 2 is not avallable on pumps fited uth te Speed Seasing Horsepower Limiter. I option? Is foqures sien wih hrsepawar ining, an xtra tg waves hws fd. Contact Rexcah for deta Fe Ordering Code Option Number § Filter ir charge pressure loop of AMV. Fier drect mounted fo AAGY y pump. Fa(@) Contact Resrath fr dotalts and availabilty of ths option. | PRESSURE OVERRIDE With porting for pressure oreride valve (ROR), The prssure Deri valve vos Ino omachplate angles require ot the ‘aximtim press of pat Aor. The cere eb prevents cor tinuous damping of excessive flow at fad pressure ough ths ‘ros por role! valves contained i ine pum Ts enna ur ‘Nocoskary heatng othe ol and pote the pump end moto rom fenyphanded operators, oth aive sae causing the pump 0 | Ssadhend The pressure overdo wave should be ated fo 8 press 500 ps (34 bar) oss than the sting of he man ail | faves nnd have an gjsinent ange of 160-610 pat (0-420 ba). Variabo pump AAV with rycraulle manual servo control, HW with pressure ovorie valve (ROA) REXROTH 8 BESOPre-Start & Start-Up Procedure Pre-Start Procedure This should be performad prior to starLup of a now instalation, cor for systom in which new o” ovorauledl components have boon fines, 1. Ensure that hydaulle reserve piping and prossure hoses are flaanad and fished, 2. Fl the reservoir through fll pump and fer 3 If there is any doubt regarding the absolute cleanliness of the ‘system, thigh pressure bi-drectin fier nigh posure Ines 2g shawn infllowing diagram. These fiters ar inaction 10 the installed suction and rotun iter, 4. Chock tha all ters have elements of the corcact rating anc the flor housings ere filed with the Fydraulie ud to be used in the system, 5, Where passibio, i! the high pressure lines. 8. Open suction tne valves. Fl pump and motor cases tothe highest case drain or vent port (marked T ar F). 8. Check that all pressure connoctions are secur. ‘8. Ensure all mochanical gearboxos have the correct ail ype and are led 1 the prescribed level 10, Fully back of alfhigh pressure role valves and thon coset one half turn against tho spring 11, Fly back off the charge and plat prossure root vaives, and eset two Tul lus against the spring 12. Fl 10000 psi pressure gauges to each high pressure tne 13. Fil 800 psi pressure gauges to charge and pile circuits (ports Ms, Xa, as iY), 100 psi pressure gauge to pump case drain port A 15 Fitvacuum gauge to the charge pump suction ine as close 2s possible to sucton por. 16, Release brakes and jack up the diving wines, Wins should be starlad without ths cable fied 17. Ensure thatthe lid temperature in the reservoir fs 45°F: or higher Start-Up Procedure ‘Tha falling procedure has boon developed basod on experience with most types of applications, however, cortain applications may Foquito 8 departure rom, oF variations fo, this procedure. For the startup of new or overhauled installations. 1.11 the primar movor i: Irveeal combustion engine: (dese, gasoline oc LP)—Remavea the coll wr, close the injector rack o leave the gas turned of land turn the engine over unl he charge prassura roachos 50 Dsl or more Eger Motor Jog the starting circuit unt the charge pressure Feaches 50 psi ot more 2. Start tho prime mover and if possible, maintain pump speed ‘of approximately 750 rpm for 5 minutes. This will alow the ‘system to be filed 4 Liston for any abnormal noises. 4, Check for cl leaks. 5, Run prime mover to 1800 rpm, (Adjust tothe design speed it fess than 1800 rom.) 6, Set charge and pilot pressure as required for the application (Feter to circuit schematic) 7 For the HO contol, bleed the pile tines by loosening the con- nections at Yr and Yo and then acute the remote contol unit in both diroctions unt of so0ps from the connections '8. Rotighion all connections. 9. Operate contralto work the hydrostatic transmission at approx: imately 20% of maximum spaed 10, Deaaratesysiom by venting a bleed valve or by cracking the highest connection until fluid seeps out without bubbles. 41. Check lid lovel and ad ud it necessary 12, Continue operating tranemission and gradualyIneraase to fl speed, sill with no load. +3. With contols neutralized, chock for creep in neutral. evident, ‘anlar the contol in accordance wih the instructions on Pages {and 18 "4, Check thatthe contos are connected so tha the transmission ‘operas int correct diractionroltod 10 the cori input 415. Continue to monitor all prossure gauges and correct any iragularves. 16. Apply brakes and set high pressure role valves (and pressure ‘veri installed) 1 levels require forthe application by sok Ing the pump to approximately 20% of maximum dsplacemont ‘Se Pagos 19 and 20, 17. Gheck security of high pressure connections. 18. Check ol ovel and temperature. 18, Remove and inspect high pressure iter olomaonts. Replace with ew elements. 20, Operate ransmission under nooad conditions for about 15 minutes to stabiize the femporaturo and remova any residual fi Wom the tu 2. Again fomewe aa inspect high pressure iter element clean, the high pressure, bltecton Klars may be removed rom the Creu If contamination i sit evident, ft now elements and continue flushing unl the sytem i clean, 22, Replace he elements inthe charge pump suction or pressure filler, whichever is Installed. 28, Opetato tho transmission under ull and normal load conto. 24. Erac operation may indicate there is stil alr trapped inthe system. By working tho pump contol to one o both sides the remaining ar can bo eminated. Tho aytom Is fee of ak when all fntions can be operatog smooth and whion there is no foam on tho surlace ofthe olin the servo (usualy fess han ‘hour of operation) NOTE: if alter fllowing the Pre.Start and Star-Up procedures the lvansmission dos not perform correct, ror tothe rel vant sections ol the troubleshooting procedures on Pages 4,15, and 16 10Diagnostic Ports HD Control Diao GF ROATGN —cuoornst_eouNTENLOGRNEE| PILOT PRESSURE AT WY yn Ye, Postiowna nessun AT, Yokel HM | aR ouwur iow rw rom |b | a [aa wonwna eessune wr | te | we {ta | ty HW Control ineciON OF ROTTON” [Looe eninTeNCGoRNE jevtnwovemaromecran | a |v | a | rosmoune wats at [eG] Re cwwur now row ror | a | 8 | 6 [a worse eassune ar | a [te | tet EL Control DiRON OF ROTATION | Gowwist_[eouNTENBDORNE sounap oriraron [a |» |» [2 POSITION PRESSURE AH) Ko] Ra | aX | ourpur r.ow Faomromr |B | A | A | 8 oan eeasune AT [ay | a | te) Port Des ns Pressure Limits DA or ELINP Control om BRE FR [TERRE Ht SOLENOID OPERATION a[els fo | 0 Ovo b POSMONNG PRESSUREAT [%, YR G] He. Xe | a aa Ze ———— of working pnessune ar | my | me | Me | Me rn HM Control TiRECTION OF ROTATION |_CLOCKMISE_[SOUNTEROLGORWSE uO PRESSURE ar Ye POSTONING PAESSUNE AT ree | ‘OUTPUT FLOW FROM PORT | a [working PressuRe at | ts | Me | Me m | NOTE: Prossure gauge connections should be located as close as possible to the pump port being gauged. PRESSURE Lint " Beene am BEXROTHDiagnostic Ports Ro —case vent poet IN lees e"-20 UNE x1, Xe —Contol pressure ga ontiees) Al sizos 2 port (before conteol “DUNE Xs, Xa —Contol pressure gauge por (alter contro! coiees) Al sizes "he" 20 UNE A,B —Servica ports ‘Siar 40,58 SAE 24" - 6000 pst Size'90.' "SAE 1” 6000 psi Size 125 SAE f1V0"~ 6000 pa Motor sree uP Ys, Yt —omote hydraulic plot eoatral posts (HO ane HM contol only) All sizes er-10 UNE As, Bi —Auxlary service ports ‘Al'sized see -16 ONF Charge pump access port ‘Sieoa 40, $6" Yareid ONE Sizes 90, 125 ee"-12 UNF 8 —Gharge pump suction post ‘Sizes 4,90 as" 14| UNE Siee 900 )a"-12 UNF Sees 12513)" i2 UNF SIZE 40, 56, 90 SIZE 125 REXROTH 12% Troubleshooting Procedure ‘ead in roubloshooting, reer to the diagnostic port connections ‘ocles gauge insta norman, rocadue nssunos gauges aro inlaid, “This procedure was ween toad he Youbleshoate In fllowing slog! approach ton system tau 1. TRANSMISSION DOES NOT DRIVE WITH THE PRIME MOVER RUNNING. No. Fil coservot, Yes Proved to Stop 1.2 No. Engage clutch Yes Procesd to slop 13 No Coroct the piping os Proceed to Sep 1. Is thore of in tho resarval? 1.2 Is engine clutch ‘ongaged? 1.3 Is the hysiaute pip tn soonance fh te hyareutic crew? 1.4 Is the pump direction of rotation correct? ‘No Fit pump having ‘cortect direction of ‘otaton Yes Proceed to step 1. No. Provoed io stop 16. Yes Repair tho faut 1.5 Is tore a brokon Tose ting, oF Edis hose? 1.6 eo the brakes released? No Check brake release sircut oF mechanism. ‘Yes Proceed 10 stop 17 Charge Pump and Relie! Valve “U7 Is toro any obarge proasre a port? 1.8 Is the charge prossure 2 Speciicaton while, the pump running at oral operating speed? No Proceed to step 1.10 Yes Proceed to step 18 8. No. Proceed t0 step 1 Yes Proceed 10 step 119 1.9. Can the charge pressure No Proceed to step 1.10 be radjustod at tie charge Yos Adjust charge prossure to Spociteaton and brogaed fo step 18 esse roi! valve? otro rie! vale. adjustment) ose than charge pump rl for information ans sting procedura No. Open valve. Yoo Procoed ta sop 1.1 No Proceed to step 1.12 Yoo Proceed! fo step 136. 1.10 Is suction tine shut-off valve open? 4.41 Is the ergo pump. suction prossure within recommended lis? 32 psig or 83 In, ig vactum) 1.12 Ig suction filer element No Proceed! fo step 1.13. plugged? Yes Replace titer elrmant 1.19 Qoos tho eso No Coroct the osorvoie osign ensue that Satin pipe s aways covered ih ol? 1.1418 the suction pipe size adequate Tor the flow? Yes Procted to sop 4:14 No Fun at lower speed and raturn to paint 17,08 Fauwork suction piping. Yes Provood to stop 115 No. Proceed to stop 1.16 ‘Yes Claan or replace air breather 115 ts the roservoie air breather Blocked oF Undersized? 1.16 Remove charge pressure No Relit cartridge and (ollel valve carvioge and pracsed to step 1.17 Inspect st damaged?” Yos Fit a now cartudge ‘and tien 1 St9p 17. No Proceed to step 1.18 Yes Repair or replace sdamnaged components fand roturn to alop 17 Note replace charge pump 36 complete uni, 1.18 Is the eharge pump No Rott charge pump by Installed for coroct rotating pump housing ‘lection of rotation? ‘aoe. Heturn fo stop 17. Yes With proper charge pressure, and {rancmission still doos ‘ol operate, proceed fo step 118 1.17 Remove and inap thargo pump assembly, fet damaged? Pump Contrek 4.19 Is contol medium connected fo pump No. Gonnost appropiate tmocium and heck that anita? onal signals actully NO“ pitt pressure Bing applied tothe HWy—mechanical cable control wave or nk ‘os Proceed to siap 1.20. EL'T2e24 vos de ° foctica curant 1.2011 variable displacement motors are Intalled, fs maximum daplacement Seleciod? (i not done ‘automaticaly No Select maximum sdsplacement Yes Proceed to slap 1.21 4.21 Actuate the conto ‘ot coctions Does pump stroke? 1.22 Soke the pump in bath No etmowecontel module rections. Bo the land replace with now proscures at Xa and Xe Uni. Repeat sop 121 fllerate between 30 and Yes Pracaed to sep 1.23 250 psi during cycle? 1.28 g the pressure at port Files! than 21 pt No Proceed to stap 122. Yes Oporate tho transinission. No Repipe pump case drain line so thal ease pressure al pat Fis ese than 21 Ba Foturn to step. 121 ves Provead to step 12 No. Verity that loading of the ‘ump wil cause system roseure to increase Above charge pre Proceed to step 1.18 Yes Proceed 19 slop 125, No Replace high pressuro th ress oe to vale cfg ane ‘eho using te 010900 elu fo sop 12 5 gauges al Nana Mm, Yes Aust Nah posto Le sont pensive alt altos roqured otor rat vabo doa press Schisimont) Proceed sop 26 1.26 Actuate contol in both Sroctions, Dove transmission run? 4.24 Stroke pump in bath ‘rections. 00s any pressure grostor than £850 pst aterate between Ports M, and 1.25 fst possible to adjust No Check if moter sizing is ‘Sdoquate Yor application Chea for mechanical fault inthe drive beyond shall the transmission, REXROTH 13Troubleshooting Procedure 2. TRANSMISSION DRIVE IS SLUGGISH OR ERRATIC 2.1. fe the contol medium in No Ratt the cont ge condor HD-Bloed pit ‘example: contro HW—ubredte or treo Imadiam fs notin geod the cable o linkage Condon Ie HO contol _EL—“cheek control curont ain pit ines Yes Proceed 1 step 2:2 HW contral~sticking ‘able or inkage EL control—flectuating ‘conlrol curren. 22 Are the brakos fully No Chock brake reloase Feleased? reut or mechanism, Yes Brocaed to slop 23, 23 Ara the stroking time No Remove the plugs in ‘riions correctly sped ports X: ana Xsan lor the application? Femove contol orcas wi'soerann ty ested pum stoking fate atansd. Yes Proceed to step 24 No. Grange spring to suit BAA pupae 05 00 ot tr plot 2.4 With HO eonteal is the Contiol curve ol remote pilot valve corecty Iatched ta the puma? ‘pera Yes Proceed to step 25 No Procood 10 29. £25 Doos the cha vat ‘Yes Proceed to step 26. pressure fuctusta more {han 30 psi when sroking the pump? No Proceed to tap 28 Yes Proceed 19 slop 27 26 W the charge pump fulput is used to fications pressure Os 27 ‘olate he aura funtion snd rn te tranemsion re he charg pressra. fiettarane reiced orelinnaod? 2.8. Are there system Pressure fuctations linich ae synchronous win the charge pressure Tiucuations? 29 W variable displacement No. Add motor stroking time mmotgr is used, fs motor Adjustment valve to the roking me coract for arial motor or mostly No Proceed to step 28 Yes Operato transmission fand relumn 10 sop 21 No Proceed to step 28 ‘Yos Determine the cause of system pressure ihetuatons. the application? the eantat ect fo provide desired stoking 3. TRANSMISSION DRIVES IN ONE DIRECTION ONLY 3.41 With contol ines No Proceed to stop 22. 34 Check sping vo | No {Not nied) Switciod, docs pump Yes Cantal signal fom ono Instaled)- 18 shuttle spool Proceed to step 35. ‘Side does nat Work eee oceseary. No. Procged 10 stop 33, ‘Yes Problom 's inane side of control module or Sve inthe oppaste ‘roetion only? 32 With contol tines stil ‘ichod, does pump sre in fil drection nly? the pump. Procoed to step 33h 3.9. Is there contol pressure No Correct control signal ‘or current tom bath problom: ‘ona ines? Yes Procsed to step 3, Yes Remove flushing vale fand ean of roplac. No Proceed to ston 26, Yes Repair or replace rit vale on nomiving side suckin one postion 35. Switch reliot valves. Does teansmission Seve in the other ‘Seaton ony? 86. Replace control module Ho. Replace or rear pump, {nd reconnect contol i " Yes Operate tansmisslon ines, Does puny operate propery 4, TRANSMISSION DRIVES IN THE WRONG DIRt |ECTION 4.41 Pump with HD contro, Switch con nes fon pots 18 Ye ‘Switch electrical ennooirs on eolenoids wae 4.2. Pump with EL contol FRowork tinkago of cable tovgie correct drive diseton 43. Pump with HW contol 5, PUMP DOES NOT FIND OR HOLD NEUTRAL (Also refer to Pages 16 and 17.) 5.1 Does pump return 0 No. Proceed to step 52. 52. Cheok mochanial No Ropar or replace pump. Reutial wih contol” Yes Check eantol ontoring ol pomp and Yes Replace corel module fines removed? leetial signa problem ontol pr Pages 10 IMoeded, Operate {eC contoiy or Back nd 17. Dove pump transmission pressure n tho pict feturn io noutal with fines (0 conto, onto ines removed? REXROTH 14‘Troubleshooting Procedure 6. TRANSMISSION DRIVES AT A HIGH NOISE LEVEL 6.1. Aro the drive gearboxes No Fl guarbox with correct | 6.4. Is the suction prossuro filed with coeet race ft alo the at the charge pun oto Proseroes ove inet within tecommonded vos Procood to sop 62 tts? {62 Is the crive coupling No. Install couning por 6.5 fs thre ai in tha ‘corroclyInsaleg and ‘manufacturer's rahe of Ts may aligned’ instructions and oe i BB indicat by foaming tolerances, ‘or milky colorado Ys Proceed 1 sop 63 ° 86 Is the hydraule motor No. Procood to slop 6 ‘poraing a excessive ‘is Install shor ength ot Spoca? hose between pressure pots ofthe pump and fho'sytem ppg. {633 roi piping connected to the pump? No Return to step 17, Yoo Progond to slap 65 No. Proceed fo stop 66 ‘es Bosra he'd an ingpost syst for cause ov a indution Yes Chock motor sizing in Falation to avalabie ol How from the pump. 7.4 ts the oporating No 195°F Is the upper iil. | 7.4 Check diferent Temperature above If temp. fs cose to 195° pressure across al the alf cooler may need Ecoler as compared to tg be cleaned, the manufacturers specs Yes Proceed to sip 72. al charge pump Now. No Proceed 19 73 is or than it Yes Hydraulc ol belog Bae tipner nan hated through systom reli valves, Shut down System and recy cause ofthe motor stl 7.2 Is the hydraulo motor sain Inormtenty? 75. Disconnect pump case Stain rom a cool 7.3 Does temperature No Operate transmission. ‘main above 1059 Chick al costar and chock flow from Stor leaning cooler? more often. sharge pum ow Yes Proceed to step 74, ‘Forma TRANSMISSION OPERATES AT A HIGHER THAN NORMAL TEMPERATURE NOTE: Max. case pressure is 30 ps No Provead ta step 75, Yes Check piping trom oll cooler othe reserva Check: for plugged o+ ‘damaged éoater No Aeter to charge pump Femove and inspection procedure, Yes Gnack ot cooler locaton 8, PUMP DOES NOT DEVELOP MAXIMUM HORSEPOWER (FLOW & PRESSURE) No Return 1 19, 1 ts th charge pressure zi Yes Proceed to 8.2. atleast 220 ps ‘measured at port G? 8.3 Are the high pressure fell! valves acjusted {0 the required pressure [No Chock sling of rtuen Bena eY do rot 2 Is the case proseure pass? fess than 20 poi? lines trom T port of me Pump and the cooler NOTE: If presoure override valve is Eizng olated v0 ow Yes Prooed to 83 pressure setting Is sulfleient for the. application. No Adjust or ceplace rliot valve cartridge, ‘Yes Replace the puimp. lo 0 pump. cheek that 15 REXROTHMechanical Centering of Pump The conto piston has song conoting springs to ensure that ance tho pump 1s adjusted for noutral postion (wil ways return to outa fan aejustmont ie necossary flow the stops feta below Joansvo tov wil be no contol pressure at he convo} node fring the contring operation, rervave tne piping assembly. Al ‘izes require 18mm bex wrench ug the conto pressure ote port bole running the pump. Block pump ports A&B, or neal a hyeraulis motor NOTE: ‘Tho contol pressure outlet port has an MI4x15 thread. Uso a Miase1 plop (Part Nor 7611-001) or combination ot M445 10 S/16—iGUNE adapter (Part Nbr 3974-10702) and a/16—iaUNF lug, 10 lug this port during the mechanical centering operation, ‘Alternate method to neutralize contra: Instead of removing contol pipo, connect ports Xe & Xs by means ora low pressure hose, With pressura gauges installed al M, and My as per Page 12, and tn the pump tanning, foasen the fn nut aa tin the aiusting Sci neal pres charge rosie) 8 reitred an the two gauges: Alternatively, i'a hydrallle motes connected othe urn turn the austin ere nt the motor shai does net rete. Tighten the jam nut, tap the pump dive, remove the plugin the Conrl prassure pos, pen ports A&B, and relstall fhe contol pressure pipe, Alternate method: Remove te low pressure hose connecting ports Xo ie and plug ports Ka & Xe [Pump Size [_—Wrenet. 0 mm So mm 0 iamm 28 _8mm | 22mm REXROTH 16Hydraulic Centering of Control Modules HD, HW, EL Won contro! modiles are axchanged or replaced, i's gonerally nacosay conta ha naw mac Tha done by uang ths pump with gauges stl at ports Xa and Xe, and Xa By as ‘shown on Page 12, Then release the jam nut and turn the adjust: iment seroeron lop ofthe eontol meddle vale body, NoTE: ‘Tho adjustmant sere is eovenktc therelore, ursing more than 90° Inothordrecion wit have no urthercentenng elt ana may cause the contol fo bind, FOR ALL PUMP S.ZES A SMALL SCREW. DRIVER AND omm WRENCH ARE REQUINED 10 PERFORM THIS ADJUSTMENT, Centering the HD Control Module with zero plot prossure at both plot ports Yi and Yo, neutral post. tion of he HD Eontrol is correctly adusted when any or all ofthe following conditions exis 4. The hydraulic motor dows not turn when the brako is roleasod. 2. Charge pressure is ogisterd equally at ports My and My when flow output ofthe pum is Geadheaded agains’ locked motor or valve. 9. Approximately equal conto pressures are obtained at contol pressure porls Xv ang Xs Centering the HW Control Module ‘wit tho contal over allowed to feel sping to ts canter pasiin, the HW control modules carcoctly adjusted when any ors ofthe Folowing conditions exis 1. Tho hydraulic motor does not turn when the brake is released 21 Charge pressure is restored equalYy al ports My and My when Tow output ofthe pump i deadheaded gaint & locked moto! ora vale. 3. Approximately equal contol prassures are obained al contol pressure parts 0 and Xe. Centering the EL Control Module With no electrical signal to solenoids A and ® (‘move both plug in connector) tho EL contol macula ts correctly adjisted when {ny oF all of te folowing conditions exis 1, The hydraulic motor does not tun when the brake i released. 2! Charge prossure is registered equally al pols My an My when flow output ofthe purip fs deadhoaded againe 8 tacked motor ‘8 Approximatoly equal control pressures are obtained at conteot pressure ports Yo and Xe 1 ficulties are encountered in obtaining noutal position of the HD or EL conto module, check hat the Gods othe ontol spring are correctly focatod in the grooves near the end othe food sek fever arms, FEEDBACK SPRING LEVER ARM ROTHRemoval and Adjustment of Relief Valves pump | _ System Reliet TT charge rete | ‘Ste Wrench Size ‘Assembly Torque | _ Wrench Size 0 Zinm | 100 Fe Zam | so cme ory | 2 so Son arc nm ies {eo rub em Femoral ol combination high pressure elie/makeup check valvo carla new design size 90 system relate which use All relief vaive adjustments to be done with 3mm Removal of charge pressure rele! valve Ingpeot valves and goals for wear or damage. Replace sealock hl) snd O-rings i there are signs of woar or damage. Sealiock huts re inckidod in the seal Kt NOTE: Cartan clo! valves have limited adjustment ranges. Refer tothe bering eade on Page 4 or Ine rl valvo pressure range of your ump. n wrench and 10mm box wrench, except for i allen wrench and a 17enm box wreneh, ‘ajusowrt ol charge pressure rll vv. Pressure gauge pat (ftsenown on Page 12 fun pump at nermel operang speed nial and act prosaue Yo apecieaion NOTE: I pump is equpped wit f.0.8 (Presaure Overtido va {00 Pago 19 for proper scjusiment procedure REXROTH 18Adjustment of Pressure Override Valve Function of Pressure Override Tho pressure overido valvo varies the awashplate angio, as ro: quired to lint the maximum pressure al port Aor 8, The override Valve prevents. continuaus dumping of excassive flow load prossure through tho cross pot rl valves contained! in tne pump, hig olfrinates unnecessary healing f the ol and protects Ine pnp and motor om heavy-nandios operators othe drive sais caus lng the pump o deadhad. The prossure avrnice valve should bo usted to 8 prossur0 600 pales than the sting ofthe main Adjustment Procedure Following is a suggested procedure tor adjusting the ROL. IN is assumed that high pressure gauges ‘ve connected to ports My {nd My as shown on Page 12. Some apaleatione may requ & slight departure from the procedure. Block the autput fw rom tho high prossure pore A & Bo lack tho hyarautie motor by applying the brake. 2. Using'a 3mm allen wrench, turn both high pressura rele vale ‘adjusting screws counterclockwise unl the ering teneion is com Dato lieved, taan turn bath adjusting Serews one fl arm Plockwise ‘urn tho POR. adlustng crow in (locks) un tm resietanca 'g encountered. Do not force the adjustment eyand ths pain. Stroke the pump to approximately 20 percent of ful flow in ons iroction and sajust the high pressure cli! valve fr thal tow ditection toa preseure which 00 psi higher tan the required POR. pressure seting, Flopeat step 4 for the Gpposte direction of low. Nore: wy Perform steps 4 & 5 as quickly as possible to prevent avereating| ‘ofthe pump. Flow must not be permited to spl avr tho high pressurorelei valves fe longer than 10 seconds, especaly at higher pressures, 6, Neutralize the pump control and turn ROA. adjusting screw counterclockwise, all the way out 7. Stroko the pump fully inser direction, then ten the ROLR. ad justing serow i (clockwise) unt the deslod pressure eoting Is chioved, 8, Stroke the pump toc opposite tow crecton to thal used instep Frand check the operation of the POR, equal maximum pressurts should be' coun both sides f center NOTE: Allagustent ret mm allon wan an omy 1 wrench except Tor new design size 90 system relets Which ase a mm allen sirencheend tm box wrench ‘Adjusiment of POR. vaive on pumps with remote hysraulie plot Eonivol type HO, and proportional elec contra, Type EL (ius ‘Adjustment of integral POA. valve on pumps fitted with rotary ‘manual serve contol, type Hi ‘Gircit schematic of AAV hydrostatic ransmission pump with POR. HQ" contra is shown, Other contol types use. samo ROR: schematic, REXROTH 0 WORLDWIDE HYDRAULICSRemoval and Inspection of Charge Pump Before removing cap scrows, mark the positon othe charge purnp| housing and separator plato In roiatgn to the por block NOTE: ‘Charge pumps are tho samo Flowever, charge pump must be mound with correct orontaion ‘or charge pump wil nl supply of in closed top hand left hand otation pumps Lleason serowe with metric all wrench Wrench Size Pump Size (eee 40 mm allen | 56 Sm alten | 20 Simm allen 125 frm allen Remove charge pump housing and inspect fr wear or damage 10 ‘pear se and O-fing seal. Grease Oring prior to reassembly. Bo sure Oring is completely seated in groove ura pinion shat anainspet ovata and bering suraces for abnormal wea ‘when reassembling, make sute chiamfor (on outer edge ol crvon ‘geny) goes down Info charge pump housing, Torque values for bale when replacing charge pump. Pump Size Torque (in 40 220 56 200 20 220 125 440 NOTE: Terious wear or damgo has occured 1 one component, the com Diete charge pump assembiy mus be placed because ley ao Inatehned components REXROTH re)Replacement of Shaft Seal Remove the retaining ring with snap cing plas itn two secew divers, caretlly pry up on shaft seal housing to Replace O-ring and radial seal, Lubricate parts before assembly Feinstal etaining ring, NoTE: (On tho size 125 pump, use care when replacing the shat seal The 20. ofthe pump drive shat is approximately the same diameter asthe seal LD. and thereto, the seal could be damaged when ‘ling ever the spine surtaces. REXROTH 2a REXROTHRoutine Maintenance and Hydraulic Fluids Routine Maintenance Tho AAA variable pumps are coativaly.maintonancofroo, Maintonance work is canned othe fystom by way ofall changos {nd renewal of iter elements. Goth ofthese medsures promote Sysiom eloanlinass. Monitoring and porodte maintenance of tho Systom can provont promatura breakdown and ropa. Unéer no. ‘mal application eoadtions the flowing maintonanee Inovale aro suggested: 4. Renewal of Filter Elements fa. Aer commissioning ‘tr 500 operating hours th b ‘ roof foes than 2 sig (08 bar absolut} bocars oven with tho ans: £S5a fn warm running conation (ndiates cotarinaton). Win charg tow tation, watch for high peseure dite {al acroas the titer elomént (oer titer manufacturers Spectionions Caution: One elements capable of nesting or exceed elt Sones al eam a 8 sho Oe Note: Paper inserts eanno! be cleaned; use thom-awey er trdge (maintain 9 sock. 7 2. Nyaa Ol change, \ane) Alter 900 operatteg hous (ital han 3 Alter 2000 Operating hours (end-of chnge) ©. ‘Theretter every 2000 operaing Nout o anual respec {he of operating hours achieves The ollchange shouabe carried out wt he system in warm un nino condition. Bair reling, the roserwi should be cleaned to'emove any ol sudo. ‘Caution: Rags or other theading material must not be use. Note:The recommended interval between a changes is based on ‘rious factor and should bo cared out according othe ype ot ile degree of agg. and catia tine ha, The wetr Contents also cortbutoy factor Under application cantons with a heavy eeourrence of ust or Sowre amperatrelasuatons, the neraisbetweon o changes Should be Shortened aceordngh auton: racial eguvenen shows that most mantra e fore occur curing anol ehange duo 0 2 ania frau ok se oft coniaminatod dv to uly storage ©: Paiyo fo clan reserva yes 6 Tradenin laine who ing (ry runs or oats) 3. Leakage inspection 1 Aer commissioning 2. The complete ransiission (pump. mctor and al pipelines, iors, waves ote) should be chobked for loakage Bi regula intervals Gaurion: Leaking joints and connections must only bo tightened in pressureass conditions. 4, Cleanliness Inspection ‘The al tank breather should be regulary cleaned of dt and dust {oprovent clogging. The cooing surlaces should be cleaned atthe Caution: I hose couplings are used inthe high pressure tines, Icig imperative that the vimost care be taken that no foreign bodies initrte the i creut when coupling ‘and uncouping (danger of damage ta rolary gaup, ‘and oven posebllly of tla breakdown) 5. oll Love! inspection inapect ot vein reservoir ator commissioning, thereter daily Ceauson: Top up only with spect oi ype Bo mds : Hydraulic Fluids ‘Most good quality, mineral oi based, hydraulic uid exhibiting he fotoring characteristics are sutable Yor use ina ResToth hyaro- Stale transmission Good antiwoar performance Fsstant wo oxeaton dogredation Pratetion against rust and corrosion Resisiance to foaming ‘Abily 10 separate water rapidly Suitable fr wily varying temperature conditions oad ow tompertro ow propa Felans viscouiy-temperatute characteristics in service Unversaiy aval “The prime consideration inthe selection of hydraulle Mud is the expetled of temperature extremes that wl be experlented in s- Wee, These extremes shuld be considered whet selecting au otha he ast suitable tomporature—viscosy charactovsi— ire obtained “The fui chosen should port the system to operate within the folowing viscosity ranges ee ee fea " years {16-30 Si) ee \Whien the fuid viscosity ts grater than 1900 SUS (216 cSt) the \ransinision shouldbe ported af educed speed unl he of as been warmed toa tomporatuo of 40". (45°C). For applications thal wll oprato nea tho extames of viscosi ncloriomporatre, th ld manutacturer Should be conse ee fzsstance nselction othe mos! sab ype ang grade ots for your appcation Roxrath strongly recommends the soloton and use of Mids om reputable ‘and staid Suppor ROTH 22.Replacement Subassemblies & Parts Control Module Size “The servo fedack over ogi dimonsion “A vats wth pu Sim "the dmneion can MGehad to dotomine We cont Remote Hydraulic Pilot Control Module, Type HD* Pimp See Pas Wo ‘o ai 8201 so Saeraszen! © Saraszon! 125, '5451-552.001 Rot, Conta Module Manual Rotary Servo Control Module, Type HW" Pump Size Part No, 0 ‘5412 552.001 56 5122-552.001 90 5442.552.001 125 5452-55201 Proportional Electric Control Module, Type EL" Pump 24 Volt oC ‘Sze _ "part No. 40 5419-552.001| 352.008 56 5428:552.001, 5423.852.002 90 ‘5443-552.001 5443-559.002 125 5453:552.001 5455-552.002 Non-Proportional Electric Control" Pump [2a vonoo [von oc ] | ‘Size Part NO, art No, Wits ROR, 406-552-008 | 5#06-552-004 Without | saossseo01 | 5406.552.002 Without Contro! Module With P.0.R., Type HM" “Ai contol module mounting bolts equi a Smm allen wronch and a torque of 80 nibs, 23 REXROTHReplacement Subassemblies & Parts Proportional Solenoids P 24 Volt DG vor bo Part No, Part No, (03.580-001 509-580-002 Non-Proportional Solenoids Pump lt Bi 2 Volt BC ‘Size art No, art No, al ‘406-500-007 546-580-002 Plug-In Connectors ~ Solenoid B Black Color 400-005-002 Pump Solenaid A ‘Size Gray Color ‘il "400-085-008 Ammeter With Sandwich Plug Pump Sze Ta EL Gonl Conversion Kit OV Control Pump Size o ‘5404-635-001 Pressure Override Valve (P.0.R.) For HD & EL Controls includes gasket & bots) ran See Pa No. NOTE: Anew conto pipe and a high pressure pipes equited with the ROR. Those can be found on Page 25. Gasket Only (ior ROR) Pump Size i NOTE: This is no the same gaskot used on other contol mode Fas: Gontrel module gasket can bo ordered from Page 26, Manual Rotary Servo Control (HW) Module With Integral P.0.R. Pump Si [Pato sr10.ss0.002 sio0ss0.002 sueneszn2 Sas0.s52008 REXROTH REALE 24Replacement Subassemblies & Parts Control Pipe With Fittings [Howe Ww Controls contol ‘BH10-695.001 | 6412.696-007 seio-cse001 | s410.695-004 se | wiriour | s120.895001 | ~5422.636-001 with | s420.05.004 | _5420-695-004 30 | wrnour | saeo-easa01 | 542.605-007 wir | seao.ea6-004 | 5440-695-004 15 | wirkout |” 5450-65007 | s452695.001 L wit | s4s0.095.004 | _5450-635-004 High Pressure Pipe With Fittings P.O.R. To Check Valves "7 f ‘0 sa 008 i Seo ssea Moose 15 0 5.450.635.0068 Charge Pump Pump Size 40 “5410-490.001 56 5420-490-001 90 I 125 ‘5¢40-490.001 Relief Valve Cartridge $5450-490-001 Pump Main Reet ‘Charge Rolie! “Size ure Range | Part No. Part No, 6000 psi ao : [© [Hisoseiops 400-566-004 [2600-6000 55 |-2800:8000 p $5400-506-004 566.006 6-008, "2600-6000 pst 1160-4640 psi NOTE: Maximum setting on harge rele is S80 psi 125 '5440-566:006 5450-566.007 Charge Pressure Foliet Valve } Main High Pressure Rete vais / Np § 25 REXROTHReplacement Subassemblies & Parts Sleeve Adapter For External Charge Flow Filtering 15400-08001 56 $5400-083-001 ft 440-083-001 5450-083.001 Stroking Time Orifices Size | - Part No, a woe ¥ Sea Kits ee | as sisossso0 | O) 088800 Shaft Seal Only O/ 000 OO "Pump Size Part No. 0 5000-07605, 56 5000-076 021 90 5000-076015 125, 000-076-004 | Contro! Module Gasket Only Shatt Seat [Pump size | all "5400-082.001 REXROTH REA 26Through Drive Conversion Kit & Parts eee == Pump Size = Through dive a 6 0 [ne A (Code oF Sai0.036-005 540.635 008 Baa0-505000 i sai0.636.010 '5420695:010 5440.695-005 SAE 8. | ser0.8a5.011 5420635011 5440-695 012 SAE € (Code 5480.636.015 ‘Through Drive Charge Pump Adapter Flange Kit L Pump Sie Through drive “a0 I 6 0 5 [SAE A (Code 6) | Sa10-420.003 | 840-430-003 ‘5440-430-003 450-490-005 ~st10-190.004 ‘sig0c0004 | s190-400.004 450-490-000 410-490-004 5#20-400004 544-490-004 5450-490-000 ‘540-490-005 _ _Through dive 5410-696-009 '5410.695-012 ‘AE C (Code Mi NOTE: Kitincludes bots, Ovings and spline adaptor iraquired) to mount flange to though dive charge pump, 0 ‘aa0.696010 540-695-011 5140-636 013, 5440-605.014 as 5450-635-008 '5460-695-000 5460.65.01 ~sa50.695-015 | 27 REXROTHOrdering of AA4V Subassemblies For Rexroth to supply the correct parts for your unit, please include all of the following information with your parts order. TYPE CODE TYPE NUMBER SERIAL NUMBER, PART NUMBER, PART NAME Due to modifications and improvements to our products, minor changes can ogcur 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 paris for your unit are supplied. O HYDROMATIK GMBH ° ULM (DONAU) SSSR OTS) TYPE. ‘AAV90HD1A30101 NO, 239,22:45.23 SERALNO YEAR MINERAT E 1127809" 40.80 | OL WADE NW. GEAVANY ° ° ORDERING EXAMPLE To order a replacement charge pump for an AAAV hydrostatic transmission pump having the above nameplate, the following information would be required. + Type Code AAAVSOHDIRGOTOT + Type Numbor 293,22.16.23 + Serial Number 1127809 * Part Number 440-430-001 * ParName Charge pump + This information is taken from the nameplate on the pump. “This information is taken from Pages 23 through 27 of this publication. REXROTH Fomine tent 28