Re94010 01 B - 2010 09

Axial Piston Variable Pump RE 94010-01-B/09.
10
Replaces: 11.08
A7VK English
Series 10
Instruction manual
The data specified above only serve to describe
the product. No statements concerning a certain
condition or suitability for a certain application can
be derived from our information. The information
given does not release the user from the obligation
of own judgment and verification. It must be
remembered that our products are subject to a
natural process of wear and aging.
© 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 operating instructions were created in

the German language.
RE 94010-01-B/09.10 | A7VK Series 10 Bosch Rexroth AG 3/44
Contents
Contents
1 About this document.......................................................................................4
1.1 Related documents....................................................................................4
1.2 Abbreviations used....................................................................................4
2 General safety instructions............................................................................5
2.1 Intended use..............................................................................................5
2.2 Improper use..............................................................................................5
2.3 Personnel qualifications.............................................................................6
2.4 Safety instructions in this manual..............................................................6
2.5 Adhere to the following instructions...........................................................7
2.6 Operator's obligations................................................................................8
3 Delivery contents.............................................................................................9
4 Product description.......................................................................................10
4.1 Performance description..........................................................................10
4.2 Device description...................................................................................10
4.3 Product identification...............................................................................12
5 Transport and storage...................................................................................13
5.1 Transporting the axial piston unit.............................................................13
5.2 Storing the axial piston unit......................................................................15
6 Installation......................................................................................................17
6.1 Unpacking................................................................................................17
6.2 Installation conditions .............................................................................17
6.3 Installation position..................................................................................19
6.4 Installing the axial piston unit...................................................................20
7 Commissioning..............................................................................................29
7.1 First commissioning.................................................................................30
7.2 Recommissioning after standstill.............................................................32
7.3 Running-in phase.....................................................................................33
8 Operation........................................................................................................33
9 Maintenance and repair.................................................................................34
9.1 Cleaning and care....................................................................................34
9.2 Inspection................................................................................................34
9.3 Maintenance............................................................................................35
9.4 Repair......................................................................................................35
9.5 Spare parts..............................................................................................35
10 Decommissioning..........................................................................................36
11 Removal and replacement............................................................................36
11.1 Required tools..........................................................................................36
11.2 Preparing for removal..............................................................................36
11.3 Removing the axial piston unit.................................................................36
11.4 Preparing the components for storage or further use.............................. 37
12 Disposal.......................................................................................................... 38
12.1 Environmental protection.........................................................................38
13 Extension and conversion............................................................................38
14 Troubleshooting............................................................................................39
14.1 How to proceed for troubleshooting.........................................................39
14.2 Malfunction table......................................................................................40
15 Technical data................................................................................................42
16 Appendix........................................................................................................ 42
16.1 Address directory ....................................................................................42
17 Alphabetical index.........................................................................................43
4/44 Bosch Rexroth AG A7VK Series 10 | RE 94010-01-B/09.10
About this document
1 About this document

This manual contains important information on the safe and appropriate
installation, transport, commissioning, maintenance, removal and simple
troubleshooting of the A7VK series 10 axial piston variable pump.
ff Read this manual completely, especially chapter "2 General safety
instructions" on page 6, before working with the A7VK axial piston variable
pump.
1.1 Related documents

The A7VK axial piston variable pump is a system component. Also observe the
manuals for the other system components.
Further information on the A7VK axial piston variable pump, its installation and
operation can be found in the Rexroth documents listed in the following table.
Table 1: Related documents
Related
Contents
documents
Order confirmation Contains the preset technical data of your A7VK axial piston variable
pump.
Installation Contains the outer dimensions, all connections and the hydraulic
drawing circuit diagram for your A7VK axial piston variable pump. The
installation drawing can be requested from your responsible contact
person at Rexroth.
Data sheet Contains the permissible technical data for the A7VK series 10 axial
RE 94010 piston variable pump.
Also observe the generally applicable, legal or otherwise binding regulations of
the European and national legislation and the rules for accident prevention and
for environmental protection applicable in your country.
1.2 Abbreviations used

As an umbrella term for "A7VK axial piston variable pump", the designation "axial
piston unit" will be used in the following.
As an umbrella term for "polyurethane components", which are intended for
pumping through the A7VK axial piston variable pump, the designation "hydraulic
fluid" will be used in the following.
Table 2: Abbreviations
Abbreviation Meaning
A7VK Axial piston variable pump for pumping polyurethane components
DIN Deutsche Industrie Norm (German Institute for Standardization)
EC European Community
EU European Union
ISO International Organization for Standardization
MA Control, manual with handwheel
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)
General safety instructions
2 General safety instructions

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 the following general safety instructions and the warnings
before the steps contained in this manual are not complied with.
ff Read this manual completely and thoroughly before starting work with the
axial piston unit.
ff Keep this manual in a location where it is accessible to all users at all times.
ff Always include the instruction manual when you pass the axial piston unit on
to third parties.
2.1 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.
The product is intended for the following use:
The axial piston unit is only approved for pumping polyurethane components
(polyol and isocynate).
ff Observe the technical data, application operating conditions and performance
limits as specified in data sheet RE 94010 and in the order confirmation.
Information about approved hydraulic fluids can be found in data
sheet RE 94010.
ff For other hydraulic fluids, consult with Rexroth Service
(see chapter "9.5 Spare parts" for address).
The axial piston unit is only intended for professional use and not for private use.
Intended use includes having read and understood this documentation, especially
chapter "2 General safety instructions".
2.2 Improper use

Any use other than that described as intended use shall be considered as
improper and is therefore impermissible.
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, products should
only be used in safety-relevant applications if this usage is expressly specified
and approved in the documents related to the product. For example, in ex-
protection areas or in safety-related parts of a control system (functional safety).
Bosch Rexroth AG shall accept no liability whatsoever for damages resulting from
improper use. The user shall bear all risks arising from improper use.
Similarly, the following predictable faulty usages are also considered to be not as
intended:
•• Using the axial piston unit in an explosive environment
•• Pumping non-approved fluids as per the data sheet RE 94010, e.g. water.
•• Modification of factory settings by non-authorized persons
•• Using axial piston unit fittings (e.g. mountable filter, control unit, valves) for
other applications
•• Using the axial piston unit under water
•• Using the axial piston unit in aircraft or space craft
•• Using with a sustained pressure differential between exterior and interior
pressure of more than 6 bar with the exterior pressure greater than the interior
pressure (case pressure).
•• Using the axial piston unit in an aggressive atmosphere
•• Using outside the operating parameters approved in the data sheet (unless
special approval has been granted)
2.3 Personnel qualifications

Installation, commissioning and operation, removal, care and maintenance require
basic mechanical, hydraulic and electrical knowledge, as well as knowledge of the
appropriate 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 operating safety, these
activities may therefore only be performed by 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.
2.4 Safety instructions in this manual

In this manual, there are safety instructions before the steps whenever there is a
danger of personal injury or damage to equipment. The measures described for
danger prevention must be observed.
Safety instructions are structured as follows:
Signal word! Type of danger!

Consequences
ff Precautions
•• Safety signs: (warning triangle): draw attention to danger

•• Signal word: identifies the degree of the danger
•• Type of danger: identifies the type or source of the danger
•• Consequences: describes what could occur if the safety instructions are not
complied with
•• Precautions: states how the danger can be avoided.
The signal words have the following meaning:

Signal word Application
Danger! Indicates a large, impending danger which, if not avoided, will
certainly result in death or serious injury.
Warning! Indicates a potential danger which, if not avoided, could result

in death or serious injury.
Caution! Indicates a potentially hazardous situation which, if not

avoided, could result in minor or moderate injury or damage to
equipment.
If this information is disregarded, the operating procedure may

be impaired.
2.5 Adhere to the following instructions

General instructions •• Observe the regulations for accident prevention and environmental protection
for the country where the product is used and at the workplace.
•• Only use Rexroth axial piston units in good technical order and condition.
–– Inspect the product for obvious defects.
•• Do not modify or convert the axial piston unit.

•• Use the product only within the performance range provided in the technical
data.
•• Persons who install, commission, operate, remove or maintain Rexroth
products must not consume any alcohol, drugs or pharmaceuticals that may
affect their ability to respond.
•• The warranty applies only to the delivered configuration.
•• The warranty is rendered void if the product is incorrectly installed,
commissioned or operated, as well as if not used as intended and/or handled
improperly.
•• Do not expose the product to any mechanical loads under any circumstances.
Never use the product as a handle or step. Do not place/lay any objects on it.
•• 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. This can cause hearing damage.
–– Always wear hearing protection while working in the vicinity of the operating
axial piston unit.
•• The axial piston unit may heat up so much during operation that you can burn
yourself on it.
–– Allow the axial piston unit to cool down sufficiently before touching it.
–– Wear heat-resistant protective clothing, e.g. gloves.
•• There is fire hazard when using highly inflammable hydraulic fluids.

–– Keep open flames and ignition sources away from the axial piston unit.
–– Observe the information in the safety data sheet for the hydraulic fluid and the
specifications provided by the system manufacturer.
•• Contact with hydraulic fluids may cause health damage.

–– When working with hydraulic fluids, strictly observe the safety instructions
provided by the hydraulic fluid manufacturer.
During transport •• Make certain that the lifting device has adequate lifting capacity. The weight can
be found in chapter "5 Transport and storage".
During installation •• Before installation, make sure that all fluids have been removed from the axial
piston unit to prevent mixing with the hydraulic fluid used in the system.
•• Always switch the relevant part of the system so that it is non-pressurized
before you install the product. Protect the system against being energized.
•• Lay lines so that they cannot be damaged and no one can trip over them.
•• Before commissioning, make sure that all hydraulic connections are leakproof
and undamaged to prevent fluids and contaminants from penetrating the
product
•• When installing, provide for utmost cleanliness in order to prevent
contaminants, such as welding beads or metal cuttings, from getting into the
hydraulic lines and causing product wear or malfunctions.
During commissioning •• Make sure that all hydraulic connections and ports are occupied or plugged.
Only commission a completely installed product.
•• Before commencing series production, check that the hydraulic fluid, including
any additives used, is fully compatible with the axial piston unit.
During cleaning •• Plug all openings with the appropriate protective equipment in order to prevent
detergents from penetrating the system.
•• When using solvents or detergents, compatibility is to be tested in advance or
clarified with the service personnel.
•• Do not point the power washer at sensitive components, e.g. the shaft seal.
During maintenance and repair •• Perform the prescribed maintenance work at the intervals specified in the
instruction manual (see chapter "9.3 Maintenance").
•• Make certain that no lines, connections or components are disconnected
as long as the system is under pressure. Protect the system against being
energized.
During disposal •• Dispose of the product and the hydraulic fluid in accordance with the currently
applicable national regulations in your country.
2.6 Operator's obligations

The operator of the Rexroth axial piston unit must provide personnel training on a
regular basis regarding the following subjects:
•• Observation and use of the instruction manual and the legal regulations
•• Intended use and operation of the axial piston unit
•• Observation of the instructions from the factory security offices and of the work
instructions from the operator
Delivery contents
3 Delivery contents
1 1
Fig. 1: Axial piston unit A7VK open design, clockwise rotation
1
1
Fig. 2: Axial piston unit A7VK closed design
Included in the delivery contents are:

•• 1 axial piston unit
The following parts are also installed on delivery:

•• Seal screws (1)
Product description
4 Product description
Caution! Risk of damage!
The use of additives in the hydraulic fluid may affect the service life of the axial
piston unit.
ff Before commencing series production with the axial piston unit, the customer
should check that the hydraulic fluid, including any additives used, is fully
compatible with the axial piston unit.
4.1 Performance description

The axial piston unit generates and meters a hydraulic fluid flow. It is approved
for pumping polyurethane components (polyol and isocynate, referred to in the
following as hydraulic fluid).
Refer to the data sheet and order confirmation for the technical data, operating
conditions and operating limits of the axial piston unit RE 94010.
4.2 Device description

The A7VK is an axial piston variable pump of bent-axis design. There is an open
design and a closed design. Flow is proportional to drive speed and displacement.
The displacement can be steplessly varied by adjusting the tilted-axle drive.
Open design With the open design, the hydraulic fluid, which is under no or only low admission
pressure, flows from the reservoir to the hydraulic pump and is pumped from
there to the consumer, e.g. mixing head. Optional pressure safeguarding is via a
high-pressure relief valve mounted at the pressure outlet. Depending on the
direction of rotation (counter-clockwise or clockwise), there is a high-pressure and
a low-pressure side.
Closed design With the closed design, the hydraulic fluid, which is under an increased admission
pressure, flows to the hydraulic pump and is pumped from there to the consumer,
e.g. mixing head. Optional pressure safeguarding is via a high-pressure relief
valve mounted at the pressure outlet. Depending on the direction of rotation
(counter-clockwise or clockwise), there is a high-pressure and a low-pressure side
(inlet from the reservoir).
4.2.1 Assembly of the axial piston unit
2 2
3 3
1 1
4 4
5 5
6 6
8 7 8 7
Fig. 3: Assembly of the A7VK series 10, left-hand illustration – open design, right-hand illustration – closed design
Product description
1 Drive shaft 5 Cylinder

2 Tapered pistons 6 Stroke piston
3 Handwheel with position indicator 7 Lens plate
4 Adjustment spindle 8 Drive flange
For axial piston units of bent-axis design, the tapered pistons (2) are arranged
at an angle to the drive shaft (1). When the drive shaft is turned, the cylinder (5)
is picked up and set into motion cardan-free by the tapered pistons, which are
flexibly connected to the drive flange (8). The tapered pistons execute a stroke
within the cylinder, whose amplitude depends on the swivel angle (angle of tilt) of
the bent axis.
4.2.2 Functional description

Pump By turning the drive shaft (1), the cylinder (5) is set into motion by the tapered
pistons (2) arranged in a ring on the drive flange (8). The cylinder then glides over
the spherical lens plate (7), in which two kidney-shaped control slots have been
incorporated. As they turn, each of the tapered pistons moves from top to bottom
dead center and back, executing a stroke that depends on the swivel angle. On
the low-pressure side, fluid flows into the enlarging piston chamber. At the same
time, on the pressure side the fluid is pushed out of the cylinder chamber into the
system by the pistons. The tapered pistons are braced against the drive shaft by
the load of the hydraulic pressure. The variable pump pumps polyurethane
components (polyol or isocynate) to the consumer, e.g. mixing head.
High-pressure safety device A safety mechanism to prevent the maximum permissible pressure from being
(optional) exceeded should generally be provided in the system (high-pressure safety
device).
Optionally, the axial piston unit can be supplied with a high-pressure relief valve
mounted on the pressure outlet.
Control Turning the handwheel (3), which controls the swivel angle, steplessly adjusts the
angle of the tilted-axle drive and thus the displacement in the range from Vg 0 to
Vg max. Turning the handwheel clockwise results in a reduction in displacement.
Turning it counter-clockwise results in an increase in displacement.
A manual locking device, which is fitted as standard equipment, prevents
unintentional adjustment.
Position indicator The position indicator is integrated in the handwheel.
Further information on the control and position indicator can be found in data
sheet RE 94010.
Product description
4.3 Product identification

The axial piston unit can be identified from the name plate. The following example
shows an A7VK name plate:
13
14
Rexroth
DE - 89275 Elchingen
CNR: X1234567890Y
Typ: A7VKG028MA/10MRSL4P550-0
12 MNR: R90XXXXXXX SC: X 2
11 SN: 12345678 7202 3
FD: 2010W24 4
Rotation:
10 n XXXX min-1 P XXX kW m XXX kg
9 5
Made in Germany 6
7
8
Fig. 4: Name plate A7VK
1 Manufacturer 8 Barcode
2 Sample category (optional) 9 Rotational speed
3 Internal plant designation 10 Production date
4 Specified area for test stamp 11 Serial number
5 Direction of rotation (viewed from 12 Material number of the axial piston
drive shaft) – here: clockwise unit
6 Weight (optional) 13 Ordering code
7 Power 14 Customer material number
Transport and storage
5 Transport and storage
5.1 Transporting the axial piston unit
CAUTION! Risk of damage!

Striking or impulsive forces could damage the axial piston unit.
ff Do not strike the coupling or 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).
Axial piston units can be transported with a forklift truck or with a lifting device.
ff Make certain that the forklift truck or lifting device has adequate lifting
capacity.
Dimensions and weights Table 3: Dimensions and weights

Size 12 28
Weight kg 11.7 22.1
Width mm The dimensions vary with the unit type. The values applicable
for your axial piston unit can be found in the installation
Height mm
drawing (request if necessary).
Depth mm
The weight specifications may vary depending on the unit type.
Carrying the axial piston unit The size 12 axial piston unit weighs approximately 11.7 kg and can be
transported by hand if necessary.
ff Never carry the axial piston unit holding it by the handwheel or the clamping
bracket.
Axial piston units heavier than 15 kg (size 28) must be transported using a lifting
device.
Caution! Risk of personal injury and property damage!

Carrying the axial piston unit by the handwheel or clamping bracket can cause
property damage. When the axial piston unit is being carried, it could slip out of
your hands, causing injury and damage to equipment.
ff Never carry the axial piston unit holding it by the handwheel or the clamping
bracket.
ff Axial piston units heavier than 15 kg (size 28) must be transported using a
lifting device.
5.1.1 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 drive shaft can be used to transport the axial piston unit as long as only
outward (pulling) axial forces occur. Thus, you can suspend the axial piston unit
from the drive shaft.
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 each ring screw can bear the total weight of the axial piston
unit plus approx. 20%.
You can hoist the axial piston unit as shown in Fig. 5 with the ring screw screwed
into the drive shaft.
Fig. 5: Fixing the ring screw
Transport with lifting strap 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 (handwheel or clamping bracket) (see
Fig. 6).
WARNING! Risk of injury!

During transport with lifting device, the axial piston unit could fall, causing injury,
when parts (handwheel, clamping bracket) are being attached or the unit is being
tipped from the lifting strap.
ff Use the widest possible lifting strap.
ff Make sure that the axial piston unit is securely fixated with the lifting strap.
ff Never fix the lifting strap to the handwheel or the clamping bracket.
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.
Fig. 6: Transport with lifting strap

5.2 Storing the axial piston unit

Requirement •• The storage areas must be free from corrosive materials and gasses.
•• 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 intense lights.
•• Do not stack axial piston units and store them shock-proof.
•• Do not store the axial piston unit on sensitive attachment parts.
•• For other storage conditions, see Table 4.
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).
Listed in the following table are the maximum permissible storage times for an
originally packed axial piston unit.
Table 4: Storage time with factory corrosion protection

Standard corrosion Long-term
Storage conditions
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 warranty is rendered void if the requirements and storage conditions are
not adhered to or after expiry of the maximum storage time (see Table 4).
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 must be replaced.
After expiry of the maximum storage time, we recommend that you have the
axial piston unit inspected by your responsible Rexroth Service partner.
In the event of questions regarding repair and spare parts, contact your
responsible Rexroth Service partner or the service department of the
manufacture's plant for the axial piston unit, see chapter "9.5 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.
If a removed axial piston unit has to be put into storage, it must be properly
cleaned prior to a new preservation (depending on the hydraulic fluid used).
If necessary, consult with Rexroth Service (see chapter "9.5 Spare parts" for
address).
Rexroth recommends the following procedure for preserving (following

professional cleaning).
4. 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 case drain port "T1" or "T2“,
see chapter "6.4 Installing the axial piston unit", Fig. 11 to 13.
5. Seal all ports airproof.
6. Moisten the corrosion-prone surfaces of the axial piston unit with mineral oil or
a suitable, easily removed corrosion protection agent, e.g. acid-free grease.
7. Package the axial piston unit airproof together with desiccant in corrosion
protection film.
8. Store the axial piston unit so that it is protected against jolts. Further
conditions for storage can be found at the start of this section.
Installation
6 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 Rexroth)
•• Hydraulic circuit diagram for the axial piston unit (in the installation drawing)
•• Hydraulic circuit diagram for the system (available from the system
manufacturer)
•• Order confirmation (contains the preset data of the axial piston unit)
•• Data sheet for the axial piston unit (contains the technical data)
6.1 Unpacking
The axial piston unit is delivered in a corrosion protection film made of
polyethylene material (PE).
ff Dispose of the packaging according to the national regulations of your country.
CAUTION! Risk of parts falling out

If the packaging is not opened correctly, parts may fall out and damage the parts
or even result in injury.
ff Place the packaging on a flat and solid underground.
ff Only open the packaging from the top.
6.2 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).
•• Correct filling and air bleeding is necessary to prevent damage to the axial
piston unit and to maintain correct function.
ff Observe all limits specified in the data sheet, e.g. temperature, viscosity, filter
grade of the hydraulic fluid and direction of rotation.
ff Make sure that the axial piston unit is air bled and filled with hydraulic fluid
during commissioning and operation, and that the barrier fluid chambers are
filled with suitable barrier fluid. This is also to be observed following relatively
long standstill periods as the axial piston unit may empty via the hydraulic
lines.
For monitoring the shaft seals for zero leakage, we recommend connecting a
barrier fluid monitor at ports U1 to U4. See also data sheet RE 94010.
Installation
ff For the closed design, the case drain fluid in the case interior must be
drained to the reservoir via the highest case drain port. Use the line size
which is appropriate for the port. For the open design, a case drain line is not
necessary.
ff For the closed design, avoid the use of a check valve in the case drain line.
ff To achieve favorable noise values, decouple all connecting lines from all
vibration-capable components (e.g. reservoir) using elastic elements.
ff For the closed design, make certain that the case drain lines flow into the
reservoir below the minimum fluid level in all operating conditions.
ff Make sure that a minimum pressure of 1.0 bar absolute is present at the
service line port during operation and on cold starts in all installation positions
and installation locations for the axial piston pump. See data sheet for
additional values.
To prevent cavitation, we recommend monitoring the pressure in the feed line

with a pressure gauge. The filling pressure is to be calculated for the system
in question. The permissible values are available in data sheet RE 94010.
ff Utmost cleanliness is required. The axial piston unit must be installed in a

clean condition. Contamination of the hydraulic fluid can have a considerable
impact on the function and service life of the axial piston unit.
ff Do not use any cotton waste or linty cloths for cleaning.
ff Use suitable liquid detergents to remove lubricants and other difficult-to-
remove contamination. Detergents must not penetrate the hydraulic system.
Caution! Risk of damage due to lack of lubrication!

Sufficient lubrication must be guaranteed to prevent damage to the axial piston unit.
ff During installation, make certain that the axial piston unit is adequately
supplied with hydraulic fluid in all installation positions and installation
locations while in operation and on cold starts (e.g. no air intrusions).
ff Completely bleed air from the axial piston unit prior to commissioning.
ff During commissioning and during operation, the feed line must be filled with
hydraulic fluid.
Caution! Risk of damage by hydraulic fluid loss!

With unfavorable installation situations, the case interior may drain via the case
drain line after longer standstill periods (air enters via the shaft seal) or via the
service line (gap leakage). The bearings are thus insufficiently lubricated when
the pump is restarted.
ff Check the hydraulic fluid level in the case interior regularly; if necessary,
recommission.
Installation
6.3 Installation position

The following installation positions are permissible.
Other installation positions are possible after consulting with your responsible
Rexroth Service contact.
Preferred installation position: drive shaft horizontal.
1 2
T1 U T1 U
U4 U4
U3 U1 U3 U1
U2 U2
S A
T2 T2
Fig. 7: Installation position 1: open design, installation position 2: closed design
T1/T2 Filling /air bleeding case U Bearing flushing

drain port
S Suction / fill port U1 to Barrier fluid port
U4
A Service line port
Table 5: Filling and air bleeding

Installation position Air bleeding Filling
1 (open design) T1 S
2 (closed design) T1 T1
Installation
6.4 Installing the axial piston unit
Danger! Systems which are in operation pose a risk of injury!

Working on operating systems poses a danger to life and limb. The work steps
described in this chapter must only be performed on systems which are at a
standstill. Before beginning work:
ff Ensure that the engine cannot be switched on.
ff Ensure that all power-transmitting components and connections (electric,
pneumatic, hydraulic) are switched off according to the manufacturer's
instructions and are secured against being switched on again. If possible,
remove the main fuse for the system.
ff Ensure that the system is completely hydraulically relieved and depressurized.
Please follow the system manufacturer's instructions.
ff Only qualified personnel (see chapter "2.3 Personnel qualifications") are
authorized to install the axial piston unit.
6.4.1 Preparation
1. Check the delivery contents for completeness and transport damages.
2. 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 Rexroth Service for clarification, see chapter
"9.5 Spare parts" for address.
3. Before installing, drain the axial piston unit to prevent mixing with the hydraulic
fluid used in the system (see chapter "7.1.4 Performing flushing cycle").
4. Check the direction of rotation of the axial piston unit (on the name plate) and
make sure that this corresponds to the direction of rotation of the engine.
Fig. 8: Direction of rotation
L Counter-
clockwise
R Clockwise
The direction of rotation as specified on the name plate determines the

direction of rotation of the axial piston unit as viewed on the drive shaft.
For information on the direction of rotation of the engine, please refer to
the engine manufacturer's instruction manual.
Installation
6.4.2 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 components when selecting the required tools.
6.4.3 General instructions

During installation and removal of the axial piston unit, observe the following
general instructions and handling instructions:
ff Fix the axial piston unit so that the expected forces and torques can be
transferred without any danger.
WARNING! Risk of damage!

Striking or impulsive forces could damage the axial piston unit.
ff Do not strike the coupling or 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).
How to install the axial piston unit depends on the connecting elements to the
drive side. The following descriptions explain the installation of the axial piston
unit:
•• with a coupling
•• on an engine
6.4.4 Installation with coupling

How to install the axial piston unit with a coupling is described in the following:
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. Refer to
the installation drawing for the dimensions of the threaded bore.
2. Make certain that the installation location is clean and free from dirt and
contaminants.
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 onto the input according to the instructions of the coupling
manufacturer.
The axial piston unit must not be tightened down until the coupling has been
correctly installed.
Installation
6. Fix the axial piston unit at the installation location.

7. If necessary, details on the required tools and tightening torques for the fixing
screws are available from the machine or system manufacturer.
–– For bell housing installation, check the coupling axial play through the bell
window according to the manufacturer's instructions.
–– For flange installation, align the support for the axial piston unit with the
input.
8. When using flexible couplings, check that the input is free of resonance after
completing the installation.
6.4.5 Installation on an engine

How to install the axial piston unit on an engine is described in detail in the
following:
After installing on an engine, 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 axial or radial forces act on
the drive shaft of the axial piston unit (installation length).
ff Protect the spline of the drive shaft from frictional corrosion by providing
permanent lubrication.
6.4.6 Completing installation

1. Remove any mounted transport screws.
2. Remove the transport protection.
The axial piston unit is delivered with protective covers and seal screws.
These must be removed before connecting. Use appropriate tools.
3. Make certain that the sealing and functional surfaces are not damaged.
Ports that are intended for connecting lines are provided with protective
covers and seal screws, which serve as transport protection. If no connection
is made, these ports must be plugged with a suitable metal locking screw,
since the seal screw is not pressure-proof.
Installation

Operating the axial piston unit with seal screws can result in injuries or damage to
the axial piston unit.
ff Before commissioning, remove all seal screws and replace them with suitable,
pressure-proof, metal locking screws.
1 1
Fig. 9: Remove the transport protection, A7VK open design, clockwise rotation
1
1
Fig. 10: Remove transport protection, A7VK closed design
1 Seal screws
Installation
6.4.7 Hydraulically connecting the axial piston unit

The machine or 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 or system
manufacturer.

Hydraulic lines and hoses that are installed under stress create additional
mechanical forces during operation which reduce the service life of the axial
piston unit and the entire machine or system.
ff Install hydraulic lines and hoses without mechanical stress.

For axial piston pumps, a minimum permissible filling pressure at the service
line port (closed design) or port S (open design) is generally specified for all
installation positions. If the minimum filling pressure at the service line port or
port S drops below the specified values, damage may occur which may lead to
destruction of the axial piston pump.
ff Make certain that the necessary filling pressure is not undercut. This is
influenced by:
–– a suitable fill pump
–– the piping (e.g. suction cross-section, pipe diameter, length of feed line)
–– the position of the reservoir or reservoir charging
–– the viscosity of the hydraulic fluid
–– if fitted, a filter cartridge or check valve in the feed line (regularly check the
level of soiling of the filter cartridge)
Only connect suitable hydraulic lines to the service and function ports.
CAUTION! Wear and malfunctions!

The cleanliness of the hydraulic fluid has a considerable impact on the cleanliness
and service life of the hydraulic system. Any contamination of the hydraulic fluid
leads to wear and malfunctions. In particular, contaminants, such as welding
beads or metal cuttings in the hydraulic lines, may damage the axial piston unit.
ff Utmost cleanlinessis required.
ff The axial piston unit must be installed in a clean condition.
ff Make certain that all ports, hydraulic lines and add-on units (e.g. measuring
equipment) are clean.
ff Make certain that no contaminants enter when sealing the ports.
ff Make certain that no detergents enter the hydraulic system.
ff Do not use any cotton waste or linty cloths for cleaning.
ff Do not use hemp as a sealant under any circumstances.
Installation
Notes on routing the lines Observe the following notes when routing the inlet, pressure and case drain lines.
ff Make certain that the feed line (pipe or hose) is as short and straight as
possible.
ff The line cross section of the feed line is to be dimensioned so that the
minimum permissible pressure at the service line port or port S is not undercut
and the maximum permissible pressure is not exceeded.
ff Be certain that the design of all junctions is air tight and that the pressure
capability of all hoses meet specifications, also with respect to the external air
pressure.
ff With the pressure lines, make certain that the pipes, hoses and connecting
elements are approved for the operating pressure range.
ff For the closed design, always route the case drain lines so that the case
is constantly filled with hydraulic fluid and air bled and to prevent air from
entering at the shaft seal even during extended standstill periods. The case
internal pressure must not exceed the maximum values listed for the axial
piston unit in the data sheet under any operating conditions. The case drain
line in the reservoir must end up below the minimum fluid level under all
conditions (see chapter "6.3 Installation position").
The ports and fixing threads are designed for the maximum pressure specified
in the data sheet. The machine or 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.
Procedure To connect the axial piston unit to the hydraulic system:

1. Remove the locking screws at the ports at which the connections are to be
made according to the hydraulic circuit diagram.
2. Only use clean hydraulic lines or rinse out the hydraulic system with a
flushing unit before commissioning. Follow the instructions of the flushing unit
manufacturer.
3. Connect the lines according to the hydraulic circuit diagram.
Either pipes or hoses must be connected to all ports according to the
installation drawing and machine or system circuit diagram or the ports
plugged using suitable locking screws.
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.
4. Make certain that the union nuts on the fittings and flanges are tightened
correctly (observe the manufacturer's tightening torques!). Mark all checked
fittings using e.g. a permanent marker pen.
5. Make certain that the pipes and hose lines and every combination of
connecting piece, coupling or connecting point with hoses or pipes have been
inspected by a technically qualified person for safe working condition.
Installation
Port overview
U T1 U
T1 U1
U1
U3
U4
A
U2
U2 S
T2
Fig. 11: A7VK port overview, open design, clockwise rotation
U T1 U
T1 U1
U1
U3
U4
S
U2
A
U2 T2
Fig. 12: A7VK port overview, open design, counter-clockwise rotation
U T1 U
T1 U1
U1
U3
U4
B
U2
A
U2 T2
Fig. 13: A7VK port overview, closed design

Installation
Table 6: Ports, A7VK series 10

Designation Port for Standard Maximum State
pressure [bar]1)
A3) Service line DIN 38522) Clockwise: 30 O
Counter- 315
clockwise:
B3) Service line DIN 38522) Clockwise: 315 O
Counter- 30
clockwise:
A4) Service line DIN 38522) 315 O
S4) Suction / fill line DIN ISO 2282) 6 O
T1 Case drain fluid DIN 38522) 6 O5)
T2 Case drain fluid DIN 38522) 6 X5)
U Bearing flushing DIN 38522) 6 X
U1, U2 Barrier fluid DIN 38522) 36) O
U3, U4 Barrier fluid DIN 38522) 36) O
1) Short-term pressure spikes may occur depending on the application. Keep this in mind
when selecting measuring equipment and fittings.
2) The countersink may be deeper that specified in the standard.
3) Closed design only.
4) Open design only.
5) Depending on installation position, "T1" or "T2" must be connected for the closed design
(see chapter "6.3 Installation position"). With the open design, a case drain line is not
necessary, "T1" and "T2" are plugged.
6) he minimum case pressure must be equal to or greater than the barrier fluid pressure. In
T
addition, the barrier fluid pressure must be equal to or greater than the external pressure
on the outer shaft seal.
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
threaded holes and must not be exceeded. For values, see the following table.
•• Fittings:
Observe the manufacturer's instruction regarding the tightening torques of the
used fittings.
•• Fixing screws:
For fixing screws according to DIN 13/ISO 68, we recommend checking the
tightening torque in individual cases as per VDI 2230.
•• Locking screws:
For the metallic locking screws supplied with the axial piston unit, the required
tightening torques of locking screws MV apply. For values, see the following
table.
Fig. 14: Table 7: Tightening torques of the internal threaded holes and locking screws
Ports Maximum permissible
Required tightening torque Size of hexagon socket for
tightening torque of the
Standard Thread size of the locking screws MV the locking screw
threaded holes MG max
DIN 3852 M10 x 1 30 Nm 12 Nm 5 mm
M12 x 1.5 50 Nm 25 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
M27 x 2 330 Nm 135 Nm 12 mm
DIN ISO 228 G1 1/4 720 Nm – –
G1 1/2 960 Nm – –
Installation
Risk of mix-ups with threaded The axial piston units are used in application areas with metric as well as with
connections Imperial systems of units.
Both the system of units and the size of threaded hole 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! Risk of personal injury and property damage!

If a threaded plug which is of a different measurement system and size with
respect to the threaded hole 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 locking screws.
ff For all threaded holes, use a threaded plug from the same system of units and
of the correct size.
Commissioning
7 Commissioning
Warning! Danger while working in the danger zone of a machine or system!
It is not permissible to work in the danger zone of a machine or system.
ff The machine or system must only be operated if safe working is ensured.
ff Pay attention to and rectify potential danger sources before operating the
machine or system.
ff Nobody may stand in the danger zone of the machine or system.
ff The emergency stop button for the machine or system must be within the
operator's reach.
ff Always follow the instructions of the machine or system manufacturer during
commissioning.

Commissioning of the axial piston unit requires basic mechanical and hydraulic
knowledge.
ff Only qualified personnel (see chapter "2.3 Personnel qualifications") are
authorized to commission the axial piston unit.
WARNING! Risk of toxication and injury!

Contact with hydraulic fluids may cause health damage (e.g. eye injuries, skin
damage, toxication upon inhalation).
ff Always check the lines for wear and damage before each commissioning.
ff While performing these checks, wear safety gloves, safety glasses and
suitable working clothes.
ff If hydraulic fluid should, nevertheless, come into contact with your eyes or
penetrate your skin, consult a doctor immediately.
ff When working with hydraulic fluids, strictly observe the safety instructions
WARNING! Fire hazard!

There is fire hazard when using highly inflammable hydraulic fluids.
ff Keep open flames and ignition sources away from the axial piston unit.
ff Observe the information in the safety data sheet for the hydraulic fluid and
the specifications provided by the system manufacturer.
Commissioning
7.1 First commissioning
CAUTION! Risk of damage to the product!

Any contamination of the hydraulic fluid leads to wear and malfunctions. In
particular, contaminants, such as welding beads or metal cuttings in the hydraulic
lines, may damage the axial piston unit.
ff Ensure utmost cleanliness during commissioning.
ff Make certain that no contaminants penetrate when plugging the gauge ports.
Caution! Risk of damage to the product!

If you commission the axial piston unit without or with insufficient hydraulic fluid,
the axial piston unit will be damaged immediately, possibly beyond repair.
ff When commissioning or recommissioning a machine or system, make sure
that the case interior and the feed and service lines of the axial piston unit are
filled with hydraulic fluid and remain filled during operation
When commissioning the axial piston unit, observe the general safety
instructions and notes about the intended use provided in chapter "2 General
safety instructions".
ff Connect the pressure gauge to the measurement points provided for operating
pressure, case pressure and filling pressure to allow the technical data to be
checked during initial operation.
7.1.1 Filling the axial piston unit

You will require a tested hydraulic fluid: The axial piston pump is approved for
pumping polyurethane components (polyol and isocynate). For permissible
temperatures, see the data sheet RE 94010.
Caution! Risk of damage due to lack of lubrication!

Sufficient lubrication must be guaranteed to prevent damage to the axial piston
unit.
ff Check the hydraulic fluid level in the case interior regularly; if necessary,
recommission. With unfavorable installation situations, the case interior may
drain via the case drain line after longer standstill periods (air enters via
the shaft seal) or via the service line (gap leakage). The bearings are thus
insufficiently lubricated when the pump is recommissioned.
ff Make certain that the feed line is always filled with hydraulic fluid during
commissioning and operation.
If possible, fill the axial piston unit with a filling device. The axial piston unit
must not be operated while it is being filled.
Commissioning
Caution! Danger of environmental contamination!

The discharge or spillage of hydraulic fluid while filling the axial piston unit can
lead to environmental pollution and contamination of the groundwater.
ff When filling and changing the hydraulic fluid, always place a drip tray under
the axial piston unit.
ff Observe the information in the safety data sheet for the hydraulic fluid and the
specifications provided by the system manufacturer.
1. Fill and air bleed the axial piston unit via the appropriate ports, see chapter
"6.3 Installation position". The hydraulic lines of the system must also be filled.
2. Test the direction of rotation of the engine. To do this, rotate the engine briefly
at the lowest rotational speed (inching). Make sure that direction of rotation of
the axial piston unit matches the details on the name plate, see also chapter
"4.3 Product identification", Fig. 4: Name plate.
3. Operate the axial piston pump at the lowest speed (starter speed for
combustion engines or inching operation for electric motors) until the pump
system is completely filled and air bled. To inspect, drain the hydraulic fluid
at the case drain port for the closed design and wait until it drains without
bubbles.
4. Make certain that all ports are either piped up or plugged according to the
general circuit diagram.
7.1.2 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
with the closed design, 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 engine to run at the lowest speed. The axial piston unit must be
operated without load. Pay attention to leakage and noise.
2. For the closed design, check the case drain line of the axial piston unit here.
The case drain fluid should not contain any bubbles.
3. Increase the load and check whether the operating pressure rises as
expected.
4. Check the filling pressure at the service line port or port S of the axial piston
pump. Refer to data sheet RE 94010 for the permissible value.
5. For the closed design, check the case drain pressure at connected port "T1" or
"T2”. Refer to data sheet RE 94010 for the permissible value.
Commissioning
7.1.3 Performing functional test
Warning! Risk of injury in case of incorrectly connected machine or system!

Interchanging the ports will cause malfunctions resulting in danger for persons
and equipment.
ff When connecting hydraulic components, observe the specified piping
according to the hydraulic circuit diagram of the machine or system
manufacturer.
Once you have tested the hydraulic fluid supply, you must perform a functional
test on the machine or system. The functional test should be performed according
to the instructions of the machine or system manufacturer.
ff In particular, check whether the axial piston unit builds up pressure after the
engine is started and that the case pressure does not rise to an impermissible
level.
ff If necessary, remove the pressure gauge and plug the ports so that they are
airproof.
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 in accordance with the design of the machine or system.
7.1.4 Performing flushing cycle

In order to remove foreign bodies from the system, Rexroth recommends a
flushing cycle for the entire system.
During the flushing cycle, the axial piston unit must be operated without load.
The flushing cycle can be performed, e.g. by using an additional flushing unit.
Follow the instructions of the flushing unit's manufacturer for the exact
procedure during the flushing cycle.
7.2 Recommissioning after standstill

Depending on the installation conditions and ambient conditions, changes may
occur in the system which make recommissioning necessary.
Among others, the following criteria may make recommissioning necessary:
•• Air in the hydraulic system
•• Water in the hydraulic system
•• Old hydraulic fluid
•• Other contamination
ff Before recommissioning, proceed as described in chapter "7.1 First

commissioning".
Operation
7.3 Running-in phase

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.
Caution! Risk of damage by insufficient viscosity!

The increased temperature of the hydraulic fluid during the running-in phase can
cause the viscosity to drop to an impermissible level.
ff Monitor the operating temperature during the running-in phase.
ff Reduce the loading (pressure, rpm) of the axial piston unit if impermissible
operating temperatures and/or viscosities occur.
8 Operation
Use the product only within the performance range provided in the technical
data. The machine or system manufacturer is responsible for the proper project
planning of the hydraulic system and its control.
8.3.1 Adjusting the displacement

Turning the handwheel steplessly adjusts the displacement in the range from
Vg 0 to Vg max. Turning the handwheel clockwise in a reduction in displacement.
Turning it counter-clockwise results in an increase in displacement.
A manual locking device, which is fitted as standard equipment, prevents
unintentional adjustment. A position indicator is integrated in the handwheel.
Additional information about this topic can be found in chapter "4 Product
description".
No other adjustments or modifications are necessary.
Maintenance and repair
9 Maintenance and repair
9.1 Cleaning and care
Caution! Damage to the surface caused by solvents and aggressive detergents!

Aggressive detergents may damage the seals on the axial piston unit and cause
them to age faster.
ff Avoid the use of solvents or aggressive detergents.
ff When using solvents or detergents, compatibility is to be tested in advance or
clarified with the service personnel.
Caution! Damage to the hydraulic system and the seals!

The water pressure of a power washer could damage the seals of the axial piston
unit.
ff Do not point the power washer at sensitive components, e.g. the shaft seal.
For cleaning and care of the axial piston unit, observe the following:
ff Plug all openings with suitable protective caps/devices.
ff Check that the ports are free of leaks to ensure that no moisture can penetrate
the axial piston unit during cleaning.
ff Only clean the axial piston unit with tested detergent.
ff Remove any coarse dirt on the outside and keep sensitive components clean.
9.2 Inspection
In order to enable long and reliable operation of the axial piston unit, Rexroth
recommends testing the hydraulic system and axial piston unit on a regular basis
and documenting the following operating conditions:
Table 7: Inspection schedule
Tasks to be performed Interval
Hydraulic system Check level of hydraulic fluid in the reservoir. continuous
Check operating temperature weekly
(comparable load condition).
Perform a hydraulic fluid analysis: as per
viscosity, aging, contamination specifications of
hydraulic fluid
manufacturer
Axial piston unit Check barrier fluid level continuous
Check axial piston unit for external leakage. daily
Early detection of hydraulic fluid loss can
help to find faults on the machine or system
and to rectify them. For this reason, Rexroth
recommends that the axial piston unit and
system always be kept in a clean condition.
Check axial piston unit for noise development. daily
Check fasteners for tight seating. monthly
All fasteners have to be checked when the
system is switched off, non-pressurized and
cooled down.
Maintenance and repair
9.3 Maintenance
The axial piston unit is low maintenance when used as intended.
Changes in the case drain flow indicate wear in the axial piston unit. For this
reason, for the closed design we recommend that the case drain quantity be
measured and documented at regular intervals. This will enable unscheduled
wear in the axial piston unit to be detected at an early stage and thus enable the
cause to be rectified quickly.
9.4 Repair
Rexroth offers a comprehensive range of services for the repair of Rexroth axial
piston units.
Repairs to the axial piston unit may only be performed by authorized, skilled and
instructed personnel.
ff Only use genuine spare parts from Rexroth for repairing the Rexroth axial
piston units.
ff Only send completely empty and cleaned axial piston unit back to Rexroth
Service.
Tested and pre-installed original Rexroth assembly groups allow for successful
repair requiring only little time.
9.5 Spare parts
CAUTION! Danger of personal injury and damage to equipment due to faulty spare
parts!
Spare parts that do not meet the technical requirements specified by Rexroth may
cause personal injury or property damage.
ff Use only original spare parts from Rexroth.
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 Rexroth Service
partner or the service department of the manufacture's plant for the axial piston
unit.
Rexroth is obliged to supply spare parts to the system or equipment
manufacturer.
Bosch Rexroth AG
Glockeraustraße 4
89275 Elchingen, Germany
Tel. +49-7308-82-0
Fax +49-7308-72-74
[email protected]
For the addresses of foreign subsidiaries, please refer to

www.boschrexroth.com/addresses
Decommissioning
10 Decommissioning
The axial piston unit is a component that does not require decommissioning.
For this reason, this chapter of the manual does not contain any information.
For details about how to remove or replace your axial piston unit, please refer
to chapter "11 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
WARNING! Risk of injury if removing under pressure!

If you do not switch off pressure before removing the product, you may get injured
or the device or system components may be damaged.
ff Make sure that the relevant system components are non-pressurized.
1. Decommission the entire system as described in the overall manual for the
machine or system.
2. Relieve the hydraulic system according to the instructions of the machine or
system manufacturer.
11.3 Removing the axial piston unit

Proceed as follows to remove the axial piston unit:
1. Make sure that the hydraulic system is non-pressurized.
2. Check whether the axial piston unit has cooled down far enough so that it can
be removed without danger.
3. Place a drip tray under the axial piston unit to collect any hydraulic fluid that
may escape.
WARNING! Risk of toxication and injury!

Contact with hydraulic fluids may cause health damage (e.g. eye injuries, skin
damage, toxication upon inhalation).
ff While performing these checks, wear safety gloves, safety glasses and
suitable working clothes.
ff If hydraulic fluid should, nevertheless, come into contact with your eyes or
penetrate your skin, consult a doctor immediately.
ff When working with hydraulic fluids, strictly observe the safety instructions
Removal and replacement
Caution! Danger of environmental contamination!

The discharge or spillage of hydraulic fluid while removing the axial piston unit
can lead to environmental pollution and contamination of the groundwater.
ff When draining the hydraulic fluid, always place a drip tray under the axial
piston unit.
ff Observe the information in the safety data sheet for the hydraulic fluid and
the specifications provided by the system manufacturer.
4. Loosen the lines and collect the escaping hydraulic fluid in the vessel.
5. Remove the axial piston unit. Use an appropriate lifting device.
6. Completely empty the axial piston unit.
7. Plug all openings.
11.4 Preparing the components for storage or further use

ff Proceed as described in section "5.2 Storing the axial piston unit".
Disposal
12 Disposal
Observe the following points when disposing of the axial piston unit:
1. Completely empty the axial piston unit.
2. Dispose of hydraulic fluid in compliance with the national regulations of your
country and in accordance with the safety data sheet for the hydraulic fluid.
3. Remove the axial piston unit into its individual parts and properly recycle these
parts.
4. Separate parts by:
–– Cast parts
–– Steel
–– Non-ferrous metal
–– Electronic waste
–– Plastic
–– Seals
12.1 Environmental protection

Careless disposal of the axial piston unit, the hydraulic fluid and the packaging
material could lead to pollution of the environment.
ff Therefore, dispose of the axial piston unit, the hydraulic fluid and the
packaging material in accordance with the currently applicable regulations in
your country.
ff Dispose of hydraulic fluid residues according to the applicable safety data
sheets for these hydraulic fluids.
13 Extension and conversion

Do not convert the axial piston unit.
The warranty from Rexroth only applies to the delivered configuration. In case
of extensions or conversions, the warranty will become void.
Troubleshooting
14 Troubleshooting
The following tables may assist you in troubleshooting. The tables make 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 changing of settings could result in the inability to
ascertain the original error 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?
–– Were there any changes or repair works on the complete system
(machine / system, electric works, control) or on the product? If yes, which?
–– Was the hydraulic fluid changed?
–– Were the product and machine used as intended?
–– How did the malfunction appear?
ff Try to get a clear idea of the error cause. Directly ask the (machine) operator.
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 8: Malfunction table - A7VK variable pump
Malfunction Possible cause Remedy
Unusual noises Drive speed too high. Machine or system manufacturer.
Wrong direction of rotation. Ensure correct direction of rotation.
Inadequate feed conditions, e.g. air in the Machine or system manufacturer (e.g. optimize
feed line, insufficient diameter of the feed line, inlet conditions, use suitable hydraulic fluid).
viscosity of the hydraulic fluid too high, filling
Completely air bleed axial piston unit, fill feed
pressure too low, contaminants in the feed line.
line with hydraulic fluid.
Remove contaminants from the feed line.
Improper fixing of the axial piston unit. Check fixing of the axial piston unit according
to the specifications of the machine or system
manufacturer. Observe tightening torques.
Improper fixing of the attachment parts, e.g. Fix attachment parts according to the
coupling and hydraulic lines. information provided by the coupling or fitting
manufacturer.
Malfunction of the pressure relief valves of the Air bleeding the axial piston unit
axial piston unit (boost pressure, high pressure). Check viscosity of the hydraulic fluid
Contact Rexroth Service.
Mechanical damage to the axial piston unit Exchange axial piston unit, contact Rexroth
(e.g. bearing damage). Service.
No or insufficient flow Faulty mechanical input Machine or system manufacturer.
(e.g. defective coupling).
Drive speed too low. Machine or system manufacturer.
Hydraulic fluid not in optimum viscosity range. Use suitable hydraulic fluid (machine or system
manufacturer).
Manual control device incorrectly set. Check the adjustment of the handwheel and the
position indicator. Pull locking lever tight.
The value in the position indicator is not correct. Check value of the indicator; while turning
counter-clockwise, the stop must turn back
to "0".
Malfunction in axial piston unit control device. Contact Rexroth Service.
Wear of axial piston unit. Exchange axial piston unit, contact Rexroth
Service.
Mechanical damage to the axial piston unit. Exchange axial piston unit, contact Rexroth
Service.
Troubleshooting
Table 8: Malfunction table - A7VK variable pump

Malfunction Possible cause Remedy
No or insufficient pressure Faulty mechanical input Machine or system manufacturer.
(e.g. defective coupling).
Drive power too low. Machine or system manufacturer.
Hydraulic fluid not in optimum viscosity range. Use suitable hydraulic fluid (machine or system
manufacturer).
Manual control device incorrectly set. Check the adjustment of the handwheel and the
position indicator. Pull locking lever tight.
The value in the position indicator is not correct. Check value of the indicator; while turning
counter-clockwise, the stop must turn back
to "0".
Malfunction in axial piston unit control device. Contact Rexroth Service.
Service.
Mechanical damage to the axial piston unit Exchange axial piston unit, contact Rexroth
(e.g. bearing damage). Service.
Output unit defective Machine or system manufacturer.
(e.g. hydraulic motor or cylinder).
Pressure/flow fluctuations Axial piston unit not or insufficiently air bled. Completely air bleed axial piston unit.
Hydraulic fluid temperature too high Excessive inlet temperature at the axial piston Machine or system manufacturer: inspect
unit. system, e.g malfunction of the cooler,
insufficient hydraulic fluid in the reservoir.
Malfunction in pressure control valve Contact Rexroth Service.
(e.g. high-pressure relief valve).
Service.
Instability/vibrations Setpoint value not stable. Machine or system manufacturer.
Resonance in the case drain line. Machine or system manufacturer.
Malfunction of the control device. Contact Rexroth Service.

Technical data
15 Technical data
The technical data of your axial piston unit can be found in
data sheet RE 94010.
The data sheet can be found on the internet at
www.boschrexroth.com/industrial-hydraulics-catalog
The preset 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 R
Abbreviations 4 Related documents 4
Address directory 42 Removal 36
Appendix 42 Performing 36
Preparing 36
Repair 35
C Replacement 36
Carrying 13 Ring screw 14
Connecting
Hydraulic 24
Conversion 38 S
Safety instructions 6
Spare parts 35
D Storage 15
Decommissioning 36
Dimensions 21
T
Technical data 42
E Transport 13
Environmental protection 38 With lifting device 14
Troubleshooting 39
F
Filling 30 U
Flushing cycle 32 Unpacking 17
Functional description
Control 11
High-pressure safeguarding 11 W
Position indicator 11 Waste disposal 38
Pump 11 Weight 13
H
Hydraulic fluid 30
I
Inspection 34
Installation 17
Completing 22
General instructions 21
On an engine 22
Preparation 20
With coupling 21
Installation conditions 17
Installation position 19
Installing 20
L
Lifting device 13
M
Maintenance 34, 35
Malfunction table 40
P
Position indicator 11
Bosch Rexroth AG
Hydraulics
Axial piston units
Glockeraustraße 4
89275 Elchingen, Germany
Tel. +49 (0) 73 08-82-0
Fax +49 (0) 73 08-72 74
[email protected]
www.boschrexroth.com/brm
Printed in Germany
RE 94010-01-B/09.10

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Axial Piston Variable Pump RE 94010-01-B/09.

© This document, as well as the data,

The cover shows an example application. The

The original operating instructions were created in

About this document

1 About this document

1.1 Related documents

1.2 Abbreviations used

General safety instructions

2 General safety instructions

2.1 Intended use

2.2 Improper use

General safety instructions

2.3 Personnel qualifications

2.4 Safety instructions in this manual

Signal word! Type of danger!

•• Safety signs: (warning triangle): draw attention to danger

General safety instructions

The signal words have the following meaning:

Warning! Indicates a potential danger which, if not avoided, could result

Caution! Indicates a potentially hazardous situation which, if not

If this information is disregarded, the operating procedure may

2.5 Adhere to the following instructions

•• Do not modify or convert the axial piston unit.

•• There is fire hazard when using highly inflammable hydraulic fluids.

•• Contact with hydraulic fluids may cause health damage.

General safety instructions

2.6 Operator's obligations

Fig. 1: Axial piston unit A7VK open design, clockwise rotation

Fig. 2: Axial piston unit A7VK closed design

Included in the delivery contents are:

The following parts are also installed on delivery:

4.1 Performance description

4.2 Device description

4.2.1 Assembly of the axial piston unit

1 Drive shaft 5 Cylinder

4.2.2 Functional description

4.3 Product identification

Fig. 4: Name plate A7VK

Transport and storage

5 Transport and storage

5.1 Transporting the axial piston unit

CAUTION! Risk of damage!

Dimensions and weights Table 3: Dimensions and weights

Caution! Risk of personal injury and property damage!

Transport and storage

5.1.1 Transporting with lifting device

Fig. 5: Fixing the ring screw

WARNING! Risk of injury!

Fig. 6: Transport with lifting strap

Transport and storage

5.2 Storing the axial piston unit

ff Check the axial piston unit monthly to ensure proper storage.

Table 4: Storage time with factory corrosion protection

Procedure after expiration of the maximum storage time:

Transport and storage

Rexroth recommends the following procedure for preserving (following

CAUTION! Risk of parts falling out

6.2 Installation conditions