HYDROTRAC GFT. Drive unit with integrated axial-piston motor A32VT RE B/ Replaces:. English. General Operating Instructions

Transcription

1 HYDROTRAC GFT Drive unit with integrated axial-piston motor A32VT 2000 series General Operating Instructions RE B/ Replaces:. English

2 The data specified above serve to describe the product. If there is also information on the intended use, it is meant only as examples of use and suggestions. Catalog information does not constitute guaranteed properties. The information given does not release the user from obligation of own judgment and verification. 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 brand, product and company names, which are mentioned in this operating instructions, are registered trademarks of their respective owners. The copying or changing of products with registered trademarks is not permitted without the permission of the respective owner. A CE marking of the gearboxes as well as the EC declaration of conformity are not necessary, because the gearboxes are not a machine for the purposes of the EC-machine directive. An example configuration is shown on the title page. The delivered product may, therefore, differ from the product which is pictured. The original operating instructions were created in the German language.

3 RE B/ General Operating Instructions HYDROTRAC GFT2000 Bosch Rexroth AG 3/58 Contents Contents 1 About this documentation Validity of the documentation Required and supplementary documentations Presentation of information Safety instructions Symbols Terminology Abbreviations Safety instructions About this chapter Intended use Improper use Qualification of Personnel General safety instructions Product-dependent safety instructions Personal Safety Equipment (PSA) General information concerning damage to property and product damages 13 4 Scope of supply About this product Performance description Product description Parking brake Product overview Identification of the product Standard name plate Transport and storage Transporting the HYDROTRAC GFT Storage the HYDROTRAC GFT Preservation Storing in ventilated Rooms Storing in air conditioned Rooms Long-term Preservation Assembly Unpacking Installation conditions Installation position Sub-tank assembly (standard) Required tools Assembling the HYDROTRAC GFT Preparing assembly Installing the drive unit in the machine or vehicle frame Connecting the drive unit integrated axial-piston motor to the hydraulic system Performing a flushing cycle Completing assembly Commissioning Initial commissioning... 32

4 4/58 Bosch Rexroth AG General Operating Instructions HYDROTRAC GFT 2000 RE B/ Contents Initial commissioning the integrated axial-piston Filling the integrated axial-piston motor Testing the hydraulic fluid supply Performing a function test Before filling the planetary gearbox Filling the planetary gearbox with lubricating oil Filling lubricating oil via the oil filler opening Completing commissioning and run-in period Recommissioning after standstill Operation Servicing and repair Cleaning and care Inspection Visual inspections Checking the oil level of the planetary gearbox Acoustic inspections Checking and tightening screw connections Maintenance schedule drive unit Maintenance Checking the lubricating oil/hydraulic fluid quality Recommended lubricating oil Changing the lubricating oil Static multiple-disk parking brake Repair Spare parts Decommissioning Disassembly and replacement Required tools Preparing the disassembly Disassembling the drive unit from the machine or vehicle frame Preparing the drive unit for storage/reuse Disposal Environmental protection Extension and conversion Troubleshooting and fault correction Troubleshooting procedure Technical data Appendix... 56

5 RE B/ General Operating Instructions HYDROTRAC GFT2000 Bosch Rexroth AG 5/58 About this documentation 1 About this documentation 1.1 Validity of the documentation This documentation is valid for the following product: HYDROTRAC GFT 2000 series / Drive unit with integrated axial-piston motor A32VT For simplification purposes, the product is referred to as HYDROTRAC GFT 2000 drive unit or as drive unit in the following chapters. This documentation addresses installers/service technicians/machine or vehicle operators. This documentation contains important information on the safe and appropriate transport, storage, assembly, commissioning, operation, use, maintenance, disassembly and simple troubleshooting of the drive unit. Please read this documentation, and in particular chapter 2 Safety Instructions and chapter 3 General information concerning damage to property and product damages, prior to working with the drive unit. 1.2 Required and supplementary documentations Please only commission the drive unit once the documentation marked, with the book icon, has been made available to you and make sure you have read, understood and followed it. Tabelle 1: Required and supplementary documentations Description Document type Material number specific operating instructions Operating instructions (included within Rexroth's scope of supply) 1.3 Presentation of information So that you can work with this documentation fast and with certainty when using your drive unit, uniform safety instructions, icons, terminology and abbreviations are being used. For better understanding, these are explained in the following sections.

6 6/58 Bosch Rexroth AG General Operating Instructions HYDROTRAC GFT 2000 RE B/ About this documentation Safety instructions In this documentation, safety notes are located in chapter 2.6 Product-dependent safety instructions and in chapter 3 General information concerning damage to property and product damages, as well as before any sequence of actions, or sequence of instructions, where there is a danger of damage to persons or property. The measures described for avoiding hazards must be observed. The safety instructions are structured as follows: SIGNAL WORD Type and source of danger Consequences in the case of non-compliance Measures for danger aversion <List> Warning symbol: draws attention to the danger Signal word: identifies the degree of the danger Type and source of danger: identifies the type and source of danger Consequences: describes what occurs if the safety instructions are not complied with Precautions: states how the danger can be avoided. Tabelle 2: Danger categories according to ANSI Z Warning symbol, signal word Meaning DANGER WARNING CAUTION NOTE identifies a dangerous situation where death or serious personal injury will result if it is not avoided identifies a dangerous situation where death or serious personal injury may result if it is not avoided identifies a dangerous situation where mild to medium personal injury will result if it is not avoided identifies damage to property: The product or the environment can get damaged Symbols The following symbols identify information which is not relevant for safety, however, does increase the coherency of the documentation. Tabelle 3: Meaning of symbols Symbol Meaning If this information is not observed, the product cannot be optimally used and/or operated individual, independent action step numbered action instructions: The figures show that the action steps follow on each other.

7 RE B/ General Operating Instructions HYDROTRAC GFT2000 Bosch Rexroth AG 7/58 About this documentation Terminology The following terminology is used in this documentation: Tabelle 4: Terminology Name Meaning HYDROTRAC GFT 2000 Registered trademark G = Gearbox F = Drive T = Turas (sprocket) 2000 = Series A32VT SHELL S 7294 Tectyl 502 C-EH Tectyl 150 Screw plug Guard plug Integrated axil-piston variable motor, open circuit Mineral oil Preserving agents Detergent to remove preserving agents Metallic screw, pressure-resistant made of plastic, not pressure-resistant, only for transport Abbreviations The following abbreviations are used in this documentation: Tabelle 5: Abbreviations Abbreviation Meaning RE RDE DIN ISO SAE JIS PSA Rexroth-Document in English Language Rexroth-Document in German (D) and English Language Deutsche Industrie Norm (German Industrial Standard) International Organization for Standardization Society of American Engineers Japanese Industrial Standard Personal Safety equipment (A)

8 8/58 Bosch Rexroth AG General Operating Instructions HYDROTRAC GFT 2000 RE B/ Safety instructions 2 Safety instructions 2.1 About this chapter The HYDROTRAC GFT 2000 drive unit was produced according to the generally approved good engineering practice. 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 these instructions are not complied with. Read this documentation thoroughly and completely before working with the HYDROTRAC GFT drive unit. Keep the documentation in a place where it is accessible at all times to all users. When passing on the drive unit to third parties, always do so together with the required documentation. 2.2 Intended use The drive unit is a subassembly. You may only use the product as follows: as travel drive in a tracked vehicle Observe the operating conditions and power limits as mentioned in the technical data sheet. For this refer to the material number-specific operating instructions. The drive unit is intended only for professional use and not for private use. Intended use includes that this documentation, especially chapter 2 Safety instructions has been read and understood. 2.3 Improper use Any use other than described in chapter 2.2 Intended use is not in accordance with the requirements and, therefore, is not permitted. Bosch Rexroth AG assumes no liability for damage resulting from improper use. The risks associated with improper use are with the user alone. Improper use of the drive unit includes: the use of the drive unit in other applications than described in chapter 2.2 Intended use. the use of the drive unit and its mounting parts in explosion-prone environments the use of the drive unit as a safety-related part of a control unit the use of the drive unit in an environment with aggressive substances and gases Changes of the factory settings by unauthorized persons the use of the drive unit when the external pressure exceeds the internal pressure (housing pressure)

9 RE B/ General Operating Instructions HYDROTRAC GFT2000 Bosch Rexroth AG 9/58 Safety instructions the use of mounting parts (e.g. attached filter, controller, valves) other than the intended Rexroth components the use beyond the performance data released in the technical data sheet 2.4 Qualification of Personnel The activities described in this documentation require basic knowledge of mechanics / electrics / hydraulics as well as knowledge of the related technical terms. For transporting and handling the drive unit, additional knowledge is necessary with regard to working with a crane or a forklift (e.g. crane/forklift operator training, crane/forklift operator's license) and the corresponding attachment equipment. To guarantee safe use, hence, all activities may be carried out only by authorized staff with credentials showing that they have been trained for these activities, socalled qualified personnel, or by persons under qualified instruction by 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 the work to be done. 2.5 General safety instructions Observe all binding regulations for accident prevention and environmental protection. Observe all safety instructions and provisions of the country where the drive unit is going to be used. Only use Rexroth products which are in perfect technical condition. Observe all instructions on the drive unit. Persons who assemble, commission, operate, disassemble, or maintain Rexroth products must not consume alcohol, drugs or pharmaceuticals that may affect their ability to respond. Only use Rexroth original accessories and spare parts in order to prevent any hazards to persons due to improper spare parts. You may only start using the HYDROTRAC GFT 2000 drive unit once it has been established that the end product (see intended use of the material number specific operating instructions) in which the Rexroth-products are installed complies with the country-specific provisions, safety regulations and standards of the application. The assembly, commissioning, maintenance and disassembly of the HYDROTRAC GFT 2000 drive unit takes place under the responsibility of the end-product manufacturer. Therefore, the product safety of the HYDROTRAC GFT 2000 drive unit cannot be guaranteed by Rexroth during these life phases. You must adhere to the technical data, operating conditions and performance limits shown in the product documentation. The warranty shall apply to the delivered configuration only. The warranty is void in case of faulty installation, commissioning and operation, as well as in case of improper use and/or improper handling. You may not modify the HYDROTRAC GFT 2000 drive in principle.

10 10/58 Bosch Rexroth AG General Operating Instructions HYDROTRAC GFT 2000 RE B/ Safety instructions 2.6 Product-dependent safety instructions The following safety instructions apply to chapters 6 to 14. WARNING Danger during all works on the HYDROTRAC GFT 2000 drive unit during the operation of the machine or the vehicle! Mortal danger, risk of severe injury or damage to property during all works! Secure the entire unit against restarting. Relieve any system pressure in the relevant part of the machine or vehicle before you start working on the drive unit. Cut off power supply in the relevant part of the machine or vehicle before you start working on the drive unit. Do not loosen any cable connections, connections or components on the drive unit, as long as the drive unit or the machine, the vehicle part is under oil pressure and under voltage. Risk of fire from fire, smoking and naked light! Risk of injury or damage to property from combustible materials, as for example: Lubricating oil, preserving agent, solvent, detergents and hydraulic fluid! In dealing with combustible materials, please observe the product data sheets and safety data sheets of the respective manufacturer. Do not use fire or naked light when working on the drive unit, its mounting parts and when handling with combustible materials. Do not smoke in the vicinity of combustible materials. Always wear the protective equipment which is specified in the safety data sheets of the respective substance. When the drive unit is positioned near ignition sources or heat radiators, a shield must be installed so that leaking hydraulic fluid cannot ignite and hoses are protected against premature aging. Risk of toxicity and injury! Risk of toxicity and injury by contact with harmful substances, as for example: Lubricating oil, preserving agent, solvent, detergents and hydraulic fluid! In dealing with harmful substances, please observe the product data sheets and safety data sheets of the respective manufacturer. Always wear the protective equipment which is specified in the safety data sheets of the respective substance. Carefully wash off harmful substances that have come into contact with the skin. Wash out your eyes thoroughly with water if harmful substances have gotten into the eyes and go see a doctor. See a doctor immediately if you have inhaled, for example, solvent-based detergents or have swallowed harmful substances.

11 RE B/ General Operating Instructions HYDROTRAC GFT2000 Bosch Rexroth AG 11/58 Safety instructions CAUTION Locally hot surfaces on the gearbox! Danger of burns! Do not touch any hot surfaces on the drive unit. The drive unit heats up during operation locally to a max. temperature of 90 C. Allow the drive unit and its mounting parts to cool down before touching. To protect yourself from burns, wear heat-resistant protective clothing and heat-resistant safety gloves. Hot lubricating oil during operation! Danger of scalding during oil change, oil sampling and draining oil! To protect yourself from scaldings, wear heat- and oil-resistant safety gloves and heat-resistant protective clothing. Wear protective goggles. Avoid oil temperatures of much more than 50 C when taking oil samples or draining oil. When taking the oil sample or draining the lubricating oil, carefully open the oil sampling point or oil drain. Sharp edges and tensioned tension belts and cable fasteners as well as rebounding parts! Risk of injury! Carefully remove any attached tension belts and chains. When cutting tension belts and detaching chains, always wear protective goggles and cut-resistant safety gloves. Danger in the case of mix-up with metrical and inch threads! Risk of injury and damaging to the gearbox! Only assemble the drive unit, if you have the dimensioned drawing available, indicating the thread types and sizes. Danger in the case of faulty installation of cables and lines! Risk of injury or property damage! Lay cables and lines so that they cannot be damaged and no one can trip over them. Metal particles or metal abrasion in the lubricating oil or in screw plugs! Risk of injury! When refilling the lubricating oil, during the oil change and when draining oil, always wear oil-resistant safety gloves and protective goggles.

12 12/58 Bosch Rexroth AG General Operating Instructions HYDROTRAC GFT 2000 RE B/ Safety instructions CAUTION Setting down the drive unit on unsuitable, non-load-bearing base! Risk of injury or property damage by tipping over the drive unit! Always load the drive unit on a load-bearing surface. Secure the drive unit against tipping over by the use of chocks, wooden bars or the load boards provided by Rexroth. Leaking hydraulic fluid due to leakages of the machine or vehicle! Risk of burns and injuries due to leaking oil jet! Relieve any system pressure in the machine or vehicle and repair the leak. Never try to stop or seal the leak or oil jet using a cloth. 2.7 Personal Safety Equipment (PSA) The personal safety equipment for users of the drive unit comprises: Safety gloves The required characteristics of the safety gloves are determined by the conditions encountered in practice. Wear resistant safety gloves of the corresponding classification (according to action step, for example, heat-resistant, oil-resistant, cut-resistant). Safety glasses (tight) Safety shoes Heat-resistant safety wear, if necessary, flameproof protective clothing If necessary, safety helmet When in contact with lubricating oil, preserving agents, solvents, detergents and hydraulic fluid, please wear the mandatory safety equipment as outlined in the respective product data sheets and safety data sheets. All components of the personal safety equipment must be intact.

13 RE B/ General Operating Instructions HYDROTRAC GFT2000 Bosch Rexroth AG 13/58 General information concerning damage to property and product damages 3 General information concerning damage to property and product damages The following instructions apply to chapters 6 to 14. NOTE Danger caused by improper handling! The drive unit can be damaged! Do not submit the drive unit to mechanical load in an unacceptable way. Do not place any objects on the product. Do not hit against sensitive mounting parts (e.g. sensors or valves). Do not hit against sealing surfaces (e.g. on the working connections of the integrated axial piston motor). Leave the protective cover on the integrated axial piston motor until just before connecting the cables. Damage of the drive unit caused by a lack of knowledge when handling the crane and the slinging equipment! Lack of knowledge when handling a crane, or wrong slinging equipment, may lead to uncontrolled movements of the drive unit and therefore damage the machine or vehicle! Use a crane with sufficient lifting capacity for lifting the drive unit. Only use approved transport equipment. Use e.g. eye bolts, straps, chains, swivel hooks, shackles or suitable equipment as slinging equipment. Damage caused by improper assembly! Improper assembly of the drive unit may lead to damage of the drive unit or the machine or vehicle! Make sure that the drive unit has been properly mounted by qualified personnel before operating it. Damage to the drive unit caused by commissioning without or with insufficient lubricating oil! When commissioning the drive unit and the static multiple-disk parking brake integrated in the drive unit without or with insufficient lubricating oil, the drive unit may be damaged or completely destroyed! When commissioning the machine or vehicle, make sure that the housing chamber and the service lines of the integrated axial-piston motor are filled with hydraulic fluid and remain filled during operation. Check the oil level carefully. When commissioning or restarting the machine or a vehicle, fill the drive unit with the correct quantity of oil.

14 14/58 Bosch Rexroth AG General Operating Instructions HYDROTRAC GFT 2000 RE B/ General information concerning damage to property and product damages NOTE Damage to the drive unit caused by commissioning with too much lubricating oil! When commissioning the drive unit and the static multiple-disk parking brake integrated in the drive unit with too much lubricating oil, thermal overloads may occur, causing damage to the gears, seals and bearings as well as failure of the static multiple-disk brake! When commissioning or restarting the machine or a vehicle, fill the drive unit with the correct quantity of oil. Check the oil level carefully. Damage caused by penetrating liquids, foreign objects and dirty lubricating oil! Wear and malfunctions caused by impurities! Check whether all seals, connections and plug-in connectors have been correctly installed and are intact. When performing any work on the drive unit, please ensure extreme cleanness to prevent foreign objects, for example weld spatter or metal particles, from getting into the drive unit and, therefore, causing wear and malfunction. Only use clean connections. Exclusively install clean hydraulic lines. No dirt shall penetrate when closing the ports. Damage to the drive unit caused by cleaning agents or solvents! Damage caused by aggressive detergents or solvents and/or fiber from cleaning cloths getting into the drive unit! When removing the preserving agent make sure that no aggressive detergents or solvent enters the seal areas, the hydraulic system, or the drive unit. Only use a dry cloth made of lint-free fabric to remove lubricating oils and other soils. Damage to the drive unit caused by mechanical stress! Oil lines and hoses which you install under tension cause additional mechanical stress during operation, which reduces the service life of the drive unit! Assemble hydraulic lines and hoses without mechanical stress. Ensure vibration-free fastening of tubings. Only use hoses and fasteners which have been approved for the respective operating pressure range. Damage to the drive unit caused by improper installation! Material damage to the drive unit or its mounting parts! Assign or close all necessary connections properly, particularly the static multiple-disk brake. Only commission a completely installed drive unit. Take the required connections from the dimensioned drawing in appendix D Technical data / Drawings of the material number-specific operating instructions.

15 RE B/ General Operating Instructions HYDROTRAC GFT2000 Bosch Rexroth AG 15/58 General information concerning damage to property and product damages NOTE Risk of environmental pollution! Ground water and/or soil contamination by escaping or spilled lubricating oil or pressure medium! Place a catch basin with sufficient capacity under the drive unit when replacing, draining lubricating oil, or working with a pressure medium. Bond any passing flow of lubricating oil or spilled lubricating oil or pressure medium with appropriate absorption material such as oil absorbent granule. Dispose the lubricating oil or pressure medium in accordance with local country regulations and provisions. Observe the product data sheets and safety data sheets of the lubricating oil manufacturer and pressure medium manufacturer. These data sheets are not included within Rexroth's scope of supply. Damage to the drive unit caused by improper handling! Damage to the drive unit during installation into the machine/vehicle frame, maintenance and repair work and during disassembly! Avoid strong impacts on the drive unit during assembly or disassembly. Never use the mounting parts as a handle or step. Make sure that the drive unit is not canted. Damage to the drive unit and mounting parts! Material damage caused by securing and lifting equipment! When lifting the drive unit, take care that mounting parts do not get damaged by securing or lifting equipment. Insufficient lubrication! Damage to the drive unit and mounting parts! Supply the gearbox with a sufficient lubricating oil amount in all modes of operation. Any irregularities manifesting during maintenance and inspection! Damage to the drive unit and its mounting parts! Take drive unit out of operation and contact the nearest Rexroth service point, if you find there to be any irregularities during maintenance work or inspections. Unpunctual inspection and maintenance work! Risk of damage! Adhere to the drive unit s maintenance intervals schedule when carrying out mandatory maintenance work. Damage to the drive unit by retightening Loctite secured screws! Destruction of the screw locking! Check in the drive unit general drawing which screws are secured with Loctite. Never retighten screws which are secured with Loctite.

16 16/58 Bosch Rexroth AG General Operating Instructions HYDROTRAC GFT 2000 RE B/ About this product 4 Scope of supply Refer to your material number-specific operating instructions for the complete scope of supply. 5 About this product 5.1 Performance description For the performance-related data of the HYDROTRAC GFT 2000 drive unit, please refer to appendix D Technical data / Drawings of the material number-specific operating instructions. 5.2 Product description The HYDROTRAC GFT 2000 drive unit consist of a planetary gearbox with integrated A32VT axial-piston motor. The following product description includes different models. For details on your drive unit, refer to the chapter Product description and the dimensional drawing in appendix D Technical data / Drawings of the material number-specific operating instructions. This is where you find details on: Transmission ratio A32VT Axial-piston motor design, Scope of supply Connections Lubrication, etc. The entire planetary gearbox, which is mounted in non-friction bearings, is equipped with a splash oil lubrication. The externally toothed planet gears are case-hardened. A special output seal ensures best contamination and dust protection of the Turas (sprocket) bearing. The drive unit is intended exclusively for use in the technical environment approved by Rexroth for the application referred to in the material number-specific instructions Parking brake The A32VT axial-piston motor is equipped with an integrated wet-running static multiple-disk parking brake. Use the multiple-disk parking brake only as statically operating parking brake. This ensures a safe unit standstill when the opening pressure is not reached. It is hydraulically actuated. In the unpressurized state, the static multiple-disk brake is permanently closed by spring force and is only opened by the supply of hydraulic fluid.

17 RE B/ General Operating Instructions HYDROTRAC GFT2000 Bosch Rexroth AG 17/58 About this product 5.3 Product overview Abb. 1: Overview of HYDROTRAC GFT 2000 drive unit (the represented model is exemplary and may differ from the supplied model) 1. Integrated axial-piston motor A32VT 2. Planetary Gearbox 3. Bore 3: To check the oil level or to fill in lubricating oil 4. Bore 4: To check the lubricating oil or to drain A, B T X MA, MB MBR Service lines Tank line (leakage fluid) Control signal Measurement pressure A, B Measurement breake release pressure You can put bores 3 and 4 in the drive unit cover in different positions by turning the ring gear. The alignment of bores 3 and 4 to each other remains fixed, however. Fig. 1 therefore only shows examples for a possible position of the cover that may deviate from the dimensioned drawing of the drive unit in Annex D Technical data / Drawings in the material-number referencing operating instructions. Chapters Filling the planetary gearbox with lubricating oil, Checking the oil level of the planetary gearbox and Changing the lubricating oil, the cover is displayed in the position necessary to perform these tasks.

18 18/58 Bosch Rexroth AG General Operating Instructions HYDROTRAC GFT 2000 RE B/ About this product In addition observe the dimensioned drawing and the general arrangement drawing of the HYDROTRAC GFT 2000 drive unit in Appendix D Technical data/drawing of the material number-specific operating instructions. 5.4 Identification of the product A name plate is located on the drive unit, enabling you to identify the product. Refer to the general arrangement drawing in appendix D Technical data / Drawings of the material number-specific operating instructions for the location and position of the name plate Standard name plate The following information is indicated on the name plate: Abb. 2: Example of a name plate on the drive unit 1. Internal factory code 2. Date of manufacture 3. Product material number 4. Serial number 5. Factory specific order number 6. Ratio of the gearbox 7. Type code 8. Customer material number 9. Manufacturer The name plate shown above is only an example of a standard Rexroth name plate. In addition, the order number and serial number are engraved on the gearbox housing. You can find the information near the name plate.

19 RE B/ General Operating Instructions HYDROTRAC GFT2000 Bosch Rexroth AG 19/58 Transport and storage 6 Transport and storage Please read chapter 7.1 Unpacking before you transport the drive unit. 6.1 Transporting the HYDROTRAC GFT 2000 WARNING Hazardous, uncontrolled movements during the transport of the drive unit! Mortal danger, risk of injury, severe physical injury or damage to property! Observe the national laws and regulations regarding occupational safety and health protection and transport. Weight information about the drive unit can be found in the shipping documents, the technical data sheet or on the name plate. Make sure that the drive unit is attached to the crane or the forklift exclusively by qualified staff with credentials, using attachment means, and is transported only by said qualified staff, with a crane or forklift. In addition, observe chapter 2.4 Qualification of Personnel. Adjust the lifting means (crane or forklift) and attachment means (chains and shackles or straps or ropes) to the weight and the dimensions of the drive unit. Design the load-carrying capacity of the lifting means to match the weight of the drive unit. Tighten the means of attachment before lifting the drive unit. You may only lift the drive unit with a forklift if it is protected by a transport frame / pallet designed for the drive unit. Make sure that the crane loads (such as the drive unit on the crane hook) do not start swaying. Danger from suspended loads! Danger to life or risk of injury! Use a crane or forklift whose load-carrying capacity is sufficient to lift the drive unit. Never step or put your hands under suspended loads.

20 20/58 Bosch Rexroth AG General Operating Instructions HYDROTRAC GFT 2000 RE B/ Transport and storage Carefully attach the drive unit with approved lifting equipment, such as chains and shackles adapted to weight, suitable ropes or eye bolts (see illustration on the left) to the crane hook or transport the drive unit in a suitable transport frame using a suitable forklift. Choose the chain or cable length such that the attachment angle remains smaller than 90. Place the drive unit on a load-bearing surface as shown in the adjacent diagram. Your drive unit may deviate from this presentation! 6.2 Storage the HYDROTRAC GFT 2000 NOTE Risk of damage of the drive unit! A drive unit stored for more than 36 months has to be thouroughly inspected and submitted to a test run before use! This product should only be tested by qualified personnel (refer to chapter 2.4 Qualification of personnel ). Preservation and storing of the drive unit is described in this chapter. For queries concerning preservation and storage, please contact a Rexroth's subsidiary located near you or the main plant directly. Refer to and the address directory in appendix A "Address directory" of the material number-specific operating instructions Preservation Rexroth delivers the drive unit without oil filling. The drive unit inside is preserved using SHELL Oil S, 7294, SAE 50. The external surfaces of flanges and flanging surfaces are preserved with Valvoline TECTYL 502 C by the manufacturer. After removing the packing, you must check whether the outside preservation is still correct. If the preservation is damaged and gearbox parts on the outside have bright spots, preserve these spots again with Valvoline TECTYL 502 C. Observe the manufacturer's product data sheets and safety data sheets when using Valvoline TECTYL 502 C. These data sheets are not included within Rexroth's scope of supply.

21 RE B/ General Operating Instructions HYDROTRAC GFT2000 Bosch Rexroth AG 21/58 Transport and storage Apply a layer of grease on to the output seal area, before you apply the external preservation. Use a lithium/mineral oil based lubricating grease DIN KP 3 K-30. This prevents ingress of VALVOLINE TECTYL 502 C-EH in the output seal. For the output sealing, refer to the general arrangement drawing. Use a brush to apply the Valvoline TECTYL 502 C evenly onto the bright spots Storing in ventilated Rooms In ventilated rooms, the drive unit is protected against corrosion up to 24 months from delivery ex works. After removing the packing, you must check whether the outside preservation with Valvoline TECTYL 502 C is still correct. If necessary, renew preservation professionally as described in chapter Preservation Storing in air conditioned Rooms A corrosion protection for max. 36 months is only possible when stored in closed, air conditioned rooms. Condensation and high air humidity have to be absolutely avoided. If packing is removed beforehand, the blank parts have to be checked and possibly preserved again using Valvoline TECTYL 502 C Long-term Preservation Completely fill the drive unit with oil (e.g. Rexroth preservation oil). Completely wet external parts using Valvoline TECTYL 502 C. Visually inspect the external parts every 6 months and preserve again if necessary. Every 24 months, lower the oil level to normal filling, turn the drive unit at idling speed to rated speed and then drain the oil (if possible, visually inspect the gears). Check the drained oil for water contents according to DIN (reference value 0,1 % by wt.). Determine the content of solids in the drained oil according to DIN (Z) (reference value 0,1 % by wt.). Then fill the drive unit with oil and repeat the procedure after 24 months. After storing the drive unit for more than 36 months: Contact the Rexroth Service before installation. Refer to appendix A Address directory of the material number-specific operating instructions for the appropriate contact person.

22 22/58 Bosch Rexroth AG General Operating Instructions HYDROTRAC GFT 2000 RE B/ Assembly 7 Assembly Prior to assembly, the following documents must be readily accessible: Operating instructions for the machine or vehicle (supplied by the manufacturer) Dimensioned drawing of the drive unit Technical data of the drive unit Material number-specific operating instructions for the drive unit Hydraulic diagram for the entire machine or vehicle (supplied by the manufacturer) Assembly drawing for the machine or vehicle (supplied by the manufacturer) 7.1 Unpacking Procedure As a standard, the drive unit comes in a wooden box. To protect it against moisture, the drive unit is packed in a VCI corrosion protection film with additional desiccant bags. For unpacking the drive unit: 1. Place the packing on a flat, stable surface. 2. Only open the packing from the top. 3. Check the scope of supply for transport damage and completeness, see chapter 4 "Scope of supply". 4. Compare material number and designation (type code) with those specified in the order confirmation. If the material number of the drive unit does not comply with the material number indicated in the order confirmation, contact the Rexroth Customer Service for clarification. Refer to appendix A List of addresses of the material number-specific operating instructions for the address. 5. Lift the drive unit out of the box using suitable lifting equipment and slings (see chapter 6.1 Transporting the HYDROTRAC GFT 2000 ). 6. Make sure that the drive unit is placed on a stable surface. 7. Put down the drive unit with the cover down on two suitable squared timbers. Secure the drive unit against tipping over. 8. Dispose of the packaging in accordance with regulations in your local country.

23 RE B/ General Operating Instructions HYDROTRAC GFT2000 Bosch Rexroth AG 23/58 Assembly 7.2 Installation conditions The assembly conditions depend on the machine, the chassis frame or the equipment frame where the drive unit is integrated. Make sure that the chassis or equipment frame the HYDROTRAC GFT 2000 drive unit is attached to is torsion resistant. The frame must be able to withstand the weight and torque specified for the design. During assembly, observe by all means the ambient conditions that are specified in appendix D Technical data / Drawings of the material numberspecific operating instructions Make sure that the integrated axial-piston motor is vented and filled with hydraulic fluid during commissioning and in operation. This is also to be observed in case of longer downtimes as the axial-piston motor may be drained through the hydraulic lines. Drain the leakage fluid in the housing chamber through the highest leakage port to the tank. Use the appropriate pipe size for the port. A check valve in the tank line is not allowed. To achieve a low noise level, disconnect all connecting lines from all vibratory components (e.g. tank) using elastic elements. Make sure that the tank and return lines flow into the tank under all operating conditions below the minimum fluid level. This will prevent foam formation. Make sure that the work environment on site is free of dust and foreign substances. The drive unit must be installed free of dirt. Contamination of the hydraulic fluid may considerably affect the function and service life of the integrated axial-piston motor. Use cloths made of lint-free fabric for cleaning. Use mild detergents for removing lubricants and other heavy contaminations. No detergents may penetrate into the hydraulic system. 7.3 Installation position The installation position of the drive unit is horizontal. The drive unit installation position approved and recommended by Rexroth is indicated on the drawing in appendix D Technical data / Drawings of the material number-specific operating instructions.

24 24/58 Bosch Rexroth AG General Operating Instructions HYDROTRAC GFT 2000 RE B/ Assembly NOTE Installation of the drive unit in an installation position not approved by Rexroth! Damage or failure of the drive unit and expiry of the warranty! Only mount the generator gearbox in the installation position approved by Rexroth in accordance with the dimensioned drawing. Damage to the drive unit through misalignment with the machine frame! Property damage! Do not tilt the drive unit during installation and insert it into the machine frame torsion-free and tension-free. Avoid misalignment of the drive unit during installation. Align the gearbox precisely to the machine frame or vehicle frame Sub-tank assembly (standard) Sub-tank assembly is present if the integrated axial-piston motor is installed outside of the tank below the minimum liquid level. Recommended installation position: 1 Abb. 3: A32VT sub-tank assembly with installation position 1 T Highest leakage liquid connection hmin Minimum required distance to the tank bottom (100 mm) ht min Minimum required immersion depth (200 mm) Tabelle 6: Sub-tank assembly Installation position Vent Fill 1 (Drive shaft horizontal) - T

25 RE B/ General Operating Instructions HYDROTRAC GFT2000 Bosch Rexroth AG 25/58 Assembly 7.4 Required tools The drive unit can be assembled with standard tools. No special tool is required. 7.5 Assembling the HYDROTRAC GFT 2000 The required, proper order in which the assembly takes place depends on the machine frame or vehicle frame and therefore may differ from the sequence given in these operating instructions Preparing assembly Procedure 1. Check the scope of supply for completeness and transport damage. Refer to the material number-specific operating instructions for the complete scope of supply. 2. Compare the material number and the type designation on the name plate with the information given in the order confirmation or delivery note. If the material number of the drive unit does not comply with the material number indicated in the order confirmation or delivery note, please contact Rexroth Customer Service. 3. Compare the connecting dimensions of drive unit and chassis or equipment frame. 4. Compare the connection dimensions of the drive unit to the sprocket. The mounting order depends on the machine, the vehicle or the chassis or equipment frame design. Refer to the instructions in chapter 7.2 Installation conditions. In addition, observe the assembly instructions of the machine or vehicle manufacturer. The dimensioned drawing contains the dimensions of all connections of the HYDROTRAC GFT 2000 drive unit. 5. Remove the preservative Valvoline TECTYL 502 C from the outside flange surfaces with a suitable grease-dissolving agent, e.g. Valvoline TECTYL 150. Wear suitable protective gloves and protective goggles when cleaning the drive unit and observe the manufacturer's safety notes when handling Valvoline TECTYL 502 C and Valvoline TECTYL 150. These data sheets are not included within Rexroth's scope of supply. NOTE Damages to the seals! Aggressive detergents or solvents can damage the seals of the drive unit and can cause the seals to age faster! When removing the preserving agent make sure that no aggressive detergents or solvents enter the seal areas. This applies in particular to the area of the output seals.

26 26/58 Bosch Rexroth AG General Operating Instructions HYDROTRAC GFT 2000 RE B/ Assembly Installing the drive unit in the machine or vehicle frame The drive HYDROTRAC GFT 2000 has an axial-piston motor integrated in the drive unit. The axial-piston motor outer contour is located inside the equipment frame centering. The complete drive may therefore be installed as a unit. NOTE Failure or damage to the integrated axial-piston motor! If the chamber of the integrated axial-piston motor is not or not sufficiently filled with hydraulic fluid during commissioning or operation, the integrated axialpiston motor is immediately damaged or destroyed! Fill the integrated axial-piston motor housing chamber with a sufficient quantity of hydraulic fluid prior to commissioning. Make sure that the integrated axial-piston motor housing is vented and filled with hydraulic fluid during commissioning and in operation. Make sure that the complete hydraulic system is tight. Procedure Installing the drive unit at/in the machine or vehicle frame: 1. For installation, strictly observe the corresponding data in the dimensioned drawing of the drive unit in appendix D Technical data / Drawings of the material number-specific operating instructions. 2. Also observe the primary operating instructions of the machine or vehicle and the manufacturer s frame drawing. 3. For the drive unit weight, refer to appendix D Technical data / Drawings of the material number-specific operating instructions. 4. Transport the drive unit to the application machine. 5. Make sure that the surface is stable. 6. Put down the drive unit with the cover down on two suitable squared timbers. Secure the drive unit against tipping over. 7. Attach the drive unit carefully using appropriate means of attachment e.g. eye bolts, swivel hooks, shackles or suitable equipment on an appropriate lifting equipment such as a crane hook. In addition, observe chapter 6.1 Transporting the HYDROTRAC GFT Tighten the means of attachment without lifting the drive unit. 9. Make sure that the part of the machine or vehicle frame to which the drive unit is to be mounted is free of dirt and foreign objects. 10. Lift the drive unit into the machine or vehicle frame. 11. Attach the drive unit to the machine or chassis frame using mounting screws having a strength class of at least 10.9 according to EN ISO The mounting screws are not included within the scope of supply. 12. Connect the integrated axial-piston motor to the hydraulic system. Observe chapter Connecting the drive unit integrated axial-piston motor to the hydraulic system. 13. Remove all means of attachment, transport and lifting equipment.

27 RE B/ General Operating Instructions HYDROTRAC GFT2000 Bosch Rexroth AG 27/58 Assembly Connecting the drive unit integrated axial-piston motor to the hydraulic system CAUTION Hazard caused by operation with guard plugs! Operating the axial-piston unit with guard plugs may cause injury or damage to the axial-piston motor! Before commissioning, remove all guard plugs and replace them by suitable pressure-resistant, metallic screw plugs. 1. Remove the transport protection. The integrated axial-piston motor of the drive unit is delivered with a guard plug (1). They have to be removed before connection. Use appropriate tools in order to prevent damage to sealing and functional surfaces. If sealing or functional surfaces are damaged, contact the competent Rexroth Service or the drive unit manufacturer's service department. Abb. 4: Removing the transport protection 1 Guard plugs Connections intended for connecting lines are provided with guard plugs being used as transport protection. All connections required for functioning have to be connected (refer to table 6 A32VT connections, series 10 ). Failure to observe may lead to malfunctions or damage. If a connection is not connected, seal it using a screw plug as the guard plugs are not pressureresistant. The machine/vehicle manufacturer is responsible for laying the lines. The integrated axial-piston motor or the static multiple-disk brake (multiple-disk parking brake) has to be connected to the remaining hydraulic system according to the machine or vehicle manufacturer's hydraulic diagram.

28 28/58 Bosch Rexroth AG General Operating Instructions HYDROTRAC GFT 2000 RE B/ Assembly The connections and mounting threads are designed for the maximum pressure specified in the data sheet. The machine/vehicle manufacturer must make sure that the connecting elements and lines meet the intended operating conditions (pressure, volume flow, hydraulic fluid, temperature) with the required safety factors. Only connect hydraulic lines that are suitable for the axial-piston unit connection (pressure level, size, measurement system). Notes for installing the lines Observe the following instructions for installing pressure and tank lines. Lines and hoses must be fitted without prestress so that no additional mechanical forces act during operation, reducing the lifetime of the axial-piston unit and possibly of the complete machine/vehicle. Use suitable sealants. Pressure line Only use pipes, hoses and connection elements dimensioned for the operating pressure range for the high-pressure lines (see table 6 A32VT connections, series 10 ). Tank line Generally install the tank lines so that the integrated axial-piston motor is always filled with hydraulic fluid and air intake at the shaft sealing is prevented even in case of longer downtimes. During operation, the housing internal pressure of the axial-piston motor must not exceed the limits specified in the RE data sheet. The tank line opening to the tank must always be below the minimum fluid level (refer to chapter 7.3 Installation position ). Risk of confusion in case of threaded connections The integrated axial-piston motor of the drive unit is used in applications using metric as well as inch systems. The system of units as well as the size of ports and stud ends (e.g. screw plug) must match. Risk of confusion due to low optical differentiation possibilities. WARNING Risk caused by leaking or jumping stud ends! When pressurizing a stud end that does not match the system of units and port size, the stud end may come loose automatically our jump out like a bullet. This may cause serious injury and property damage. Hydraulic fluid may penetrate through the leakage point! Check the required stud end for each screw connection using the drawings (assembly drawing/data sheet). Make sure that confusions are avoided when mounting fittings, mounting screws and screw plugs. Use a stud end of the same system of units and size for the port.