PDF Repair Manual Manitou Bosch Pump Serie 10 - 580 KB
This repair manual provides detailed service information for the Bosch Serie 10 pump used in Manitou equipment.
It includes instructions for disassembly, inspection, and reassembly of the pump components.
Technicians will find this guide essential for accurately diagnosing and repairing pump-related issues.
Following these factory procedures ensures the pump is restored to its proper working condition.
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647525EN (02/03/2015) SERVICE PUMP BOSCH
SERIE 10
Repair Manual
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12/56 Bosch Rexroth AG A10VO, A10VSO, A10VNO, A10VSNO Series 52 and 53 | RE 92703-01-B/01.2012
Safety instructions
2.6 Product-specific safety instructions
The following safety instructions apply for chapters 6 to 14.
WARNING
Danger from suspended loads!
Danger to life or risk of injury, damage to equipment!
Improper transportation may cause the axial piston unit to fall down lead to
injuries e.g. crushing or broken bones or damage to the product.
ff Make sure that the forklift truck or lifting device has adequate lifting capacity.
ff Never stand under or put you hands under suspended loads.
ff Ensure your position is stable during transportation.
ff Use your personal protective equipment (e.g. safety glasses, safety gloves,
suitable working clothes, safety shoes).
ff Use suitable lifting devices for transportation.
ff Observe the prescribed position of the lifting strap.
ff Observe the national laws and regulations on work and health protection and
transportation.
Pressurized machine/system!
Danger to life or risk of injury, serious injuries when working on machines/
systems not shutdown! Damage to equipment!
ff Protect the complete system against being energized.
ff Make sure that the machine/system is depressurized. Please follow the
machine/system manufacturerβs instructions.
ff Do not disconnect any line connections, connections and components when
the machine/system is pressurized.
ff Switch off all power-transmitting components and connections (electric,
pneumatic, hydraulic) in accordance with the manufacturer's instruction and
secure them against being switched back on.
Escaping oil mist!
Danger of explosion, danger of fire, allergic reactions, environmental pollution!
ff Depressurize the machine/system and repair the leak.
ff Only perform welding work then the machine/system is depressurized.
ff Keep open flames and ignition sources away from the axial piston unit.
ff If axial piston units are to be situated in the vicinity of ignition sources or
powerful thermal radiators, a shield must be erected to ensure that any
escaped hydraulic fluid can not ignite, and to protect hose lines from
premature aging.
Electrical voltage!
Risk of injury due to electric shock or damage to equipment!
ff Always set up the relevant part of the machine/system so that it is free of
electrical voltage before you install the product or when connecting and
disconnecting plugs. Protect the machine/system against being energized.
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RE 92703-01-B/01.2012 | A10VO, A10VSO, A10VNO, A10VSNO Series 52 and 53 Bosch Rexroth AG 23/56
Transport and storage
After removal If a removed axial piston unit is to be stored, it must be preserved against
corrosion for the duration of storage.
The following instructions only refer to axial piston units which are operated
with a mineral-oil based hydraulic fluid. Other hydraulic fluids require
preservation methods that are specifically designed for them. In such a case,
consult with Bosch Rexroth Service, see chapter 10.5 "Spare parts" for
address.
Bosch Rexroth recommends the following procedure:
1. Clean the axial piston unit, see chapter 10.1 "Cleaning and care".
2. Empty the axial piston unit.
3. For storage time up to 12 months: Moisten the inside of the axial piston unit
with mineral oil and fill with approx. 100 ml mineral oil.
For storage time up to 24 months: Fill the axial piston unit with corrosion
protection medium VCI 329 (20 ml).
Filling is done via the reservoir port L, L1 or L2, see chapter 7.4 "Installing the
axial piston unit", Fig. 12 to 16.
4. Seal all ports airproof.
5. Moisten the unpainted surfaces of the axial piston unit with mineral oil or a
suitable, easily removed corrosion protection agent, e.g. acid-free grease.
6. Package the axial piston unit airproof together with desiccant in corrosion
protection film.
7. Store the axial piston unit so that it is protected against jolts, see
"Requirement" in this chapter.
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34/56 Bosch Rexroth AG A10VO, A10VSO, A10VNO, A10VSNO Series 52 and 53 | RE 92703-01-B/01.2012
Installation
7.4.8 Hydraulically connecting the axial piston unit
NOTE
Insufficient suction pressure!
Generally, a minimum permissible suction pressure at port S is specified for
axial piston pumps in all installation positions. If the pressure at port S drops
below the specified values, damage may occur which may lead to the axial
piston pump being damaged beyond repair!
ff Make sure that the necessary suction pressure is not undercut. This is
influenced by:
ββ the piping (e.g. suction cross-section, pipe diameter, length of suction line)
ββ the position of the reservoir
ββ the viscosity of the hydraulic fluid
ββ if fitted, a filter cartridge or check valve in the suction line (regularly check
the level of soiling of the filter cartridge)
The machine/system manufacturer is responsible for dimensioning the lines.
The axial piston unit must be connected to the rest of the hydraulic system
in accordance with the hydraulic circuit diagram of the machine/system
manufacturer.
The ports and fixing threads are designed for the maximum pressure specified
in the data sheet. The machine/system manufacturer must ensure that the
connecting elements and lines correspond to the specified application conditions
(pressure, flow, hydraulic fluid, temperature) with the necessary safety factors.
Connect only hydraulic lines that are appropriate for the axial piston unit port
(pressure level, size, system of units).
Notes on routing the lines Observe the following notes when routing the suction, pressure and reservoir
lines.
β’β’ Lines and hoses must be installed without pre-charge pressure, so that no
further mechanical forces are applied during operation that will reduce the
service life of the axial piston unit and, if applicable, the entire machine/system.
β’β’ Use suitable seals as sealing material.
β’β’ Suction line (pipe or hose)
ββ The suction line should be as short and straight as possible.
ββ Measure the line cross section of the suction line so that the pressure at the
suction port does not drop below the minimum permissible pressure. Make
sure that the maximum suction pressure is not exceeded (e.g. when pre-
filling).
ββ Make sure the connections and connecting elements are air-tight.
ββ The hose must be pressure-resistant, also for external air pressure.
β’β’ Pressure line
ββ For the pressure lines, use only pipes, hoses and connecting elements rated
for the operating pressure range specified in data sheet RE 92703, RE 92735
and RE 92741 (see Table 11).
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RE 92703-01-B/01.2012 | A10VO, A10VSO, A10VNO, A10VSNO Series 52 and 53 Bosch Rexroth AG 45/56
Maintenance and repair
10 Maintenance and repair
NOTE
Inspection and maintenance work carried out too late!
Damage to equipment!
ff Carry out the specified inspection and maintenance work at the intervals
described in this manual.
10.1 Cleaning and care
NOTE
Damage to seals and electrical system by mechanical effects!
The water jet of a power washer may damage the seals and electrical system of
the axial piston unit!
ff Do not point the power washer at sensitive components, e.g. shaft seal,
electrical connections and components.
For cleaning and care of the axial piston unit, observe the following:
ff Check whether all seals and fittings on the connections are securely seated
to ensure that no moisture can penetrate into the axial piston unit during
cleaning.
ff Use only water and, if necessary, a mild detergent to clean the axial piston
unit. Never use solvents or aggressive detergents.
ff Remove coarse external dirt and keep sensitive and important components,
such as solenoids, valves, indicators and sensors, clean.