Description

Mannesmann Rexroth A2F 1996 Repair Manual

Mannesmann Rexroth A2F 1996 Repair Manual – if you are wrenching on one of these axial piston pumps, you do not want to guess on clearances or seal stack order. I have seen more than my share of burnt up hydraulic units because someone thought a seal kit was universal. This 19‑page factory publication, RDE 91001‑01‑R, was printed in July 1996 by Brueninghaus Hydromatik. It gives you the exact sequence for disassembly, inspection, and reassembly of the A2F series 6.1. No reprints, no third‑party redrawn diagrams. This is the document your local dealer used.

General Repair Instructions – Page 4

Page 4 opens with a warning you need to read twice: “Observe the following notices when carrying out repair work at hydraulic…” The manual makes clear that all repairs require operating temperature on a test bench. If you are working on a pump pulled from a forklift or a wood chipper, you must have clean fluid, proper filtration, and a bench setup that can handle case drain pressures. Skip this page and you risk contamination damage the second the pump spins.

Seal Kits and Sub‑Assemblies (Page 5)

Page 5 lists the Dichtsätze und Baugruppen – seal kits and sub‑assemblies. This is where you identify which seal kit matches your pump’s factory number. The manual references Brueninghaus Hydromatik groups with factory numbers. Do not mix seal suppliers; use only the listed part numbers. The exploded view on the sectional view (page 3) shows measuring points for case drain flow – you need that data before you even open the pump.

Does This Manual Cover the Rotary Group Removal?

Yes. Page 10 walks through removing the Rotorkranz (rotary group). The procedure calls for specific pullers and a cleanliness level you cannot achieve with rags and brake cleaner. The manual states the correct order to remove the cylinder barrel, pistons, and swashplate. If you skip the step of marking the running surfaces for wear, you will be installing new parts into a housing that may be oblong. Section 6 (page 10) is your friend here.

Torque Specs: Page 15

Page 15, labeled “Anzeldrehteile” (installation torquing), covers every fastener the manual addresses. You will find torque values for the end cover bolts, shaft seal retainer, and valve plate screws. These are OEM numbers – not generic “30 Nm” guesses. Use a calibrated torque wrench that reads in inch‑pounds for the smaller fasteners. Do not assume you can “feel” the spec on a hydraulic pump; one overtightened screw deforms the sealing face and you get internal leakage.

Safety Regulations – Pages 17‑18

The final two pages cover Sicherheitsbestimmungen (safety regulations). This is not legalese. It tells you how to lock out the hydraulic circuit, depressurize accumulators, and handle the pump under residual pressure. I have seen a technician get sprayed with 200°F hydraulic oil because he cracked a line without relieving the charge pressure. Read these pages even if you have worked on hydraulics for twenty years. The manual states: “Protection of personnel and property has to be guaranteed by appropriate measures.” Means what it says.

Audience Fit: Who Should Buy This Manual

If you maintain a mobile crane, excavator, or industrial press with an A2F pump, this manual belongs on your bench. DIYers rebuilding a used pump will find the seal kit identification and clearance check notes (pages 11‑12) worth the price. Professional hydraulic shops will use it as a cross‑reference when customer unit data plates are worn off. Beginners should pair this with a basic Manual Transmission overhaul video to understand general pump principles before diving in. The manual assumes you know hydraulic theory – it does not teach you fluid dynamics, but it does give you the exact sequence to avoid damaging the valve plate.

Source Validity: Why Factory OEM Matters

I have seen aftermarket manuals that tell you to install a shaft seal with a hammer. This one does not. The 1996 Mannesmann Rexroth publication was printed from Brueninghaus Hydromatik’s own presses. Every drawing matches the production parts. Page 2 includes a notice that specifications, descriptions, and illustrations were accurate at the time of printing. That is better than a generic “this manual covers most models” promise. If you need the load‑sensing trim, check the Rexroth Load-Sensing Control Block Technical Manual separately. For fixed‑displacement motor variants, see the Mannesmann Rexroth A2FM A2FE Fixed Displacement Motors Manual. For engine‑driven pump installations, the INTERACT 4.0/6.0 Engine Repair Manual Mechanical Repairs covers the mechanical side.

One more thing: the manual says adjustment and tests must be done on a test bench under operating temperatures. That is not optional. You can watch a Manual Transmission rebuild video to see how bench testing works, but the pump test requires a flow meter and a load valve. Ignore that and you will not know if your repair holds pressure until the pump is back on the machine.

Does this manual cover every A2F variant?

It covers the A2F series 6.1. For other series or frame sizes, you need the corresponding repair instructions. Page 1 shows “Baureihe/Series 6.1”.

What torque values are listed?

Page 15 gives installation torquing values for the fasteners used in the pump assembly. The manual does not list every bolt on the machine – only the ones you remove during a full teardown.

Is the manual in English or German?

Both. The PDF includes side‑by‑side English and German text. The table of contents, warnings, and procedures are bilingual. No guesswork on translation.

Can I use this manual for a repair if I have never seen a hydraulic pump before?

You can use it, but you need basic hydraulic knowledge. The manual tells you the steps but does not explain how a piston pump works. Pair it with a textbook or a qualified mentor. Safety regulations on pages 17‑18 are mandatory reading before you put a wrench on the housing.

Factory documentation saves you time and parts money. The 19 pages in this 1996 repair manual deliver the exact sequence for disassembly, inspection, seal replacement, and reassembly of the Mannesmann Rexroth A2F. Do not trust your repair to a photocopy that blurs the torque table. Access the Factory Manual and keep it within arm’s reach of your bench.