Re92202 2012-05

Axial Piston Variable Pump RE 92202/05.
12
Replaces: 12.07
1/36
A7VO
Data sheet
Series 63
Size 28 to 160
Nominal pressure 350 bar
Maximum pressure 400 bar
Open circuit
Contents Features
Ordering code for standard program 2 Variable pump with axial tapered piston rotary group of bent-
axis design, for hydrostatic drives in open circuit
Technical data 4
For use in mobile and stationary applications
LR Power controller 9
The flow is proportional to the drive speed and displacement.
DR Pressure controller 12
The flow can be infinitely varied by adjusting the bent axis.
HD Proportional control hydraulic 15
Wide selection of control devices
EP Proportional control electric 17
Compact, robust pump with long service life
Dimensions size 28 18
Connector for solenoids 33
Installation instructions 34
General instructions 36
2/36 Bosch Rexroth AG A7VO Series 63 | RE 92202/05.12
Ordering code for standard program

A7V O / 63 V B 01
01 02 03 04 05 06 07 08 09 10 11 12
Axial piston unit

01 Bent-axis design, variable, nominal pressure 350 bar, maximum pressure 400 bar A7V
Operating mode
02 Pump, open circuit O
Sizes (NG)
Geometric displacement, see table of values on page 7 28 55 80 107 160
03
Sizes 250, 355 and 500 See RE 92203
Control devices 28 55 80 107 160

Power controller LR
with pressure cut-off LRD
with stroke limiter negative control p = 25 bar LRH1
with pressure cut-off and stroke limiter negative control p = 25 bar LRDH1
Pressure controller DR
remote controlled DRG
with load sensing DRS
04
Proportional control hydraulic positive control p = 10 bar HD1
p = 25 bar HD2
with pressure cut-off, remote controlled positive control p = 10 bar HD1G
p = 25 bar HD2G
Proportional control electric ,
positive control U = 24 V DC EP2
without manual override
with pressure cut-off, remote controlled positive control U = 24 V DC EP2G
Series
05 Series 6, index 3 63
Directions of rotation 28 to 160

Viewed on drive shaft clockwise R
06
counter-clockwise L
Seals
07 FKM (fluor-caoutchouc) V
Drive shafts 28 to 160

Splined shaft DIN5480 Z
08
Parallel keyed shaft DIN 6885 P
Mounting flange
09 ISO 3019-2 4 hole B
Port plate for service lines

10 SAE flange port A and S at rear (fastening thread metric) 01
= Available = Not available = Preferred program

RE 92202/05.12 | A7VO Series 63 Bosch Rexroth AG 3/36
Ordering code for standard program

A7V O / 63 B 01
01 02 03 04 05 06 07 08 09 10 11 12
Connector for solenoids (see page 33)

Without connector (without solenoid, only with hydraulic controls; without code)
11
DEUTSCH - molded connector, 2 pin without suppressor diode1) P
Standard / special version

Standard version (without code)
12
Special version -S
= Available = Not available = Preferred program

1) Other connectors on request
Technical data
Hydraulic fluid Details regarding the choice of hydraulic fluid
Before starting project planning, please refer to our data The correct choise of hydraulic fluid requires knowledge of the
sheets RE90220 (mineral oil), RE90221 (environmentally operating temperature in relation to the ambient temperature:
acceptable hydraulic fluids), RE 90222 (HFD hydraulic fluids) in an open circuit the reservoir temperature.
and The hydraulic fluid should be chosen so that the operating vis-
RE 90223 (HFA, HFB, HFC hydraulic fluids) for detailed infor- cosity in the operating temperature range is within the optimum
mation regarding the choice of hydraulic fluid and application range (opt see the shaded area of the selection diagram). We
conditions. recommended that the higher viscosity class be selected in
The variable pump A7VO is not suitable for operation with each case.
HFA hydraulic fluid. If HFB, HFC and HFD or environmentally Example: At an ambient temperature of XC, an operating tem-
acceptable hydraulic fluids are used, the limitations regarding perature of 60C is set in the circuit. In the optimum operating
technical data or other seals must be observed. viscosity range (opt, shaded area), this corresponds to the
viscosity classes VG 46 or VG 68; to be selected: VG 68.
Selection diagram
-40 -20 0 20 40 60 80 100 Note
1600 1600 The case drain temperature, which is affected by pressure and
1000
600 speed, can be higher than the reservoir temperature. At no
400 point of the component may the temperature be higher than
200 115C. The temperature difference specified below is to be
VG 68
VG
VG 32
VG 46
VG 2
10
2
taken into account when determining the viscosity in the bear-

0
100
ing.
60
40 36 If the above conditions cannot be maintained due to extreme
Viscosity [mm2/s]
opt operating parameters, we recommend flushing the case at

20 portU.
16
10
5 5
-40 -25 -10 0 10 30 50 70 90 115
Temperature t [C]
tmin = -40 C Hydraulic fluid temperature range tmax = +115 C
Viscosity and temperature of hydraulic fluid

Viscosity [mm2/s] Temperature Comment
Transport and storage Tmin50C factory preservation: up to 12 months with standard,
at ambient temperature Topt=+5C to +20C up to 24 months with long-term
(Cold) start-up1) nmax=1600 TSt40C t3 min, without load (p50 bar), n1000rpm
Permissible temperature difference DT25K between axial piston unit and hydraulic fluid
Warm-up phase n<1600 to 400 T=40C to 25C at p0.7pnom, n0.5nnom and t15min
Operating phase
Temperature difference DT=approx.12K between hydraulic fluid in the bearing and at port R1/R2.
The bearing temperature can be reduced by flushing
via port U.
Maximum temperature 115C in the bearing
103C measured at port R1/R2
Continuous operation n=400 to 10 T=25C to +90C measured at port R1/R2,
nopt=36 to 16 no restrictions within the permissible data
Short-term operation nmin7 Tmax=+103C measured at port R1/R2, t<3 min, p<0.3pnom
FKM shaft seal1) T+115C see page 5
1) At temperatures below 25C, an NBR shaft seal is required (permissible temperature range: 40C to +90C).
Technical data
Filtration of the hydraulic fluid Shaft seal
Finer filtration improves the cleanliness level of the hydraulic
Permissible pressure loading
fluid, which increases the service life of the axial piston unit.
The service life of the shaft seal is influenced by the speed of
To ensure the functional reliability of the axial piston unit, a gra-
the axial piston unit and the case drain pressure (case pres-
vimetric analysis of the hydraulic fluid is necessary to determine
sure). The mean differential pressure of 2bar between the
the amount of solid contaminant and to determine the cleanli-
case and the ambient pressure may not be enduringly exceed-
ness level according to ISO 4406. A cleanliness level of at
ed at normal operating temperature. For a higher differential
least 20/18/15 is to be maintained.
pressure at reduced speed, see diagram. Momentary pressure
At very high hydraulic fluid temperatures (90C to maximum spikes (t<0.1s) of up to 10bar are permitted. The service life
115C), a cleanliness level of at least 19/17/14 according to of the shaft seal decreases with an increase in the frequency of
ISO 4406 is necessary. pressure spikes.
If the above classes cannot be achieved, please contact us. The case pressure must be equal to or higher than the ambient
pressure.
Case drain fluid Speed n [rpm]
5
The case drain chamber is connected to the suction chamber.
NG28
Differential pressure p [bar]

A case drain line from the case to the reservoir is not required
(both ports "R" are plugged). 4
For versions with pressure controller or pressure cut-off, a case NG55
drain line for discharge from port T1 to the reservoir is abso- 3
lutely essential. NG107 NG80
2
Direction of flow NG160
Direction of rotation, view on drive shaft 1
clockwise counter clockwise
S to B S to A 0
0 2000 4000 6000
These values are valid for an ambient pressure pabs=1bar.
Temperature range
The FKM shaft seal may be used for case drain temperatures
from -25 C to +115 C.
Note
For application cases below -25C, an NBR shaft seal is
required (permissible temperature range: -40C to +90C).
State NBR shaft seal in plain text when ordering. Please con-
tact us.
Technical data
Operating pressure range Definition
(Operating with mineral oil) Nominal pressure pnom
The nominal pressure corresponds to the maximum design
Pressure at service line port A pressure.
Nominal pressure pnom__________________ 350 bar absolute Maximum pressure pmax
Maximum pressure pmax _ _______________ 400 bar absolute The maximum pressure corresponds to the maximum operat-
Single operating period _____________________________ 10s ing pressure within the single operating period. The sum of the
Total operating period at nnom_______________________ 300h single operating periods must not exceed the total operating
period.
Minimum pressure (high-pressure side) ____ 10 bar absolute
Minimum pressure (high-pressure side)
Rate of pressure change RA max _ _____________ 16000bar/s Minimum pressure at the high-pressure side (A or B) which is
required in order to prevent damage to the axial piston unit.
pnom
Minimum pressure (Inlet)
t Minimum pressure at suction port S (inlet) which is required in
order to prevent damage to the axial piston unit. The minimum
Pressure p
pressure is dependent on the speed and displacement of the

p axial piston unit (see diagram on page 7).
Rate of pressure change RA
Maximum permissible rate of pressure rise and reduction dur-
ing a pressure change over the entire pressure range.
Time t
t2
Pressure at suction port S (Inlet) Single operating period t1 tn
Minimum pressure pS min _ _________________ 0.8 bar absolute
Maximum pressure pS max ____________________ 2 bar absolute Maximum pressure pmax
Nominal pressure pnom
Note
Pressure p
Values for other hydraulic fluids, please contact us.
Minimum pressure (high-pressure side)
Time t
Total operating period = t1 + t2 + ... + tn
Please contact us if these conditions cannot be satisfied.
Technical data
Table of values (theoretical values, without efficiency and tolerances; values rounded)
Size NG 28 55 80 107 160
Displacement geometric, per revolution Vg max cm3 28.1 54.8 80 107 160
Speed maximum1) at Vg max nnom rpm 3150 2500 2240 2150 1900
at Vg < 0.74 Vg max2) nmax1 rpm 4250 3400 3000 2900 2560
Speed maximum2) nmax2 rpm 4750 3750 3350 3200 2850
Flow at nnom and Vg max qV L/min 89 137 179 230 304
Power at nnom, Vg max and p = 350 bar P kW 52 80 105 134 177
Torque at Vg max and p = 350 bar T Nm 156 305 446 596 891
Rotary stiffness Vg max to Vg/2 cmin Nm/rad 5546 10594 15911 21469 36073
Vg/2 to 0 (interpolated) cmax Nm/rad 16541 32103 48971 67666 104622
Moment of inertia for rotary group JGR kgm2 0.0042 0.0042 0.0080 0.0127 0.0253
Maximum angular acceleration a rad/s2 35900 31600 24200 19200 15300
Case volume V L 0.5 0.75 1.2 1.5 2.4
Mass approx. m kg 17 25 40 49 71
1) The values are valid:

-- at an absolute pressure pabs = 1 bar at suction port S
-- for the optimum viscosity range from opt = 36 to 16 mm2/s
-- with hydraulic fluid based on mineral oils
2) Maximum speed (limiting speed) with increased inlet pressure pabs at the suction port S and Vg < Vg max,
see the following diagram.
1.5 2.3
1.4 2.0
1.9
Inlet pressure pabs [bar]
1.8
1.3 1.7
Speed n / nnom
1.6
1.2 1.5
1.4
1.3
1.1 1.2
1.1
1.0 1.0
0.9
0.9
0.8
0.8
0.6 0.7 0.8 0.9 1.0
Displacement Vg / Vg max
Note
Operation above the maximum values or below the minimum values may result in a loss of function, a reduced service life or in the
destruction of the axial piston unit. Other permissible limit values, with respect to speed variation, reduced angular acceleration as
a function of the frequency and the permissible start up angular acceleration (lower than the maximum angular acceleration) can
be found in data sheet RE 90261.
Determining the operating characteristies
Vg n v
Flow qv = [L/min] Vg = Displacement per revolution in cm3
1000
p = Differential pressure in bar
Vg p n = Speed in rpm
Torque T = [Nm]
20 mh v = Volumetric efficiency
mh = Mechanical-hydraulic efficiency
2Tn qv p
Power P = = [kW] t = Total efficiency (t = v mh)
60000 600 t
Technical data
Permissible radial and axial forces of the drive shafts
Size NG 28 55 80 107 160
Drive shaft mm 25 30 35 40 45
Maximum radial Fq max N 5696 9280 11657 13580 18062
Fq
force
at distance a a mm 12.5 15 17.5 20 22.5
a
(from shaft collar)
Maximum axial + Fax max N 315 500 710 900 1120
Fax +

force1) Fax max N 0 0 0 0 0
Permissible axial force per bar
Fax per /bar N/bar 4.6 7.5 9.6 11.3 15.1
of operating pressure
1) Maximum permissible axial force during standstill or when the axial piston unit is operating in non-pressurized condition.
Note
Influence of the direction of the permissible axial force:
+ Fax max = Increase in service life of bearings
Fax max = Reduction in service life of bearings (avoid)
Effect of radial force Fq on the service life of bearings

By selecting a suitable direction of radial force Fq, the load on the bearings, caused by the internal rotary group forces can be
reduced, thus optimizing the service life of the bearings. Recommended position of mating gear is dependent on direction of rota-
tion. Example:
Toothed gear drive V-belt drive
o Jop =
= 45 t 45 0o Jo
t
J op o =7 pt =7
op
t 0
J
o
Clockwise Counter-clockwise Clockwise

direction of rotation direction of rotation direction of rotation
Pressure at port B Pressure at port A Pressure at port B
LR Power controller
The power controller regulates the displacement of the pump Characteristic LR
depending on the operating pressure so that a given drive
power is not exceeded at constant drive speed.
Operating pressure pB [bar]

pB Vg = constant
pB = operating pressure; Vg = displacement
220 bar
The precise control with a hyperbolic control characteristic,
provides an optimum utilization of available power.
The operating pressure acts on a rocker via a measuring
piston. An externally adjustable spring force counteracts this, 50 bar
it determines the power setting.
If the operating pressure exceeds the set spring force, the Vg min Displacement Vg max
control valve is actuated by the rocker, the pump swivels back
(direction Vg min). The lever length at the rocker is shortened
and the operating pressure can increase at the same rate as Schematic LR
the displacement decreases without the drive powers being
exceeded (pB Vg = constant).
When depressurized, the pump is swiveled to its initial position
Vg max by a return spring.
Setting range for beginning of control__________ 50 to 220 bar U R1
B(A)
The hydraulic output power (characteristic LR) is influenced by
the efficiency of the pump. A1
When ordering, state in plain text:
Drive power P in kW
Drive speed n in rpm
Maximum flow qv max in L/min
Vg min
After clarifying the details a power diagram can be created by
our computer. Vg max
X3
T1
S
R2
M1
LR Power controller
LRD Power controller with pressure cut-off Characteristic LRD
The pressure cut-off corresponds to a pressure control which

adjusts the pump displacement back to Vg min, when the pres- max
350
sure setting is reached.

This function overrides the power control, i. e. below the preset
pressure value, the power function is effective.
The pressure cut-off is preset to a specified value at the
factory. 200
min
Setting range for pressure cut-off_ ___________ 200 to 350 bar
Please state the pressure cut-off setting in plain text when
ordering.
Note
The pressure setting for the pressure cut-off must be at
least a factor of 5 higher than the beginning of control of the
power control. Vg min Displacement Vg max
Example: Beginning of control of the power controller:
50bar Schematic LRD
Minimum setting for pressure cut-off:
550=250bar
Higher settings for pressure cut-off are always possible.
On versions with pressure cut-off, a case drain line from port
T1 to the reservoir is required.
For a plugged case drain port the allowable actuated time for U R1
pressure cut-off is2min for treservoir50C. B(A)
Any pressure-relief valve included in the system to limit the A1

maximum pressure must be set to a cracking pressure at
least 20 bar above the pressure cut-off setting.
Vg min
Vg max
X3
T1
S
R2
M1
LR Power controller
LR... Power controller with stroke limiter Schematic LRH1
The hydraulic stroke limiter, the displacement of the pump X1

can be continuously varied or limited over the entire allowable
range.The displacement is set proportionally by the pilot pres-
sure pSt (maximum 40bar) applied at port X1.
The power controller overrides the hydraulic stroke limiter, i. e.
Y3
below the hyperbolic power characteristic, the displacement U R1
is controlled by the pilot pressure.When exceeding the power B(A)
characteristic with a set flow or operating pressure, the power
control overrides and reduces the displacement following the A1
hyperbolic characteristic.
A control pressure of 40bar is required to swivel the pump
from its initial position Vgmax to Vgmin.
The necessary control power is taken from the operating pres-
sure or the external control pressure applied to port Y3. Vg min
To ensure functioning of the stroke limiter even at low operat- Vg max
ing pressure <40bar, port Y3 must be supplied with external X3
control pressure of approx. 40bar.
T1
LRH1 Hydraulic stroke limiter S
(negative control) R2
Control from Vgmax to Vgmin M1
With increasing pilot pressure the pump swivels to a smaller Schematic LRDH1
displacement. X1
Beginning of control (at Vgmax), adjustable_________4to15bar
Please state the beginning of control in plain text when
ordering.
Initial position without control signal (pilot pressure): Vgmax Y3
U R1
B(A)
Characteristic LRH1
Pilot pressure increase (Vg maxVg min)___________Dp=25bar A1
40
35
Pilot pressure pSt [bar]
30
25
Vg min
20
Vg max
15 X3
T1
10
4 S
R2
0 0.2 0.4 0.6 0.8 1.0 M1
Displacement Vg/Vg max
DR Pressure controller
The pressure controller limits the maximum pressure at the Schematic DR
pump outlet within the control range of the pump. The variable
pump only delivers as much hydraulic fluid as the consumers
actually need. If the operating pressure exceeds the pressure
setpoint set at the integrated pressure valve, the pump will
regulate to a smaller displacement to reduce the control devia-
tion. U R1
In a non-pressurized state, the pump is swiveled to its initial B(A)
position to Vg max by a return spring.
A1
Setting range for pressure control_____________ 50to350bar
Please state the pressure control setting in plain text when
ordering.
Note
On versions with DR controller, a case drain line from port T1
Vg min
to the reservoir is essential.
Vg max
Any pressure-relief valve included in the system to limit the X3
maximum pressure must be set to a cracking pressure at T1
least 20bar above the controller setting.
Characteristic DR S
R2
M1
max. 10 bar
max
350
Zero stroke operation
The standard version is designed for intermittent, constant-

pressure operation. Short-term (< 1min), zero-stroke operation
is permissible up to an operating pressure pmax=315bar with
reservoir temperature 50C.
In the case of longer zero-stroke operation, the bearings should
be flushed by way of the flushing port U.
Flow port
50
min U R1
T1
qv min Flow rate qv [L/min] qv max

S
R2
Flushing flow (Recommended)

NG 28 55 80 107 160
qv flush L/min 3 4 6 8 12
Temperature of the flushing fluid reservoir temperature

DRG Pressure controller remotely controlled Schematic DRG
A separate sequence valve with port plate provides the pres- 1)

sure control functionality. The valve is mounted away from the
pump, whereby the length of the line should not exceed 5 m.
The valve is supplied with high pressure from port A1 of the 2)
pump. The control power of the valve is returned to the pump P A T
U R1
via port X3 which retards the pump down to Vg min. Care should
be taken that the ports T on the sequence valve and T1 on the A
pump are connected to the reservoir (cooler). A1
Setting range for pressure control _ ____________50 to 315 bar
Please state the pressure control setting in plain text when
ordering.
Note
On versions with DRG controller, a case drain line from port Vg min
T1 to the reservoir is essential.
Vg max X3
Any pressure-relief valve included in the system to limit the
T1
least 20 bar above the controller setting.
S
Sequence valve and port plate must be ordered separately.
Sequence valve (1): DZ5DP2-1X/315YMSO21 R2
M1
(Mat.No. R900495604)
Port plate (2): G 115/1 (Mat.No. R900424379) Positions (1) and (2) are not included in the delivery contents
for the pump.
Characteristic DRG
max. 10 bar
max
315
50
min
qv min Flow qv [L/min] qv max

DRS Pressure controller with load sensing Characteristic DRS
The load sensing controller is a flow control option that oper-
max. 10 bar
ates as a function of the load pressure to regulate the pump max
350
displacement to match the consumer flow requirement.

The flow of the pump depends here on the cross section of
the external sensing orifice (1) fitted between the pump and
the consumer. Below the setting for the pressure control and
within the control range of the pump, the flow is independent
of load pressure.
The sensing orifice is usually a separately mounted load-
sensing directional valve (control block). The position of the
directional valve piston determines the opening cross section
of the sensing orifice and thus the flow of the pump. 50
min
The load sensing controller compares pressure before and af-
ter the sensing orifice and keeps the pressure drop (differential
pressure p) and with it the pump flow constant. qv min Flow qv [L/min] qv max
If the differential pressure p at the sensing orifice increases,
the pump is swivelled back (towards Vgmin) and if the differen- Schematic DRS
tial pressure p decreases, the pump is swivelled out (towards
Vgmax) until equilibrium is at the sensing orifice is restored.
psensingorifice=ppumppconsumer
Setting range for p_ _________________________14 to 25 bar
X4
Standard setting __________________________________18 bar U R1
(1)
A
Please state the p setting in plain text when ordering.
The stand-by pressure during zero-stroke operation (sensing A1
orifice closed) is slightly above the p setting.
Note
On versions with DRS controller, a case drain line from port T1
to the reservoir is essential.
The pressure controller overrides the load sensing controller, Vg min
i.e. the load sensing function operates below the set pressure.
Vg max
X3
T1
R2 M1
(1) The sensing orifice (control block) is not included in the

delivery contents.
HD Proportional control hydraulic

The proportional hydraulic control provides infinite setting of Schematic HD
the displacement, proportional to the pilot pressure applied to
port X1. U R1 M1
B(A)
Maximum permissible pilot pressure pSt=40bar
A1
Adjustment from Vgmin to Vgmax (positive control) T1
Vg min
With increasing pilot pressure the pump swivels to a higher X3
Vg max
displacement.
Beginning of control (at Vgmin), adjustable _ ______ 4to15bar
Please state the beginning of control in plain text when
ordering.
from its initial position Vgmin to Vgmax.
sure or the external control pressure applied to port Y3.
S
In order to ensure control function even at low operating R2
pressures <40bar, port Y3 must be supplied with an external Y3
Characteristic HD1 positive control

Control pressure increase Vg min to Vgmax________ Dp=10bar X1
40
35
Pilot pressure ppilot [bar]
Note
30
The spring return feature in the controller is not a safety
25 device.
20 The controller can stick in an undefined position by internal
15 contamination (contaminated hydraulic fluid, abrasion or
residual contamination from system components). As a result,
10 the control will no longer respond correctly to the operator's
4 commands.
Check whether the application on your machine requires ad-
0 0.2 0.4 0.6 0.8 1.0 ditional safety measures, in order to bring the driven actuator
Displacement Vg/Vg max into a controlled and safe position (e. g. - immediate stop).
Characteristic HD2 positive control

Control pressure increase Vg min to Vg max________ Dp = 25 bar
40
35
Pilot pressure ppilot [bar]
30
25
20
15
10
0 0.2 0.4 0.6 0.8 1.0

HD Proportional control hydraulic

HD.G Hydraulic control Schematic HD.G
with pressure cut-off, remotely controlled 1)
A separate sequence valve with port plate provides the pres-
sure cut-off functionality. The valve is mounted away from the
pump, whereby the length of the line should not exceed 5m. 2)
The valve is supplied with high pressure from port A1 of the U R1 M1 P A T
pump. By way of port X3 the control power of the pump is B(A)
transmitted to the valve and into the reservoir at port A of the A1
port plate of the sequence valve whereby the pump is retarded
to Vgmin, if the target pressure value is exceeded. Vg min T1
X3
Setting range for pressure cut-off_ _____________50to315bar Vg max
Please state the pressure cut-off setting in plain text when

ordering.
Note
Port A of the sequence valve must be connected to the
reservoir (cooler).
Any pressure-relief valve included in the system to limit the
least 20 bar above the controller setting. S
Sequence valve and port plate must be ordered separately. R2
Y3
Sequence valve (1): DZ5DP2-1X/315XYMSO20
(Mat.No. R900490554)
Port plate (2): G 115/1 (Mat.No. R900424379)
X1
Characteristic HD.G positive control
Positions (1) and (2) are not included in the delivery contents
max. 10 bar
for the pump.

max
315
50
min
qv min Flow qv [L/min] qv max

EP Proportional control electric

The proportional electric control provides infinite adjustment of Schematic EP2
the displacement, proportional to the control current applied to
the solenoid. U R1 M1
B(A)
Adjustment from Vgmin to Vgmax (positive control)
A1
With increasing control current the pump swivels to a higher T1
Vg min
displacement. X3
Vg max
from its initial position Vgmin to Vgmax.
sure or the external control pressure applied to port Y3.
In order to ensure control function even at low operating
pressures <40 bar, port Y3 must be supplied with an external
Characteristic EP2 positive control

S
800 R2
Y3
700
Control current I [mA]
600
500
400
300 EP2G Electric control
200 with pressure cut-off, remotely controlled
100 See HD.G
Note
0 0.2 0.4 0.6 0.8 1.0
The spring return feature in the controller is not a safety
device.
Technical data, solenoid The controller can stick in an undefined position by internal
EP2 contamination (contaminated hydraulic fluid, abrasion or
residual contamination from system components). As a result,
Voltage 24V (20%) the control will no longer respond correctly to the operator's
Control current commands.
Beginning of control 200mA Check whether the application on your machine requires ad-
End of control 600mA ditional safety measures, in order to bring the driven actuator
Limiting current 0.77A into a controlled and safe position (e. g. - immediate stop).
Nominal resistance (at 20C) 22.7W
Dither frequency 100Hz
Duty cycle 100%
Type of protection see connector design page 33
The following electronic controllers and amplifiers are available
for controlling the proportional solenoids:
BODAS controller RC
Series 20_ _________________________________ RE 95200
Series 21___________________________________ RE 95201
Series 22_ _________________________________ RE 95202
Series 30_ _______________________ RE 95203, RE 95204
and application software
Analog amplifier RA__________________________ RE95230
Further information can also be found on the Internet at
www.boschrexroth.com/mobile-electronics
Dimensions size 28 Before finalizing your design, request a binding

installation drawing. Dimensions in mm.
LR Power controller
Note: All versions of the controller are illustrated for clockwise direction of rotation (View Y).
215
209 (A1)
207
16 T1 A1
261) U R1 45
45
X3
92
100 -0.022
33
11
20
62
118
5
12
29
18
'
Y
30
12
119
118
7
R2
13.4 max
25 198
Flange 209 (X3)
ISO 3019-2 View Y
clockwise
direction of rotation
View Y 71 79
counter-clockwise 49 60
direction of rotation 52
T1 X3 X3 T1
A1 A1
S S
LR LR
69.9
50.8
38
19
24
A B
23.8 35.7
49
108.5
1) To shaft collar

Drive shafts
Z Splined shaft DIN 5480 P Parallel keyed shaft
W25x1.25x18x9g DIN 6885, AS8x7x40
19
M8 x 1.251)2)
19
M8 x 1.251)2)
25+0.002
+0.015
6
6 Key width 8
35
35
28
28
50
43
Ports
Designation Port for Standard Size2) Maximum State6)
pressure [bar]3)
A Service line (high pressure series) SAE J5184) 3/4 in 400 O
Fastening thread DIN 13 M10 x 1.5; 17 deep
S Suction line (standard series) SAE J5184) 1 1/2 in 2 O
U Bearing flushing DIN 38525) M16 x 1.5; 12 deep 2 X
R1, R2 Air bleed DIN 38525) M18 x 1.5; 12 deep 2 X
A1 Measuring high pressure DIN 38525) M12 x 1.5; 12 deep 400 X
T1 Pilot fluid drain DIN 38525) M12 x 1.5; 12 deep 400 X
T1 Pilot fluid drain (only DR, ..D..) DIN 38525) M12 x 1.5; 12 deep 400 O
X3 Override DIN 38525) M12 x 1.5; 12 deep 400 X
Y3 External pilot pressure DIN 38525) M14 x 1.5; 12 deep 40 X
X1 Pilot pressure DIN 38525) M14 x 1.5; 12 deep 40 O
M1 Measuring control pressure DIN 38525) M12 x 1.5; 12 deep 400 X
1) Center bore according to DIN 332 (thread according to DIN 13)
2) Observe the general instructions on page 36 for the maximum tightening torques.
3) Momentary pressure spikes may occur depending on the application. Keep this in mind when selecting measuring devices and
fittings.
4) Only dimensions according to SAE J518, metric fastening thread is a deviation from standard.
5) The spot face can be deeper than specified in the appropriate standard.
6) O = Must be connected (plugged on delivery)
X = Plugged (in normal operation)

LRD
Power controller with pressure cut-off
D 236
124
LR
108.5
DR/DRG
Pressure controller / pressure controller remotely controlled
DR 236
DRG
132 (DR)
92 (DRG)
HD1, HD2/HD1G, HD2G EP2/EP2G

Proportional control hydraulic, positive control Proportional control electric, positive control
and variants with pressure cut-off, remotely controlled and variants with pressure cut-off, remotely controlled
216 216
85
85
76 (X3)
76 (X3)
78 (A1)
78 (A1)
153
153
170
199
A1 X3 A1 X3
264
X3 A1 X3 A1
Y3 Y3
X1
Y3
4.5 15 155 (X1) Y3
49 159 (Y3) X1
187 (A1) 49 15 159 (Y3)
188 (X3) 187 (A1)
188 (X3)

LR Power controller
262
241 (T1)
232
20
321)
45 45
U R1 T1
A1
140
X3
125 -0.025
13.5
36
35
150
70
12
35
0
16
0'
Y
3
12
142 150
7.5 R2
14.6 max
31 241 (A1)
Flange 242 (X3)
ISO 3019-2
View Y
clockwise
View Y
57 62
LR LR
12
T1 A1 A1 T1
S X3 X3 S
50.8
77.8
49
19
32
A B
23.8 42.9
49
100
1) To shaft collar

Drive shafts
W30x2x14x9g DIN 6885, AS8x7x50
M12 x 1.751)2)
M12 x 1.751)2)
28 28
30+0.002
+0.015
9.5 9.5 Key width 8
45
45
33
27 60
35
Ports
pressure [bar]3)
A Service line (high pressure series) SAE J5184) 3/4 in 400 O
S Suction line (standard series) SAE J5184) 2 in 2 O
Fastening thread DIN 13 M12 x 1.75; 20 deep2)
X4 Load pressure DIN 38525) M14 x 1.5; 12 deep 400 O
fittings.

LRD LRDH1
Power controller with pressure cut-off Power controller with pressure cut-off and stroke limiter
262
12 257 (X1)
D
252 (Y3)
X1 D X1
Y3 Y3
128
170
LR
127
105
LR
119
119
DR/DRG DRS
Pressure controller / pressure controller remotely controlled Pressure controller with load sensing
6 300
DR X4 DR 238
DRG X4
135 (DR)
114 (DRG)
151
141
S

256 256 100

100
82
101
82
101
170
170
192
A1 X3
221
286
A1 X3
X3 Y3 A1
X3 Y3 A1
X1
12 12 186 (X1) Y3
Y3
57 190 (Y3) X1 12 12 190 (Y3)
209 (A1) 57 209 (A1)
221 (X3) 221 (X3)

LR Power controller
287
270 (T1)
253
23
45 45
321)
U R1 T1
A1
144
X3
13.5
165
140 -0.025
40
38
0
83
18
17
37
0'3
Y
12
157
165
7.5 R2
14.6 max
31 265 (X3)
Flange 270 (A1)
ISO 3019-2 View Y
clockwise
View Y 80 102
direction of rotation 22 64
LR LR
T1 A1 A1 T1
S X3 X3 S
88.9
57.2
62
25
34
A B
27.8 50.8
57
111
1) To shaft collar

Drive shafts
W35x2x16x9g DIN 6885, AS10x8x56
M12 x 1.751)2)
28
M12 x 1.751)2)
28
35+0.002
+0.018
9.5
9.5 Key width 10
50
50
38
32
70
40
Ports
pressure [bar]3)
A Service line (high pressure series) SAE J5184) 1 in 400 O
fittings.

LRD LRDH1
290
14 284 (X1)
D 279 (Y3)
X1 D X1
Y3 Y3
132
182
LR
138
116
LR
130
130
DR/DRG DRS
6 327
DR X4 DR 265 X4
DRG
125 (DRG)
139 (DR)
161
151
S

287 287
114
114
92
92
113
113
187
209
187
240
A1 X3 A1 X3
305
X3 Y3 A1 X3 Y3 A1
X1
22 14 207 (X1) Y3 Y3
62 212 (Y3) X1
237 (A1) 22 14 212 (Y3)
241 (X3) 62 237 (A1)
241 (X3)

LR Power controller
307
286 (T1)
272
25
45 45
401)
U R1
A1
150
X3
17.5
160 -0.025
46
37
190
90
18
0
41
20
0'3
12
170
190
R2
7.5
14.6 max
39 284 (X3)
Flange 289 (A1)
ISO 3019-2
View Y
clockwise
View Y 88 105
counter-clockwise
70 74
direction of rotation 22 72
LR LR
T1 T1
A1 A1
S X3 S
X3
88.9
57.2
25
62
36
A B
27.8 50.8
55
115
1) To shaft collar

Drive shafts
Z Splined shaft, DIN 5480 P Parallel keyed shaft
W40x2x18x9g DIN 6885, AS12x8x63
M12 x 1.751)2)
28
M12 x 1.751)2)
28
40+0.002
+0.018
9.5
9.5 Key width 12
60
43
60
37
80
45
Ports
pressure [bar]3)
A Service line (high pressure series) SAE J5184) 1 in 400 O
fittings.

LRD LRDH1
309
18 300 (X1)
D
295 (Y3)
X1 D X1
Y3 Y3
138
189
LR
144
122
LR
134
134
DR/DRG DRS
352
DR
X4 DR 290 X4
DRG
132 (DRG)
145 (DR)
167
154
S

306
306
122
122
100
119
100
119
199
199
221
252
A1 X3
316
A1 X3 Y3 A1
X3 Y3 A1 X3
X1
Y3
22 18 220 (X1) Y3
70 225 (Y3) X1
22 18 225 (Y3)
254 (A1) 70 254 (A1)
259 (X3) 259 (X3)

LR Power controller
349
328 (T1)
310
28 45
45
401)
U R1 T1
A1
160
X3
17.5
180 -0.025
55
46
210
100
27
47 22
0'
123
193 Y
210
7.5
R2
14.9 max
39
327 (X3)
Flange 331 (A1)
ISO 3019-2
View Y
clockwise
View Y 100 126

counter-clockwise
78 84
direction of rotation LR
LR 22
T1 A1 A1 T1
S X3 X3 S
106.4
66.7
32
75
40
A B
31.8 61.9
66
1) To shaft collar

Drive shafts
W45x2x21x9g DIN 6885, AS14x9x70
36
M16 x 21)2)
36
45+0.002
12
+0.018
M16 x 21)2)
12 Key width 14
70
48.5
70
42
50 90
Ports
pressure [bar]3)
A Service line (high pressure series) SAE J5184) 1 1/4 in 400 O
S Suction line (standard series) SAE J5184) 3 in 2 O
R1, R2 Air bleed DIN 38525) M26 x1.5;16 deep 2 X
fittings.

LRD LRDH1
351
19 340 (X1)
D
334 (Y3)
X1 D X1
Y3
Y3
150
207
LR
162
140
LR
145
145
DR/DRG DRS
392
DR X4 DR
DRG
329 X4
150 (DRG)
155 (DR)
185
172
S

348 348
137
137
120
120
139
139
225
225
248
278
A1 X3
343
A1 X3
X3 Y3 A1 X3 Y3 A1
X1
22 19 249 (X1) Y3 Y3
78 253 (Y3) X1
290 (A1) 22 19 253 (Y3)
294 (X3) 78 290 (A1)
294 (X3)
Connector for solenoids Before finalizing your design, request a binding

DEUTSCH DT04-2S-EP04
Molded, 2-pin, without bidirectional suppressor diode
There is the following type of protection with mounted mating
connector:
IP67_ ___________________________________DIN/EN 60529
and IP69K_ _______________________________ DIN 40050-9
Circuit symbol
Mating connector
DEUTSCH DT06-2S-EP04
Bosch Rexroth Mat. No. R902601804
Consisting of: DT designation
1 housing _____________________________ DT06-2S-EP04
1 wedge _______________________________________ W2S
2 sockets ____________________________ 0462-201-16141
The mating connector is not included in the delivery contents.
This can be supplied by Bosch Rexroth on request.
36.7
(2)
(1)
36.7
37
50
68.5
Changing connector orientation

If necessary, you can change the connector orientation by turn-
ing the solenoid housing.
To do this, proceed as follows:
1. Loosen the mounting nut (1) of the solenoid. To do this, turn
the mounting nut (1) one turn counter-clockwise.
2. Turn the solenoid body (2) to the desired orientation.
3. Retighten the mounting nut. Tightening torque: 5+1 Nm.
(WAF26, 12-sided DIN 3124)
On delivery, the connector orientation may differ from that
shown in the brochure or drawing.
Installation instructions
General Below-reservoir installation (standard)
During commissioning and operation, the axial piston unit Below-reservoir installation means that the axial piston unit is
must be filled with hydraulic fluid and air bled. This must also installed outside of the reservoir below the minimum fluid level.
observed following a relatively long standstill as the axial piston
unit may drain back to the reservoir via the hydraulic lines. 1 2
1
Particularly in the installation position "drive shaft upwards"
filling and air bleeding must be carried out completely as there 2 SB
SB
is, for example, a danger of dry running. ht min ht min
hmin
The case drain chamber is internally connected to the suction U R1 amin hmin amin
R2
chamber. A case drain line from the case to the reservoir is not S
required. Exception: for operation with pressure controller or T11)
pressure cut-off, a case drain line from port T1 to the reservoir
is required. S T11)
R2 R1 U
To achieve favorable noise values, decouple all connecting
lines using elastic elements.
3 4
In all operating conditions, the suction and case drain lines
must flow into the reservoir below the minimum fluid level. The SB 4 SB
minimum suction pressure at port S must also not fall below 3
ht min ht min
0.8 bar absolute during operation.
amin hmin hmin amin
T11)
Installation position S R2
U
See the following examples 1 to 4. R1
Further installation positions are possible upon request. R1
Recommended installation position: 1 and 2. U R2
Note S T11)
Axial piston units with electric components (e.g. electric con-
trols, sensors) must not be installed in a reservoir below the Installation
Air bleed Filling
fluid level. position
1 R1 S
2 R2 S
3 T1 S
4 U S
R1, R2 Air bleed port

U Bearing flushing
S Suction port
T1 Drain port
ht min Minimum required immersion depth (200 mm)
hmin Minimum required spacing to reservoir bottom
(100mm)
SB Baffle (baffle plate)
amin When designing the reservoir, ensure adequate
space between the suction line and the case drain
line. This prevents the heated, return flow from being
drawn directly back into the suction line.
1) Only for versions with pressure controller or pressure cut-off,
a case drain line form port T1 to the resorvoir is essential.
Notice
General instructions
The pump A7VO is designed to be used in open circuit. Pressure cut-off and pressure controller do not provide secu-
rity against pressure overload. A pressure-relief valve is to be
The project planning, installation and commissioning of the
provided in the hydraulic system.
axial piston unit requires the involvement of qualified person-
nel. The data and notes contained herein must be adhered to.
Before using the axial piston unit, please read the corre- The product is not approved as a component for the safety
sponding instruction manual completely and thoroughly. If concept of a general machine according to ISO 13849.
necessary, these can be requested from Bosch Rexroth.
The following tightening torques apply:
During and shortly after operation, there is a risk of burns on
-- Fittings:
the axial piston unit and especially on the solenoids. Take
Observe the manufacturer's instructions regarding the
appropriate safety measures (e. g. by wearing protective
tightening torques of the fittings used.
clothing).
-- Mounting bolts:
Depending on the operating conditions of the axial piston
For mounting bolts with metric ISO thread according to
unit (operating pressure, fluid temperature), the characteris-
DIN 13 or thread according to ASME B1.1, we recommend
tic may shift.
checking the tightening torque in individual cases in accor-
Service line ports: dance with VDI 2230.
-- The ports and fastening threads are designed for the speci- -- Female threads in the axial piston unit:
fied maximum pressure. The machine or system manufac- The maximum permissible tightening torques MGmax are
turer must ensure that the connecting elements and lines maximum values of the female threads and must not be
correspond to the specified application conditions (pres- exceeded. For values, see the following table.
sure, flow, hydraulic fluid, temperature) with the necessary
-- Threaded plugs:
safety factors.
For the metallic threaded plugs supplied with the axial pis-
-- The service line ports and function ports can only be used ton unit, the required tightening torques of threaded plugs
to accommodate hydraulic lines. MV apply. For values, see the following table.
Ports Maximum permissible Required WAF

tightening torque of the tightening torque of the hexagon socket of the
Standard Size of thread female threads MG max threaded plugs MV1) threaded plugs
DIN 3852 M12 x 1.5 50Nm 25 Nm2) 6 mm
M14 x 1.5 80 Nm 35 Nm 6 mm
M16 x 1.5 100 Nm 50Nm 8 mm
M18 x 1.5 140 Nm 60 Nm 8 mm
M22 x 1.5 210 Nm 80 Nm 10 mm
M26 x 1.5 230 Nm 120 Nm 12 mm
1) The tightening torques apply for screws in the "dry" state as
received on delivery and in the "lightly oiled" state for instal-
lation.
2) In the "lightly oiled" state, the MV is reduced to 17 Nm for
M12 x 1.5.
Bosch Rexroth AG This document, as well as the data, specifications and other information set
Mobile Applications forth in it, are the exclusive property of Bosch Rexroth AG. It may not be repro-
Glockeraustrae 4 duced or given to third parties without its consent.
89275 Elchingen, Germany The data specified above only serve to describe the product. No statements
Tel. +49 7308 82-0 concerning a certain condition or suitability for a certain application can be de-
Fax +49 7308 7274 rived from our information. The information given does not release the user from
info.brm@boschrexroth.de the obligation of own judgment and verification. It must be remembered that our
products are subject to a natural process of wear and aging.
www.boschrexroth.com/axial-piston-pumps
Subject to change.

Re92202 2012-05

Încărcat de

Informații document

Titlu original

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Re92202 2012-05

Încărcat de

Drepturi de autor:

Formate disponibile

Axial Piston Variable Pump RE 92202/05.

Ordering code for standard program

Axial piston unit

Control devices 28 55 80 107 160

Directions of rotation 28 to 160

Drive shafts 28 to 160

Port plate for service lines

= Available = Not available = Preferred program

Ordering code for standard program

Connector for solenoids (see page 33)

Standard / special version

= Available = Not available = Preferred program

taken into account when determining the viscosity in the bear-

opt operating parameters, we recommend flushing the case at

Viscosity and temperature of hydraulic fluid

Differential pressure p [bar]

pressure is dependent on the speed and displacement of the

Values for other hydraulic fluids, please contact us.

Minimum pressure (high-pressure side)

1) The values are valid:

Determining the operating characteristies

Effect of radial force Fq on the service life of bearings

Toothed gear drive V-belt drive

Clockwise Counter-clockwise Clockwise

Operating pressure pB [bar]

The pressure cut-off corresponds to a pressure control which

Operating pressure pB [bar]

Any pressure-relief valve included in the system to limit the A1

The hydraulic stroke limiter, the displacement of the pump X1

The standard version is designed for intermittent, constant-

qv min Flow rate qv [L/min] qv max

Flushing flow (Recommended)

Temperature of the flushing fluid reservoir temperature

A separate sequence valve with port plate provides the pres- 1)

qv min Flow qv [L/min] qv max

The load sensing controller is a flow control option that oper-

Operating pressure pB [bar]

(1) The sensing orifice (control block) is not included in the

HD Proportional control hydraulic

Characteristic HD1 positive control

Characteristic HD2 positive control

0 0.2 0.4 0.6 0.8 1.0

HD Proportional control hydraulic

Please state the pressure cut-off setting in plain text when

for the pump.

qv min Flow qv [L/min] qv max

EP Proportional control electric

Characteristic EP2 positive control

Dimensions size 28 Before finalizing your design, request a binding

Dimensions size 28 Before finalizing your design, request a binding

Dimensions size 28 Before finalizing your design, request a binding

HD1, HD2/HD1G, HD2G EP2/EP2G

Dimensions size 55 Before finalizing your design, request a binding

Dimensions size 55 Before finalizing your design, request a binding

Dimensions size 55 Before finalizing your design, request a binding

HD1, HD2/HD1G, HD2G EP2/EP2G

256 256 100

Dimensions size 80 Before finalizing your design, request a binding

Dimensions size 80 Before finalizing your design, request a binding

Dimensions size 80 Before finalizing your design, request a binding

HD1, HD2/HD1G, HD2G EP2/EP2G

Dimensions size 107 Before finalizing your design, request a binding

Dimensions size 107 Before finalizing your design, request a binding