SECTION 04-01-09 (Hydraulic Vendor Literature) p1

Literatura do fornecedor
Sistemas hidráulicos
SEÇÃO 04-01-09
A Joy Global fez todos os esforços para tornar este manual o mais preciso possível com base nas
informações disponíveis à época de sua publicação e impressão. A melhoria e o avanço contínuos no projeto
de produtos poderão causar alterações às máquinas que podem não ter sido incluídas nesta publicação. A
Joy Global reserva-se o direito de fazer alterações e melhorias a qualquer momento. Para garantir a
obtenção das informações mais atualizadas, entre em contato com o seu centro de serviços.
Literatura do fornecedor
VL38 - Bomba de palheta dupla de alta pressão e alto desempenho
Vickers - modelo 2525VPF, série 21
VL 34B - Manual de serviço do amplificador de fluxo OSQA/OSQB
Danfoss (HN.25.D2.93)
VL 34A - Unidade de direção hidrostática OSPB-OSPC Danfoss
(EN.21.AC.02)
VL 77-1 – Válvulas proporcionais Danfoss PVG 32
VL 77-2 – Informações técnicas sobre Danfoss PVE - série 4
VL 77-3 – Guia de montagem/desmontagem para manutenção do
PVG 16 e 32
VL 112 – Guia de resolução de problemas da bomba hidráulica de
palheta Denison
VL 113 – Bomba de pistão axial variável Rexroth A10V0 (versão
para os EUA)
VL 114 – Bomba dupla de pistão axial variável Rexroth (A20VO)
VL 115 – Bomba de pistão axial variável Rexroth (A11VO)
AVISO
A literatura do fornecedor nesta seção abrange diversos componentes. Antes de usar a literatura,
verifique qual é seu modelo. Algumas partes da literatura mostram componentes ligeiramente
diferentes. Para solicitar peças, é essencial usar o manual de peças da Joy Global emitido para a
máquina na qual o trabalho está sendo realizado.
____________________________________________________________________________________________________________
Seção 04-01-09 DOC C-r00 1 Copyright © 2016 Joy Global
L-950/1150/1350/1850/2350
3/1/2016
Literatura do fornecedor – Sistemas hidráulicos Generation 2
Esta página foi deixada intencionalmente em branco
Copyright © 2016 Joy Global 2 Seção 04-01-09 DOC C-r00

L-950/1150/1350/1850/2350
3/1/2016
VL-38
VL-38
VL-38
VL-38
Flow-Amplifier
OSQA / OSQB
Service Manual
VL34B
Flow-Amplifier OSQA / OSQB
Service Manual
Tools
A
Guide screws Material : M8x1
Hook Material : Wire
Tools B
• Hexagon keys 4, 5, 6, 8, and 10 mm
• Ratchet for socket spanners
• Hexagon socket for external hexagon
13, 17, and 19 mm
• Hexagon socket for internal hexagon
8 and 10 mm
• Multigrip pliers
• Ring spanner 13 mm
• Screwdrivers 3 and 10 mm
• Steel mandrels 3, 5 and 8 mm
• Torque wrench for 12 daNm [1060 lbf in]
• Magnetic rod
Tools mentioned in A and B cannot be bought

from Sauer-Danfoss.
2 HN.25.F3.93 • Rev AC • Sep2010

Service Manual
Dismantling OSQA / OSQB
Dismantling Counter 1 Unscrew plug with O-ring

Pressure Valve (hexgon socket for 8 mm internl hexagon).
2 Take out small spring (hook).
3 Take out ball (magnetic rod).
4 Take out piston.
HN.25.F3.93 • Rev AC • Sep2010 3

Service Manual
5 Take out spring.
6 Counter pressure valve shown dismantled.
7 Counter pressure valve with orifice shown

dismantled.
Removing Pressure Relief 8 Unscrew plug with washer

Valve (hexagon socket for 8 mm internal
hexagon).
4 HN.25.F3.93 • Rev AC • Sep2010

Service Manual
9 Unscrew pressure relief valve

(10 mm hexagon key).
10 Take out washer (magnetic rod).
Dismantling Pressure 11 H
old cartridge (multigrip pliers)
Relief Valve and unscrew the adjustment screw
(5 mm hexagon key).
12 Pressure relief valve shown dismantled.
HN.25.F3.93 • Rev AC • Sep2010 5

Service Manual
Removing End Cover at 13 U

nscrew screw with spring washer using
PP-Connection hexagon socket for 13 mm external
hexagon and 10 mm internal hexagon.
14 Remove end cover.
15 Remove stop and 2 springs.
16 Remove spring.
6 HN.25.F3.93 • Rev AC • Sep2010

Service Manual
17 Remove plate and 6 O-rings.
18 Remove spring guide.
Removing End Cover at 19 U

nscrew screws with spring washer
LS-Connection using hexagon socket for 13 mm external
hexagon and 10 mm internal hexagon.
20 Remove end cover.
HN.25.F3.93 • Rev AC • Sep2010 7

Service Manual
21 Remove stop and 2 springs.
22 Remove stop and spring.
23 Remove plate and 4 O-rings.
24 Remove spring guide.
8 HN.25.F3.93 • Rev AC • Sep2010

Service Manual
Removing Spools 25 Remove directional spool.
26 Remove amplifier spool.
27 Remove priority valve spool.
Removing Orifices and 28 U

nscrew orifice in LS-connection
Throttle Check Valve with 6 mm hexagon key.
HN.25.F3.93 • Rev AC • Sep2010 9

Service Manual
29 U
nscrew throttle check valve in
PP-connection with 6 mm hexagon key.
30 U
nscrew orifice in housing with 4 mm
hexagon key.
Removing Shock Valves 31 R

emove shock valve with screwdriver
and hexagon key.
Overview of Dismantled 32 Housing and end cover with accessories.

Parts
10 HN.25.F3.93 • Rev AC • Sep2010

Service Manual
33 Spool with accessories.
Dismantling of 34 U
nscrew orifice with 4 mm hexagon key.
Directional Spool Use a mandrel.
35 Directional spool shown dismantled.
Dismantling of Priority 36 U
nscrew plug or throttle check valve
Valve Spool with 8 mm hexagon key.
HN.25.F3.93 • Rev AC • Sep2010 11

Service Manual
37 P
riority valve spool with plug for
external PP shown dismantled.
38 P
riority valve spool with throttle check
valve for internal PP shown dismantled.
Dismantling of Amplifier 39 C
arefully remove the spring ring from
Spool the recess with 3 mm screwdriver.
Note: Avoid damage to the spring ring.
40 Carefully guide the spring ring back.
12 HN.25.F3.93 • Rev AC • Sep2010

Service Manual
41 C
arefully take the spring ring from the
recess and guide it back with 3 mm
screwdriver.
Note: Avoid damage to the spring ring.
42 Press pin out gently with finger.
43 Take out plug.
44 Take out spring.
HN.25.F3.93 • Rev AC • Sep2010 13

Service Manual
45 Take out pin with 3 mm screwdriver.
46 Take out inner spool.
47 U
nscrew check valve with hexagon
socket for 17 mm external hexagon and
mandrel in the pin hole.
Note: Avoid damaging the spool surface.
48 U
nscrew orifice out of plug with 4 mm
hexagon key. Use a mandrel.
14 HN.25.F3.93 • Rev AC • Sep2010

Service Manual
49 Amplifier spool shown dismantled.
50 U
nscrew plug with 4 mm hexagon key
and hexagon socket for 17 mm external
hexagon.
Dismantling of Check 51 Check valve shown dismantled.

Valve
HN.25.F3.93 • Rev AC • Sep2010 15

Service Manual
Dismantling of Shock 52 U
nscrew locknut with hexagon socket for
Valve/Suction Valve 13 mm external hexagon. Use a mandrel.
53 Take out disc and spring.
54 Take off housing.
55 U
nscrew pilot valve with hexagon
socket for 19 mm external hexagon.
Use a mandrel.
16 HN.25.F3.93 • Rev AC • Sep2010

Service Manual
56 Take out pilot valve and spring.
57 Take out spool.
58 U
nscrew adjustment screw and take
out spring and ball.
HN.25.F3.93 • Rev AC • Sep2010 17

Service Manual
59 S hock valve/suction valve shown

dismantled.
Cleaning Clean all parts carefully with low aromatic

kerosene.
Inspection and Replace all gaskets and sealing washers.

Replacement Check all other parts carefully and replace
if necessary.
Lubrication Before assembly, lubricate all parts with

hydraulic oil.
18 HN.25.F3.93 • Rev AC • Sep2010

Service Manual
Assembly of OSQA / OSQB
Assembly of Shock Valve/ 60 Guide spring with cone into housing.

Suction Valve
61 Fit adjustment screw.
62 Fit spool.
63 Fit spring.
HN.25.F3.93 • Rev AC • Sep2010 19

Service Manual
64 Fit pilot valve. Remember O-ring.
65 T ighten with torque wrench for 19

mm external hexagon. Use a mandrel.
Tightening torque: 2 ± 0.5 daNm.
[175 ± 45 lfb in].
66 Fit housing.
67 Fit spring.
20 HN.25.F3.93 • Rev AC • Sep2010

Service Manual
68 Fit disc.
69 Fit
locknut.
Tightening torque 1.5 ± 0.2 daNm
[135 ± 29 lbf in].
Contact Sauer-Danfoss Service Shop for

adjustment
HN.25.F3.93 • Rev AC • Sep2010 21

Service Manual
Assembly of Check Valve 70 Fit ball, spring and plug. Tightening

torque: 0.5 ± 0.1 daNm.
[45 ± 10 lbf in].
Assembly of Amplifier 71 Fit orifice in plug. Tightening

Spool torque: 0.5 ± 0.1 daNm. [45 ± 90 lbf in].
72 Fit check valve. Tightening

torque: 2 ± 0.3 daNm. [175 ± 25 lbf in].
Note: void damaging spool surface.

A
Remember O-ring.
73 Place inner spool in the correct position.
Note: hen assembling OSQA 5 and OSQB

W
5 there are two ways of placing the
inner spool, only one is correct. The
pilot channel witch is faced upwards
must be lined up with one of the 5
amplification holes in the outer spool.
22 HN.25.F3.93 • Rev AC • Sep2010

Service Manual
74 Guide inner spool in.
75 Fit pin.
76 Push spring ring into position.

Place spring ring into the recess with
end facing away from pin holes.
77 Fit spring.
HN.25.F3.93 • Rev AC • Sep2010 23

Service Manual
78 Fit plug.
79 Fit pin.
80 Push spring ring into position.

Place spring ring into the recess with
ends facing away from pin holes.
Assembly of Priority 81 Fit prop or throttle check valve.

Valve Spool External pp: plug. Internal pp:
throttle check valve. Tightening
24 HN.25.F3.93 • Rev AC • Sep2010

Service Manual
Assembly of Directional 82 Screw in orifice. Tightening torque:

Spool 0.5 ± 0.1 daNm [45 ± 10 lbf in].
Installation of Orifice and 83 Fit orifice in housing. Tightening torque:

Throttle Check Valve 0.5 ± 0.1 daNm. [45 ± 10 lbf in].
84 Fit orifice in LS-connection.

[90 ± 25 lbf in].
85 Fit throttle check valve in PP-connection.

[90 ± 25 lbf in].
Comments on Flow 1 ¼ BSP.F in PP-connection. Fit washer

Amplifiers with Internal and plug. Tightening torque 4 ± 0.3 daNm
PP: [355 ± 25 lbf in].
2 7/16 – 20 UNF in PP-connection: fit
O-ring and plug. Tightening torque:
1.5 ± 0.5 daNm [135 ± 45 lbf in].
HN.25.F3.93 • Rev AC • Sep2010 25

Service Manual
Installation of Shock 86 G
uide shock valve in and secure it by hand.
Valves Remember O-ring.
Assembly of Pressure 87 G
uide adjustment screw, spring and
Relief Valve cone up into the cartridge.
88 S crew the adjustment screw so far in that

the 10 mm hexagon fully engages.
Contact Sauer-Danfoss service shop

for adjustments.
26 HN.25.F3.93 • Rev AC • Sep2010

Service Manual
Installation of Pressure 89 Let the washer drop into the hole.

Relief Valve
90 Fit pressure relief valve. Tightening

91 Fit plug washer. Tightening torque:

6 ± 0.5 daNm. [530 ± 45 lbf in].
Installation of Back 92 First fit spring in position with vaseline.

Pressure Valve Fit assembled piston and spring.
HN.25.F3.93 • Rev AC • Sep2010 27

Service Manual
93 Let the ball drop down.
94 Fit spring in plug with vaseline.

Fit assembled plug and spring.
Remember O-ring. Tightening torque:
2.5 ± 0.3 daNm. [220 ± 25 lbf in].
Installation of Spools 95 Fit directional spool. Fit priority valve

spool.
Note: S pring control must be placed

in correct position against
LS-connection.
96 Fit spring.
Note:Spring must be by the LS-connection
28 HN.25.F3.93 • Rev AC • Sep2010

Service Manual
97 Fit amplifier spool. Note: the orifice

must be placed in correct position
against LS-connection.
Installation of End Cover 98 Fit spring with vaseline on amplifier

at PP-Connection spool.
Note: The spring must be fitted at the

PP-connection.
99 Fit spring guide with vaseline.
100 Fit large and small springs with vaseline.
HN.25.F3.93 • Rev AC • Sep2010 29

Service Manual
101 Fit guide screws.
102 Fit 4 large and 2 small O-rings.
103 Guide plate in.
104 F it stop (thickness: 5mm) in end cover

with vaseline.
30 HN.25.F3.93 • Rev AC • Sep2010

Service Manual
105 Guide end cover in.
106 Fit screw with spring washer.
107 F it screw with spring washer.

Tightening torque: 2.5 + 0.5 daNm.
[220 + 45 lbf in].
Tightening torque for large screws:
8 ± 1 daNm. [710 ± 90 lbf in].
Installation of End Cover

at LS-Connection 108 F it guide screws.
Fit remote control with vaseline.
HN.25.F3.93 • Rev AC • Sep2010 31

Service Manual
109 F it large and small springs with

vaseline.
110 Guide in plate with 4 O-rings.
111 F it stop for priority valve spool

(thickness: 8mm) with vaseline.
112 F it stop for directional spool

(thickness: 5 mm) with vaseline.
32 HN.25.F3.93 • Rev AC • Sep2010

Service Manual
113 Guide in end cover.
114 Fit large screw with spring washer.
115 F it screw with spring washers.

Tightening torque: 2.5 + 0.5 daNm.
[220 ± 45 lbf in].
Tightening torque for large screw:
8 ± 1 daNm. [710 ± 90 lbf in].
116 Fit plastic plugs.
OSQA/OSQB is now assembled

and ready for installation.
HN.25.F3.93 • Rev AC • Sep2010 33

Service Manual
Spare Parts
Spare Parts Spare Parts Code no

-------------------------------------------------------------------------
Set of seals
Complete (NBR) 150F0278

End covers only (Viton) 11020933
-------------------------------------------------------------------------
Relief valve kit
After oct 2004 11011038

-------------------------------------------------------------------------
Shock and suction
valve complete
Setting pressure
Bar psi
140-160 2030-2320 150F0281
165-185 2395-2685 150F0282
200-220 2900-3190 150F0286
215-235 3120-3410 150F0283
230-250 3335-3625 150F0284
270-290 3915-4205 150F0285
-------------------------------------------------------------------------
For other parts please contact Sauer-Danfoss Technical

Support Team.
34 HN.25.F3.93 • Rev AC • Sep2010

Service Manual
Notes
Notes
HN.25.F3.93 • Rev AC • Sep2010 35

Products we oﬀer: Sauer-Danfoss is a global manufacturer and supplier of high-
quality hydraulic and electronic components. We specialize in
• Bent Axis Motors providing state-of-the-art technology and solutions that excel in
the harsh operating conditions of the mobile off-highway market.
• Closed Circuit Axial Piston Pumps
Building on our extensive applications expertise, we work closely
and Motors
with our customers to ensure exceptional performance for a broad
• Displays range of off-highway vehicles.
• Electrohydraulic Power Steering
We help OEMs around the world speed up system development,
• Electrohydraulics reduce costs and bring vehicles to market faster.
Sauer-Danfoss – Your Strongest Partner in Mobile Hydraulics.
• Hydraulic Power Steering
• Integrated Systems
• Joysticks and Control Handles
Go to www.sauer-danfoss.com for further product information.
• Microcontrollers and Software
• Open Circuit Axial Piston Pumps
• Orbital Motors Wherever off-highway vehicles are at work, so is Sauer-Danfoss.
• PLUS+1™ GUIDE
We offer expert worldwide support for our customers, ensuring
• Proportional Valves the best possible solutions for outstanding performance. And with
an extensive network of Global Service Partners, we also provide
• Sensors
comprehensive global service for all of our components.
• Steering
• Transit Mixer Drives
Please contact the Sauer-Danfoss representative nearest you.
Local address:
Members of the Sauer-Danfoss Group:
Comatrol
www.comatrol.com
Schwarzmüller-Inverter
www.schwarzmueller-inverter.com
Sauer-Danfoss (US) Company Sauer-Danfoss ApS
2800 East 13th Street DK-6430 Nordborg, Denmark
Ames, IA 50010, USA Phone: +45 7488 4444
Turolla
Phone: +1 515 239 6000 Fax: +45 7488 4400
www.turollaocg.com Fax: +1 515 239 6618
Hydro-Gear Sauer-Danfoss GmbH & Co. OHG Sauer-Danfoss-Daikin LTD.

www.hydro-gear.com Postfach 2460, D-24531 Neumünster Shin-Osaka TERASAKI 3rd Bldg. 6F
Krokamp 35, D-24539 Neumünster, Germany 1-5-28 Nishimiyahara, Yodogawa-ku
Phone: +49 4321 871 0 Osaka 532-0004, Japan
Sauer-Danfoss-Daikin Fax: +49 4321 871 122 Phone: +81 6 6395 6066
Fax: +81 6 6395 8585
www.sauer-danfoss-daikin.com
HN.25.F3.93 • Rev AC • Sep2010

www.sauer-danfoss.com
VL-34 A
VL-34
VL-34
VL-34
VL-34
VL-34
VL-34
VL-34
VL-34
VL-34
VL-34
VL-34
VL-34
VL-34
VL-34
VL-34
VL-34
VL-34
VL-34
VL-34
VL-34
VL-34
VL-34
VL-34
VL-34
VL-34
VL-34
VL-34
VL-34
VL-34
PVG 32
Proportional Valves
Service Manual
VL77-1
PVG 32
Service Manual
Revisions
HISTORY OF REVISIONS Table of Revisions

Date Page Changed Rev.
November 2012 41 Revised torque on assembly nuts AE

December 2011 41 Revised torque on assembly nuts AD
October 2010 last new back page AC
March 2010 last Fix Osaka address AB
August 2008 - First edition AA
© 2012 Sauer-Danfoss. All rights reserved.
Sauer-Danfoss accepts no responsibility for possible errors in catalogs, brochures and other printed material.
Sauer-Danfoss reserves the right to alter its products without prior notice. This also applies to products
already ordered provided that such alterations aren’t in conflict with agreed specifications. All trademarks in
this material are properties of their respective owners. Sauer-Danfoss and the Sauer-Danfoss logotype are
trademarks of the Sauer-Danfoss Group.
2 11039167 • Rev AE • November 2012

PVG 32
Service Manual
Contents
INTRODUCTION Overview............................................................................................................................................................ 5
General instructions....................................................................................................................................... 5
Safety precautions.......................................................................................................................................... 6
Unintended machine movement........................................................................................................ 6
Flammable cleaning solvents................................................................................................................ 6
Fluid under pressure................................................................................................................................. 6
Personal safety............................................................................................................................................ 6
Hazardous material................................................................................................................................... 6
Acronyms........................................................................................................................................................... 7
OPERATION PVG 32 group with open center PVP (PVB with flow control spool)............................................. 8
PVG 32 group with closed center PVP (PVB with flow control spool).......................................... 8
PVG 32 sectional drawing............................................................................................................................ 9
PVPC plug for external pilot oil supply..................................................................................................10
PVPC with check valve for open center PVP..................................................................................10
PVPC without check valve for open center PVP............................................................................10
Friction detent................................................................................................................................................11
PVMR Friction detent..............................................................................................................................11
PVMF Mechanical float position lock................................................................................................11
PVBS, main spools for flow control (standard)....................................................................................12
PVBS, main spools for flow control (with linear characteristics)...................................................12
PVBS, main spools for pressure control.................................................................................................12
PVPX Electrical LS unloading valve.........................................................................................................13
SYSTEM Overview..........................................................................................................................................................14
TROUBLESHOOTING Troubleshooting a PVG valve....................................................................................................................14
No cylinder/motor response in either direction when remote controller is actuated.........16
Cylinder/motor responds in one direction only.................................................................................16
Main valve spool moves without oil passing to cylinder/motor..................................................17
Cylinder/motor operates without remote controller being operated.......................................18
Cylinder/motor responds slowly to remote electrical or hydraulic controller actuation....19
Erratic cylinder/motor response to electrical or hydraulic controller operation....................19
Hydraulic oil supply......................................................................................................................................20
Electrical supply.............................................................................................................................................21
Hydraulic (remote) pilot control pressure............................................................................................21
11039167 • Rev AE • November 2012 3

PVG 32
Service Manual
Contents
PVG 32 COMPONENT Pressure relief valve......................................................................................................................................22

TROUBLESHOOTING Pressure reducing pilot valve....................................................................................................................22
Pressure gauge connection.......................................................................................................................24
Open center plug..........................................................................................................................................25
Closed center plug and orifice..................................................................................................................26
Pressure adjustment spool........................................................................................................................27
LS connection.................................................................................................................................................28
LS signal............................................................................................................................................................29
Shuttle valve....................................................................................................................................................30
LS pressure limiting valve...........................................................................................................................31
LS A, B shuttle..................................................................................................................................................32
Main spool.......................................................................................................................................................32
Shock and anti-cavitation valve PVLP....................................................................................................34
Pressure compensator.................................................................................................................................35
Load drop check valve . ..............................................................................................................................36
Maximum oil flow adjustment screws for ports A and B................................................................37
PVM module....................................................................................................................................................38
PVS module.....................................................................................................................................................39
PVPVM module..............................................................................................................................................40
PVAS module...................................................................................................................................................41
PVPX LS unloading valve............................................................................................................................41
PVEH, PVES, PVEA electrical actuators....................................................................................................42
PVEO On/Off electrical actuator..............................................................................................................44
4 11039167 • Rev AE • November 2012

PVG 32
Service Manual
Introduction
OVERVIEW This manual includes information for servicing PVG 32 valves. It includes a description
of the units and their individual components, troubleshooting information, and minor
repair procedures.
Performing minor repairs may require removal from the vehicle/machine. Thoroughly
clean the unit before beginning maintenance or repair activities. Since dirt and
contamination are the greatest enemies of any type of hydraulic equipment, follow
cleanliness requirements strictly. This is especially important when changing the system
filter and when removing hoses or plumbing.
A worldwide network of Sauer-Danfoss Global Service Partners is available for major

repairs. Sauer-Danfoss trains and certifies Global Service Partners on a regular basis. You
can locate your nearest Global Service Partner using the distributor locator at www.
sauer-danfoss.com.
For specifications and operating parameters on PVG 32 valves, refer to PVG 32 Technical
Information Manual 520L0344.
Do not attempt to service PVG valves without build sheet specifications for reference.
GENERAL INSTRUCTIONS Follow these general procedures when repairing PVG 32 valves.
w Remove the unit

Chock the wheels on the vehicle or lock the mechanism to inhibit movement. Prior to
performing repairs, remove the unit from the vehicle/machine. Be aware that hydraulic
fluid may be under high pressure and/or hot. Inspect the outside of the valve stack and
fittings for damage. Cap hoses after removal to prevent contamination.
e Keep it clean
Cleanliness is a primary means of assuring satisfactory motor life, on either new or
repaired units. Clean the outside of the valve thoroughly before disassembly. Take care
to avoid contamination of the port connections on the valve stack. Clean parts using a
clean solvent wash and air dry.
As with any precision equipment, keep all parts free of foreign materials and chemicals.
Protect all exposed sealing surfaces and open cavities from damage and foreign material.
If left unattended, cover the valve with a protective layer of plastic.
d Replace all O-rings and gaskets

Sauer-Danfoss recommends you replace all O-rings. Lightly lubricate all O-rings with
clean petroleum jelly prior to assembly.
t Secure the unit

For repair, place the unit in a stable position with the shaft pointing downward. Secure
the motor while removing and torquing controls, and valves.
11039167 • Rev AE • November 2012 5

PVG 32
Service Manual
Introduction
SAFETY PRECAUTIONS Always consider safety precautions before beginning a service procedure. Protect
yourself and others from injury. Take the following general precautions whenever servicing a
hydraulic system.
Unintended machine movement

W Warning
Unintended movement of the machine or mechanism may cause injury to the technician
or bystanders. To protect against unintended movement, secure the machine or disable/
disconnect the mechanism while servicing.
Flammable cleaning solvents

W Warning
Some cleaning solvents are flammable. To avoid possible fire, do not use cleaning
solvents in an area where a source of ignition may be present.
Fluid under pressure

W Warning
Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin
causing serious injury and/or infection. This fluid may also be hot enough to cause burns.
Use caution when dealing with hydraulic fluid under pressure. Relieve pressure in the
system before removing hoses, fittings, gauges, or components. Never use your hand
or any other body part to check for leaks in a pressurized line. Seek medical attention
immediately if you are cut by hydraulic fluid.
Personal safety
W Warning
Protect yourself from injury. Use proper safety equipment, including safety glasses, at all
times.
Hazardous material
W Warning
Hydraulic fluid contains hazardous material. Avoid prolonged contact with hydraulic
fluid. Always dispose of used hydraulic fluid according to state and federal environmental
regulations.
6 11039167 • Rev AE • November 2012

PVG 32
Service Manual
Introduction
ACRONYMS This table provides a definition of commonly used terms.
P = Proportional V = Valve
PVP Pump side module
PVPV/M Pump side module
PVB Basic module
PVLA Anti-cavitation valve
PVLP Shock and anti-cavitation valve
PVS/PVSI End plate
PVAS (PVP, PVPV/M) Assembly kit for PVP, PVPV/M
PVPX, LS LS Unloading valve
PVPC Plug for external pilot oil supply
PVBS Main spool
PVM Mechanical activation
PVMD Cover for mechanical activation
PVH Cover for hydraulic activation
PVMF Cover for mechanical float
PVMR Cover for friction detent PVMR or float position
PVEH, PVES, PVEA Electrical activation
PVEM Electrical activation
PVEO Electrical activation
11039167 • Rev AE • November 2012 7

PVG 32
Service Manual
Operation
PVG 32 GROUP WITH When the pump starts, and the main spools in the individual basic modules (11) are in
OPEN CENTER PVP (PVB the neutral position, oil flows from the pump, through connection P, across the pressure
WITH FLOW CONTROL adjustment spool (6) to tank. The oil flow led across the pressure adjustment spool
SPOOL) determines the pump pressure (stand-by pressure).
When one or more of the main spools actuate, the highest load pressure is fed through
the shuttle valve circuit (10) to the spring chamber behind the pressure adjustment
spool (6), and completely or partially closes the connection to tank.
Pump applies pressure to the right-hand side of the pressure adjustment spool (6). The
pressure relief valve (1) opens if the load pressure exceeds the set value, diverting pump
flow back to tank.
In a pressure-compensated basic module the compensator (14) maintains a constant

Pressure drop across the main spool—both when the load changes and when a module
with a higher load pressure is actuated.
With a non pressure-compensated basic module incorporating a load drop check valve
(18) in channel P, the check valve prevents return oil flow. The basic module can have the
load drop check valve in channel P for functions with over-center valves.
The shock valves PVLP (13) with fixed setting and the suction valves PVLA (17) on ports
A and B are used for the protection of the individual working function against overload
and/or cavitation.
An adjustable Load Sensing (LS) pressure limiting valve (12) can be built into the A and B
ports of pressure-compensated basic modules to limit the pressure from the individual
working functions.
The LS pressure limiting valves save energy compared to the shock valves PVLP. With
PVLP all the oil flow to the working function flows across the combined shock and
suction valves to tank if the pressure exceeds the fixed setting. With LS pressure limiting
valves, an oil flow of about 2 l/min [0.5 US gal/min] flows across the LS pressure limiting
valve to tank if the pressure exceeds the valve setting.
PVG 32 GROUP WITH In the closed center version, an orifice (5) and a plug (7) are fitted instead of the plug (4).
CLOSED CENTER PVP This means that the pressure adjustment spool (6) only opens to tank when the pressure
(PVB WITH FLOW in channel P exceeds the set value of the pressure relief valve (1).
CONTROL SPOOL)
In LS systems, the load pressure flows to the pump regulator via the LS connection (8).
In the neutral position the pump control sets the displacement so that leakage in the
system is compensated to maintain the set stand-by pressure. When a main spool is
actuated, the pump regulator adjusts the displacement to maintain the set differential
pressure between P and LS.
The pressure relief valve (1) in PVP should be set at a pressure of approximately 30 bar
[435 psi] above maximum system pressure (set on the pump or external pressure relief
valve).
8 11039167 • Rev AE • November 2012

PVG 32
Service Manual
Operation
PVG 32 SECTIONAL
DRAWING
PVP
PVB
PVB
1. Pressure relief valve 11. Main spool

2. Pressure reduction valve for pilot oil supply 12. LS pressure limiting valve
3. Pressure gauge connection 13. Shock and suction valve, PVLP
4. Plug, open centre 14. Pressure compensator
5. Orifice, closed centre 15. LS connection, port A
6. Pressure adjustment spool 16. LS connection, port B
7. Plug, closed centre 17. Suction valve, PVLA
8. LS connection 18. Load drop check valve
9. LS signal 19. Pilot oil supply for PVE
10. Shuttle valve 20. Max. oil flow adjustment screws for
ports A and B
11039167 • Rev AE • November 2012 9

PVG 32
Service Manual
Operation
PVPC PLUG FOR PVPC with check valve for open center PVP
EXTERNAL PILOT OIL PVPC, with check valve, is used in systems
SUPPLY where it is necessary to operate the
PVG 32 valve by means of the electrical
remote control without pump flow.
When the external solenoid valve is
opened, oil from the pressure side of the
Oil
cylinder is fed via the PVPC through the Flow
pressure reducing valve to act as the Direction
pilot supply for the electrical actuators.
This means that a load can be lowered
by means of the remote control lever
without starting the pump. The built-in
check valve prevents the oil from flowing
via the pressure adjustment spool to
tank.
With the pump functioning normally, the external solenoid valve is closed to ensure that
the load is not lowered due to the pilot supply oil flow requirement of approximately
1 l/min [0.26 US gal/min].
With closed center PVP, the external pilot oil supply can be connected to the pressure
gauge connection without the use of a PVPC plug.
PVPC without check valve for open center PVP

PVPC, without check valve, is used
in systems where it is necessary to
supply the PVG 32 valve with oil from a
manually operated emergency pump
without directing oil flow to the pilot oil
supply (oil consumption about 1 l/min)
[0.25 US gal/min]. Oil
When the main pump is working Flow
Direction
normally, the oil is directed through
the PVPC plug through the pressure
reduction valve to the electrical
actuators.
When the main pump flow fails, the
external shuttle valve ensures that the
oil flow from the manually operated
emergency pump is used to pilot open For specifications on PVG 32 valves, refer
the over center valve and lower the load. to PVG 32 Technical Information Manual
The load can only be lowered using the 520L0344.
mechanical operating lever of the PVG
32 valve.
With closed center PVP, the external pilot oil supply can be connected to the pressure
gauge connection without the use of a PVPC plug.
10 11039167 • Rev AE • November 2012

PVG 32
Service Manual
Operation
FRICTION DETENT PVMR Friction detent

The friction detent PVMR allows the
directional spool to be held in any
position, resulting in infinitely variable,
pressure compensated flow. The spool
position will be held indefinitely without
the necessity of holding the mechanical
lever.
PVMR should only be used together

with PVB basic modules with pressure
compensator.
PVMF Mechanical float position lock

This allows the float spool to be held in the float position after release of the mechanical
handle.
PVMF PVMF
P A F P B F
(Standard assembly) (Standard assembly)
P B F P A F
(Optional assembly) (Optional assembly)
11039167 • Rev AE • November 2012 11

PVG 32
Service Manual
Operation
PVBS, MAIN SPOOLS When using standard flow control spools, the pump pressure is determined by the
FOR FLOW CONTROL highest load pressure. This is done either via the pressure adjustment spool in open
(STANDARD) center PVP (fixed displacement pumps) or via the pump regulator (variable displacement
pumps).
In this way the pump pressure will always correspond to the load pressure plus the
stand-by pressure of the pressure adjustment spool or the pump regulator.
This will normally give optimum and stable adjustment of the oil flow.
PVBS, MAIN SPOOLS PVBS main spools with linear characteristic have less dead band than standard spools
FOR FLOW CONTROL and a completely proportional ratio between control signal and oil flow in the range
(WITH LINEAR beyond the dead band.
CHARACTERISTICS)
W Warning
PVBS with linear characteristic must never be used together with PVEM electrical
actuators.
The interaction between the small dead band of the spools and the hysteresis of the
PVEM actuator of 20% involves a risk of building up a LS pressure in neutral position.
PVBS, MAIN SPOOLS FOR In a few systems load sensing pump

PRESSURE CONTROL pressure may result in unstable
adjustment of the oil flow and a
tendency towards system hunting. This
may be the case with working functions
that have a large moment of inertia
or over-center valves. In such systems
main spools for pressure control can be
advantageous. The spools are designed
in such a way that the pump pressure is
controlled by the spool travel. The main
spool must be displaced until the pump
pressure just exceeds the load pressure
before the working function is applied.
If the main spool is held in this position, the pump pressure will remain constant – even if
the load pressure changes – giving a stable system.
The use of pressure control spools, however, also means that:
• the oil flow is load dependent
• the dead band is load dependent
• the pump pressure can exceed the load pressure by more than is usual.
Due to these factors use pressure control spools only when you know for certain that
problems with stability will arise – or already have arisen.
Use LSA/B when pressure stability is an issue.
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PVG 32
Service Manual
Operation
PVPX ELECTRICAL LS PVPX is a solenoid LS unloading valve. PVPX is fitted into the pump side module enabling
UNLOADING VALVE a connection to be made between the LS and the tank lines. Thus the LS signal can be
relieved to tank by means of an electric signal.
For a PVP pump side module in open center version the relief to tank of the LS signal
means that the pressure in the system is reduced to the sum of the tank port pressure
plus the neutral flow pressure for the pump side module.
For a PVP pump side module in closed center version, relief to tank of the LS signal
occurs when the pressure is reduced by the sum of the tank port pressure for the pump
side module plus the stand-by pressure of the pump.
C Caution
Protect yourself from injury. Use proper safety equipment, including safety glasses, at all
times.
11039167 • Rev AE • November 2012 13

PVG 32
Service Manual
System Troubleshooting
OVERVIEW This section provides general steps to follow if undesirable system conditions are
observed. Follow the steps listed until the problem is solved. Some of the items will be
system specific. Always observe the safety precautions listed in the Introduction section,
page 6, and related to your specific equipment.
Confirm that valve is built properly according to the specification sheet.

W Warning
This troubleshooting If necessary, install a lever to the valve to verify proper mechanical function.
guide for the PVG valve
assemblies does not cover Refer to PVG 32 Technical Information Manual 520L0344 for valve configuration
valves that have been information.
altered from original valve
build specifications Refer to PVG 32 Parts Manual 11006794 for part numbers.
TROUBLESHOOTING A THINK - before troubleshooting a problem.

PVG VALVE Every fault location process should follow a logical and systematic order.
It is wisest to start at the beginning:
• Is the oil level correct when the pump is operating?
• Is the condition of oil and filters acceptable?
• Are pressure, flow, and flow direction as specified?
• Is the oil temperature too high or too low (oil viscosity)?
• Are there any unusual vibrations or noise (cavitation)?
If the driver of the vehicle is available, ask him:

• What type of fault it is and how it affects the system?
• How long he has felt that something has been wrong?
• If he has “fiddled” with the components?
• If he has any hydraulic and electrical diagrams available?
Diagrams are often found in the instructions included with vehicles/machines.

Unfortunately they are often so technical that they are not of much use in a fault
location situation. However; the diagram usually shows the order of, and the connections
between, the individual components.
When a defective component is identified, clean the component and its surroundings
before removal.
Remove loose paint from pipes and fittings.
Cover all holes, hoses and pipe ends with plugs or seal with, for example, plastic bags
after removal to avoid the entry of dirt during repairs.
Never disassemble hydraulic components outside.
Perform repairs in a workshop on a clean workbench (covered with clean cloth or
newspaper).
Make sure that a Sauer-Danfoss service manual for with the product is handy.
Follow the instructions word for word during disassembly and assembly.
If these instructions are not followed closely the system may not operate correctly after
repairs are completed.
Note that in some cases special tools are necessary for assembling the product.
Our service manuals give full guidance on use of special tools.
14 11039167 • Rev AE • November 2012

PVG 32
Service Manual
Troubleshooting flow chart
Problem?
No
No
Mechanical
Mechanical
No
No
Hydraulic
Hydraulic
No
No
Electrical
Electrical
No
No
Electronic
Electronic
Software
P107 823
11039167 • Rev AE • November 2012 15

PVG 32
Service Manual
NO CYLINDER/MOTOR RESPONSE IN EITHER DIRECTION WHEN REMOTE CONTROLLER IS ACTUATED
Cause Check Corrective action

Verify if fault is mechanical, Operate manual lever to confirm mechanical or If moving the manual lever operates the cylinder/
electrical or hydraulic electrical or hydraulic motor check electrical or hydraulic
Remove manual, electrical, and hydraulic Replace the valve module and main spool. If any
actuators from the valve section. Remove main damage is found on the main spool
spool from valve section and inspected for
damage. If no damage reinstall the main valve
Sticking main spool spool and it should move freely in the valve
section bore.
Check movement of manual lever when If manual lever does not move check electrical
electrical controller is operated voltage signal from controller, wiring at the PVE
module
Check movement of manual lever when If manual lever does not move check hydraulic
hydraulic controller is operated controller pressure at the PVG valve module - 25 Bar
[360 PSI]
If none of the above check pump per Repair or replace pump per manufacturers
manufacturers recommended procedure recommended procedure
Internal filters blocked Check for blockage in internal filters Remove blockage
CYLINDER/MOTOR RESPONDS IN ONE DIRECTION ONLY

Operate manual lever in both directions to If moving the manual lever operates the cylinder/
Verify if fault is mechanical, confirm if mechanical or electrical or hydraulic motor in both directions check electrical or
electrical or hydraulic hydraulic
If operating the manual lever strokes the Back out manual stop on manual controller and
cylinder/motor in one direction only, check torque the jam not to 8 Nm [70 lbf•in] Do not
manual stop screw adjustment exceed maximum torque
Check movement of manual lever when If manual lever does not move in one direction
electrical controller is operated check electrical signal from controller and wiring at
the PVE module
Check movement of manual lever when If manual lever does not move in both directions
hydraulic controller is operated check hydraulic pressure at the PVG module
Air in system Entrained air generates heat under pressure Look for foam or bubbles in reservoir. Check for
leaks on inlet side of charge pump.
Internal leakage Excessive internal leakage may overheat the Install loop flushing defeat option and monitor case
system. flow. If case flow is excessive, motor may require
major repair. Contact Sauer-Danfoss Service.
Shock valves Swap and see if problem follows Replace valves
Solenoid actuation If power is OK from controller Repair wiring to PVE module
Main spool travel restricted Stop on manual controller turned in too far Back out manual stop on manual controller
Remote electrical controller Insufficient signal from electrical controller Repair or replace electrical controller
PVEO connections Incorrect PVE/PVEO connections Connect correct way
Remote hydraulic controller Insufficient pilot oil pressure from remote Repair or replace remote hydraulic controller
PVRH hydraulic controller Pressure needs to be 25 Bar
[360 psi]
16 11039167 • Rev AE • November 2012

PVG 32
Service Manual
MAIN VALVE SPOOL MOVES WITHOUT OIL PASSING TO CYLINDER/MOTOR

Insufficient oil supply to valve Check the pump per manufacturers procedure Repair or replace pump per manufacturers procedure
Optional pressure compensator in Check compensator spool Replace spool
valve section not functioning
Insufficient load pressure at LS drilling holes plugged Clean or replace
compensator spring chamber
Cylinder/motor load too high for Check pressure at the valve If pressure is set to spec. per valve lower load on
pressure setting of the system cylinder/motor
Blocked LS galleries Inspect for blockage in LS galleries Remove blockage in LS galleries
Shuttle valve faulty Inspect shuttle valve Repair or replace
Blocked LS lines to pump controller Inspect LS lines from PCG to pump controller Remove blockage in LS lines from the PVG valve to
pump controller
Oil bypassing at shock valve/anti- Check if stuck open or damaged Replace valve
cavitation check valve
Internal leakage in cylinder/motor Inspect for by-passing of oil per cylinder/motor Repair or replace cylinder/motor per manufactures
manufacture per manufactures procedure procedure
Too much leakage in LS spool in Check bleed orifice in LS control Use a LS pump control with no bleed orifice
pump control
Blocked thermal orifice check thermal orifice (blocked) Replace thermal orifice
Load too high for system Check for proper system pressure Adjust pressure to valve specification
Internal leakage in cylinder/motor Inspect for bypassing of oil per cylinder/motor Repair or replace cylinder/motor
manufacturer specification
Shock valve or anti-cavitation check Inspect for damage and contamination Repair or replace cylinder/motor
valve faulty
System relief valve pressure set too Install pressure gauge and check pressure Adjust pressure to system specification
low for load Lower load
Cylinder/motor load too high for Check load pressure at PVB-LS port Reduce load pressure if exceeds maximum pressure
pressure settings of system limit of the system
Maximum system pressure should be approx. 25 Adjust maximum system pressure if necessary
Bar [365 PSI] above highest load pressure
Adjust pump pressure compensator setting if
necessary
11039167 • Rev AE • November 2012 17

PVG 32
Service Manual
CYLINDER/MOTOR OPERATES WITHOUT REMOTE CONTROLLER BEING OPERATED

Spool control tension rod loose Confirm torque on spool control tension rod Torque to 8 Nm [70 lbf•in]
Electrical feedback transducer not in Check the feedback pin in the PVE. It should be Replace transducer
neutral position loose
Remote electrical controller neutral Disconnect the connection at the PVE. It should Repair or replace faulty switch or wiring at remote
position switch faulty come back to neutral controller
Sticking pressure control valve in Disconnect the hydraulic signal line from valve Repair or replace faulty remote hydraulic controller
remote hydraulic controller
Sticking main spool in valve section Remove manual, electrical, and hydraulic Replace the valve module and main spool if any
actuators from the valve section. Remove main damage is found on the main spool
spool from valve section and inspected for
damage. If no damage reinstall the main valve
spool. Spool should move freely in the valve
section bore.
Internal fault in the PVE/PVEH/PVEM/ PVEO check continuity. All other PVE, check LED Replace faulty PVE/PVEH/PVEM/PVEO
PVEO (Red means internal error)
Contamination in the hydraulic oil Take oil samples to confirm Flush hydraulic system. Fill with clean filtered oil.
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PVG 32
Service Manual
CYLINDER/MOTOR RESPONDS SLOWLY TO REMOTE ELECTRICAL OR HYDRAULIC CONTROLLER ACTUATION

Insufficient system pressure Install pressure gauge and record pressure If pressure is low adjust pressure setting to valve
specification or pump manufacturers specification
Main spool travel limited Check stops on manual lever controller end Adjust the manual lever stops and torque the jam
for proper adjustment. Refer to Component nuts to 8 Nm [70 lbf•in] Do not exceed maximum
troubleshooting section, page 22. torque
Incorrect signal voltage from Check the signal voltage from the controller with If signal voltage is incorrect repair or replace
electrical controller a volt meter electrical controller
Incorrect hydraulic pressure Check pressure from the remote hydraulic If pressure is too low, repair or replace remote
signal from remote hydraulic controller - 25 Bar [360 PSI] hydraulic controller per manufacturers instructions.
controller
Insufficient pilot oil - all sections Check pilot for contamination and correctly Replace inlet module NOTE: Check with S-D TST
assembled parts - 10-15 bar [145-218 psi] Electric
- 25 bar [360 psi] Hydraulic
Insufficient LS pump stand by Check pilot PSI - 10-15 bar [145-218 psi] Electric - Adjust or replace pump
pressure 25 bar [360 psi] Hydraulic
Flow is not load independent PVLP check for cracks Replace valve
Check LS pressure vs load pressure
ERRATIC CYLINDER/MOTOR RESPONSE TO ELECTRICAL OR HYDRAULIC CONTROLLER OPERATION

Electrical actuator faulty Check signal from controller to PVE Repair or replace PVE
Main spool centering spring Check tension rod for correct torque or damage Torque to 8 Nm [70 lbf•in] or replace
damaged
Main spool position feedback Check feedback pin for damage Replace PVE
transducer signal incorrect
Contamination in hydraulic oil Take oil sample Flush complete system.
Fill reservoir with clean filtered fluid per OEM
specification
Air in hydraulic pilot lines Check for air trapped in signal lines from the Bleed air from the hose connection at the valve
controller to the valve section module section
Hydraulic remote actuator faulty Check signal pressure from the remote hydraulic Repair or replace cylinder/motor
controller
Low hydraulic oil supply Check fluid level in reservoir Fill reservoir with clean filtered fluid per OEM
specification
11039167 • Rev AE • November 2012 19

PVG 32
Service Manual
HYDRAULIC OIL SUPPLY

Pump not running Check prime mover for operation Repair or replace prime mover
Check condition of drive coupling Repair or replace drive coupling
Insufficient oil in reservoir Check fluid level in reservoir Fill with clean filtered oil
Leaking or burst supply hose Inspect lines to valve stack Repair or replace damaged hose
Relief valve malfunction Check for contamination and operation of relief Repair or replace relief valve
valve
Isolating valves are closed Check that all isolating valves are open and clear
Faulty pump control Check pump compensator for correct operation Repair or replace pump compensator per pump
and setting per pump manufacturers manufacturers recommendations
Low standby pressure in PVP - Check idle standby pressure - 10 Bar [145 PSI] Replace
open center pump Check condition of compensator spool spring Replace module due to worn components
Low standby pressure in pump Check pump LS control for operation and setting Repair or replace LS control per pump
control - variable pump Stand by pressure should be 15 bar [220 psi] manufacturers procedures
minimum
PVP pressure relief valve faulty Check pressure relief valve spool and spring for Replace
freedom of operation
PVP orifices blocked Check PVP orifices for blockage Remove blockage
Internal filters blocked Check for blockage in internal filters Remove blockage
Supply lines blocked Inspect supply lines for blockages Remove blockage
Internal hydraulic pilot pressure Inspect pilot oil pressure reducing valve for Repair or replace
insufficient proper operation
Blocked LS galleries Check LS galleries for blockage Clean blockage from LS galleries
Shuttle valves faulty Check LS system shuttle valves for wear and Replace as needed
damage
Check for contamination per specification HPP 030. Refer to Design Guideline for Hydraulic Fluid Cleanliness, Technical
Information Manual 520L0467. If fluid is out of spec., flush hydraulic system and fill with clean filtered oil.
20 11039167 • Rev AE • November 2012

PVG 32
Service Manual
ELECTRICAL SUPPLY
No electrical power Check electrical circuit Repair as needed
Verify emergency stop switch is in the proper operating Reset
position
Neutral position switch faulty Check operation of neutral position switch in remote controller Replace switch
(if connected in circuit) PVRE/PVRES/PVREL
Incorrect signal voltage Check voltage levels at solenoid plug
Proportional operation - Refer to page 43
Udc: Supply voltage (100%)
Us: Supply signal voltage (25-50-75%)
Ground: Live or ground connection
On-Off Operation
Udc: Supply voltage if selected
Us: Supply voltage if selected
Ground: Live or ground connection
Solenoid valve faulty PVHC Check coil resistance Check data for resistance
Insufficient pilot supply Check pilot pressure - 10-15 bar [145-218 psi]/PVHC 25 bar [360 Replace
psi]
Main spool position feedback Test oil for contamination and or water content If oil contamination is too high, flush
transducer signal incorrect hydraulic system or replace oil if necessary.
If problem persists change PVE
Incorrect PVE connections Check that the proportional remote electrical controller has not Connect wires correctly
been connected to an ON-OFF PVEO solenoid
HYDRAULIC (REMOTE) PILOT CONTROL PRESSURE

Insufficient pilot pressure Check pilot oil pressure 5-15 bar [72-220 psi] delta between A
and B port on remote
PVG32: 5-15 Bar [72-217 PSI]
Insufficient pilot oil supply Check pilot oil flow rate is adequate
Pilot flow should be 1.0 L/min [0.264 GPM] per section
Check pilot lines for blockage Remove blockage
Air in pilot line Check for trapped air in pilot lines Bleed air from pilot lines at PVH
Pilot lines incorrectly sized Check pressure drop Check and reduce length or pilot lines
Increase diameter of pilot lines
Use steel tube for long pilot line runs
Hydraulic remote pilot operator Check operation of hydraulic remote pilot controller Repair or replace
faulty Check supply pressure to hydraulic remote controller - Repair or replace
minimum 25 bar [360 psi]
Check and inspect movement of pressure control valve in Repair per manufacturers procedure, or
hydraulic controller replace
Check operation of remote hydraulic controller Clean and/or repair as necessary
11039167 • Rev AE • November 2012 21

PVG 32
Service Manual
PVG 32 Component Troubleshooting
PRESSURE RELIEF VALVE Description: Adjustable relief valve. Adjustment range 50 Bar [700 PSI] to 350 Bar [5000
PSI].
Location: The relief is in all PVP Inlet modules
Function: Provides maximum pressure setting above pump pressure setting 30 Bar [450
PSI] Delta for open center and closed inlet sections
Failure mode Cause Corrective action

Will not build pressure Contamination While under pressure, back out to minimum pressure and allow
oil to leak by for approx. 5 seconds and then readjust to correct
pressure - Replace valve
External leaking Damaged seat and poppet Replace complete assembly
Pressure setting is wrong Pressure adjustment backs off (on open Adjust to model code specification
center application)
Instability when PC and inlet PC at pump should be set 20 bar below Adjust to model code specification
relief has too low of a delta relief valve
between them
Serviceability: Non serviceable.
Valve removal tool P/N: 155L6485. Torque to 20 Nm [180 lbf•in].
PRESSURE REDUCING Description: Pressure reducing valve at fixed pressure.

PILOT VALVE
Location: The pressure reducing valve is a option in some PVP Inlet modules.
Function: Provides 10-15 bar [145-218 psi] internal pressure for electrical (PVE) actuators or
provide 25 Bar (360 PSI) (PVHC) and supply for external remote hydraulic actuators (HRC).
These pressures are only present when the load pressures are high enough to satisfy
the required regulated pressure. The open center system at low pump flow may only
develop 9 Bar (130 PSI)
22 11039167 • Rev AE • November 2012

PVG 32
Service Manual
PRESSURE REDUCING PILOT VALVE (CONTINUED)

Main spools are slow, driven by Contamination Disassemble and clean
PVE 13 Bar [190 PSI] pilot system Pump pressure too low - below 9 Bar [130 Closed center: System increase stand-by to 13 Bar [190 PSI]
PSI] Open center: Check gear per pump manufacture procedure
Check system for other components before valve inlet that may
provide a path tank
High tank port pressure. Do not exceed Clear restrictions in return system.
40 Bar [580 PSI] tank pressure (For PVPs
without T0 option)
Oil viscosity 460 mm2/S [2128 SUS] too high Warm up system or replace oil with correct viscosity
(cold oil or incorrect viscosity oil)
Main spools will not move For T0 option only not being connected to Connect T0 (PVP) port option to tank or remove restriction
mechanically or electrical tank or restricted to tank
Internal pressure reducing valve parts Reassemble the internal pressure reducing valve parts correctly
misassembled
PVHC 25 bar [360 psi] pilot Contamination Disassemble and clean
system - main spools are slow Pump pressure too low - below 20 Bar [290 Closed center: System increase stand-by to 20 Bar [290 PSI]
PSI] Open center: Check gear per pump manufacturers procedure
Check system for other components before valve inlet that may
provide a path tank
High tank port pressure. Tank pressure Check for restrictions in return system and remove
should not exceed 40 Bar [580 PSI] (For
PVPs without T0 option)
Oil viscosity - 460 mm2/S [2128 SUS] too Warm up system or replace oil with correct viscosity
high (cold oil or incorrect viscosity oil)
Serviceability: All internal components Pressure reducing pilot valve

can be removed from the cavity, cleaned,
inspected and reassembled back into the
valve Plug
6 mm
1. Use a 6 mm internal hex wrench to 25 Nm
remove the plug, and then remove [220 lbf•in]
all the other internal components in O-ring
the cavity
Spool
2. Clean all components with clean
solvent
Cone
3. Replace any damaged components.

Lubricate with clean hydraulic oil
Spring
4. Correctly reassemble the
components back into the cavity and
torque the plug to 25 Nm [221 lbf•in] P107 733E
(use an M5 screw to install spool).
11039167 • Rev AE • November 2012 23

PVG 32
Service Manual
PRESSURE GAUGE Description: Port to install a pressure gauge to check pressure relief valve setting to
CONNECTION valve specification.
Location: On inlet cover to valve stack.
1. Use a 6 mm internal hex to remove and install plug.
2. Torque plug to 35 Nm [308 lbf•in].

Leaking Bad seal Replace with new seal (same type as original seal)
Pressure gauge port
Pressure gauge port
P107 735E
When valve is equipped with the PVPC option use a running tee to measure pressure.
Torque tee to hose adaptor torque specification.
PVPC with check valve

Tee into pressure port
to measure pressure
P107 734E
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PVG 32
Service Manual
OPEN CENTER PLUG Description: Plug that is installed in the inlet cover for a system with a fixed
displacement pump.
Location: In the PVP module (Inlet cover).
Function: Connection for the load sense signal to shift the unloading spool to build
main system pressure and provides a connection to the main system relief valve.

Valve operates at system relief Open center plug is not seated properly Reinstall plug and torque to 4 Nm [35 lbf•in] using a 3 mm
setting at all times internal hex wrench
Serviceability: Open center plug is serviceable.
1. Use a 6 mm internal hex to remove cavity plug from valve.
2. Use a 3 mm internal hex to remove open center plug.
3. Clean or replace open center plug.
4. Install open center plug.
5. Torque plug to 4 Nm [35 lbf•in].
6. Install new seal washer and install cavity plug. Torque to 35 Nm [130 lbf•in].
Open center plug

Plug
6 mm
35 Nm
[308 lbf•in]
Seal
washer
Open
center
plug
3 mm
4 Nm
[35 lbf•in]
P107 736E
11039167 • Rev AE • November 2012 25

PVG 32
Service Manual
CLOSED CENTER PLUG Description: Plug that is installed in the inlet cover for a system with a variable
AND ORIFICE displacement pump.
Location: In the PVP module (Inlet cover).
Function: Allow connection for the load sense signal to the pump and provide
connection to the main system relief valve.

Valve operates at system relief Plug and orifice are not seated properly Reinstall orifice and torque to 4 Nm [35 lbf•ft] using a 3 mm
setting at all times internal hex wrench.
Reinstall plug and torque to 8 Nm [71 lbf•in] using a 8 mm
internal hex wrench
Can not adjust main relief above Orifice is plugged Remove and clean orifice. Reinstall
pump pressure setting of 30 Bar
[450 psi] Delta for closed inlet
sections
Serviceability: Closed center plug and orifice are serviceable.
1. Use a 6 mm internal hex to remove cavity plug from valve.
2. Use a 4 mm internal hex to remove closed center plug.
3. Use a 2.5 mm internal hex to remove orifice.
4. Clean or replace orifice. Install orifice. Torque to 4 Nm [35 lbf•in].
5. Install new seal and install closed center plug. Torque to 8 Nm [71 lbf•in].
6. Install new O-ring and install plug. Torque to 35 Nm [130 lbf•in].
Closed center plug

Plug
6 mm
35 Nm [308 lbf•in]
O-ring
Seal
Closed center
plug
4 mm Orifice
8 Nm
[70 lbf•in] 2.5 mm
4 Nm
[35 lbf•in]
P107 737E
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Service Manual
PRESSURE ADJUSTMENT Description: Main pump flow unloading spool.

SPOOL
Location: PVP (inlet) module.
Function: For open center systems it is the main relief and unloading spool
For closed center systems it is the main relief spool.

In open center systems the valve High wear allows leakage to tank Replace compete module
sections are unstable
The adjusted pressure will not Low viscosity oil allowing high leakage Remove and clean orifice. Reinstall
remain static in a closed center around spool to tank.
system High wear Replace compete module
Serviceability: Spool is not serviceable. Replace complete module.
Pressure adjustment spool
Pressure adjustment spool
Orifice
Plug
P107 739E
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PVG 32
Service Manual
LS CONNECTION Description: Port for LS signal for LS (static) option only controller for variable flow
pump.
Location: PVP (inlet) module.
Function: Provide a signal to the variable pump controller to create a pressure

differential to have the pump come on stroke for a closed center system.

In closed center systems the Insufficient LS flow to satisfy pump Ensure that the LS controller on the pump does not have
valve sections are unstable controller excessive internal leakage - 0.4 l/min [0.106 gal/min]. Repair or
replace the variable pump controller per pump manufactures
specifications
If there is more than one valve in the system ensure that the LS
shuttles are all working properly
Excessive air entrained in the hydraulic oil Ensure that the oil has enough dwell time in tank, has
good anti-foaming agent, and pump inlet vacuum is within
manufacturers specifications
Air trapped in LS line Bleed air for LS line at highest point
Valve operation is slow to Insufficient LS flow to satisfy pump If more than one section, ensure that the LS controller on the
respond or does not respond controller pump does not have excessive internal leakage. Repair or
replace the variable pump controller per pump manufactures
specifications
Excessive air entrained in the hydraulic oil Ensure that the oil has enough dwell time in tank, has
good anti-foaming agent, and pump inlet vacuum is within
specifications
Air trapped in LS line Bleed air for LS line at highest point
PVG valve is mounted above hydraulic oil reservoir when shut down and sits idle for some time, the valve could be
voided of oil and this would cause the valve to operate erratically and be slow to respond.
Serviceability: Port is serviceable. Need to connect hose to LS port on pump.
LS connection plug
LS Plug
6 mm
35 Nm [308 lbf•in]
P107 740E
28 11039167 • Rev AE • November 2012

PVG 32
Service Manual
LS SIGNAL Description: The PVG32 uses an internal LS signal network for both Open Center and
Closed Center systems. In Open Center systems the internal LS signal network provides
a resolved load sense signal to the pressure adjustment spool controlling the proper
amount of flow and pressure to the operating valve sections. In Closed Center systems
the internal LS signal network provides a resolved load sense signal directly to the LS
pump control which in turn provides the proper amount of flow and pressure to the
operating valve sections.
Location: PVP/PVB Modules.
Function: Directs the highest load pressure to either OC or CC pump control to satisfy
the operating valve section.

No pump pressure developed in LS passages blocked or restricted Disassemble valve. Inspect passages for blockage
one or more valve sections
Serviceability: Not serviceable. Ensure entire system is clean.
LS circuit
PVP
PVB
PVB
LS
circuit
10. Shuttle valve

P107 815E
11039167 • Rev AE • November 2012 29

PVG 32
Service Manual
SHUTTLE VALVE Description: Self cleaning internal shuttle system.
Location: PVB (valve section) module.
Function: Determines which valve section is developing highest load pressure.

Valve sections will not build Worn shuttle disc Replace complete module (seat is pressed into module)
pressure (NOTE: Normally it Excessive air entrained in the hydraulic oil Ensure that the oil has enough dwell time in tank, has
will be one section, but not all good anti-foaming agent, and pump inlet vacuum is within
sections) specifications
Serviceability: Not serviceable. Ensure entire system is clean.
Shuttle valve
Exploded view shows internal parts. Ball should move
Do not disassemble valve. freely behind disk.
Ball should move

freely behind disk.
P107 804
30 11039167 • Rev AE • November 2012

PVG 32
Service Manual
LS PRESSURE LIMITING Description: Optional adjustable pilot relief valve.

VALVE
Location: PVB (spool body section) module.
Function: Controls the maximum working pressure delivered to each work port.
There is one LS pressure limiting valve for each work port.

Section will not build pressure in Contamination While under pressure back out to minimum pressure and allow
one spool direction oil to leak by for approx. 5 seconds and then readjust to correct
pressure - Ensure system is clean - Replace PVB
External leaking Low cartridge torque Torque to 20 Nm [177 lbf•in] maximum
Replace complete assembly
Pressure adjustment backs off Adjust pressure to valve specifications If adjustment doesn’t hold, replace valve
Serviceability: Adjustable and non-serviceable. If adjustment does not solve the

problem, replace complete cartridge.
Valve removal tool P/N: 155L6485. Torque to 20 Nm [177 lbf•in].
11039167 • Rev AE • November 2012 31

PVG 32
Service Manual
LS A, B SHUTTLE Description: The shuttle valve isolates the LS(A) and LS(B) load sense signal.
Location: Option PVB module with only load sense relief.
Function: Ensure that each pressure limiter valve can create separate pressures for A and
B LS signal.

Will not build pressure in A or B Contamination preventing shuttle ball from Replace complete PVB module
work port building load sense relief pressure
LS A, B shuttle
Shuttle
ball
P107 821
MAIN SPOOL Description: Main directional control.
Function: Controls oil flow from pump to work ports A or B.

Section will not build pressure in Load sense passages in spool are blocked Flush out load sense passages in the spool. Spool will need
one spool direction to be removed to clean
Main valve spool stuck in valve Refer to Pressure reducing valve section, Replace PVM and PVE. Be sure that pilot valve is assembled
body (if being used with electrical page 22 correctly.
actuator)
Mechanical actuator main valve Hard particle binding spool in bore Look down into the A and B work ports to see if the particle
spool stuck in valve body can be removed while the spool is in the valve body. Replace
valve section.
NOTE: Valve body and spool will need to be replaced per
valve specifications
Main spool stuck in valve body Tie rod over torqued Replace tie rod kit which includes section seals and torque to
28 Nm [248 lbf•in]
Valve stack mounting surface is not flat Ensure the mounting surface is flat*
causing a bind on the valve stack
* Flatness in millimeters - T= 0.35 mm X number of PVB modules + 1

32 11039167 • Rev AE • November 2012
PVG 32
Service Manual
MAIN SPOOL Serviceability: Main spool is serviceable depending on failure mode.

(CONTINUED)
1. Remove manual actuator using a 5 mm internal hex wrench to remove the 4
mounting screws.
CAREFULLY place the main spool in to an appropriate fixture or vice with card board,
rubber hose or heavy shop towels on the jaws and tighten just enough to keep the spool
from turning in the vice. DO NOT over tighten the main spool in the vice as it will be
distorted and or scratched on sealing lands and the spool will need to be replaced.
2. Remove the tension rod end using a 13 mm open end wrench.
3. Remove the plug at the other end using an 11 mm, or if it has a detent option, use a
12 mm open end wrench.
3. Flush out openings into the main spool cavity at each end.
4. Install plug with a 11 mm or 12 mm open end wrench. Torque to 8 Nm [70 lbf•in].
5. Install centering spring and tension rod using a 13 mm open end wrench and torque
to 8 Nm [70 lbf•in].
6. Carefully reinstall the main valve spool into the valve housing. Do not force the
main spool back into the housing as you will damage the sealing lands in the valve
housing. The spool should move freely in the main spool bore when fully installed.
7. Install a manual actuator. Reassemble in reverse order and torque the 4 mounting
screws to 8 Nm [70 lbf•in]
If section does not build pressure in one direction, wrong spool may have been installed
in valve.
Main spool
Screw
11 mm
8 Nm
[70 lbf•in]
Clean holes
P107 805E
11039167 • Rev AE • November 2012 33

PVG 32
Service Manual
SHOCK AND Description: Optional work ports non adjustable pressure relief valve.
ANTI-CAVITATION
VALVE PVLP Location: PVB (valve section) Module.
Function: Removes any transient pressure spikes generated by the load.

The shock valves PVLP with fixed setting and the anti-cavitation valves PVLA on ports A
and B are used for the protection of the individual work function against overload and/
or cavitation.
There is one shock valve for each work port.

Will not build pressure in A or Valve may be damaged and not able to seal Replace with correct part number per valve specification
B port
Serviceability: This valve may be disassembled and cleaned, however, internal parts are
not available separately. If you suspect valve malfunction, replace with a new valve and
test system operation.
PVLP valve
Plug
13 mm
36 Nm
[310 lbf•in]
Do not try to adjust

or disassemble PVLP
P107 743E
34 11039167 • Rev AE • November 2012

PVG 32
Service Manual
PRESSURE Description: Optional pressure compensator maintains a constant pressure drop across
COMPENSATOR the main spool.
Location: PVB (Valve section) Module.
Function: In a pressure-compensated basic module the compensator maintains a

constant pressure drop across the main spool – both when the load changes and when a
module with a higher load pressure is actuated.

Valve section unstable flow High wear allows leakage Replace complete module
LS pressure limiting valve pressure High wear Replace complete module

adjustment will not remain static
Serviceability: Pressure compensator is not serviceable. If you suspect valve

malfunction, replace complete module.
Pressure compensator valve
P107 744E
Pressure compensator spool
Pressure compensator spool
P107 822
11039167 • Rev AE • November 2012 35

PVG 32
Service Manual
LOAD DROP CHECK Description: Keeps the load from dropping when transitioning from spool neutral to
VALVE lifting the load.
Function: Optional drop check to keep the load from dropping. Prevents high
pressure functions from supplying low pressure functions when both are actuated
simultaneously.

Load drops excessively when Worn parts. Replace complete PVB module
trying to lift load Hard particle in seat area does not allow the Replace complete module
seat to seal
Serviceability: Load drop check valve is not serviceable. If you suspect valve
malfunction, replace complete module.
Load drop check valve
P107 747E
P107 748E
36 11039167 • Rev AE • November 2012

PVG 32
Service Manual
MAXIMUM OIL FLOW Description: Optional mechanical flow limiter.

ADJUSTMENT SCREWS
FOR PORTS A AND B Location: PVM manual control handle.
Function: Determines the stroke of the main spool in the PVB.

Cylinder/motor functions too Mechanical stop screws out of adjustment Use a 8mm open end wrench to loosen the jam nut and then
slow or too fast per valve spec. 3mm internal hex wrench to adjust the mechanical adjusting
screw CCW to increase speed. After adjusting hold the adjusting
screw and torque the jam nut to 8 Nm [70 lbf•in] maximum
Leaking past adjusting screws Check torque on seal nut 8 Nm [71 lbf•in] Retorque or replace seal nuts
C Caution
When adjusting main spool flow ensure that electrical or hydraulic actuators are not
active at the time, if so equipped.
Adjusting screws for ports A and B
For standard mount, top adjusting screw is B

and bottom adjusting screw is A
P107 816E
11039167 • Rev AE • November 2012 37

PVG 32
Service Manual
PVM MODULE Description: Manual control lever.
Location: Mounted on either end of the PVB main spool.
Function: Manual override capable of limiting the stroke of the main spool, and is used
to center the spool in neutral.

Leaking externally between PVM Back pressure is exceeding 40 Bar [580 PSI] Replace PVM module, seals, and lower tank port pressure
and PVB on tank line
T0 port not connected to tank or restricted Connect to tank, remove restriction, and remove blockage
or blocked
PVM module
O-rings
Seal
Screw (x4)
5 mm
8 Nm [70 lbf•in]
P197 806E
38 11039167 • Rev AE • November 2012

PVG 32
Service Manual
PVS MODULE Description: End cover.
Location: Mounted on the last PVB of the valve stack.
Function: Serves as blanking cover and drain for LS circuit.

Leaking externally between PVS Back pressure is exceeding 40 Bar [580 PSI] Replace PVS module, seals, and lower tank line pressure
and PVB on tank line
Maximum pressure: Reduce system pressure

Aluminum - 300 bar [4500 psi]
Steel - 350 bar [5000 psi]
PVS plugs
P107 707E
For specifications and operating parameters on PVG 32 valves, refer to PVG 32 Technical
Information Manual 520L0344.
11039167 • Rev AE • November 2012 39

PVG 32
Service Manual
PVPVM MODULE Description: Mid-inlet module only for closed center systems.
Location: Mounted between multiple PVB’s in a valve stack.
Function: Provides pressure and tank connections to the valve stack allowing increased
flow.

Leaking externally between Uneven mounting surface and mounting Ensure the valve stack is mounted on a even surface and torque
PVPVM and PVB screw torque down correctly
Tie rods torqued too tight Replace tie rod kit which include section seals and torque to 28
Nm [248 lbf•in]
Flow exceeding 61 gpm Lower flow to 61 gpm, and replace the tie rod kit and seals
Valve stack can not build Option PVLP (shock valve) not seating Install components correctly or replaced damaged components
pressure per valve spec. correctly in cavity caused by valve not
being installed correctly or it has failed
* Flatness in millimeters - T= 0.35 mm X number of PVB modules + 1
PVPVM module
Do not try to adjust

or disassenmble PVLP
13 mm
40 Nm
[354 lbf•in]
Plug
P107 808E
40 11039167 • Rev AE • November 2012

PVG 32
Service Manual
PVAS MODULE Description: Tie rod kit.
Location: Through the valve stack.
Function: Holds the stack together.

Leaking externally between Tie rods under torqued Check and retorque - 28 Nm [248 lbf•in]
sections
Tie rods torque too tight Replace and retorque - 28 Nm [248 lbf•in]
If replacing seal kit,

replace tie rods also
8-
248 - P107 817E
PVPX LS UNLOADING Description: Optional two way two position solenoid.

VALVE
(REFER TO PAGE 13 FOR Location: In the PVP.
VALVE OPERATION)
Function: A safety device that dumps load sense to tank to prevent the pump from
building pressure.

Manual override leaking Not torqued correctly Check and retorque to 45 Nm [400 lbf•in]
externally
High usage Replace per valve specification
Manual override is bent Replace per valve specification
Solenoid will not shift Coil not working Replace coil per valve specification
Check with OHM meter:
12 volt system - 8.7 OHMs
24 volt system - 33 OHMs
Too high or too low of voltage Confirm voltage in system from remote controller:
12 volt system should not exceed 13.2 volts
24 volt system should not exceed 26.4 volts
11039167 • Rev AE • November 2012 41

PVG 32
Service Manual
PVEH, PVES, PVEA Description: Proportional electrical actuator.

ELECTRICAL ACTUATORS
Location: On the end of the main spool of the PVB.
Function: Convert an electrical command to move the main spool to a set position.
Troubleshooting considerations
Wiring Check: It is highly possible that in the case of one PVE failing that there could be a poor connection between
the joystick and the PVE in question. The PVE is reverse polarity protected and suppression protected; however an
intermittent connection could degrade the input electronics to a point of failure. Inspect all wiring and connectors for
corrosion and or pinch points.
Hirshman Receptacle and Mating Connector: Each PVE is supplied with a field installable 4-pin Hirshman mating
connector and gasket. It is recommended that the gasket be installed between the mating connector and PVE
receptacle also the rubber grommet be sealed around a multi-wire jacket in order to seal off moisture from the wiring
connections. The PVE is rated for IP65 only when the Hirshman connector is sealed.
Temperature Capability: The PVE is rated for 1000 hours @ 160 °F. ambient temperature. Oil temperature wise, the
area of the valve that creates the highest horsepower loss usually creates the highest temperature in the system. If
one PVE section is operated more frequently than others this would create more heat than any other part of the valve.
Under these conditions it is extremely important to insure that the hydraulic system is well cooled. Oil temperature
measurements at the reservoir and at the center of the PVG32 valve stack. The valve should be mounted to provide
the best ventilation for the PVE electronics. Poor filtration and low fluid levels may also add to temperature.

Does not work in either direction No control voltage from the electrical controller Check voltage from the electrical controller
LED is green (25% to 75% of supply)
Command pin wire in mating connector is broken Repair broken wire
Connector corroded - This condition is caused by Replace PVE and mating connector
water ingression or ground connection
Does not work in either direction No power from the battery Check power to electrical actuator
LED is off
Power pin wire in mating connector is broken Repair broken wire
Connector corroded - This condition is caused by Replace PVE and mating connector
Ground connection must be hard wired straight Repair ground connection
from the battery or from the electrical controller
LED is flashing Red Control signal is out of range Check wiring harness for short
Works in one direction No control voltage from the electrical controller Ensure voltage from the electrical controller exists for
(Assuming that the manual that direction
control lever and the main spool Lack of voltage to actuator (Minimum voltage 11 Check system voltage
move freely both directions) volts for 12 volt system and 22 volts for 24 volt
system)
Electrical actuator is defective Replace electrical actuator per spec. on the valve
Works intermittently (if LED is Loose connection between the electrical actuator Repair connector
green it indicates a long on/off and controller
Short in wiring harness Repair wiring harness
42 11039167 • Rev AE • November 2012

PVG 32
Service Manual
PVEH, PVES, PVEA Failure mode Cause Corrective action

ELECTRICAL ACTUATORS Works with no command Short in wiring harness Repair wiring harness
(CONTINUED) from controller
Electrical actuator position Replace the electrical actuator per valve spec.
feed back out of adjustment
Fine particulate contamination Replace PVE or electric actuator per valve
specs.
Checking input control signal:
1. Install volt meter to ground pin connection and signal pin with PVE in circuit.
2. Turn the power on for the electrical controller.
3. Actuate the electrical controller and read the voltage.
4. The control voltage should be per the electrical controller output signal.
On electrical actuators - coil resistance can not be measured at the pins.
When replacing an electrical actuator be sure that it has the same part number on it to
ensure original functionality.
If filter in the electrical actuator has pieces of contamination trapped in it, this is a good
indication that the complete system is contaminated and needs to be flushed. The filter
in the electrical actuator can be removed and cleaned.
P107 809E
11039167 • Rev AE • November 2012 43

PVG 32
Service Manual
PVEO ON/OFF Description: Proportional electrical actuator.

ELECTRICAL ACTUATOR
Location: On the end of the main spool of the PVB.
Function: Convert an electrical command to move the main spool to a set position.

Does not work in either direction No control voltage from the electrical Check voltage from the electrical controller
controller Resistance check (measures between pin 2 and ground):
17 OHMs for 12 volt systems
63 OHMs for 24 volt systems
Command pin wire in mating connector is Repair broken wire
broken
Connector corroded Replace PVE and mating connector - This condition is caused by
24 volt electrical actuator used on a 12 volt Replace with the correct electrical actuator for a 24 volt system
system
No power from the battery Check power to electrical actuator
Power pin wire in mating connector is Repair broken wire
broken
Ground connection must be hard wired Repair ground connection
straight from the battery or from the
electrical controller
Works in one direction No control voltage from the electrical Check voltage from the electrical controller is there for that
(Assuming that the manual controller direction
control lever and the main spool Lack of voltage to actuator (Minimum Check system voltage
moves freely both directions) voltage 11 volts for 12 volt system and 22
volts for 24 volt system
Works intermittently Loose connection between the electrical Repair connector
actuator and controller
Works with no command from Fine contamination Replace the electrical actuator per valve spec. and flush the
controller complete system and fill with filtered oil
44 11039167 • Rev AE • November 2012

PVG 32
Service Manual
PVPC PLUG FOR Description: Pilot oil supply from another pump.
EXTERNAL PILOT
CONTROL Location: On the end of the PVP.
Function: Provides a hydraulic pilot supply to the valve stack.

Main spool moves slow, or not at External hydraulic pilot pressure is too low Check external hydraulic pressure from pilot pump and/or
all, in all sections restrictions
PVPC plug for external pilot
Tee into pressure port

to measure pressure
P107 734E
11039167 • Rev AE • November 2012 45

PVG 32
Service Manual
PVMR FRICTION MODULE Description: Mechanical friction hold.
Location: Mounted on main spool in the PVB.
Function: Infinite mechanical positioning of the main spool.

Flow changes Excessive flow across the main spool Reduce flow (100 l/min or less)
Vibration Reduce vibration
Broken spring Replace broken springs
Flow changes or will not stay in Check for proper assembly of parts Install parts correctly per specification sheet
detent
PVMR module
Plug
36 mm
15 Nm
[133 lbf•in]
Plug (x3)
11 mm
4 Nm Mechanical detent
[35 lbf•in] Screw (x4)

5 mm
8 Nm
[71 lbf•in]
P107 811E
46 11039167 • Rev AE • November 2012

PVG 32
Service Manual
PVEO ON/OFF Checking input control signal:

ELECTRICAL ACTUATOR
(CONTINUED) 1. Install a volt meter to the ground pin connection and to the signal pin.
2. Turn the power on for the electrical controller.
3. Actuate the electrical controller and read the voltage.
4. The control voltage should be per the electrical controller output range.
When replacing an electrical actuator be sure that it has the same part number on it to
ensure original functionality.
P107 812E
11039167 • Rev AE • November 2012 47

Products we offer: Sauer-Danfoss is a global manufacturer and supplier of high-
and Motors
• PLUS+1™ GUIDE
• Sensors
• Steering
Local address:
Members of the Sauer-Danfoss Group:
Comatrol
www.comatrol.com
Sauer-Danfoss (US) Company Sauer-Danfoss ApS
Ames, IA 50010, USA Phone: +45 7488 4444
Turolla
Phone: +1 515 239 6000 Fax: +45 7488 4400
www.turollaocg.com Fax: +1 515 239 6618

Fax: +81 6 6395 8585
www.sauer-danfoss-daikin.com
11039167 •Rev AE • November 2012

PVE – Series 4
for PVG 32, PVG 100
and PVG 120,
Including PVHC
Technical
Information
VL77-2
PVE Series 4 for PVG 32, PVG 100 and PVG 120, Including PVHC
Technical Information
Revisions, Abbreviations
Revision History Table of Revisions

Date Page Changed Rev
Jun 2011 All Major update FA
Jan 2012 44-45 Various changes FB
May 2012 All Major update GA
Aug 2012 All Various, new articles about -NP, 1 page more moved all. GB
List of Abbreviations Abbreviation Description

ASIC Application Specific Integrated Circuit - the part of the PVE where spool position is
controled to follow setpoint
ATEX Certificated for use in explosive environment
AVC Auxillery Valve Comand - ISOBUS/J1939 standard signal for valve control
AVCTO Auxillery Valve Comand Time Out - Fault monitoring setting
AVEF Auxillery Valve Estimated Flow - ISOBUS/J1939 standard signal for valve feedback
CAN Controller Area Network - Communication method used by PVED
CLC Closed Loop Circuit
CRC Cyclic Redundancy Check - Method for ensuring validity of data.
-DI PVE with Direction Indication
DM1 Diagnostic Message 1 - J1939 message informing about present fault
DM2 Diagnostic Message 2 - J1939 message informing about fault history
DM3 Diagnostic Message 3 - J1939 message clearing fault history
DSM Device State Machine. Deterministic description of system process
ECU Electronic Control Unit
EH Electro Hydraulic
-F PVE for Float spool. Two variants: 4 pin with float at 75%. 6 pin with separate float.
FMEA Failure Mode Effect Analysis
ISOBUS Communication standard for CAN
J1939 Communication standard for CAN
LED Light Emitting Diode
LS Load Sensing
LVDT Linear Variable Differential Transducer - Position sensor
NC Normally Closed solenoid valve in PVE
NC-H Normally Closed standard solenoid valve - like in PVEH
NC-S Normally Closed solenoid valve Super - like in PVES
NO Normally Open solenoid valve in PVE

Sauer -Danfoss reserves the right to alter its products without prior notice. This also applies to products already
ordered provided that such alterations can be made without affecting agreed specifications. All trademarks
in this material are properties of their respective owners. Sauer-Danfoss, the Sauer-Danfoss logotype, the
Sauer-Danfoss S-icon, PLUS+1™, What really matters is inside® and Know-How in Motion™ are trademarks of the
Sauer-Danfoss Group.
Front cover illustrations:V310299, V310300, V310294, V310292 ,V310295, V310291, F300704, drawing 157-506.
2 520L0553 • Rev GC • Mar 2013

Revisions, Abbreviations
List of Abbreviations Abbreviation Description

(continued) PLC Programmable Logical Circuit
PLUS+1™ Trademark for Sauer-Danfoss controllers and programming tool
POST Power On Self Test. Boot up evaluation for PVED
Pp Pilot Pressure. The oil gallery for PVE actuation
PVB Proportional Valve Basic module - valve slice
PVBS Proportional Valve Basic module Spool
PVBZ Proportional Valve Basic module Zero leakage
PVE Proportional Valve Electric actuator
PVEA PVE variant with 2-6 % hysteresis
PVED PVE variant Digital controlled via CAN communication
PVEH PVE variant with 4-9% Hysteresis
PVEM PVE variant with 25-35% hysteresis
PVEO PVE variant with ON/OFF actuation
PVEP PVE variant PWM controled
PVES PVE variant with 0-2% hysteresis
PVEU PVE variant with US 0-10V
PVG Proportional multi-section Valve Group
PVHC PV variant with Current controlled valve actuator
PVM Proportional Valve Manual control with handle
PVP Proportional Valve Pump side module.Inlet
PVS Proportional Valve end plate
PVSK Proportional Valve end plate crane. Inlet module with Spool Control
PWM Pulse Width Modulation
S4 DJ Series 4 Digital J1939 service tool software for PVED-CC
SAE Society Automotive Engineering
-R PVE with Ramp function
-NP PVE with solenoid disable in Neutral Position
-SP PVE with Spool Position feedback
uC Micro-Controller
uCSM Micro-Controller State Machine
UDC Power supply Direct Current; also called Vbat for battery voltage
US Steering voltage for the PVE control; also called VS
520L0553 • Rev GC • Mar 2013 3

Contents
General Information List of Abbreviations...................................................................................................................................... 2

Reference............................................................................................................................................................ 6
Standards........................................................................................................................................................... 6
Warnings............................................................................................................................................................. 6
Introduction...................................................................................................................................................... 7
PVE stands for Proportional Valve Electrical actuator. ................................................................. 7
Overview............................................................................................................................................................ 8
Functionality PVG Functionality............................................................................................................................................ 9

PVE Functionality..........................................................................................................................................10
Hydraulic subsystem..............................................................................................................................10
Hydraulic variant: PVEA.........................................................................................................................11
Hydraulic variant: PVHC.........................................................................................................................11
PVE with ramp...........................................................................................................................................11
Electronic subsystem...................................................................................................................................13
Safety and Monitoring Safety and Monitoring.................................................................................................................................14

Fault monitoring and reaction............................................................................................................14
Spool Position Feedback (-SP)..................................................................................................................16
Direction Indication Feedback (-DI)........................................................................................................17
Solenoid disabling function (-NP)...........................................................................................................18
Safety in Application Building in Safety..........................................................................................................................................19

Hazard and Risk Analysis ISO 12100-1 / 14121.............................................................................19
Control System Example.............................................................................................................................20
PVG32– Mainly used in system with fixed displacement pumps...........................................23
PVG100 – Alternative LS dump or pilot supply disconnect......................................................23
PVG120 – Pump disconnect/block for variable pumps.............................................................23
PVE Control PVE Control by Voltage................................................................................................................................24

PLUS+1™ compliance.............................................................................................................................24
ATEX PVE.....................................................................................................................................................24
PVEU–PVE with fixed control signal range.....................................................................................25
PVE controlled with PWM signal........................................................................................................25
PVEP...................................................................................................................................................................26
PVEO...................................................................................................................................................................27
PVE ON/OFF activation................................................................................................................................27
PVE for Float Spool........................................................................................................................................27
PVHC control...................................................................................................................................................29
Hysteresis.........................................................................................................................................................30
PVES Series 4..............................................................................................................................................30
PVEA Series 4.............................................................................................................................................30
PVEH Series 4.............................................................................................................................................30
Example of Use...............................................................................................................................................31
4 520L0553 • Rev GC • Mar 2013

Contents
Technical Data Operating Parameters.................................................................................................................................32

Declaration of conformity ....................................................................................................................32
PVHC.............................................................................................................................................................32
PVEO and PVEM........................................................................................................................................33
PVEA, PVEH, PVES and PVEU................................................................................................................33
PVEP..............................................................................................................................................................34
PVE dimensions for PVG 32 and PVG 100.............................................................................................36
PVE dimensions for PVG 120.....................................................................................................................38
PVE pinout.......................................................................................................................................................40
Standard PVE.............................................................................................................................................41
Standard PVE with DI..............................................................................................................................42
Standard PVE with SP.............................................................................................................................42
Standard PVE with NP............................................................................................................................42
PVE with separate Float pin..................................................................................................................43
PVE with PWM controled – PVEP........................................................................................................43
PVHC connection.....................................................................................................................................44
Product Warnings..........................................................................................................................................45
Code Numbers PVE Code Numbers for use on PVG 32 and PVG 100........................................................................47
PVE Code Numbers for use on PVG 120................................................................................................49
PVE Accessories..............................................................................................................................................50
Connector Code Numbers at Other Suppliers ...................................................................................50
PVED Code Numbers for use on PVG 32 and PVG 100.....................................................................51
520L0553 • Rev GC • Mar 2013 5

General Information
Reference Sauer-Danfoss Doc 520L0344, PVG 32 Proportional Valve Groups, Technical Information.
Sauer-Danfoss Doc 520L0720, PVG 100 Proportional Valve Groups, Technical Information.
Sauer-Danfoss Doc 520L0356, PVG 120 Proportional Valve Groups, Technical Information.
Sauer-Danfoss Doc 520L0665, PVED-CC Electro Hydraulic actuator, Technical Information
Sauer-Danfoss Doc 11070179, PVED-CX Electro Hydraulic actuator, Technical Information.
Sauer-Danfoss Doc 11051935, PVG 32 Metric ports, Technical Information.
Standards •• International Organization for Standardization ISO 13766 Earth moving machinery -
Electromagnetic compatibility.
•• EN 50014:1997 +A1, A2: 1999
•• EN 50028: 1987. For ATEX approved PVE
–– IEC EN 61508
–– ISO 12100-1 / 14121
–– EN 13849 (Safety related requirements for control systems)
–– Machinery Directive 2006/42/EC” (1st Edition December 2009)
PVE with connector variants:

Hirschmann or DIN Deutsch AMP
Warnings Please work through all warnings before implementing actuators in any application.
The list of warnings must not be seen as a full list of potential dangers. Depending on
application and use other potential dangers can occur.
Warnings are listed next to the most relevant section and repeated in a special section at
the end of Technical Data.
WWarning
All brands and all types of directional control valves – including proportional valves
– can fail and cause serious damage. It is therefore important to analyze all aspects of
the application. Because the proportional valves are used in many different operation
conditions and applications, the machine builder/ system integrator alone is responsible
for making the final selection of the products – and assuring that all performance, safety
and Warning requirements of the application are met.
6 520L0553 • Rev GC • Mar 2013

General Information
Introduction PVE Series 4 is the common name for the Sauer-Danfoss PVG electrical actuator.
This technical information covers our voltage controlled PVE and our current controlled
PVHC actuator. For the PVHC please see in the PVHC section. The digital actuators
PVED-CC and PVED-CX are covered in their special technical information.
PVE controlled PVG with PVSK
PVE stands for Proportional Valve Available PVE variants

Electrical actuator. On/Off
The Sauer-Danfoss PVE is built on more Proportional - Closed loop
Actuation
than thirty years experience of electrical controlled
valve control and is the perfect fit for our Proportional - Direct control
high performance proportional valves Voltage
PVG32, PVG100 and PVG120, as it is for Control signal PWM
our EH steering. Current (PVHC)
Standard precision
All our products are developed in close Precision High precision
cooperation with system manufacturers Super high precision
Spool position
from the mobile hydraulic market. That
Direction indicator
is the reason for our high performance in Feedback
Error
all market segments
None
Deutsch
The PVE can be controlled from a switch,
Connectors AMP
a joystick, a PLC, a computer or a Sauer-
DIN/Hirschmann
Danfoss PLUS+1™ micro-controller.
Active
Fault detection
Passive
The PVE is available in multiple variants. and reaction
None
A short list here just gives the main 11V – 32V multi-voltage
variations. Power supply 12V
24V
520L0553 • Rev GC • Mar 2013 7

General Information
Overview The PVG is a sectional spool valve stack with up to 12 individually controlled proportional
valves. With the PVE the PVG can be operated as single valves or several valves in
cooperation.
The oil flow out of the work section (A- or B-port) can be controlled by a combination of
the following:
•• PVE controlling the spool position using pilot oil pressure.
•• A handle (PVM) in mechanical interface with the spool.
PVG 32 structural lay-out with naming
B-port
PVS - end plate A-port
PVE
PVE retract = P→ A P→ A
Connector
PVB - basic module
Pin
LED
T - Tank port P - Work flow
V310329.A
8 520L0553 • Rev GC • Mar 2013

Functionality
PVG Functionality The PVG valve distributes oil from pump flow to a particular work function in the
application via a specific valve section. This is done by moving the spool (PVBS).
Depending on the choice of components the oil work flow enters the PVG through
the PVP (proportional valve pump side module), a PVSK, a mid inlet or other system
interface and enters the PVB (proportional valve basic module) via the P gallery and
leaves through the T gallery. The PVP/PVSK also supplies the Pilot oil pressure (Pp) for the
PVE to activate the spool (PVBS). Special designed float spools also allow oil flow in both
directions between A- and B-port not opening to pump nor tank.
When looking at the figure you see the valve section from PVP towards PVS with the
PVM and PVE standard mounted. When PVM and PVE are interchanged it’s called option
mounted.
Valve section with naming - standard mounted - seen from PVP

P -> A
Pilot oil supply
B port Oil A port

PVE
PVB
PVM
Electronics
Neutral spring
NC Solenoid valve PVBS

LVDT <- Retract towards PVE
Extend away from PVE ->
NO solenoid valve
V310072.A
Oil out of A-port = PVM pushed towards PVB = retract = LVDT moves into PVE.
With the spool in neutral, default position when held by the neutral spring,
the connection to the application via ports is blocked.
Moving the PVBS towards the PVE, as in the figure, opens a connection between P and A
and also between B and T. This is done by either pushing the PVM or activating the PVE.
The PVE moves the PVBS by letting Pilot Oil Pressure (Pp) push on the right end of the
PVBS and releasing pressure from the left end.
For details on PVG 32 please see PVG 32 Proportional Valve Groups, Technical Information,
520L0334.
520L0553 • Rev GC • Mar 2013 9

Functionality
PVE Functionality This section has focus on how the PVE works and interacts. The description here is
general and variant specific descriptions will all refer to this.
The PVE is an electro mechanical device, meaning that functionality is depending on

mechanical, hydraulic, electrical and control conditions given by PVE, PVG, application
and vehicle. The result of this is that implementing operation and safety conditions also
must include vehicle specific considerations.
Hydraulic subsystem
The hydraulic subsystem is used for moving the spool and thereby open the valve for
work flow.
Pilot oil diagram
Set point
Electronics Pp
NC1
NC3
Spool
LVDT
NO4
NO2
1.0 [0.039]
Tank
V310073.A
The hydraulic sub system moves the spool and thereby opens the valve for work flow.
The heart in the hydraulic subsystem is the solenoid valve bridge which controls the Pilot
Pressure (Pp) on spool ends. It consist of four poppet valves, the two upper are normally
closed (NC) and the two lower are normally open (NO). The Pp will work against the PVBS
neutral spring when the spool is moved out of blocked (neutral) and together with the
spring when going in blocked. This combined with a larger opening in the NO than in
the NC will give a faster movement towards blocked than out of blocked.
When the PVE is powered the solenoids are all put in closed state. To move the PVBS to
the right NC1 and NO4 are opened and NC3 and NO4 are kept closed.
The activation of the solenoid valves represents oil consumption and thereby also a
pressure drop in the pilot oil gallery. By simultaneous use of multiple PVE the Pp can fall
and result in performance problems.
The two check valves next to the NO are anti-cavitation valves.

The orifice to tank reduces tank pressure spikes and can also be used for ramp function.
WWarning
Obstacles for the Pilot oil pressure (Pp) can have direct influence on spool control.
Reduced Pp will limit spool control. Too high Pp can harm the PVE.
10 520L0553 • Rev GC • Mar 2013

Functionality
PVE Functionality Hydraulic variants: PVEA PVE with ramp

(continued) NO2 and NO4 are replaced with orifices. Tank orifice has smaller diameter.
WWarning
PVEA is not for use on PVG
100.
Hydraulic variant: PVHC

The PVHC does not work as a PVE and does not have transducer, anti cavitation nor
protection against tank pressure spikes.
It is necessary to use the PVHC in combination with 25 bar [362.6 psi] pilot pressure, and
standard FC spools fitted for hydraulic actuation. See PVG 32 Proportional Valve Groups,
Technical Information 520L0344, PVG 100 Proportional Valve Groups, Technical Information
520L0720, and PVG 120 Proportional Valve Groups, Technical Information 520L0356.
Because of the 25 bar pilot pressure, it is not possible to combine PVHC with PVE on
a PVG.
Hydraulic variant: PVHC
With electrical proportional actuation, the main spool position is adjusted so that its
position corresponds to an electrical control signal.
The control signal is converted into a hydraulic pressure signal that moves the main
spool in the PVG. This is done by means of two proportional pressure-reducing valves.
The electrical actuator can be controlled either by a current amplifier card, or directly
from a programmable micro-controller.
520L0553 • Rev GC • Mar 2013 11

Functionality
PVE Functionality Mechanical Subsystem

(continued) The mechanical subsystem gives interface to valve and control system and provides
protection to hydraulic and electrical/electronic subsystem. The LVDT, not used on
all variants, gives feed back to electronics on spool position. The LVDT is calibrated in
production and recalibration should only be done in special cases. The standard PVE has
an aluminum block for distributing pilot oil. PVE with anodized block are available.
The connector gives the electrical interface to power and control system. Sauer-Danfoss
have a variety of connectors. We know that tradition and the aspects of serviceability
are important when our customers choose. We have chosen the Deutsch connector
as our main solution. The quality of wiring has direct influence on water integrity and
signal quality therefore disturbance or changes in cabling can influence safety and
performance.
PVE, Hirschmann/DIN connector PVE, AMP connector PVE, Deutsch connector
V310390.A
12 520L0553 • Rev GC • Mar 2013

Functionality
PVE Functionality Electronic subsystem

(continued) The PVE (A/ H/ M/ S/ U) control signal is a low current voltage, a PWM can also be used.
The PVEP has build-in a PWM evaluation and cannot be controlled by proportional
voltage. The control signal is referred to as US.
Function blocks for electronics
The PVE features Closed Loop Control (CLC). This is made possible by on board electronics
and an integrated feedback transducer that measures spool movement. The integrated
electronics compensate for flow forces on the spool, internal leakage, changes in oil
viscosity, pilot pressure, etc. This results in lower hysteresis and better resolution.
In principle the set-point determines the level of pilot pressure which moves the main
spool. The position of the main spool is sensed in the LVDT which generates an electric
feed-back signal registered by the electronics. The variation between the set-point signal
and feed-back signal actuates the solenoid valves. The solenoid valves are actuated so
that hydraulic pilot pressure drives the main spool into the correct position.
The LVDT (Linear Variable Differential Transducer) is an inductive transducer with

very high resolution. When the LVDT is moved by the main spool a voltage is induced
proportional to the spool position. The use of LVDT gives contact-free connection
between mechanics and electronics. This means an extra long lifetime and no limitation
as regards the type of hydraulic fluid used.
The PVEO and PVHC do not have embedded control electronics and do not support
closed loop control.
520L0553 • Rev GC • Mar 2013 13

Safety and Monitoring
Safety and Monitoring The choice of PVE also decides the level of feedback and safety. PVE are available with
fault monitoring, spool direction indication, spool position feedback and separate float
control.
The fault monitoring is available in PVEA/H/S/P/U and is a utilization of the ASIC.
Direction Indication is available in PVEO/A/H and they are dual powered PVE where
separate pins give an active feedback for spool movement.
Spool position is available in PVES and is a precise feedback on a separate pin for actual
spool position.
The separate float control is a protection against unintended float activation.
The PVEM, PVEO and PVHC do not have fault monitoring.
Fault monitoring and reaction

The fault monitoring system is available in two versions:
•• Active fault monitoring provides a Warning signal and deactivates the solenoid
valves. A reboot of the PVE is required to reactivate.
•• Passive fault monitoring provides a Warning signal only. A reboot is not required.
Both active and passive fault monitoring systems are triggered by the same four main
events:
1. Control signal monitoring
The Control signal voltage (US) is continuously monitored. The permissible range
is between 15% and 85% of the supply voltage. Outside this range the section will
switch into an error state. A disconnected US pin (floating) is recognized as neutral
set point.
2. Transducer supervision
The internal LVDT wires are monitored.
If the signals are interrupted or short-circuited, the PVE will switch into an error state.
3. Supervision of spool position

The actual position must always correspond to the demanded position (US).
If the actual spool position is further out from neutral than the demanded spool
position (>12%, PVEA: >25%) or in opposite direction, the PVE will switch into an
error state. With neutral/blocked setpoint the tolerance is +- 0,5 mm relative the
calibrated neutral position. Spool position closer to neutral and in same direction
will not cause an error state. The situation is considered “in control”.
4. Float monitoring
Float must be entered or left within a time limit. On the six pin float PVE too high
delay will cause an error state. The float Time Outs has own thresholds. Only relevant
for the six pin PVEH-F.
14 520L0553 • Rev GC • Mar 2013

Safety and Monitoring Active fault reaction is activated after 500 ms of error (PVEA: 750 ms).
(continued) •• The solenoid valve bridge is disabled and the PVBS is released to spring control
•• The error pin is powered*
•• The LED change color
•• The state is memorized and continues until PVE reboot
Passive fault reaction is activated after 250 ms of error (PVEA: 750 ms)
•• The solenoid valve bridge is NOT disabled and the PVBS is NOT released
•• The error pin is powered*
•• The LED change color
•• The state is active for minimum 100 ms and is reset when error disappears
* for PVE with direction indication both DI pins goes low by fault.
WWarning
Error pins from more PVEs may not be interconnected.
Not activated error pins are connected to ground and will disable any active signal.
Error pins are signal pins and can only supply very limited power consumption.
To avoid the electronics in undefined state a general supervision of power supply (UDC)
and internal clock frequency is implemented. This function applies to PVEA, PVEH, PVEP,
PVES and PVEU independently of fault monitoring version and PVEM - and will not
activate fault monitoring.
The solenoid valves are disabled when:

•• the supply voltage exceeds 36 V
•• the supply voltage falls below 8.5 V
•• the internal clock frequency fails
520L0553 • Rev GC • Mar 2013 15

Safety and Monitoring Fault monitoring overview

(continued) Error Fault Memory
Fault Delay before
Type Error mode output output on LED light (reset
monitoring error out
status PVE 1) needed)
PVEO
No fault
PVEM - - - - - -
monitoring
PVHC
No fault Low <2V Green -
500 ms Input signal faults Flashing red
Active
PVEA (PVEA: 750 ms) Transducer (LVDT) High ∼UDC Yes
PVEH Constant red
Close loop fault
PVEP
PVES No fault Low <2V Green -
PVEU 250 ms Input signal faults Flashing red
Passive
(PVEA: 750 ms) Transducer (LVDT) High ~UDC No
Constant red
Close loop fault
PVE 500 ms Float not active
Float Active High ~UDC Constant red Yes
six pin 750 ms Float still active
1) Measured between fault output pin and ground.
WWarning
It’s up to the customer to decide on the required degree of safety for the system.
For PVE with direction indication:

•• both DI pins go low when error is active.
•• when UDC1 is disabled, US is not monitored and defined as 50%.
Spool Position Feedback The –SP functionality is a 0,5V to 4,5V feedback, inverted in direction relative to US with
(-SP) 2,5V as neutral value.
Spool Position Feedback

Us Usp
75% UDC Us 4.5V
Usp
50% UDC 2.5V
25% UDC Us Usp

0.5V
Spool travel 7 mm 0 mm 7 mm Spool travel
100% Neutral 100%
A port B port
16 520L0553 • Rev GC • Mar 2013

Direction Indication PVE with build in indication for spool movement direction are available.
Feedback (-DI)
The PVE–DI has dual power supply. UDC1 only supplies solenoid valves. UDC2 supplies
electronics and feed back. The PVE does not work without UDC2. DI-A and DI-B are relative
standard mounting. The input signal fault monitoring is disabled if UDC1 is disabled.
DI-A and DI-B are relative standard mounting.
The DI has two direction feeedback signals with output high (close to UDC) when the
spool is in neutral position. If the spool moves out of neutral position, the direction
signal switches to low (< 0.2 V). One of the signals goes low by spool ~0,8 mm out of
neutral and high by spool within 0,4 mm out of neutral.
Both direction indication signals go low when the error indicator goes high.
Direction Indication Feedback
DI-A high
DI-A low
DI-B high
DI-B low
Spool position ‘x’
A-port -0.8 -0.4 0 0.4 0.8 B-port mm [in]
PVBS towards PVE PVBS away from PVE
As shown in the figure, both “DI-A” and “DI-B” signals are “High” when the spool is in
neutral position.
When the spool is moving in the A direction, the “DI-A” signal goes “Low” and the “DI-B”
signal stays “High”.
The reverse is true when the spool is moved in the B direction.
Values for both Direction Indicators, pin A and pin B

Transition to low from high 0.8 ± 0.1 mm [0.031 in]
Transition to high from low 0.4 ± 0.1 mm [0.015 in]
Transition to low both pins error pin goes high
Maximum load of “DI-A” , “DI-B” 50 mA
Voltage DI high by load 20 mA > UDC – 1.5 V
Voltage DI high by load 50 mA > UDC – 2.0 V
Voltage DI low < 0.2 V
520L0553 • Rev GC • Mar 2013 17

Solenoid disabling PVEH-NP and PVEA-NP have a build in feature that disables the solenoids by US at 50%
function (-NP) and gives a feedback on the solenoid status. This is done to facilitate application
monitoring.
The fault monitoring is still activated but the closed loop will remain passive until the
control signal shifts.
US disable range 48 % UDC to 52 % UDC

From active to passive 750 ms <-> 1000 ms
Solenoid disable reaction time
From passive to active 0 ms <-> 50 ms
Maximum load 50 mA
Solenoid feedback vs US
Voltage if solenoid active by load 20 mA > UDC – 1.5 V
Solenoid feedback signal
Voltage if solenoid active by load 50 mA > UDC – 2.0 V
Voltage if solenoid passive <1V
PVEH-F (six pin) has also the disable function but not the feedback.
Our general recommendation is disabling of PVE that are not in active use.
Solenoid disabling function (-NP) curves
UDC
Sfb
US
Gnd
18 520L0553 • Rev GC • Mar 2013

Safety in Application
Building in Safety All brands and all types of control valves (incl. proportional valves) can fail. Thus the
necessary protection against the serious consequences of function failure should
always be built into the system. For each application an assessment should be made for
the consequences of pressure failure and uncontrolled or blocked movements.
To determine the degree of protection that is required to be built into the application,
system tools such an FMEA (Failure Mode and Effect Analysis) and Hazard and Risk
Analysis can be used.
FMEA (Failure Mode and Effect Analysis) IEC EN 61508

FMEA is a tool used for analyzing potential risks. This analytical technique is utilized to
define, identify, and prioritize the elimination or reduction of known and/or potential
failures from a given system before it is released for production.
Please refer to IEC FMEA Standard 61508.
Hazard and Risk Analysis ISO 12100-1 / 14121

This analysis is a tool used in new applications as it will indicate whether there are
special safety considerations to be meet according to the machine directives EN 13849.
Dependent on the determined levels conformety this analysis will detirmine if any extra
requirements for the product design, development process, production process or
maintenance, i.e. the complete product life cycle.
WWarning
520L0553 • Rev GC • Mar 2013 19

Control System Example Example of a control system for manlift using PVE Fault monitoring input signals and
signals from external sensors to ensure the PLUS+1™ main controllers correct function of
the manlift.
Control system example

B
Emergency stop /
Man present switch
C
HMI / Joystick
control
A
D
Battery
Motion
detection sensors
E
Main controller
A Main power supply with safety logic
B Emergency stop/man present switch

C HMI/Joystick control
D Movement detection sensors
E Main controller
F PVG 32 control valve F
G Hydraulic deactivation
WWarning
It is the responsibilty of the
equipment manufacturer
that the control system G Hydraulic
incorporated in the machine T P deactivation
is declared as being in
confirmity with the relevant
machine directives.
P301 316
Electrical block diagram for above illustration

Main power supply Emergency stop and Motion detection sensor
(battery) Man present switch
Supply Main control valve

Main controller
Neutral Supply Signal
PVE
HMI / Joystick Detection Control Conditioning
Joystick
neutral switch
Signal Fault
Monitoring
Control
Signal Conditioning PVE fault output
Failure
Detection Hydraulic deactivation
P301 317
20 520L0553 • Rev GA • Mar 2012

Control System Example Example of a typical wiring block diagram using PVEH with neutral power off switch and
(continued) fault monitoring output for hydraulic deactivation.
Typical wiring block diagram example

Emergency Man present
stop switch
A
PVE 1 Neutral detection / Supply control PVEH

1) with AMP
C signal connector
OFF
≠ Delay US
neutral UDC2
B Error

1) with AMP
C signal connector
OFF
≠ Delay US
neutral UDC2
B Error
E1 E2
2) Alarm
logic
Output
A Emergency stop / man present switch
OR
3) Memory
B PVE Faultmonitoring signals
C Neutral signal detection.
D Hydraulic deactivation high=on
AND
low=off
Hydraulic
Fault detection output D deactivation
P301 318
System Control Logic e.g. PLUS+1™ for signal monitoring and triggering signal for
deactivation of the hydraulic system.
WWarning
It is the responsebilty of the equipment manufacturer that the control system incorporated
in the machine is declared as being in confirmity with the relevant machine directives.
520L0553 • Rev GA • Mar 2012 21

Control System Example Similar to previous example using fault monitoring for deactivation of the hydraulic
(continued) system with extra fault inputs using the PVE’s with DI (Direction Indication) function.
Example of fault monitoring for deactivation of the hydraulic system

Stop switch
PVE 1 Neutral detection / Supply control PVEH-DI

1) AMP supply
signal connector
OFF
≠ Delay US
neutral UDC2
Error
PVEH-DI
AMP connector
2) Fault detection DI-A
DI-B 3) 4) DI-B
DI-A DI Output Delay Memory
US Logic Error

1) AMP supply
signal connector
OFF US
≠ Delay
neutral UDC2
Error
PVEH-DI
AMP connector
Fault detection DI-A
2)
DI-B 3) 4)
US Logic Error
OR
AND
high=on
low=off
Hydraulic
Fault detection output deactivation
P301 319
WWarning
It is the equipment manufacturers responsibility to ensure that the control system
incorporated in the machine is declared as being in conformity with the relevant
machine directives.
Other non-electrical modules which can be used in connection with hydraulic deactivation
at different levels.
22 520L0553 • Rev GC • Mar 2013

Control System Example PVG32– Mainly used in system with fixed displacement pumps
(continued) •• PVSK, commonly used in crane application - full flow dump
•• PVPE, full flow dump for the PVG 120
PVG100 – Alternative LS dump or pilot supply disconnect

•• PVPP, pilot oil supply shut off
•• External cartridge valve connecting LS Pressure to Tank
•• External cartridge valve connecting main Pressure to Tank
PVG120 – Pump disconnect/block for variable pumps

•• PVPX, LS dump to tank
520L0553 • Rev GC • Mar 2013 23

PVE Control
PVE Control by Voltage •• The PVE is controlled with a low current voltage signal.
•• The spool stroke is proportional to the control voltage (US).
•• The power is supplied via the supply wire (UBAT or UDC).
•• The ratio US/UDC defines the actuation. For PVEU a defined voltage.
•• A not connected US pin (floating) is recognized as US = ½UDC.
PVE characteristic – control by voltage
PVEP
control range
PVEU
2.5V 5V 7.5V fixed
Values for standard mounted PVE (PVEA/M/H/S)

Function Signal voltage (US)
Neutral US = 0.5 • UDC
Q: P → A US = (0.5 → 0.25) • UDC
Q: P → B US = (0.5 → 0.75) • UDC
PLUS+1™ compliance
CCaution PVEA, PVEH, PVES, PVEO, PVEP and PVED can be controlled by PLUS+1.
PVEM is not PLUS+1 The UDC has a capacitance of 2,2 uF which can give problems with some micro-controller
compliant. power supply. To eliminate this problem Sauer-Danfoss has designed a special resistance
supply and control cable.
ATEX PVE
The Sauer-Danfoss PVE ATEX portfolio has the same monitoring and control
characteristics as the equivalent standard PVE.
24 520L0553 • Rev GC • Mar 2013

PVE Control
PVE Control by Voltage PVEU–PVE with fixed control signal range Signal voltage - PVEU
(continued) The PVEU (PVE 0-10V) is designed for PLC/ Function Signal voltage PVEU
microcontroller(uC) control hence the U. Neutral 5V
The control signal US is fixed 0 V to 10 V Q: P → A 5V → 2,5V
independent of supply voltage UDC. Q: P → B 5V → 7,5V
PVE controlled with PWM signal

The standard PVE, PVEA/M/H/S, can also be controlled by a pulse with modulated PWM
signal.
The V1 and V2 for PWM must be symmetrically located around UDC2 and V1≤ UDC.
Duty cycles for PVE (PVEA/M/H/S/U) Recommended PWM frequency for PVE
Function Duty cycle (dc) PVEA/M/H/S PVE type PWM frequency
Neutral 50% dc PVEM > 200 Hz
Q: P → A 50% dc → 25% dc PVEA/H/S/U > 1 kHz
Q: P → B 50% dc → 75% dc
WWarning
The PWM is not evaluated by the PVE so variance/failure in period (T) will not be detected.
520L0553 • Rev GC • Mar 2013 25

PVE Control
PVE Control by Voltage PVEP

(continued) The PVEP is designed for PWM control signals only.
PVEP schematic and characteristic

Spool travel
- Driver
A mm [in]
Proportional control range
7.5 B
[0.3]
Sense
UsA
Position
Set point
to PWM
- Driver
B
UsB
Sense
-7.5
[-0.3] A
10% 80%
PWM ratio
- +
11 - 32 V
PVE
V310137.B
CCaution
It is important that the power supply (UDC) is connected before the PWM signal.
PWM signals are low power voltage signals; hence no current drivers are needed.
Current control is not possible with PVEP. The PVEP can also be connected to a control
signal like used for PVHC.
The PVEP performs a true time difference measurement on the PWM input, thus there is
no filtering or conversion involved.
PWM frequency can be chosen between 100 to 1000 Hz.
PVEP signals
Duty cycle A-signal Duty cycle B-signal Error Pin output
Function
(pin 1) (pin 2) (pin 3)
0% 0%
10% 0% Neutral Low
0% 10%
≥ 10% ≥ 10% Fault (Error) High
< 10% 10 → 80% B-port flow Low
10 → 80% < 10% A-port flow Low
A > 86% B > 86% Fault (Error) High
26 520L0553 • Rev GC • Mar 2013

PVE Control
PVEO PVE ON/OFF activation

The PVEO has two independent powered sets of solenoids. By powering a set of pins the
actuator is activated. By standard mounted PVE the A set gives full flow on A port and B
gives on B port. Both directions activated at same time will keep the spool in neutral.
PVEO schematic and characteristic
WWarning
The PVEO is designed to have UDC=12 V or UDC=24 V.
The solenoids might be activated by voltage down to 6 V.
PVE for Float Spool Sauer-Danfoss has developed two PVE variants to support the float spool. The float
spool is a 4�4 spool, where as the standard is a 4�3 spool giving another characteristic and
maximum stroke. These variations are covered by the built-in electronics.
There are two variants of float PVBS.

•• Float B – 1,5 mm dead band, max flow at 4,8 mm. Float at B = 8 mm, from 6 mm partial
float.
•• Float A – 0,8 mm dead band, max flow at 5,5 mm. Float at A = 8 mm, from 6,2 mm
partial float ( PVBZ).
PVEM-F and PVEH-F with four pin connector are for float B and give no built-in protection
against entering float.
PVEH-F with six pin connector is for float A and gives protection against entering float by
using low Us. The float signal has priority to the Us in the PVEH-F six pin.
Variants of the float spool PVBS

Float PVE PVBS Progressive control Float control
Dead band 0.8 mm UDC to float pin
A PVEH-F (6 pin) US: 25% -> 75% UDC
Max float at 5.5 mm Has priority
Dead band 1.5 mm
B PVEH-F (4 pin) US: 35% -> 65% UDC US= 75% UDC
Max float at 4.8 mm
PVE for float spools are not designed for standard 4�3 spools.
520L0553 • Rev GC • Mar 2013 27

PVE Control
PVE to the Float Spool PVE characteristic – Float A

(continued)
Proportional Proportional
Float port A Control port A Control port B
PVBS maximum float is
5.5 mm [0.22 in].
PVE has six pins.
Float when special pin
powered at UDC.
Float = Udc
PVE characteristic – Float B
PVBS maximum float is

4.8 mm [0.19 in].
PVE has four pins.
Float at US /UDC = 0.75
28 520L0553 • Rev GC • Mar 2013

PVE Control
PVHC control PVHC characteristic

Spool stroke, mm
5
Ideal curve
4
3
Hysteresis
Current in mA
0
800
200
800
400
600
400
200
600
1200
1000
1400
1200
1000
1400
1600
1600
@ 12V
@ 24V
600
400
200
300
500
400
100
100
200
300
700
600
500
700
800
800
500/1000 mA 280/560 mA 280/560 mA 500/1000 mA V310 000.A
PVHC current response and hysteresis @ 25 bar Pp, 21 ctS, 25 °C.
The PVHC control is done by dual Pulse Width Modulated (PVM) high current supply
100-400 Hz PWM control signals.
The PVHC does not have fault monitoring.

The PVHC does not have internal closed loop control of the spool.
The PVHC has high hysteresis. The hysteresis is affected by viscosity, friction, flow
forces, dither frequency and modulation frequency. The spool position will shift when
conditions are changed e.g. temperature change.
For PVG controlled by PVHC hysteresis is influenced by lever (PVM).
520L0553 • Rev GC • Mar 2013 29

PVE Control
Hysteresis The controllability of the PVE depends on the solenoid valve bridge and the electronic
capacity of the module.
Hysteresis is a measurement on spool position precision and repeatability. Hysteresis is

not a description of position maintaining.
PVES Series 4 PVEA Series 4

The PVES has an ASIC closed loop circuit The PVEA has an ASIC closed loop
and the NC-S solenoids. circuit, standard NC solenoids and orifice
instead of NO solenoids.
PVES voltage, position diagram PVEA voltage, position diagram
CCaution
PVEA is not for use on PVG 100.
PVEH Series 4
The PVEH has an ASIC closed loop circuit and the standard NC solenoids.
PVEH voltage, position diagram PVE hysteresis overview

PVE S A H M
Maximum 2% 6% 8.6 % 35 %
Typical <½ % 2% 4% 25 %
•• PVEP has the PVES characteristic.

•• PVEU is available with both
standard PVEH and super fine PVES
characteristic.
•• PVHC has hysteresis like PVEM at fixed
temperature and viscosity.
For PVHC temperature and viscosity

shifts control signal effect.
30 520L0553 • Rev GC • Mar 2013

PVE Control
Example of Use Signal leads must not act as supply leads at the same time unless the distance between
the actuator module PVE and terminal board is less than 3 m [3.3 yards] and the lead
cross-section is min. 0.75 mm2 [AWG 18].
25 Pin SUB-D connector with M3 screws (MIL-DTL-24308)
E : Emergency stop
F : Signal output, fault monitoring
NC : Not connected
: Signal leads
: Supply leads
3, 15, 16
1, 2, 14
Pin no.
19
20
21
10
22
8
7
6 Push/Dir.sw.3A
Push/Dir.sw.4A
Push/Dir.sw.3B
Push/Dir.sw.4B
Function
U- (GND)
Neut.sw.
Prop 1
Prop 2
U DC
U+
US1 US2 P3A P3B P4A P4B - + + U+ U-
F
PVEH/A/S 2
3
1
PVEM NC 2
3
1
NC
PVEO 2
3
1
E
2
3
- +
UDC
V310116.A
520L0553 • Rev GC • Mar 2013 31

Technical Data
Operating Parameters Declaration of conformity.

The PVEA/H/P/S/U have CE marking according to the EU directive EMC Directive
2004/108/EC. The declarations are available at Sauer-Danfoss.
The PVEO/M and PVHC are not subject to this directive.
WWarning
The PVE is designed for use with pilot oil supply. Use without oil supply can harm the
system. The PVE is designed for use with pilot pressure range 10 to 15 bar [145 to 220
psi]. Intermittent pressure peaks up to 50 bar [725 psi] can be accepted.
Intermittent is no longer than 5 seconds and not more than once per minute.
The following technical data are from typical test results. For the hydraulic system
mineral based hydraulic oil with a viscosity of 21 mm2/s [102 SUS] and a temperature
of 50 °C [122 °F] was used.
PVHC
PVHC control specification
Supply voltage UDC 12 VDC 24 VDC
Controller output current 0 – 1500 mA 0 – 750 mA
Pilot pressure 20 – 25 bar [290-363 psi]
Resistance 4.75 Ω ± 5% 20.8 Ω ± 5%
Response time 150 – 200 ms
PWM frequency 100 → 400 Hz
Reaction time PVHC

max. 0.235s
From neutral position to max. spool
rated 0.180s
travel at power on
min. 0.120s
max. 0.175s
From max. spool travel to neutral
rated 0.090s
position at power off
min. 0.065s
32 520L0553 • Rev GC • Mar 2013

Technical Data
Operating Parameters PVEO and PVEM

(continued) PVEO and PVEM control specification
rated 12 VDC 24 VDC
Supply voltage UDC range 11 → 15 V 22 → 30 V
max. ripple 5%
typical 740 mA 365 mA
Current consumption minimum 550 mA 290 mA
maximum 820 mA 420 mA
Current via DI maximum 100 mA
Reaction time PVEO and PVEM

Reaction time in seconds PVEO PVEO-R PVEM
max. 0.235s 0.410s 0.700s
From neutral position to max. spool travel
rated 0.180s 0.350s 0.450s
at power on
min. 0.120s 0.250s 0.230s
max. 0.175s 0.330s 0.175s
From max. spool travel to neutral position
rated 0.090s 0.270s 0.090s
at power off
min. 0.065s 0.250s 0.065s
From neutral position to max. spool travel max. 0.550s
by constant power min. 0.210s
–
From max. spool travel to neutral position max. 0.150s
by constant power min. 0.040s
PVEA, PVEH, PVES and PVEU

PVEA, PVEH, PVES and PVEU control specification
rated 11 → 32 V
Supply voltage UDC
max. ripple 5%
0.57 (0.33) A @ 12 V
Current consumption at rated voltage
0.3 (0.17) A @ 24 V
neutral 0.5 x UDC (PVEU 5V)
Signal voltage
A-port ↔ B-port 0.25 → 0.75 • UDC
Signal current at rated voltage 0.25 → 0.70 mA
Input impedance in relation to 0.5 • UDC 12 kΩ
Power consumption 7 (3.5) W
Error pin max current 100 mA
Reaction time PVEA, PVEH, PVES and PVEU in sec. (minus PVG 120)
PVEA PVEH, PVEP,
Supply voltage Function
Prop. fine PVES, PVEU
max. 0.500 0.230
Reaction time from neutral position
rated 0.320 0.150
Disconnected by to max. spool travel
min. 0.250 0.120
means of neutral
max. 0.550 0.175
switch Reaction time from max. spool travel
rated 0.400 0.090
to neutral position
min. 0.300 0.065
max. 0.500 0.200
Reaction time from neutral position
rated 0.320 0.120
to max. spool travel
min. 0.250 0.050
Constant voltage
max. 0.250 0.100
Reaction time from max. spool travel
rated 0.200 0.090
to neutral position
min. 0.150 0.065
520L0553 • Rev GC • Mar 2013 33

Technical Data
Operating Parameters PVEP

(continued)
PVEP control specification
range 11 → 32 V
Supply voltage UDC max. ripple 5%
over voltage (max. 5 min) 36 V
PWM control range (duty cycle) 10 → 80%
PWM frequency 100 → 1000 Hz
PWM input voltage swing 0 → UDC
PWM Trigger point 70% of UDC
Input impedance (standard pull down) 5 kΩ
Input capacitor ---
Power consumption 7W
Fault UDC
Error voltage:
No Fault <2V
All connector terminals are short-circuit protected, protected against reverse connection
and their combinations. Connecting error pins from two or more PVE’s will cause the
surveillance system to malfunction.
Oil consumption
PVEH/ M/ O/ U -
Supply PVEP /S / U
Function PVEA PVHC
Voltage prop. super
prop. high
0 l/min 0 l/min 0.3 l/min
neutral* OFF
[0 US gal/min] [0 US gal/min] [0.106 US gal/min]
Pilot oil flow 0.4 l/min 0.1 l/min 0.1 l/min
locked*
for PVE [0.106 US gal/min] [0.026 US gal/min] [0.026 US gal/min]
ON
continuous 1.0 l/min 0.7 l/min 0.8 l/min
actuations* [0.264 US gal/min] [0.185 US gal/min] [0.211 US gal/min]
* 12 bar [174 psi] and 21 mm2/s [102 SUS]
Oil viscosity Oil temperature

range 12 → 75 mm2/s [65 ÷ 347 SUS] range 30 → 60˚C [86 ÷ 140˚F]
Oil Oil
min. 4 mm2/s [39 SUS] min. -30˚C [-22˚F]
viscosity temperature
max. 460 mm2/s [2128 SUS] max. 90˚C [194 ˚F]
Pilot pressure PVE Pilot pressure PVHC

Pilot pressure nom. 13.5 bar [196 psi] nom. 25 bar [363 psi]
Pilot pressure
(relative to min. 10.0 bar [145 psi] min. 21 bar [305 psi]
(over tank)*
T pressure) max. 15.0 bar [217 psi] max. 25 bar [363 psi]
* Designed to be used with hydraulic activated spools.
34 520L0553 • Rev GC • Mar 2013

Technical Data
Operating Parameters Operating temperature

(continued) Min Max
Ambient -30˚C [-22˚F] 60˚C [140˚F]
Stock -40˚C [-40˚F] 90˚C [194˚F]
Recommended long time storage in packaging 10˚C [50˚F] 30˚C [86˚F]
Filtering in the hydraulic system

Required operating cleanliness level 18/16/13 (ISO 4406, 1999 version)
For further information see Sauer-Danfoss documentation Hydraulic Fluids and Lubricants, Technical Information
520L0463.
Enclosure and connector

Version of connector Hirschmann connector AMP JPT connector Deutsch connector
Grade of enclosure* IP 65 IP 66 IP 67
* According to the international standard IEC 529
NB: In particulary exposed applications, protection in the form of screening is recommended.
PVP modules, Pilot pressure curves
157-520.11
520L0553 • Rev GC • Mar 2013 35

Technical Data
PVE dimensions for PVE with Hirschmann connector for PVG 32 and PVG 100
PVG 32 and PVG 100
PVE with AMP connector for PVG 32 and PVG 100
36 520L0553 • Rev GC • Mar 2013

Technical Data
PVE dimensions for PVE with Deutsch connector for PVG 32 and PVG 100
PVG 32 and PVG 100
(continued)
157-722
PVHC for PVG 32 and PVG 100

92.2 [3.63] 92.2 [3.63]
44.5 [1.75]
44.5 [1.75]
100.5 [3.96]
90.1 [3.55]
V310388A V310387A
with Deutsch connectors with AMP connectors
520L0553 • Rev GC • Mar 2013 37

Technical Data
PVE dimensions for PVE with AMP connector for PVG 120
PVG 120
117.8 [4.638]
115.5 [4.55]
65 [2.56] 120 [4.72]
V310320A
PVE with Deutsch connector for PVG 120

125.7 [4.949]
115.5 [4.55]
65 [2.56] 120 [4.72]
V310380A
Please notice that connector needs extra space for mounting.
38 520L0553 • Rev GC • Mar 2013

Technical Data
General Dimensions PVHC with Deutsch connector for PVG 120

(continued)
115.5 [4.55]
65 [2.56] 114.5 [4.508]
V310378A
PVG 120 and PVG 32 combo with Deutsch connector
195.6 [7.70]
[1.97]
50.1
36.3 [1.43]
362 [14.25]
V310383A
520L0553 • Rev GC • Mar 2013 39

Technical Data
PVE pinout Connection PVEO with direction indication (DI) AMP version of PVEO–DI
PVEO-DI
Connector 1 A UDC B UDC Gnd Gnd
LED
AMP (grey) p1 p2 p3 p4 AUUDC
DC DI-B
Pin no.
Connector 2 DI-B DI-A Gnd UDC 2 BUUDC
DC
1 DI-A
2
AMP (black) p 1 p2 p3 p4 3
4
U DC2
Connection PVEO standard Grey connector Black connector
Connector A B P301 104
AMP/Hirschmann/
pin 1 pin 2
DIN
Deutsch pin 1 pin 4
Function A (pin 1) B (pin 2) AMP version of PVEO/PVEO–R

Neutral 0 0
Q: P → A UDC 0
0 UDC
A UDC
Q: P → B
B UDC
Control all PVEO
Connector A B
AMP/Hirschmann/
pin 1 pin 2
DIN
Deutsch pin 1 pin 4
•• Ground pins are internally connected. Hirschmann/DINPVEO/PVEO-R

version of PVEO / PVEO–R
•• Pin 3 is not connected on
Hirschmann/DIN version of PVEO.
•• UDC2 supplies electronics for feedback
signal on PVEO-DI. 3
A UUDC
UB UDC DC
2
DC
157-502.11
Deutsch version of PVEO
A UDC B UDC
40 520L0553 • Rev GC • Mar 2013

Technical Data
PVE pinout (continued) Standard PVE AMP version PVEA/PVEH/PVES/PVEU
Connection PVEA/PVEH/PVEM/PVES/PVEU
- also with float B four pin
Connector US UDC Gnd Error
AMP pin 1 pin 2 pin 3 pin 4
Hirschmann/
pin 2 pin 1 gnd pin 3
DIN
Deutsch pin 1 pin 4 pin 3 pin 2
•• On PVEM the error pin is not used and

not connected (pin 3 Hirschmann/DIN). Hirschmann/DIN version PVEH/PVEM/
•• Ground pins are internally connected. PVES/PVEH float B/PVEM float B
Control (US) for standard mounted PVEA/

PVEH/ PVEM/ PVES
Function Voltage relative PWM
Neutral 0,5 • UDC 50%
Q: P → A 0,5 → 0,25 • UDC 50% → 25%
Q: P → B 0,5 → 0,75 • UDC 50% → 75%
Control (US) for standard mounted PVEU Deutsch version PVEA/PVEH/PVES/PVEU/

Function PVEU PVEH float B
Neutral 5V
Q: P → A 5 V → 2,5 V LED
Q: P → B 5 V → 7,5 V
Control (US) for standard mounted PVEH/

PVEM float B four pin version
Q: P → A 0,5 → 0,34 • UDC 50% → 34%
Q: P → B 0,5 → 0,65 • UDC 50% → 65%
Float 0,75 • UDC 75%
PVEM is not PLUS+1 compliant.
520L0553 • Rev GC • Mar 2013 41

Technical Data
PVE pinout (continued) Standard PVE with DI AMP version PVEA–DI/PVEH–DI

PVEA-DI/PVEH-DI
Connection PVE with direction indication (DI) LED

Connector 1 US UDC 1 Gnd Error US DI-B
Pin no.
U DC1 1
AMP (grey) p1 p2 p3 p4 2
DI-A
Deutsch p1 p4 p3 p2 3
4
Error U DC2
Connector 2 DI-B DI-A Gnd UDC 2
Grey connector Black connector
AMP (black) p1 p2 p3 p4
Deutsch p4 p3 p2 p1
PVEA-DI/PVEH-DI
Deutsch version PVEA–DI/PVEH–DI
•• Ground pins are internally connected.
•• UDC2 only supplies electronics for LED
feedback signal and error pin on
PVEA-DI / PVEH-DI. Two separate power
sources can be used. Error
2 3 2 3 DI-A
US 1 4 1 4 DI-B
UDC UDC2
P301 105
PVES-SP
Standard PVE with SP Deutsch version PVES–SP
Connection PVE with Spool Position (SP) LED
Connector US Error SP Gnd UDC

Not Spool position
Deutsch p1 p2 p4 p5 p6 connected
3 4
Error 2 5
1 6
Us UDC
Standard PVE with NP PVES-SP PVES–NP

Deutsch version
Connection PVE with Neutral Power off (NP) LED

Connector US Error Sfb Gnd UDC
Deutsch p1 p2 p4 p5 p6 Not Sfb
connected 3 4
Error 2 5
1 6
Us
UDC
Control (US) for standard mounted PVEA–DI/ PVEH–DI, PVES-SP, PVEA-NP, PVEH-NP
Function US PWM
Q: P → A 0,5 → 0,25 • UDC 50% → 25%
Q: P → B 0,5 → 0,75 • UDC 50% → 75%
42 520L0553 • Rev GC • Mar 2013

Technical Data
PVE pinout (continued) PVE with separate Float pin
Connection PVEH with float A six pin

Connector US UDC Float Ground Error
AMP pin 1 pin 2 pin 5 pin 3 pin 4
Deutsch pin 1 pin 6 pin 3 pin 5 pin 2
Control (US) for standard mounted PVEH/ AMP with separate float pin
PVEM float A six pin version
Function PWM A PWM B LED
Not con-
Q: P → A 0,5 → 0,25 • UDC 50% → 25% nected
Q: P → B 0,5 → 0,75 • UDC 50% → 75%
Float
Float UDC on float pin
Error
Deutsch versionPVEH-F
with separate float pin
LED
No con-
Float nection
3 4
Error 2 5
1 6
Us UDC
157-779
PVE with PWM controled – PVEP
Connection PVEP Deutsch version with PVEP

Connector PWM A Error PWM B Gnd UDC
Deutsch p1 p2 p3 p5 p6
LED
Control (US) for standard mounted PVEP

Neutral < 10% < 10%
Q: P → A 10% → 80% < 10%
Q: P → B < 10% 10% → 80%
520L0553 • Rev GC • Mar 2013 43

Technical Data
Proportional Version PVHC connection Input control

(continued) •• 100-400 Hz PWM control signals. Control range
Parameter
•• Each connector controls one direction 12 V 24 V
and must have UDC and ground Controller
•• No constraints on pin for UDC and output current 0 - 1500 mA 0 - 750 mA
ground. range
PVHC with AMP PVHC with Deutsch

5.7 5.7
[0.224] [0.224] 5.7 5.7
44.4 [1.748] [0.224] [0.224]
44.4 [1.748]
33.0 [1.299]
33.0 [1.299]
26.75 26.75
[1.053] [1.053]
74.0 92.25 74.0 92.25

[2.913] [3.631] [2.913] [3.631]
16.5 5.75 16.5 2.5 [0.098] 5.75

[0.650] [0.226] [0.650] 56.1 [2.209] [0.226]
34.0
34.0 [1.339]
[1.339]
90.1 100.5
[3.547] [3.957]
44 520L0553 • Rev GC • Mar 2013

Technical Data
Product Warnings Warning

Not applying to the Operational Conditions can compromise safety.
Warning
Warning
A PVG with PVE can only perform according to description if conditions in this Technical
Information are met.
Warning
In particularly exposed applications, protection in the form of a shield is recommended.
Warning
When the PVE is in fault mode the quality of performance and validity of feedback is
limited depending on the fault type.
Warning
Error pins from more PVEs may not be connected. Inactive error pins are connected to
ground and will disable any active signal.
Warning
Error pins are signal pins and can only supply very limited power consumption.
Warning
Deviation from recommended torque when mounting parts can harm performance and
module.
Warning
Adjustment of the position transducer (LVDT) will influence calibration, and thereby also
safety and performance.
Warning
When replacing the PVE, the electrical and the hydraulic systems must be turned off and
the oil pressure released.
520L0553 • Rev GC • Mar 2013 45

Technical Data
Warning
Warning
Hydraulic oil can cause both environmental damage and personal injury.
Warning
Module replacement can introduce contamination and errors to the system. It is
important to keep the work area clean and components should be handled with care.
Warning
After replacement of modules or cables wiring quality must be verified by a performance
test.
Warning
By actuation at voltage below nominal PVG will have reduced performance.
Warning
The PVE is not designed for use with voltage outside nominal.
Warning
Obstacles for the Pilot oil can have direct influence on spool control.
Warning
Reduced pilot oil pressure will limit spool control.
Warning
Too high pilot oil pressure can harm the PVE.
46 520L0553 • Rev GC • Mar 2013

Code Numbers
PVE Code Numbers for use on PVG 32 and PVG 100
Deutsch connector code numbers

Fast-no
Feature std. float A float B DI NP SP
S memory ramp
Connector 1x4 1x6 1x4 2x4 1x6 1x6 1x4
active 157B4792 157B4796 11105542
PVEA*
passive 11107365
–
active 157B4092 157B4398 157B4096 11105543
PVEH
passive 157B4093 157B4392
active S 157B4892 157B4894
PVES
passive S 11089276 11108994
PVEP active S 11034832∗
PVEU passive S 11089090
12V 157B4291 11109080
PVEO –
24V 157B4292 11109092
S = super fine hysteresis, 1x4 = one plug four pins, * 1x6 = one plug six pins
AMP connector code numbers

Feature std. float A DI anodized ramp-ano ramp
S
Connector 1x4 1x6 2x4 1x4 1x4 1x4
active 157B4734 157B4736
PVEA*
passive 157B4735 157B4737 157B4775
–
active 157B4034 157B4338 157B4036 157B4074
PVEH
passive 157B4035 157B4037 157B4075
active S 157B4834
PVES
passive S 157B4835 157B4865
active S 11089091
PVEU active 157B4044
passive 157B4045
–
12V 157B4901 157B4905 157B4903
PVEO
24V 157B4902 157B4906 157B4272 157B4274 157B4904
S = super fine hysteresis, 1x4 = one plug four pins, * 1x6 = one plug six pins
WWarning
520L0553 • Rev GC • Mar 2013 47

Code Numbers
PVE Code Numbers Hirschmann/DIN connector code numbers

for use on PVG 32 and Feature std. float B anodized ramp
S
PVG 100 (continued) Connector 1x4 1x4 1x4 1x4
active 157B4032 157B4332
PVEH
passive 157B4033 157B4073
active S 157B4832
PVES
passive S 157B4833
12 V 157B4116 157B4416 157B4516
PVEM
24 V 157B4128 157B4428 157B4528
12 V 157B4216 157B4266 157B4217
PVEO
24 V 157B4228 157B4268 157B4229
S = super fine hysteresis, 1x4 = one plug four pins
ATEX (24 V) connector code numbers

PFOP,
Cable type PFOP PFOP BFOU
S cable dir PVB
Flying wire 5m 10 m 5m 5m
PVEH 11084101 11084109 11084092 11084098
passive
PVES S 11084102 11084110 11084093 11084099
PVEO 11084100 11084108 11084051 11084097
S = super fine hysteresis,
AMP/Deutsch code numbers for PVHC

Connector Code Number
PVHC 12 V 11112037
AMP 24 V 11112036
PVHC 12 V 11112038
Deutsch 24 V 11112039
48 520L0553 • Rev GC • Mar 2013

Code Numbers
PVE Code Numbers for AMP code numbers Hirschmann/DIN code numbers
use on PVG 120 Feature anodized Feature anodized
Connector 1x4 Connector 1x4
active 155G4094 active 155G4092
PVEH PVEH
passive 155G4095 passive 155G4093
12 V 155G4282 PVES passive 11111210
PVEO
24 V 155G4284 12 V 155G4272
PVEO
1x4 = one plug four pins 24 V 155G4274
Deutsch code numbers

Feature anodized
Connector 1x4
PVEH passive 11111206
PVES passive 11111207
12 V 11110601
PVEO
24 V 11110652
12 V 11110597
PVHC
24 V 11110598
ATEX (24 V) connector code numbers

PFOP,
Cable type PFOP PFOP BFOU
cable dir PVB
Flying wire 5m 10 m 5m 5m
PVEH passive 11084104 11084112 11084096 11084107
PVEO 11084103 11084111 11084095 11084106
520L0553 • Rev GC • Mar 2013 49

Code Numbers
PVE Accessories Connector code numbers

Code number Description
157B4992 AMP CONNECTING KIT (GREY) 4 pin with housing, contact and wire sealing
157B4993 AMP CONNECTING KIT (BLACK) 4 pin with housing, contact and wire sealing
984L3165 EL-PLUG, ON-OFF black Hirschmann DIN connector set*
Set of seals code numbers

Code number Description Actuator
157B4997 PVE for PVG 32/ PVG 100
155G8519 Set of seals PVE for PVG 120 (also interface plate/PVB for PVHC)
11061235 PVHC for PVG 32/ PVG 100
Cables code numbers

Feature Wire colors
Length Code number
Connector pin 1 pin 2 pin 3 pin 4 pin 5 pin 6
4 pin white blue yellow red — — 4m 11007498
Deutsch 4 pin white blue yellow red — — 4m 11099720 *24V
6 pin white blue yellow red black green 4m 11007513
4 pin white blue yellow red — — 4m 157B4994
AMP 4 pin white blue yellow red — — 4m 11099719 *24V
6 pin white red black yellow green blue 5m 157B4974
AMP/black coding 4 pin white blue yellow red — — 4m 157B4995 **-DI
Cables are with oil resistant coating.
*24V Special cable for use with PLUS+1 MC microcontroller in 24V systems.
** -DI Additional cable for PVE with direction indication.
Connector Code Numbers Connector part numbers for purchase at other suppliers
at Other Suppliers Connector House
wire sealing JPT contact sealing mat between
(blue) (loose piece) male-female part
4 pin DT06-4S
Deutsch female — — —
6 pin DT06-6S
4 pin 2-967059-1 828904-1 929930-1 963208-1
AMP female/grey
6 pin 2-963212-1 963205-1
AMP female/black 4 pin 1-967059-1
—
AMP crim tool 169400-1 —
AMP die set for crimp tool 734253-0
These connector code numbers are not Sauer-Danfoss numbers.
50 520L0553 • Rev GC • Mar 2013

Code Numbers
PVED Code Numbers for use on PVG 32 and PVG 100
Cables code numbers for PVED-CC

Feature Wire colors
Description Code number
Connector pin 1 pin 2 pin 3 pin 4
Deutsch 4 pin white blue yellow red 4 m cable 11007498
AMP 4 pin white blue yellow red 4 m cable 157B4994
AMP/black 4 pin white blue yellow red 4 m cable 157B4995
Service tool interface cable/ AMP 4 m cable 157B4977
AMP 0.1m loop cable 157B4987
AMP/black Terminator 157B4988
Deutsch 0.1m loop cable 11007531
Deutsch Terminator 11007561
Deutsch Terminator dummy 11007563
CAN Interface
10104136 CG 150 CAN USB interface Connector 2x4
Deutsch SW 2.68 11079033
AMP SW 2.68 11079034
1x4 = one plug four pins
520L0553 • Rev GC • Mar 2013 51

and Motors
• PLUS+1™ GUIDE
• Sensors
• Steering
Members of the Sauer-Danfoss Group: Local address:
Comatrol
www.comatrol.com
Turolla
www.turollaocg.com Sauer-Danfoss (US) Company Sauer-Danfoss ApS
Ames, IA 50010, USA Phone: +45 7488 4444
Valmova
Phone: +1 515 239 6000 Fax: +45 7488 4400
www.valmova.com Fax: +1 515 239 6618

www.sauer-danfoss-daikin.com Fax: +81 6 6395 8585
520L0553 • Rev GC • Mar 2013

PVG 16 and PVG 32
Service Assembly/
Disassembly Guide
Service Manual
VL:77-3
PVG 16, PVG 32 Service Assembly/Disassembly Guide
Service Manual
Revisions
Revision History Table of Revisions

Date Page Changed Rev
Dec 2012 - New edition AA
Aug 2013 19 Torgue change in drawing AB
Sauer -Danfoss reserves the right to alter its products without prior notice. This also applies to products already
ordered provided that such alterations can be made without affecting agreed specifications. All trademarks
in this material are properties of their respective owners. Sauer-Danfoss, the Sauer-Danfoss logotype, the
Sauer-Danfoss S-icon, PLUS+1™, What really matters is inside® and Know-How in Motion™ are trademarks of the
Sauer-Danfoss Group.
Front cover:157-516, F301056, F301306 and F301302
2 L1104530 • Rev AB • Aug 2013

Service Manual
Table of Contents
General Information General Description........................................................................................................................................ 4

Features of PVG 16 and PVG 32............................................................................................................ 4
PVG Modules..................................................................................................................................................... 4
PVP, pump side modules......................................................................................................................... 4
PVB, basic modules................................................................................................................................... 4
Actuation modules.................................................................................................................................... 5
Remote control units................................................................................................................................ 5
Accessories........................................................................................................................................................ 5
PVG 16, PVG 32 and Open Circuit Load Sense Example.................................................................... 6
LS control with bleed orifice.................................................................................................................. 7
Load Sensing Controls................................................................................................................................... 8
Integral PC function.................................................................................................................................. 8
Load sensing system characteristics................................................................................................... 8
Pressure Compensated Controls............................................................................................................... 9
Pressure compensated system characteristics................................................................................ 9
Typical applications for pressure compensated systems............................................................ 9
Remote Pressure Compensated Controls.............................................................................................10
Remote pressure compensated system characteristics.............................................................10
Typical applications for remote pressure compensated systems..........................................10
Safety in Application....................................................................................................................................11
FMEA (Failure Mode and Effect Analysis) IEC EN 61508.............................................................11
Hazard and Risk Analysis ISO 12100-1 / 14121.............................................................................11
Control System Examples.....................................................................................................................12
PVG 32 – Mainly used in system with fixed displacement pumps.........................................14
PVG 100 – Alternative LS dump or pilot supply disconnect....................................................14
PVG 120 – Pump disconnect/block for variable pumps............................................................14
PVG 16 and PVG 32 with Open Center PVP (fixed displacement pump) .................................15
PVG 16 and PVG 32 with Closed Center PVP (variable displacement pump) .........................16
Assembly Instructions General Conditions.......................................................................................................................................17

Assembly..........................................................................................................................................................17
Testing Leak test............................................................................................................................................................22

Pressure setting after assembly...............................................................................................................23
Function testing.............................................................................................................................................24
Recommended equipment & hand tools to assemble PVG 16 and PVG 32.......................25
Test Report Test Report.......................................................................................................................................................26
Order Specification Order Specification.......................................................................................................................................27
L1104530 • Rev AB • Aug 2013 3

Service Manual
General Information
General Description PVG 16 and PVG 32 is a hydraulic load sensing valve designed to give maximum
flexibility, from a simple load sensing directional valve to an advanced electrically
controlled load-independent proportional valve.
The PVG 16 and PVG 32 modular systems make it possible to custom build up a valve
group to meet customer requirements. The compact external dimensions of the valve
remain unchanged whatever combination is specified.
Features of PVG 16 and • Load-independent flow control:

PVG 32 –– Oil flow to an individual function is independent of the load pressure of this function
–– Oil flow to one function is independent of the load pressure of other functions
• Good regulation characteristics
• Energy-saving
• Up to 12 basic modules per valve group
• Several types of connection threads
• Low weight
• Compact design and installation
PVG Modules PVP, pump side modules

• Built-in pressure relief valve
• Pressure gauge connection
• Versions:
–– Open center version for systems with fixed displacement pumps
–– Closed center version for systems with variable displacement pumps
–– Pilot oil supply for electrical actuator built into the pump side module
–– Pilot oil supply for hydraulic actuation built into the pump side module
–– Versions prepared for electrical LS unloading valve PVPX
PVB, basic modules

• Interchangeable spools
• Depending on requirements the basic module can be supplied with:
–– Integrated pressure compensator in channel P
–– Load holding check valve in channel P
–– Shock/suction valves for A and B ports
–– LS pressure limiting valves individually adjustable for ports A and B
–– Different interchangeable spool variants
–– All versions suitable for mechanical, hydraulic and electrical actuation
4 L1104530 • Rev AB • Aug 2013

Service Manual
General Information
PVG Modules (continued) Actuation modules

The basic module is always fitted with mechanical actuator PVM and PVMD, which can
be combined with the following as required:
__
• Electrical actuator (11 - 32 V --- ):
–– PVES – proportional, Super
–– PVEH – proportional, High performance
–– PVEH-F – proportional high performance, Float
–– PVEA – proportional low hysteresis
–– PVEM – proportional, Medium performance
–– PVEO – ON/OFF
–– PVEU – proportional, voltage control, 0-10 V
–– PVED-CC – Digital CAN controlled J1939/ISOBUS
–– PVED-CX – Digital CAN controlled CANopen X-tra safety
–– PVEP – PWM voltage controlled (11-32V)
–– PVHC – High Current actuator for PVG
• PVMR, cover for Mechanical detent
• PVMF, cover for Mechanical Float
• PVH, cover for Hydraulic actuation
Rated Pressure
Product Rated pressure
PVG 16 and PVG 32 with PVS 300 bar [4351 psi]
PVG 16 and PVG 32 with PVSI 350 bar [5076 psi]
PVG 16 and PVG 32 with PVBZ 250 bar [3626 psi]
PVG 16 and PVG 32 with HIC steel 350 bar [5076 psi]
PVG 16 and PVG 32 with HIC aluminium 210 bar [3046 psi]
PVG 120/32 with PVS 300 bar [4351 psi]
PVG 120/32 with PVSI 350 bar [5076 psi]
PVG 100/32 with PVS 300 bar [4351 psi]
PVG 100/32 with PVSI 350 bar [5076 psi]
Maximum continuous P-port pressure.
Accessories Remote control units

• Electrical remote control units:
–– PVRE, PVRET
–– PVREL
–– PVRES
–– Prof 1
–– Prof 1 CIP
–– JS120
–– JS1000 Ball grip
–– JS1000 PROgrip
–– JS2000
–– JS6000
–– JS7000
• Hydraulic remote control unit:
–– PVRHH
L1104530 • Rev AB • Aug 2013 5

Service Manual
General Information
PVG 16, PVG 32 and The pump receives fluid directly from the reservoir through the inlet line. A screen in the
Open Circuit Load Sense inlet line protects the pump from large contaminants. The pump outlet feeds directional
Example control valves such as PVG-32’s, hydraulic integrated circuits (HIC), and other types of
control valves. The PVG valve directs and controls pump flow to cylinders, motors and
other work functions. A heat exchanger cools the fluid returning from the valve. A filter
cleans the fluid before it returns to the reservoir.
Flow in the circuit determines the speed of the actuators. The position of the PVG valve
spool determines the flow demand. A hydraulic pressure signal (LS signal) communicates
demand to the pump control. The pump control monitors the pressure differential
between pump outlet and the LS signal, and regulates servo pressure to control the
swashplate angle. Swashplate angle determines pump flow.
Actuator load determines system pressure. The pump control monitors system pressure
and will decrease the swashplate angle to reduce flow if system pressure reaches the
PC setting. A secondary system relief valve in the PVG valve acts as a back-up to control
system pressure.
Pictorial circuit diagram
Double-acting cylinder
K/L Frame Series 45
open circuit axial
piston pump with
load sensing control
PVG 32
multi-section
load
sensing
control
valve
Bi-directional
gear motor
System pressure
Servo pressure
Heat exchanger
Filter Actuator pressure
Reservoir
Load sense pressure
Actuator return
Suction / case drain /

P101 658E
system return
6 L1104530 • Rev AB • Aug 2013

Service Manual
General Information
Load Sensing Controls The LS control matches system requirements for both pressure and flow in the circuit
regardless of the working pressure. Used with a closed center control valve, the pump
remains in low-pressure standby mode with zero flow until the valve is opened. The LS
setting determines standby pressure.
Typical operating curve Load sensing circuit
Q max
Flow
PC setting
0
0 Pressure
P101 968E
P101 967
Most load sensing systems use parallel, closed center, control valves with special porting
that allows the highest work function pressure (LS signal) to feed back to the LS control.
Margin pressure is the difference between system pressure and the LS signal pressure.
The LS control monitors margin pressure to read system demand. A drop in margin
pressure means the system needs more flow. A rise in margin pressure tells the LS
control to decrease flow.
LS control with bleed orifice

The load sense signal line requires a bleed orifice to prevent high-pressure lockup of the
pump control. Most load-sensing control valves include this orifice. An optional internal
bleed orifice is available, for use with control valves that do not internally bleed the LS
signal to tank.
L1104530 • Rev AB • Aug 2013 7

Service Manual
General Information
Load Sensing Controls Integral PC function

The LS control also performs as a PC control, decreasing pump flow when system
pressure reaches the PC setting. The pressure compensating function has priority over
the load sensing function.
Each section includes control schematic diagrams, setting ranges, and response /
recovery times for each control available. Response is the time (in milliseconds) for the
pump to reach zero displacement when commanded by the control. Recovery is the
time (in milliseconds) for the pump to reach full displacement when commanded by the
control. Actual times can vary depending on application conditions.
For additional system protection, install a relief valve in the pump outlet line.
Load sensing system characteristics

• Variable pressure and flow
• Low pressure standby mode when flow is not needed
• System flow adjusted to meet system requirements
• Lower torque requirements during engine start-up
• Single pump can supply flow and regulate pressure for multiple circuits
• Quick response to system flow and pressure requirements
8 L1104530 • Rev AB • Aug 2013

Service Manual
General Information
Pressure Compensated The PC control maintains constant system pressure in the hydraulic circuit by varying the
Controls output flow of the pump. Used with a closed center control valve, the pump remains in
high pressure standby mode at the PC setting with zero flow until the function is actuated.
This condition is often called a dead head condition.
Typical operating curve Simple closed-center circuit
Q max
Flow
PC setting
0
0 Pressure P101 166E
P101 965
Once the closed center valve is opened, the PC control senses the immediate drop in
system pressure and increases pump flow by increasing the swashplate angle.
The pump continues to increase flow until system pressure reaches the PC setting.
If system pressure exceeds the PC setting, the PC control reduces the swashplate angle
to maintain system pressure by reducing flow. The PC control continues to monitor
system pressure and changes swashplate angle to match the output flow with the work
function pressure requirements. If the demand for flow exceeds the capacity of the
pump, the PC control directs the pump to maximum displacement. In this condition,
actual system pressure depends on the actuator load.
For additional system protection, install a relief valve in the pump outlet line
Pressure compensated system characteristics

• Constant pressure and variable flow
• High pressure standby mode when flow is not needed
• System flow adjusts to meet system requirements
• Single pump can provide flow to multiple work functions
Typical applications for pressure compensated systems

• Constant force cylinders (bailers, compactors, refuse trucks)
• On/off fan drives
• Drill rigs
• Sweepers
• Trenchers
L1104530 • Rev AB • Aug 2013 9

Service Manual
General Information
Remote Pressure The remote PC control is a two-stage control that allows multiple PC settings.
Compensated Controls Remote PC controls are commonly used in applications requiring low and high pressure
PC operation.
Typical operating curve Closed center circuit with remote PC

Q max
Flow
Remote PC setting
PC setting
0
0 Pressure P101 969E
P101 966
The remote PC control uses a pilot line connected to an external hydraulic valve. The
external valve changes pressure in the pilot line, causing the PC control to operate at a
lower pressure. When the pilot line is vented to reservoir, the pump maintains pressure
at the load sense setting. When pilot flow is blocked, the pump maintains pressure at the
PC setting. An on-off solenoid valve can be used in the pilot line to create a low-pressure
standby mode. A proportional solenoid valve, coupled with a microprocessor control,
can produce an infinite range of operating pressures between the low pressure standby
setting and the PC setting.
Size the external valve and plumbing for a pilot flow of 3.8 l/min [1 US gal/min].
For additional system protection, install a relief valve in the pump outlet line.
Remote pressure compensated system characteristics

• Constant pressure and variable flow
• High or low pressure standby mode when flow is not needed
• System flow adjusts to meet system requirements
• Single pump can provide flow to multiple work functions
Typical applications for remote pressure compensated systems

• Modulating fan drives
• Anti-stall control with engine speed feedback
• Front wheel assist
• Road rollers
• Combine harvesters
• Wood chippers
10 L1104530 • Rev AB • Aug 2013

Service Manual
General Information
Safety in Application All makes and all types of control valves (incl. proportional valves) can fail, thus the
necessary protection against the serious consequences of function failure should
always be built into the system. For each application an assessment should be made for
the consequences of pressure failure and uncontrolled or blocked movements.
To determine the degree of protection that is required to be built into the application,
system tools such an FMEA (Failure Mode and Effect Analysis) and Hazard and Risk
Analysis can be used.
FMEA (Failure Mode and Effect Analysis) IEC EN 61508

FMEA is a tool used for analyzing potential risks. This analytical technique is utilized to
define, identify, and prioritize the elimination or reduction of known and/or potential
failures from a given system before it is released for production.
Please refer to IEC FMEA Standard 61508.
Hazard and Risk Analysis ISO 12100-1 / 14121

This analysis is a tool used in new applications as it will indicate whether there are
special safety considerations to be met according to the machine directives EN 13849.
Dependent on the determined levels conformity this analysis will detirmine if any extra
requirements for the product design, development process, production process or
maintenance, i.e. the complete product life cycle.
WWarning
All makes/brands and types of directional control valves – inclusive proportional valves –
can fail and cause serious damage. It is therefore important to analyze all aspects of the
application.
Because the proportional valves are used in many different operation conditions and
applications, the manufacturer of the application is alone responsible for making the
final selection of the products – and assuring that all performance, safety and warning
requirements of the application are met.
The process of choosing the control system – and safety levels – is governed by the
machine directives EN 13849 (Safety related requirements for control systems).
L1104530 • Rev AB • Aug 2013 11

Service Manual
General Information
Safety in Application Control System Examples

(continued) Example of a control system for manlift using PVE Fault monitoring input signals and
signals from external sensors to ensure the PLUS+1™ main controllers correct function of
the manlift.
B
Emergency stop /
Man present switch
A
D
Battery
A Main power supply

B Emergency stop/man present
switch
C HMI/Joystick control
D Movement detection sensors T P
G
E Main controller
F PVG 16 and PVG 32 control
valve
G Hydraulic deactivation
WWarning
It is the responsibility of the equipment manufacturer that the control system incorporated
Electrical block diagram for above illustration

Main power supply Emergency stop and Motion detection sensor
(battery) Man present switch
Supply Main control valve

Main controller
Neutral Supply Signal
PVE
HMI / Joystick Detection Control Conditioning
Joystick
neutral switch
Signal Fault
Monitoring
Control
Signal Conditioning PVE fault output
Failure
Detection Hydraulic deactivation
P301 317
12 L1104530 • Rev AB • Aug 2013

Service Manual
General Information
Safety in Application Example of a typical wiring block diagram using PVEH with neutral power off switch and
(continued) fault monitoring output for hydraulic deactivation.

stop switch
A

1) with AMP
C signal connector
OFF
≠ Delay US
neutral UDC2
B Error

1) with AMP
C signal connector
OFF
≠ Delay US
neutral UDC2
B Error
E1 E2
2) Alarm
logic
Output
OR
3) Memory
A Emergency stop / man present switch

B PVE Faultmonitoring signals high=on
AND
C Neutral signal detection. low=off
D Hydraulic deactivation Hydraulic

Fault detection output D deactivation
P301 318
WWarning
L1104530 • Rev AB • Aug 2013 13

Service Manual
General Information
Safety in Application Example of fault monitoring for deactivation of the hydraulic system with extra fault
(continued) inputs using the PVE’s with DI (Direction Indication) function.
Stop switch

1) AMP supply
signal connector
OFF
≠ Delay US
neutral UDC2
Error
PVEH-DI
AMP connector
2) Fault detection DI-A
DI-B 3) 4) DI-B
US Logic Error

1) AMP supply
signal connector
OFF US
≠ Delay
neutral UDC2
Error
PVEH-DI
AMP connector
Fault detection DI-A
2)
DI-B 3) 4)
US Logic Error
OR
AND
high=on
System Control Logic e.g. PLUS+1™ for low=off
signal monitoring and triggering signal Hydraulic

Fault detection output deactivation
for deactivation of the hydraulic system.
P301 319
WWarning
Other modules which can be used in connection with hydraulic deactivation at different
levels.
PVG 32 – Mainly used in system with fixed displacement pumps

• PVSK, commonly used in crane application - full flow dump
• PVPX, LS dump to tank
PVG 100 – Alternative LS dump or pilot supply disconnect

• PVPP, pilot oil supply shut off
• External cartridge valve connecting LS Pressure to Tank
• External cartridge valve connecting main Pressure to Tank
PVG 120 – Pump disconnect/block for variable pumps

• PVPE, full flow dump for the PVG 120
• External cartridge valve connecting LS Pressure to Tank
14 L1104530 • Rev AB • Aug 2013
Service Manual
General Information
PVG 16 and PVG 32 with When the pump is started and the main spools in the individual basic modules (11) are in
Open Center PVP (fixed the neutral position, oil flows from the pump, through connection P, across the pressure
displacement pump) • adjustment spool (6) to tank. The oil flow led across the pressure adjustment spool
PVB with Flow Control determines the pump pressure (stand-by pressure).
Spool
When one or more of the main spools are actuated, the highest load pressure is fed
through the shuttle valve circuit (10) to the spring chamber behind the pressure
adjustment spool (6), and completely or partially closes the connection to tank to
maintain pump pressure.
Pump pressure is applied to the right-hand side of the pressure adjustment spool (6).
The pressure relief valve (1) will open should the load pressure exceed the set value,
diverting pump flow back to tank.
In a pressure-compensated basic module the compensator (14) maintains a constant

pressure drop across the main spool – both when the load changes and when a module
with a higher load pressure is actuated.
With a non pressure-compensated basic module incorporating a load drop check valve
(18) in channel P, the check valve prevents return oil flow.
The basic module can be supplied without the load drop check valve in channel P for
functions with over-center valves.
The shock valves PVLP (13) with fixed setting and the suction valves PVLA (17) on ports
A and B are used for the protection of the individual working function against overload
and/or cavitation.
An adjustable LS pressure limiting valve (12) can be built into the A and B ports of
pressure-compensated basic modules to limit the pressure from the individual working
functions. Please see the sectional drawing on the next page for better understanding of
this example.
The LS pressure limiting valves save energy compared with the shock valves PVLP:
• with PVLP all the oil flow to the working function will be led across the combined
shock and suction valves to tank if the pressure exceeds the fixed setting.
• with LS pressure limiting valves an oil flow of about 2 l/min [0.5 US gal/min] will be led
across the LS pressure limiting valve to tank if the pressure exceeds the valve setting.
L1104530 • Rev AB • Aug 2013 15

Service Manual
General Information
PVG 16 and PVG 32 In the closed center version of PVP an orifice (5) and a plug (7) have been fitted instead
with Closed Center PVP of the plug (4). This means that the pressure adjustment spool (6) will only open to tank
(variable displacement when the pressure in channel P exceeds the set value of the pressure relief valve (1).
pump) • PVB with Flow
Control Spool In load sensing systems the load pressure is led to the pump control via the LS
connection (8).
In the neutral position the pump load sense control sets the displacement so that
leakage in the system is compensated, to maintain the set stand-by pressure.
When a main spool is actuated the pump load sense control will adjust the displacement
so that the set differential pressure (margin) between P and LS is maintained.
The pressure relief valve (1) in PVP should be set at a pressure of approx. 30 bar [435 psi]
above maximum system pressure (set on the pump or external pressure relief valve).
PVG 16 and PVG 32 with Closed Center PVP), PVB with Flow Control Spool
1 2
T P
3
M
4+5
LS A
8
12 7 B A 6 13
T T
11
10
LS B P LS A
14 16 B A 17 15
B
T T
19 18 20
V310106.A
16 L1104530 • Rev AB • Aug 2013

Service Manual
Assembly Instructions
General Conditions The specification sheet is compiled by the sales department for assembly of a new
PVG 16 and PVG 32 valve groups.
1. Before, during and after the assembly/disassembly of new PVG groups, absolute
cleanliness and care must be observed with regard to internal and external parts of
the units concerned.
2. Use non-volatile, petroleum based solutions for cleaning valves and/or modules.
3. Replace all parts considered likely to cause malfunction during subsequent testing.
4. Replace all loose O-rings (without exceptions) with new O-rings.
5. Lubricate all moving parts with hydraulic oil before assembly.
6. Lubricate all O-rings with petroleum jelly.
Refer to Service Manual 520L0515 for module designations, item and spare parts numbers.
Assembly The basic assembly sequence for PVG 16 and PVG 32 group is as follows:
1. Starting from the end plate place the module with (PVS, PVSP, PVSK ) the tie rod
bolts with the long threaded end pointing upwards ready for mounting of PVB
modules.
2. Place all lubricated O-rings in their respective grooves in the different modules.
3. Locate the basic modules (PVB) against the PVP (PVS, PVSP, PVSK) using the tie rod
bolts for alignment between the PVP and the PVB modules making sure the LS
shuttle valve is able to move freely.
4. Place the PVP (the PVS if a valve group has midinlet, or HIC) as the last module and
place the washers and nuts in position and hand tighten the valve.
5. Place the valve on a plain and level surface and tighten the assembly to a torque of
2.2 +0.3/-0 N•m (195 + 25/-0 lbf•in) using a 13 mm socket.
Max. level tolerance is 0.5 mm per section e.g. this means with 8 PVB sections max.
allowable height difference between the mounting holes would be 4 mm (this
would also be seen as a twist in the valve group assembly).
The valve assembly is to be assembled in accordance with the specification sheet.
L1104530 • Rev AB • Aug 2013 17

Service Manual
Assembly (continued) 6. Install the spools (PVBS) into the PVB’s.

The assembled spool is marked with two four-digit numbers (see the figure below).
The number in the end of the spool where the plug is fitted, “B”, is the drawing
number of the spool and indicates that this end must face towards the “B” port of
the valve.
The other number, stamped on the side the PVBS pull rod “A”, is the module
number of the assembled main spool.
For spool assemblies with remote hydraulic spools, the centering spring is
different. The standard spring has a wire diameter of 1.9 mm. The remote hydraulic
spring (5-15 bar) has a wire diameter of 2.8 mm.
PVG 16 and PVG 32 are symmetrical, which allows for valve groups to be “option
mounted” This can be one by inserting the spools from the “B” port side and
mounting the PVM’s on the “B” port side of the PVB assembly.
(157B)7004 Markings pre 1998 (157B)7004

(157B)7004 Today’s spool (155L)7354
110XXXXX
A B
Relief grooves
V310342.A
7. Assemble the mechanical actuators to the valve (see the figure below). Before
fitting the PVM into engagement with the PVBS tension rod, the driver arm must
be pushed towards the PVB before engagement will occur. Once the driver arm is
engaged, rotate the mechanical actuator while pressing the PVM until the PVM is
flush against the PVB housing.
Tighten the four (4) mounting screws to a torque of 0.8 +0/-0.5 N•m [70 +0/-4.5 lbf•in]
using a 5 mm hex driver.
Assembly of PVE, electrical actuation Assembly of PVM, mechanical actuation
V310413.A
18 L1104530 • Rev AB • Aug 2013

Service Manual
Assembly (continued) Assembly of PVG 16

PVEO
PVEA
PVEA-F
PVMD
PVP
F PVB
E PVH
PVS
C
D
PVM G
V310395.B
Assembly of PVG 32
P A
PVS
6 ±1 N•m
[53 ±9 lbf•in]
Q max: P A
Q max: P B
PVM
PVB
PVP
PVEH/PVES
PVEA
PVEO
P A
PVH
PVMD
PVMR/PVMF V310164.A
V310164.A
L1104530 • Rev AB • Aug 2013 19

Service Manual
Assembly (continued) 8. Assemble the actuators. The manual cover PVMD or the remote hydraulic end cover
must be installed with the arrow pointing upwards towards the “A/B” port.
The PVE’s must be installed with the connectors pointing upwards towards the “A/B”
port. The torque for the four (4) mounting screws is 0.8 + 0/-0.5 N•m [70 +0/-4.5 in.
lbs.] using a 5 mm hex drive.
Common to all types of PVE’s is a small nylon filter in the “P” channel, under the
O-ring. Insure that the transducer stem on the PVE’s with closed loop feedback
interfaces with the end of the PVBS without any restrictions.
New and unused PVE units can be mounted without neutral adjustment to the LVDT
transducer. If an adjustment is required, contact the service department.
For control options with mechanical detent (PVMR) or mechanical float (PVMF)
function, please follow instructions in the previous section describing assembly of
the PVMD or PVH remote with reference to the below pictures.
157-224.11 157-225.11
157-226.11
157-227.11
* Spring Identification
PVMF Painted blue
PVMR Non-painted
20 L1104530 • Rev AB • Aug 2013

Service Manual
Assembly (continued) For torque tighting values of the large hexagon (Y) with the detent assembly function,
please see the table below.
Tightening Torques and Widths Across Flats

X Y Z
With across flats
8 ±0.5 N•m 15 ±2 N•m 4 ±1 N•m

Tightening torque
[70 ±4.5 lbf•in] [135 ±20 lbf•in] [35 ±9 lbf•in]
PVMR, detent option without a neutral spring PVMF, mechanical float option
The valve assembly is to be assembled in accordance with the specification sheet.
9. Assemble the shock/check (PVLP) valves into the PVB’s. The top of the PVLP valve
is marked with the last three digits of the module code number. This number also
indicates the valve pressure setting @ 15.1 I/min [4 US gal/min]. Be careful not to
swap plugs and valves. The PVLA module carries no markings. The torque for the
plug is 4.0 ± 0.3 N•m [355 ± 25 lbf•in].
10. Issue/attach label with PVG code no.

for the valve assembly.
PVP PVEH/
PVES
PVLP/PVLA PVEA
E F PVB
PVBZ PVEO
PVS PVH
B
A PVMD
PVMR/
PVMF
G
C
PVM G V310165.A
V310165.A
L1104530 • Rev AB • Aug 2013 21

Service Manual
Testing
Leak test After all components have been assembled and tightened to the proper specifications, a
leak test with compressed air must be performed.
1. Block off all “A” and “B” ports with steel plugs.
2. Block off the “P” port with a steel plug in the PVP. Screw the compressed air
connection into the “T” port. (see the figure below).
Block diagram
6.4 ± 1 bar
[93 ± 14.5 psi] A B A B A B
T
LX
P
PVP LS PVB PVB PVB PVS/I
6.9 bar [100 psi]

V310343.A
3. Apply compressed air at 6.9 bar [100 psi] for 5 minutes. At the same time, activate all
PVM control levers in order to fill fill all channels, chambers and cavities with an air.
4. Shut off the compressed air so that pressure is confined in the entire valve.
The permissible pressure drop in the valve is 0.5 bar [7 psi] per minute maximum.
Small leaks can be traced by pouring a small amount of oil onto the place where the
leak is thought to be present.
5. Try correcting small leaks by retightening the assembly. Large leaks usually indicate
forgotten or squeezed O-rings.
22 L1104530 • Rev AB • Aug 2013

Service Manual
Testing
Pressure setting after All relief valves must be set with a gauge located in the gauge port of the PVP.
assembly
Groups with CLOSED CENTER PVP’S can be tested as assembled for all pressure relief
settings.
Groups with OPEN CENTER PVP’S and PVB’S with shock valves (PVLP) and LSA/LSB valves
with opening pressure lower than the pressure setting in the PVP. The PVP must be
modified temporarily to CLOSED CENTER. After the relief settings are made, the PVP
must be corrected to OPEN CENTER. All other with OPEN CENTER PVP’S can be tested as
assembled.
The PVP pressure relief valve and LSA/LSB pressure relief valves must be set by applying
oil pressure on the “P” port in the PVP. The “T” port must be connected to tank.
All “A” and “B” ports must be blocked off with steel plugs.
The quantity of oil supplied to the valve assembly must be at least 15 l/min [4 US gal/min].
The CLOSED CENTER PVP module can be set by applying pressure to the “P” port.
The OPEN CENTER PVP module can be set by applying pressure to the “P” port and
activating the spool in the A or B direction dead headeding the A or B port.
LSA/LSB valves must be set one at a time by activating the spool in the PVB section in the
direction of the LS valve to be adjusted.
It is assumed that the PVP module has a higher setting than the LSA/LSB valves.
Adjustment of the relief valve is accomplished by using a 4 mm hex wrench.

For relief valve version and location please see the figure below.
L1104530 • Rev AB • Aug 2013 23

Service Manual
Testing
Function testing Function testing insures the correct dynamic manual and electrical operation of the
PVG 16 and PVG 32 valve assembly. This test should be performed after completing the
pressure adjustments.
Each section of the assembly must be tested:

1. With the pump connected as described in the “PRESSURE SETTING AFTER ASSEMBLY”
section, remove the plugs from the section to be tested. Connect the “A” port of the
valve to the rod end of the cylinder and the “B” port to the base end of the cylinder
(see the figure below).
Workport PVLP Pressure Measurement
32 to 350 bar [464 to 5075 psi]
Inlet Pressure Measurement

30 to 350 bar
[435 to 5075 psi]
P A B A B A B
PC Pump 14 l/min PVP LX

[3.4 US gal/min]
T LS PVB PVB PVB PVS/I
V310340.A
2. Shift the control lever of the tested section towards the valve and observe cylinder
retraction. Shift the same control lever away from the valve and observe cylinder
extension. Repeat several times. On valve groups with PVM’s on the “B” side, the
cylinder movement will be opposite when shifting the handle in the same direction.
3. Check the spool travel smoothness in both directions.
4. Check the metering of the spool in both directions. Can you control the speed of
the cylinder/motor, slow/fast?
5. Check to see if the LS signal at the PVP drops off, when the spool is in the neutral
position. This signal also should not build up pressure in the neutral position.
6. Shift the spool to one direction manually and let go of the control lever. The valve
should center itself. If the control lever sticks in any position, check for binding of
the spool. This is to be checked in both directions.
24 L1104530 • Rev AB • Aug 2013

Service Manual
Testing
Function testing 7. Utilizing a controller package, connect the EL-PLUG connector to the PVE. Set the
(continued) controller to the corresponding PVE. Insure that the proper voltage and joystick
are being used. Similar to manual testing of the valve, eclectically shift the valve to
allow flow out the “A” port.
Check to see if the PVM control level shifts in the correct direction. This should also
be done in the “B” direction. Check to insure that once the controller is not activated
the valve centers itself. Observe that the spool responds to any change in the signal
from the joystick. Any change in position of the joystick should relate to a change in
the PVM control lever. Check the metering of the PVEM/H’s.
8. After all sections have been tested, insure that all relief valves are adjusted correctly.
Refer to the “PRESSURE SETTING AFTER ASSEMBLY” section for any adjustments.
9. Remove all steel plugs, fittings and hoses. Drain the oil from the valve group. Install
plastic plugs in all ports & rubber cap (155L6377) over all pressure adjustments.
10. A certified PVG valve test report must be completed & accompany every valve, e.g.
see PVG 32 PROPORTIONAL VALVE TEST REPORT on the next page.
Sections with open ported spools will experience cylinder extension in the neutral
position.
Recommended equipment and hand tools to assemble PVG 16 and PVG 32:
• Socket driver, Allen wrench = 2.5, 3, 4, 5, 6, 8 mm.
• Sockets = 3/8 drive deep well 13 mm.
• Combo – wrenches = 10, 13 mm
• Torque wrench = 3/8 drive 0 – 10 N•m [0-885 in. lbs.]
• Ball driver hex = 4, 5, 6, 8 mm
• Plastic hammer
L1104530 • Rev AB • Aug 2013 25

Service Manual
Test Report
Test Report
26 L1104530 • Rev AB • Aug 2013

Service Manual
Order Specification
Order Specification
Subsidiary/Dealer PVG No.

Customer Customer Part No.
Application Revision No.
Section A-Port B-Port
v Function v Extra Features v
157B 157B
0
157B p= bar 157B
a 157B 157B 157B 16 157B c
1 b 157B LSA bar LSB bar 157B b
a 157B 157B 157B 16 157B c

a 157B 157B 157B 16 157B c

a 157B 157B 157B 16 157B c

a 157B 157B 157B 16 157B c

a 157B 157B 157B 16 157B c

a 157B 157B 157B 16 157B c

a 157B 157B 157B 16 157B c

a 157B 157B 157B 16 157B c

a 157B 157B 157B 16 157B c

a 157B 157B 157B 16 157B c

a 157B 157B 157B 16 157B c

157B 157B
a 157B 157B 157B 16 157B c
14 End section 157B

15 PVAS section 157B
"Reserved for Painting" 157B
Comments:
Filled in by: Date:
L1104530 • Rev AB • Aug 2013 27

and Motors
• PLUS+1™ GUIDE
• Sensors
• Steering
Members of the Sauer-Danfoss Group: Local address:
Comatrol
www.comatrol.com
Turolla
www.turollaocg.com Sauer-Danfoss (US) Company Sauer-Danfoss ApS
Ames, IA 50010, USA Phone: +45 7488 4444
Valmova
Phone: +1 515 239 6000 Fax: +45 7488 4400
www.valmova.com Fax: +1 515 239 6618

www.sauer-danfoss-daikin.com Fax: +81 6 6395 8585
L1104530 • Rev AB • Aug 2013

DENISON HYDRAULICS
VANE TROUBLESHOOTING GUIDE
1 - EN0721 - A 02 / 99 / 5000 / replaces SI - EN175 - A
DENISON Hydraulics
VL112
V - COMPONENT ANALYSIS CHART

Pages bushing cam ring pins rotor screws seals shaft side plates vanes Pages
12 X 12
13 X 13
14 X 14
15 X X X X 15
16 X X X 16
17 X X 17
18 X 18
19 X X X X 19
20 X 20
21 X X 21
22 X X 22
23 X X 23
24 24
25 25
26 X 26
27 X X X 27
PUMP
28 X 28
29 29
30 X X 30
31 X X X X 31
32 X 32
33 X 33
34 X X 34
35 X X X X 35
36 X X X 36
37 37
38 X X X 38
39 X X 39
40 X X 40
41 X 41
42 42
43 43
44 44
45 X 45
MOTOR
46 X X X 46
47 X X 47
48 X X X 48
49 X 49
VANE PUMP COMPONENTS DESIGNATION
Part nb. part designation Part nb. part designation

1 End cap 16 Round section ring
2 Square section seal P1 & P2 17 Mounting cap
3 Back-up ring P1 & P2 18 Pin-vane holdout (P1 & P2)
4 Pressure port plate P2 19 Housing
5 Rotor-insert assembly P2 20 Vane P1 & P2
6 Rear port plate P2 21 Square section seal
7 Bush 22 Screw
8 Cam ring P1 & P2 23 Dowel pin
9 O ring 24 Rear port plate P1
10 Rotor-insert assembly P1 25 Dowel pin
11 Square section seal P1 & P2 26 Pressure port plate
12 Key 27 Screw
13 Keyed shaft 28 Shaft seal
14 Splined shaft 29 Screw
15 Ball bearing
CONTENTS
I INTRODUCTION 2
I -1 PRESENTATION 2
I -2 HOW TO USE THIS GUIDE 2
I -3 WHY A DENISON VANE PUMP SHOULD NOT BREAK DOWN 2
I -4 BASIC PRECAUTIONS FOR A LONG LIFE TIME 5
II ANALYSIS OF FAILURES 6
II -1 MECHANICAL FAILURES 7
II -2 THE CONSEQUENCES OF MECHANICAL FAILURES 12

II -3 PRESSURE FAILURES 18
II -4 PHYSICAL, CHEMICAL OR HYDRAULIC FAILURES 24
III SPECIFICS OF VANE MOTOR FAILURES AND CAUSES 44
IV TROUBLESHOOTING TABLE 50
IV -1 PUMPS 51
IV -2 MOTORS 58
V COMPONENT ANALYSIS CHART Folded first page
1
I INTRODUCTION
I-1 Presentation
The main goal of this guide is to help all the cation limits and functioning of the units inevita-
DENIS ON vane pump users to understand the bly leads to premature failures. It is important to
principal causes of destruction of these pumps point out that 80 % of the failures are linked to
and motors in service. Our past experience has fluid contamination incidents (chapter II-4).
shown that the failures, occurring in the first 500 This guide comes as an addition to the existing
hours of service, are premature failures. Failing to "Installation, operation and overhaul instruc-
follow instructions or ignoring the correct appli- tions" available bulletin S1-EN081.
I-2 How to use this guide
• "The most common causes", chapter II (pages 6 to 43): details of the major incidents you may encoun-
ter (cavitation, aeration, misalignment...) and their consequences on the vane pumps. While chapter III
(pages 44 to 49) will concern the vane motors.
• "Fault finding while the pump is running", chapter IV (pages 50 to 60): the troubleshooting tables
for vane pumps and motors. If you have a problem in working conditions, "the troubleshooting table" will
help you to find out what is wrong (FAILURE-CAUSE-SOLUTION).
• "Interpret the physical damages on components", chapter V: The first page (folded) shows a chart
which summarizes all the pictures of failed components. This will enable you to recognize the failed com-
ponent and to understand the cause of this failure.
I-3 Why a DENISON Vane pump should not break down
Unlike most other hydraulic technologies, the absorb any external shaft misalignment or abnor-
DENISON vane pump design is hydraulically mal coupling loads.
balanced. You cannot calculate the life time of As shown on the drawings hereafter, the two sym-
these pumps by calculating the life time of the ball metrical high pressure zones have a self centering
bearing as no internal load (neither axial nor effect on the rotating components.
radial) is applied on the shaft. The only purpose of This is a hydrostatic balanced pump, axially and
the ball bearing in the Denison vane pump is to radially.
2
DENISON HYDRAULICS
Vane Pumps
Single series T6 - T7 - B-C-D-E sizes
Publ. 034-67110-2 02/98/5000/FB
DENISON Hydraulics
3
Each single vane is independently loaded in order On each cam ring, for example, a dry lubricant
to always be maintained on the cam ring contour. coating is laid on the cam profile. This coating
The specific Denison pin design reduces the pos- will assure, even in bad priming conditions, a
sible internal leakage, reduces the possible good start-up minimizing the risk of micro-sei-
vane/cam ring wear (due to a precise balancing of zures. With this dry lubricant coating, the defi-
the forces under and over the vanes), lowers consi- ciency of oil is compensated but not replaced.
derably the noise level, allowing higher pressure This is done for short term deficiencies.
capabilities, extends the life time... Our passed experience shows that the most com-
Added to this licensed pin design, Denison has mon failures are linked to the quality of the oil. As
engineered the double vane lip technology. This soon as there is a lack of lubricity, the failure is
vane technology combined with the pin design imminent. In addition to the pressure and the
gives unique overall performances. The double lips mechanical failures, all the problems are usually a
allow the pressure all around the vane to be the lack of lubrication (rupture of the film of oil). The
same on the top as on the bottom and as on the followings are some examples of the common
sides of it. This is possible because of the double causes:
lips and the balancing through the holes in the - air in the oil (cavitation, aeration),
vanes. Here again, the components are hydrostati- - solid large size particles,
cally balanced. Another advantage of the double - chemical agents (water, wrong additives, tar...),
lip design is the fact that the first lip seals the low - too high or too low viscosity,
pressure area and the other one seals the high pres- - overheating (shaft alignment),
sure area. This increases the life time of the pump - flow of the system coming back to the pump,
when working with contaminated oil. The wear, - poor quality of oil loosing its main chemical
due to the particles of pollution, will have a nega- characteristics,
tive effect, mainly on the first lip. The second lip,
working in the high pressure area, keeps its origi- This is why good filtration, good thermal stability,
nal seal to maintain high volumetric efficiency. good quality of oil, a good design (hose design,
This technology is unique because the wear is bleeder, tank design ...), correct hydraulic know-
compensated. The effect of contamination on the ledge (...) will always increase the life time of all
Denison vane design is not a major issue of pump hydraulic components.
failure as for other pump technologies. The DENISON vane pump technology is a heavy
Every port plate and cam ring has a surface treat- duty engineering design that will last years if ele-
ment to increase the life time capabilities. mentary precautions are taken.
4
I-4 Basic precautions for a long life time:
The Denison vane products are designed for long - good shaft alignment is a classic "weakness", as
life. Some minor precautions can help to avoid well as proper coupling with the driving source.
premature breakdowns: The lubrication of these links is also something
- have a correct air bleed at start-up, to look after,
- always check the oil velocity (inlet & outlet). - proper oil selection versus application condition:
This should then give the correct sizes of hoses viscosity index, viscosity grade (ISO 32,46,
& connectors: maximum velocity of 1,9 m/sec. 68...), environment (biodegradability, fire resis-
for the inlet & 6 m/sec. for the outlet, tance, normal conditions), pumping temperature
- no strainer on the inlet line is preferred (250 range, filterability, deaeration, thermal stability
microns minimum and check the pressure drop are the basics to consider for a good fluid,
when the Viscosity rises), - if the pump is used on a very fast pressure
- always pay attention to the viscosity of the oil cycling machine, attention should be paid to the
versus temperature. Even a small change in tem- relationship between the pressure rise/fall gra-
perature can have a big effect on the viscosity. A dient and the inlet pressure in order to avoid
good quality return line filter is the best solution. cavitation. We recommend maximum limits of
- check the pressure at the inlet port, (position of 5000 bar per second (72500 PSI/ second) for
the tank, shaft rotational speed...), pressure rise and 6000 bar per second (87000
- ratio flow/tank capacity: is cooling required ? PSI) for presssure fall.
5
II ANALYSIS OF FAILURES
II -1 MECHANICAL FAILURES 7
II -2 CONSEQUENCES OF MECHANICAL FAILURES 12
II -3 PRESSURE FAILURES 18
II -3-1 Pressure overshoot 18
II -3-2 Instant pressure overshoot 18
II -3-3 Consequences of instant pressure overshoot 18
II -3-4 Cycled overpressurization 20
II -3-5 Consequences of cycled overpressurization 21
II -3-6 Pressure gradients 23
II -3-7 Consequences of too high pressure gradients 23
II -4 PHYSICAL, CHEMICAL OR HYDRAULIC FAILURES 24

II-4-1 Start-up without a proper air bleed 25
II-4-2 Air pollution (Foaming-Aeration, Cavitation-Deaeration) 25
II-4-2-1 Aeration 25
II-4-2-2 Consequences of Aeration 26
II-4-2-3 Cavitation 28
II-4-2-4 Consequences of Cavitation 29

II-4-3 Solid particle contamination 33
II-4-4 Consequences of solid particle contamination 33
II-4-5 Water contamination 37
II-4-6 Consequences of Water contamination 38
II-4-7 Viscosity failures 39
II-4-8 Consequences of Viscosity failures 40
II-4-9 Unsuitable fluids 41
II-4-10 Unsuitable grease 43
6
II ANALYSIS OF FAILURES
The systematic analysis of failures permits the result of the tensile limit of the sensitive point of a
causes to be determined logically, these failures component.
being either distortion, shearing, surface seizure Studying the crystalline faces will allow us to
or scoring. determine the mechanical causes that provoked
If the failure is shearing, we can almost certainly the failure. This troubleshooting guide has been
say it is the consequence of a brutal or a fatigue prepared to allow everyone to quickly reach a
failure. A brutal failure is due to sudden increase satisfactory conclusion. A precise and professional
in loads exceeding the material strength limit or analysis to determine the problem is not really the
its resistance to shocks. A fatigue failure is the purpose of this guide.
II-1: MECHANICAL FAILURES
Mechanical failures are due to physical external mostly axial and radial shaft overloads. Rotary
parameters that change the mechanical structure bending (flexion) and torsion (twisted) fatigue fai-
of the materials. The causes of these incidents are lures.
II-1-1 - Problems on consequence page

- Fretting P 12, II-2-1
shafts: bad alignment, - Shaft rupture P 12, II-2-2-1
bad mechanical link P 13, II-2-2-2
- Rear bushing P 15, II-2-5-1
(bracket, chassis defor-
P 15, II-2-5-2
mation, bad bell hou- P 15, II-2-5-3
sing, too loose damping - Cam ring marked P 15, II-2-6

- Shaft seal problem P 16, II-2-7
elements...) can create: - Dissymmetrical wear on port
a) misalignment plate P 16, II-2-8
- Ball bearing worn or destroyed

- Shaft rupture P 12, II-2-2-1
P 13, II-2-2-2
b) out of squareness - Rear bushing P 15, II-2-5-1

P 15, II-2-5-2
P 15, II-2-5-3
- Cam ring marked P 15, II-2-6
- Dissymmetrical wear on port
plate P 16, II-2-8
- Ball bearing worn or destroyed
7
II-1: MECHANICAL FAILURES (continuation)
consequence page
- Fretting corrosion P 12, II-2-1

II-1-1-1 - Too tight gap - Shaft rupture P 12, II-2-2-1
between the two cou- P 13, II-2-2-2
pling flanges (axial - Ball bearing worn out

loads/radial loads).
P 15, II-2-5-2
P 15, II-2-5-3
- Check with the coupling manu-

facturer to convenient clearance
required depending on the
torque.
II-1-1-2 - Unbalanced
coupling = radial load.
- Bushing P 15, II-2-5
II-1-1-3 - Too high load
- Cam ring marked P 15, II-2-6
on a belt driven system - Shaft seal problem P 16, II-2-7
(belt drives not recom- - Dissymmetrical wear on port
mended). plate P 16, II-2-8
II-1-1-4 - Non-homoki-
netic transmission due
to unbalanced cardan
shaft (or universal joint)
means inconstant shaft
speed.
II-1-1-5 - Too great - Bushing P 15, II-2-5
moment of inertia due - Cam ring marked P 15, II-2-6
to heavy couplings (like
chain couplings) or
very large diameter
couplings.
8
consequence page
- Shaft rapture P 12, II-2-2-1

II-1-1-6 - Bracket chas- P 13, II-2-2-2
sis deformation (when - Bushing problems P 15, II-2-5
pump under load). - Marked cam ring P 15, II-2-6

- Seal problems P 16, II-2-7
- Wear on port plate P 16, II-2-8
II-1-1-7 - Hose strain

(reaction) force (brutal
pressure compression / - Shaft rapture P 12, II-2-2-1
P 13, II-2-2-2
decompression, rigid
- Bushing problems P 15, II-2-5
hoses mounting - Marked cam ring P 15, II-2-6
strain...). - Seal problems P 16, II-2-7

- Wear on port plate P 16, II-2-8
II-1-1-8 - Over torque

limits (too high pressu-
re versus displacement
for the capacity of the - Shaft rapture P 13, II-2-2-3
shaft chosen). (torsional fatigue)
- Shaft wear P 14, II-2-3
P 14, II-2-4
II-1-2 - Bad
shaft/coupling
connection:
II-1-2-1 - "Coupling - Shaft rapture P 12, II-2-2-1
screw" not properly P 13, II-2-2-2

positioned on the key
P 15, II-2-5-2
(keyed shaft). P 15, II-2-5-3
9
II-1-2-2 - Bad manu- consequence page

facturing (machining)
of the couplings:
- bad diameter fit tole- - Shaft rupture P 13, II-2-2-3
rance between the shaft - Shaft worn out P 14, II-2-4
diameter and the cou-

pling diameter
- key way in the cou-

pling is not properly
centered with the main - Shaft rupture P 14, II-2-3
bore axis P 14, II-2-4
- bad heat treatment

(too high or too low)
II-1-2-3 - Shaft not pro-

perly utilized (too small - Wear of the splines P 14, II-2-3
- Wear of the key P 14, II-2-4
surface of spline or key
used)
II-1-2-4 - Bad (or no)

- Spline wear P 14, II-2-3
lubrication of splined Denison Hydraulics requires for the lubrication of the
shafts/coupling. shafts a grease with "disulfide of molybdenum" base.
- Dowel pin rupture P 16, II-2-9

II-1-3 - Cartridge
- No pressure possible
dowel pin not posi- - Unconstant flow
tioned correctly in - Cavitation
the housing. - Noisy
10
II-1-4 - Cartridge screws not consequence page

properly mounted (after a car-
tridge modification, no precau-
tion has been taken to see if the
rotor/vanes could rotate freely
in the newly built cartridge.
Some vanes can have tilted and
- Vane marks P 11, II-1-7
therefore be squeezed inbetween - Vane marks P 17, II-2-12
the port plates). These screws
should be lightly tightened as
they just hold pieces together to
obtain a cartridge. After reas-
sembling a cartridge, always
check if the rotor & vanes can
rotate freely in the cartridge.
II-1-5 - Hollow pin-vane hold-

- Noisy
out wrongly mounted in the
- Flow unstable
T6*M, Mobile version (pin up
side down).
II-1-6 - Loose pump fasteners

(after modifying the pump, the
screws were not tightened at the -Broken screws P 17, II-2-11
proper torque and worked

loose).
II-1-7 - Marks on distribution

- Vane marks P 17, II-2-12
plates that disturb the cycle of
- Noisy
the pump. Even a small scratch - Pressure limited
between the inlet & the pressure - Flow unconstant
area can destabilize the vane.
11
II-2: THE CONSEQUENCES OF MECHANICAL FAILURES:
II-2-1 - Fretting cor- incident page

rosion.
This phenomenon
- Bad shaft / coupling link
appears when the soli- P 9, II-1-2-1
citations are great and - Bad coupling manufacturing
when there is a slight P 10, II-1-2-2

- Bad grease when assembly
vibration movement.
These movements will
"create" metallic
oxides. Being very
abrasive, they will wea-
ken the structure of the
component and will
favour start-up of the
fatigue rupture (twis-
ted).
II-2-2 - Fatigue shaft - Bad alignment P 7, II-1-1a

- Out of squareness P 7, II-1-1b
rupture:
- Unbalanced coupling
II-2-2-1
P 8, II-1-1-2
- Perpendicular, center, - Too high radial load
rotational bending P 8, II-1-1-3

- Non homokinetic P 8, II-1-1-4
fatigue rupture.
- Too great moment of inertia
P 8, II-1-1-5
- Bracket chassis deformation
P 9, II-1-1-6
- Hose strain force P 9, II-1-1-7
P 9, II-1-2-1
12
II-2: THE CONSEQUENCES OF MECHANICAL FAILURES: (continuation)
incident page
II-2-2-2 -
Perpendicular,
- Bad alignment P 7, II-1-1a
over-center rotational - Out of squareness P 7, II-1-1b
bending fatigue rupture. - Unbalanced coupling
P 8, II-1-1-2
- Too high radial load
P 8, II-1-1-3
- Non homokinetic P 8, II-1-1-4
- Too great moment of inertia
P 8, II-1-1-5
- Bracket chassis deformation
P 9, II-1-1-6
- Hose strain force P 9, II-1-1-7
P 9, II-1-2-1
II-2-2-3 - Twisted tor-

sional rupture. - Fretting corrosion
P 12, II-2-1
- Over torque limits
P 9, II-1-1-8
13
II-2: THE CONSEQUENCES OF MECHANICAL FAILURES:
II-2-2-4 incident page

- Perpendicular, torsio-
nal fatigue rupture.
- Torsional fatigue with peak

torque values
P 9, II-1-1-8
II-2-3 - Shaft splines/ - Bad shaft / coupling connection

P 10, II-1-2-2
keyed shaft worn
- Bad lubricant (Grease)
out on total length. - Over torque values
P 9, II-1-1-8
- Highly cycled
II-2-4 - Shaft splines/

keyed shaft worn - Over torque values
out on part of the P 9, II-1-1-8

- Utilized key surface or splined
length.
surface too small
P 10, II-1-2-3
14
II-2-5 - Bushing/bea- incident page

ring problems
II-2-5-1 - Front or back

- Problems on shafts
bearing/bushing with P 7, 8, 9, II-1-1
heavy wear - Bad shaft / coupling connection
P 9, 10, II-1-2
II-2-5-2 - Bushing - Problems on shafts

P 7, 8, 9, II-1-1
"welded" on the shaft
- Bad shaft / coupling connection
P 9, 10, II-1-2
II-2-5-3 - Back bushing - Problems on shafts
moving out of the rear P 7, 8, 9, II-1-1

port plate
P 9, 10, II-1-2
II-2-6 - Cam ring

marked by the rotor
on the smallest diame-
ter. If the contact bet- - Problems on shafts
P 7, 8, 9, II-1-1
ween the rotor and the
cam ring is important, it P 9, 10, II-1-2
will transform the hard-
ness of the cam ring
and create local ten-
sions (cracks).
15
II-2-7 - Seal loosing incident page

contact with the shaft
P 7, 8, 9, II-1-1
on one area: - Bad shaft / coupling connection
- air intake P 9, 10, II-1-2
P 7, 8, 9, II-1-1
- leakage P 9, 10, II-1-2
II-2-8 -
Dissymmetrical P 7, 8, 9, II-1-1
wear on the side - Bad shaft / coupling connection
P 9, 10, II-1-2
plates
- Over torque limits

II-2-9 - Dowel pin P 9, II-1-1-8
broken - Cartridge not properly mounted

in the housing P 10, II-1-3
- Hollow pin-vane P 11, II-1-5

II-2-10 - Noisy
16
II-2-11 - Broken incident page

screws
- Loose pump fasteners

P 11, II-1-6
II-2-12 - Parallel
marks on the port
plate (vane marks) - Cartridge not properly assem-
bled P 11, II-1-4
- Tilted vanes marked

the port plate but the
pump did not rotate.
- Tilted vanes but the

pump did rotate. The - Cartridge not properly assem-
bled P 11, II-1-4
result is scars on the
port plate.
17
II-3 : PRESSURE FAILURES: OVERSHOOT & PRESSURE GRADIENTS
II-3-1 - PRESSURE OVERSHOOT
Although system pressures are rising constantly, or a valve problem that opens the main security
the pressure overshoot also rises. The effects on valve. The pump is or is not protected by a check
pumps, whichever technology is used, are bad. valve. The fact is that the pressure rises over the
We have split-up this description into two diffe- initial settings or designed settings. This problem
rent categories: "Instant pressure overshoot" and is mainly seen when the valves tend to open (or
"Cycled overpressurization". The final conse- close for a check valve) too slowly. These pressu-
quences of these are the same, that is to say the re peaks can reach 2 to 5 times the pressure set-
failure of components. We will see that the failing tings. Not readable with standard manometer,
components are damaged differently if it is electronic sensors recording traces will show the
Instant pressure overshoot or Cycled overpressu- facts. When the check-valve closes itself too
rization. The valves and the pipes rigidity and slowly, the flow will come backwards into the
length around the pumps have a great impact on pump. This problem will be seen in the cycled
these pressure peaks. It can be a system problem overpressurization.
II-3-2 - INSTANT PRESSURE OVERSHOOT:
This a brutal high peak of pressure. The conse- nents such as the side plates (on the high pres-
quence is that the mechanical strength of the sure distribution area), the rotor (split), the cam
material is exceeded. ring (cracked), the shaft (broken), the dowel pin
This will cause some brutal failures of compo- (cut in two).
II-3-3 - THE CONSEQUENCES OF INSTANT PRESSURE OVERSHOOT:
II-3-3-1 - Cracks or rupture of

the pressure plate
18
II-3-3 - THE CONSEQUENCES OF INSTANT PRESSURE OVERSHOOT: (continuation)
II-3-3-2 - Cracks or rupture of

the rotor
II-3-3-3 - Cam ring cracked
II-3-3-4 - Shaft broken: perpen-

dicular "clean cut"
19
II-3-3 - THE CONSEQUENCES OF INSTANT PRESSURE OVERSHOOT: (continuation)
II-3-3-5 - Dowel pin cut in two
II-3-4 CYCLED OVERPRESSURIZATION:
The pressure rating of the system is just over the because of the narrow gap and a friction welding
allowed pressure specified. will result. The total seizure will then be the
This will give, on a long term, a fatigue failure. It consequence if the local temperature rises too
is the sum of the pressures exceeding limits that high.
will weaken the mechanical strength of the com- The system is not secured with a check valve or
ponents. These specific failures are seen on the this check valve is too slow to open.
following components: cam ring, vanes, shaft, During the opening time of the "slow" relief
side plates, rotor splines or the rotor rupture bet- valve, the flow delivered from actuators or the
ween the two vane slots bulbs of the rotor (as pump has to go somewhere. Usually, the relief
page 19, II-3-3-2). valve opens and this flow goes back to the tank.
Another effect is the deflection of the cam rings' Here, not being able to go back to the tank, the
external diameter due to this overpressure. The flow will go back to the pump. If the check valve
consequence of this expansion is to reduce the closes fast enough, the pressure will increase and
space between the rotor OD and the minor dia- accelerate the relief valve opening to allow the
meter of the cam ring. When this gap is too nar- flow back to the tank. If there is no check valve or
row, the rotor may come in contact with the cam if it is too slow, the flow will return to the pump.
ring. If both cam deflection and shaft misalign- This flow will then push the rotor forwards,
ment happen at the same time, then the contact which will wear the rotors' splines. The gap bet-
often arises. ween the rotor & the side plates will then be
Another distortion effect is this overpressure increased and create a local cavitation. This local
pushing on the pressure plate. The deflection of cavitation will suck the oil lubricating the sides.
the pressure plate will, in its center, reduce the Without enough oil, the local overheat will start a
normal clearance between the port plates and the pump seizing. The vanes will have marks on both
rotor. The film of oil lubricating these compo- sides, the splines of the shaft and the rotor will
nents will be reduced. Its temperature will rise be worn (on both splined teeth flanks)...
20
II-3-5 THE CONSEQUENCES OF CYCLED OVERPRESSURIZATION:
II-3-5-1 - Vanes
II-3-5-2 - Cam ring:
-rupture/cracks
- rotor/cam ring contact in the

"small diameter"
21
II-3-5 THE CONSEQUENCES OF CYCLED OVERPRESSURE: (continuation)
II-3-5-3 - Shaft:
- internal splines worn
- rupture:
torsional fatigue ruptures
Perpendicular: few cycles but
very high torque
Twisted: often under high

cycling
II-3-5-4 - Side plates deforma-

tions = contact on the smallest
diameter of the rotor.
22
II-3-6 PRESSURE GRADIENTS
This pressure increase/decrease decay, in bar per pumps' technology, these allowable pressure gra-
second, is known by most people but often for- dients are more or less important. The Denison
gotten in the basic hydraulic systems. The veloci- vane technology can be used safely up to 6000
ty of this increase/decrease is very important. bar per second. Over these limits, phenomena
Beyond the fact that it stresses the raw material, it such as cavitation, hose decompression effect (...)
has some big effects on the velocity of the oil. can appear. A positive inlet pressure and no inlet
These sudden pressure changes modify the inter- strainer are recommended to avoid a too high
nal leakage of the pumps. Depending on the inlet vacuum.
II-3-7 CONSEQUENCES OF TOO HIGH PRESSURE GRADIENTS:
II-3-7-1 - Cam ring fatigue

rupture
II-3-7-2 - Rotor/side plates

seizure: This is due to a very
strong cavitation when the pres-
sure decrease is dramatic. The
sudden flow required is so
important that the instant local
velocity rises and creates the
cavitation.
23
II-4 PHYSICAL, CHEMICAL OR HYDRAULIC FAILURES
All the following failures are linked, one way or is some contamination (air, particles, water...), or
another, to the quality of the lubricant, the poor some temperature problems, or a poor oil edging,
filtration or the poor inlet conditions. Either there or cavitation or fluid aeration problems.
II-4-1 Start-up without a proper air bleed. 25
II-4-2 Air pollution (contamination): 25
- Foaming-Aeration 25
Description 25
Consequences 26
- Cavitation-Deaeration 28
Description 28
Consequences 29
II-4-3 Solid particle contamination: Nature & origin of particles 33
II-4-4 Consequences of solid particle contamination 33
II-4-5 Water contamination 37
II-4-6 Consequences of Water contamination 38
II-4-7 Viscosity failures 39
II-4-8 Consequences of too high or too low Viscosity 40
II-4-9 Unsuitable fluids: 41

Wrong Viscosity choice 41
Filterability 41
Oxidation 42
Bad deaeration capabilities 42
Polluted fluids 42
Density 42
Conclusion on the fluids 43
II-4-10 Unsuitable grease 43
24
II-4-1 START-UP WITHOUT A PROPER AIR BLEED.
The vane pumps are designed and manufactured and then the metal to metal contact will create
with a dry lubricant capability. The dry graphite the friction and then the "welding seizure".
lubricant coating on the cam ring and the surface - If the column of oil does build up but the air
treatment on the distribution plates are done to bleed is not complete, the pump will not work
lubricate during start-ups. properly. The pressure will not build up correct-
- If the suction column of oil does not build up, ly, the flow could be lower than the one required,
the pump will not be lubricated enough and be the pumping will be erratic and noisy.
damaged. The consequence of this bad lubrica- - If the inlet velocity is too low, under 0,5 m/sec.,
tion is local overheating. Depending on how the air will stay trapped in the pump and in the
long this defect lasts, the consequences can go inlet pipe.
up to the seizure between the port plates and the The consequences of incorrect air bleed are seen
rotor. The local temperature is so high that the in the next paragraph.
film of oil between the components disappears,
II-4-2 AIR CONTAMINATION (creating the foaming of the oil):
When we talk about air in the oil, it is the simpli- The pressure creates the ignition and the gases
fication of a complex chemical transformation. will combust at temperatures as high as 1300°C.
What we will call air is more a mix of different The result is the destruction of the fluid giving
gases than air. This explains why under pressure, to it a black color and a "burnt" smell. This phe-
these gases will implode and create a very high nomenon is also known as the "Lorentz" or
local temperature. "diesel" effect.
II- 4-2-1- Aeration :
Description : this phenomenon is the fact that - suction pipe not sealed under vacuum, therefore
some air is brought into the system and, with sucking air,
the turbulence of the flow, generates a foamed - deteriorated shaft seal (or high radial load crea-
substance. ting an air intake),
This new "fluid" has lost all the requirements of - inlet tube in front of the return line (amplifying
the original fluid and, therefore, lost all the the foaming),
capabilities of a standard hydraulic fluid. The - turbulence created by a high velocity around the
consequences of such a transformation are dif- inlet tube (not enough suction surface),
ferent depending on the quantity of air brought - return line coming back to the reservoir over the
into the system. oil level. It is required that the lowest point of the
This problem could be caused by different exter- return line must always be under the oil level
nal problems, independent or not: (five times the pipe diameter),
25
- oil level of the reservoirs too low compared to air going to the pump will deteriorate it.
the suction level, - bad baffle design. If the fluid is to pass over the
- too small tank (high velocity in the tank,) baffle, the maximum speed has to stay under 0.5
- fluid in movement (bad tank design on mobile meter per second to avoid turbulence,
applications), - Venturi effect on a return pipe,
- bad deaeration capabilities of the fluid and/or the - anti-siphon holes drilled in the return pipes,
tank. Baffles can help "pushing" the air to the - water pollution that will create steam due to
surface. If the "vein flow" is too rapid and if no local overheating. This steam in contact with oil
baffle is there to bring to the surface these will create foaming (for more details, please go
bubbles, they will go back to the inlet area. This to page 35, chapter II-4-5, water contamination).
II- 4-2-2- Consequences of Aeration:

The vanes are going to be completely unbalanced hardened metal pieces, will start to wear the side
due to the abnormal fluid compressibility (due to plates in die cast or ductile iron.
quantity of air in the oil). The vanes, usually The marks will start in the discharge area and,
hydrostatically balanced (without air), will move depending on the quantity of air, will more or less
sideways with such erratic movements that the create a groove.
vanes will destroy their lubricant film of oil that During all these turbulences, the most noticeable
links them to the side plates. Doing so, the vanes, fact is going to be an unusual noise level.
II- 4-2-2-1 - If the quantity of

air is erratic or not too heavy,
the effects are scores only on
the port plates in the suction
area
26
II-4-2-2- Consequences of Aeration: (continuation)
II-4-2-2-2 - If under very seve-

re aeration, this groove can
mark deeply the port plates
from the suction area to the out-
let area. The width of the groo-
ve is then the width of the vane.
II-4-2-2-3 - In very heavy air

conditions, the vane is so unba-
lanced that it can even some-
times break (itself).
II-4-2-2- 4 - Noisy
27
II-4-2-2- Consequences of Aeration: (continuation)
II-4-2-2-4 - Noisy (continua-

tion)
Before obtaining such a disastrous wear, the pressure level will not be obtained. The physical
vanes being so unsteady will make a lot of noise, aspect of the oil will be "milky" on the surface as
the flow will not be the one required and/or the the oil and the air create a foam.
II-4-2- AIR CONTAMINATION (continuation)

II-4-2-3 - Cavitation-Deaeration:
Description : When a depression arises in the suc- small diameter, they will reach the surface of the
tion port, the gas (combustible) and aromatic oil tank very slowly (bad deaeration characteris-
essences dissolved in the fluid (6 to 7 %) will eva- tics). As an example, 100 liters of a foamed oil by
porate. Depending on the type of fluid, this deae- cavitation will take 4 hours to become translucent
ration will occur between 100 and 150 mm of HG again. When the fluid reaches local hot tempera-
(around -0.2 bar). Under this depression (or tures and is compressed (at the "critical pressure"),
vacuum), small bubbles of a diameter of .2 to .3 these bubbles implode and create a shock wave.
mm will be formed. The natural appearance of oil known as the diesel effect, the impact of these
is translucent. Under cavitation and because of "combustion explosions", will create erosion in the
these small "bubbles", the fluid will have a "clou- shape of the crater (cavities) when located near a
dy" appearance. Depending on the value of the metallic surface. These detached metallic particles
vacuum, the quantity of suspended bubbles will be are very likely to cause, on a medium term base, a
more or less important. As these bubbles have a seizure between the pumps' moving parts.
28
II-4-2-3 - Cavitation-Deaeration: (continuation)
This problem can be caused by different external - tank too far away from the pump (horizontally or
problems (independent or linked): vertically),
- suction strainer : - excessive shaft speed,
- clogged by a foreign contaminant, - air filter on the tank clogged or not well dimen-
- clogged by a too high viscosity, sioned generating a vacuum in the tank.
- too small in flow rate/pressure drop. - reservoirs' oil level too low compared to the suc-
- (Filtration on the return line and no suction strai- tion level (when all cylinders are extended for
ner is still what we recommend to avoid the example),
above mentioned problems). - inlet tube in front of the return line (amplifying
- too long inlet hose, the foaming),
- too small inlet hose (too small section on the - too small tank (high velocity in the tank),
whole piping or restricted in one area), - bad deaeration capabilities of the oil and of the
- inlet tube, in the tank, too close from the panel of tank. Baffles can help "pushing" the air to the
the tank, surface. If the "vein flow" is too rapid and if no
- inlet tube, in the tank, with a too small suction baffle is there to bring to the surface these
surface creating local turbulence (deaerating the bubbles, they will go back to the inlet area. This
fluid). Cut the tube on a angle to increase this air in the pump will deteriorate it.
suction surface and avoid local high Velocities, - bad filtration dimension on return line. Under
- too high or too low inlet velocity ( 0.5 to 1.9 dimension will increase the velocity and deaera-
meter per second is the velocity required), te the oil.
II-4-2-4 - Consequences when the pump is cavitating:
II-4-2-4-1 - Noise level : much

higher than usual. Under pres-
sure, this noise level is ampli-
fied.
29
II-4-2-4 - Consequences when the pump is cavitating: (continuation)
II-4-2-4-2 - Ripples on the cam

ring: the vanes are hydrostati-
cally balanced to avoid excessi-
ve loads on the vane lips. Under
suction cycle, the pin compen-
sates the out of balance load
due to the cam profile. When
the depression is over the desi-
gn limits, the vane bounces,
creating ripples on the cam ring
profile. The depth of these
marks is proportional to the
strength of the depression.
II-4-2-4-3 - Craters: these ero-

sion craters are sometimes diffi-
cult to observe as the pump
may have already seized.
These craters come from ero-
sion, caused either by an explo-
sion/implosion, either by
depressurisation.
When the fluid trapped between
the two vanes is sucked in with
a certain percentage of air in
suspension, an explosion can
occur. When this trapped volu-
me is compressed, these air
bubbles explode and create cra-
ters in the side plates in the area
between the suction port and
the pressure port, around the
pressure bleed slots.
30
II-4-2-4 - Consequences when the pump is cavitating: (continuation)
II-4-2-4-3 - Craters (continua-

tion)
- vanes
- pins
II-4-2-4-4 - "Black marks":

The local depression conse-
quences can be seen on the
vanes (top lips and on the cen-
ter of the vane), on the port
plates (in the inlet area) and on
the center of the cam ring (just
after the inlet "feeding hole").
These "black marks" can be
transformed into small craters
in the port plates near the outlet
bleed slots as the air bubbles
explosion occurs.
31
II-4-2- 4 - Consequences when the pump is cavitating: (continuation)
III-4-2-4- 5 - Seizure of the

pump.
Due to a lack of fluid, the
vacuum generated, when really
severe, will suck the oil on the
side of the pump (between the
rotor and the side plates). This
will have the effect of breaking
the film of oil that lubricates
these surfaces. The surfaces will
then heat-up and this local over-
heat will modify the standard
lubricity into a dry friction. The
result is a seizure between the
rotor and the side plates. (This
heavy contamination coming
from the digging of craters, the
particles can also badly lubrica-
te the pump and lead to the sei-
zure.)
32
II-4-3 SOLID PARTICLE CONTAMINATION:
Unlike a lot of different technologies, the Denison Nature of particles :

vane units do not generate pollution. The main particles are made up of metallic oxide,
Even if this has become an important topic and a silica, carbon and organic materials.
lot of education has been done around the cleanli- Origin of particles :
ness of the fluid, the pollution by particles stays - A common large particle is the metallic oxide
one of the greatest causes of pumps' destruction. coming from welding burrs when the welded
The consequences are either a rapid wear or a pre- piping has not been cleaned-up properly.
mature breakdown (large size particles over 25 µm). - The silica comes from the surrounding dust. This
In a hydraulic circuit, the pump is the flow/pres- dust will enter into the system through cylinders'
sure generator. Being so, it becomes the most sen- sealing, through air intakes (absence of air fil-
sitive unit to pollution and, therefore, will be the ters), dirty environment and the tank not proper-
first component to fail. ly sealed ...
II-4-4 CONSEQUENCES OF SOLID PARTICLE CONTAMINATION:
Depending on the size of the particles, the conse- It is obvious that under perfect filtration condi-
quences can go from a gentle ground finish on the tions, the rubbing of the vanes in the rotor is redu-
vane lips, cam surface, side plates to the total des- ced to a minimum by the action of the oil under
truction of the cartridge. pressure which is located all around the vanes.
II-4-4-1 - Vanes:
a)
- The vane lips edges. The par-
ticles in the fluid will have a
grinding effect between the top
of the lip and the cam ring pro-
file. When the contaminant is
too big or too stiff, the vane lip
edges can break.
33
II-4-4 CONSEQUENCES OF PARTICLE CONTAMINATION: (continuation)
II-4-4-1 - Vanes (continuation)

b)
- The vane surface. The film of
oil between the vanes and the
rotor being contaminated, there
will be a rubbing effect in this
area. These rubbing marks (pol-
lution marks) will be vertical
and of the height of the vanes'
translation (displacement).
II-4-4-2 - Cam ring:
- Between the vane lip and the

cam ring, the film of oil is
contaminated. This will wear
the inner surface of the cam
ring.
34
- On the edge of the cam ring

contour, (with a slight chamfer
when new), you will find a
sharp angle (edge). If the wear
is heavy, the cam ring can have
little burrs in this area.
II-4-4-3 - Rotor/vanes:
In the rotors' slots, the rubbing
wear between the slots and the
vanes will also lead to vertical
pollution marks. (P 32 II-4-4-2 b)
II-4-4-4 - Rotor/side plates:

When the particles in suspen-
sion in the fluid are greater than
half of the clearance between
the thickness of the rotor and
the thickness of the cam ring,
seizure occurs in the peripheral
diameter of the rotor and the
port plates.
35
II-4-4-5 - Rotor - The rubbing

effect will also appear in-bet-
ween the side of the rotor and
the side plates. This will create
a torque between the two vane
slaps. This torque causes a rea-
sonably high level of fatigue in
the materials' weakest area, bet-
ween the two bulb slots of the
rotor. If this fatigue level
exceeds the design limits, this
portion of the rotor will break.
II-4-4-6 - Rotor/side plates/

vanes: Big contamination par-
ticles damages (like the "car-
bon" welding balls) are usually
seen on the port plates (blocked
in the slots) or/and on the top of
the vanes/rotor. Each time, they
will have an effect on the vane
lips, either on the top either on
the sides. The "rubbing" action
will either destroy the vane lips
or weld the vane to the rotor,
break the cam ring...
II-4-4-7 - Side plates: Another

sign of contaminated oil is
some possible erosion craters
on the port plates at the
inlet/suction bleed slots area.
These erosion craters would
come from the abrasive fine
particles in a local high velocity
area.
36
II-4-5 WATER CONTAMINATION:
Description: modify the nature of the contacts between sur-

Depending on the type of fluid, the water conta- faces. This can lead to start local micro-seizures
mination can be different. For mineral oils, this due to a lack of convenient lubricant.
limit should not exceed 500 ppm (particles per - When polluted with water, the whole system
million). This limit for the esters and the vege- must be cleaned up and then drained two or
table oils is maximum 500 ppm. The water conta- three times until obtaining a clean translucent
mination will modify the chemical structure of oil when running.
the fluid (oxidation of the fluid increases the This water pollution can come from various
TAN*). Having an excess of water, this water can causes:
be transformed into steam under the action of the - condensation coming from a high hydrometric
pressure. Another effect of this excess is the level (big temperature variations),
modification of the "compressibility module". - a leak in the water exchanger,
- The fluid will be destroyed and lose its charac- - tank not water-tight,
teristics / performance. The oxidation of the - storage of the oil barrel outside vertically,
fluid will modify the TAN. The higher acidity of - high pressure water cleaning of the machines
the fluid will destroy the additives. This, added (water going under the seals of cylinders on off-
to the local heat created, will transform (or car- highway vehicles for example).
bonize) the fluid. It will modify the molecular
structure. The colour of the fluid will turn creamy
(milky).
- Destroying the additives means the lubricity
will be worse, the thermic stability very poor...
- The excess of water can also bring in bacteria
that can damage the fluid. A gelatinous mass in
the tank and in some components is a way to
observe this phenomenon.
- The most common consequence is the appea-
rance of rust on all metallic surfaces. This will *TAN : Total Acid Number.
37
II-4-6 CONSEQUENCES OF WATER CONTAMINATION:
II-4-6-1 - Deposit can then be

seen on the vanes. This deposit
will modify the performances of
the pump because of the dete-
rioration of the mechanical effi-
ciency (the varnish will "stick"
the vanes in the slots of the
rotor).
On the cartridge, it changes the
colour of the bronze bushing
(due to the modification of the
acidity) and leaves a deposit on
the external diameter.
II-4-6-2 - The fluid can produce

foaming because of the steam.
The specificity of the foaming
oil due to water is a milky or
creamy typical aspect. The
consequences are identical to
the aerated fluid.
38
II-4-6 CONSEQUENCES OF WATER CONTAMINATION: (continuation)
II-4-6-3 - The fluid compressi-

bility will fluctuate and therefo-
re destabilize the vanes. This
will be seen on the cam ring
surface full of ripples and on
the sharp vane lips edges. In
this case, the noise level will be
high and the flow & pressure
capabilities deteriorated.
II-4-6-4 - Due to these fluid

transformations, the mechanical
consequences go from perfor-
mance being deteriorated to the
destruction of the pump if the
local temperatures are extreme
(Here, phosphate oil additive
deposit).
II-4-7 VISCOSITY FAILURES.
Depending on the environment, the tempera- (9240 SSU), the problem is that the fluid has a
tures can considerably modify the original wan- big resistance and the Velocity will drop. This
ted Viscosity. The influence of the temperature resistance can create local vacuum, that is to
differences on the Viscosity is enormous. say deaeration of the fluid. This will ruin the
The vane components are designed to work for lubricity of the pump.
a wide possible range of Viscosity. When a pro- Under heavy Viscosity and low rotation, the
blem occurs, the Viscosity is either too high or vanes can stick and stay stuck in the rotor. The
too low. consequence is that there is no flow coming out
When the Viscosity is too high, over 2000 cSt of the pump.
39
II-4-7 VISCOSITY FAILURES.
When the Viscosity is too low, under 8 cSt (52 a tank temperature of 50°C (122°F) could mean a
SSU), it will decrease the film thickness designed local temperature in the pump of up to 130°C
to lubricate all the components in motion. If the (266°F). If the viscosity is calculated on the tanks
Viscosity is very low, it could mean that the tem- temperature, we can easily figure out the very low
perature is high. Tests carried out have shown that viscosity when the oil is at 130°C (266°F).
II-4-8 CONSEQUENCES OF VISCOSITY FAILURES.
II-4-8-1 - Too high viscosity:

- Seizure due to the high cavita-
tion not allowing the rotating
group to be lubricated.
II-4-8-2 - Too low viscosity:

- Erosion on the port plates.
40
II-4-8 CONSEQUENCES OF VISCOSITY FAILURES: (continuation)
- Scars on the side plates &

rotor due to a bad lubricity.
II-4-9 UNSUITABLE FLUIDS:
Viscosity index choice:
If the fluid was chosen by an OEM in Norway high Viscosity will probably cause cavitation
for a local sale but the application is to work in and a lack of lubrication, too low Viscosity will
Saudi Arabia, the choice of the fluid will have to lead to a too thin film of oil and therefore create
take into consideration the specific application a local heat point.
environment. In both extremes, the consequences can be fatal
Forgetting this can lead into deep trouble. Too breakdowns.
Filterability:
If the fluid does not have good filterability Bad filterability can either come from a low qua-
properties, the filters will be clogged rapidly. lity fluid, or from a fluid sensitive to any conta-
The flow will have to go through the by-pass and minant destroying its chemical homogeneity
therefore not be filtrated anymore and will heat-up (water, solvants, grease...).
the system (due to the open by-pass).
41
II-4-9 UNSUITABLE FLUIDS: (continuation)
Oxidation resistance:
Contaminants can modify the acidity of the fluid will increase the Viscosity. Increased Viscosity
and therefore become very corrosive. Such a will increase the pressure drops. Increased pres-
modified fluid will corrode the steel components sure drops will then increase the temperature and
and produce corrosion residues. These residues cause local overheat.
Deaeration capabilities:
This is another very important topic. If the fluid tank design is incorrect (inlet near return line for
chosen requires too long time to allow the air to example), if the tank is slightly pressurized (due
reach the surface of the tank, this can become a on purpose), the oil will not deaerate fast
big problem. Air in big quantities has a des- enough. The air bubbles will then be sucked by
troying effect on all pump technologies. If the the pump. Under pressure, these bubbles will
flow versus the size of the tank is small, if the then explode.
Polluted fluid:
This is an important topic and, nowadays, well the contaminant. The fluids are more and more
known at least for the solid particle contamina- high technical products. They also become more
tion. The manufacturing clearances becoming and more sensitive to their environment and any
tighter and tighter, a good filtration is required. contaminant can destroy the original characteris-
This even though our double lip technology tics. It is common for example to see fluids "des-
resists fairly well to pollution. troyed" by a high water content (chemical, other
Another pollution is the impact of another fluid fluid, particles). Refined oils will even be more
creating a reaction between the original fluid and sensitive than brand new ones.
Density:
It is important to know the specific gravity of the The specific gravity of a water-glycol (60 glycol/
fluid used. Because the density from one fluid to 40 water) will be around 1.08. Knowing this
another can vary a lot, the suction head has to be value, just check the minimum required Absolute
designed with that parameter. The specific gravity pressure in our catalogs to optimize your system.
of a standard oil (ISO 46) will be around 0.88.
42
II-4-9 UNSUITABLE FLUIDS: (continuation)
Conclusion on the fluids:
A common problem is the deterioration of the nal pollution, (solid particles, other fluids, che-
fluid. This deterioration can come either from the mical transformations, water), or from air. The
quality of the fluid (low quality or not used as consequences always lead to a low performing
recognized fluid manufacturer), or from an exter- pump or to a premature breakdown.
II-4-10 Unsuitable grease:
Bad lubricant on the shaft and coupling assem- best for heavy duty applications. It has a very
bly. We recommend for all grease lubricants to good specific load characteristic, avoids stick-
be based with disulfide of molybdenum. The slip and fretting corrosion, has a good penetrabi-
main characteristic of this grease is that it is the lity and enables easy dismantle.
43
VANE MOTOR
44
III SPECIFICS OF VANE MOTOR FAILURES AND CAUSES
Because the motor is a receptor in the hydraulic typical failures you can possibly be confronted
circuit, the incidents are not very common. It to with vane motors.
will be much easier to go through the various
III-1 - Torque over the cata-

log limits:
Front shaft rupture
Internal splines distortion
45
Ill SPECIFICS OF VANE MOTOR FAILURES AND CAUSES (continuation)
III-2- Bad air bleed

or air intake = incorrect rear
cover lubrication. Possible sei-
zure between the rotor and the
rear cover.
III-3- Over-pressure
on A or B:
Rotor rupture
Port block cracked
46
III SPECIFICS OF VANE MOTOR FAILURES AND CAUSES (continuation)
III-4- Over-pressure in the

drain line:
shaft seal blow off (extruded).
III-5- Excess of Air in the

fluid: coming from the system,
coining from an air intake bet-
ween the pump and the motor
or even coming from the front
shaft seal.
- Possible seizure between the
rotor and the rear cover.
- Possible heavy wear on the
port plates.
III-6-Cavitation: the speed of

the motor is higher than the
flow coming to the motor.
Heavy cavitation will lead to
seizure.
47
Ill SPECIFICS OF VANE MOTOR FAILURES AND CAUSES (continuation)
III-7- Pollution.
The pollution consequences will
be seen on various areas:
- In the rotor slots
- Grinding on both sides of
the slots.
- Traces of the "spring
areas" of the vanes dig-
ging in.
- On the side of the rotor / port

plates.
- On the vanes
One big particle (welding ball)
and small vertical scars.
- In the came ring

(Scars due to big particles).
48
III SPECIFICS OF VANE MOTOR FAILURES AND CAUSES (continuation)
III-8- Too low viscosity:

If the temperature rises and the
fluid becomes very "liquid", the
film of oil required to lubricate
the components is going to be
too thin. This can lead to micro-
seizures and to a total seizure if
this film of oil is minor.
CONCLUSION:
The DENISON vane technology is hydrostati- - the mechanical alignment,

cally balanced, axially and radially. As each - the fluids' quality (in the time),
and every single pump, motor or cartridge are in the limits given in the Denison
(sold as spare part) is tested in our production Hydraulics catalogue requirements, you are
plant on test benches before shipment, the qua- sure to obtain a high and long performing
lity of these components is certified. Our expe- pump/motor.
rience has shown us that if : These few requirements are the major parame -
- the inlet characteristics, ters to check when working within the catalogue
- the operating limits (pressures, RPM, values.
Viscosity...)
49
IV TROUBLESHOOTING TABLE
This following section is there to help you when ones we have seen and experienced in the field.
the hydraulic system or component does not work Please always remember that a clean system and a
as required. These solutions are the most common correct air bleed will solve a lot of incidents.
IV -1 PUMPS 51
IV -1-1 - No flow 51
IV -1-2 - Not enough flow 51
IV -1-3 - No pressure 54
IV -1-4 - Not enough pressure 54
IV -1-5 - Unusual noise level 54
IV -1-6 - Unusual heat 55
IV -1-7 - Shaft seal leakage 56
IV -2 MOTORS 58
IV -2-1 - No rotation 58
IV -2-2 - Stalls easily 59
IV -2-3 - Not enough speed 59
IV -2-4 - Erratic speed 59
IV -2-5 - Unusual noise level 59
IV -2-6 - Unusual heat 59
IV -2-7 - Shaft seal leakage 60
50
IV -1 TROUBLESHOOTING TABLE FOR PUMPS
IV-1-1 - No flow, a) Is the pump rotating ? a-1) Check if the coupling is rotating. If not, check the
no pressure rotation of the electric motor.
a-2) Check the keys of the pump and E motor shaft.
a-3) Check if the shaft is not broken.
b) Is the rotation in the b-1) Check if the rotation of the pump corresponds to
correct direction? the arrow on the name plate.
b-2) Check if the wiring of the electric motor is cor-
rect.
c) Is the air bleed-off c-1) Check that no air is still located in the pressure
done? line. Loosen a connector.
d) How are the inlet d-1) Check if the inlet gate valve is not closed.
conditions? d-2) Check the oil level.
d-3) Check if the inlet hose in the tank is under the oil
tank level.
d-4) Check if an air intake is not disturbing the inlet
(missing inlet flange seal, air trapped in suction line as
examples).
d-5) Check if the pump is not located too high above
the oil level.
d-6) Check if the tank is not completely sealed. Then
the lack of atmospheric pressure will not allow the
pump to prime.
d-7) Check if all connections and seals are air-tight.
e) Is the Viscosity not e-1) Check if the oil characteristics are not incompa-
too high? tible with the temperature and the pumps require-
ments. Too high Viscosity will "stick" the vein fluid
and enable the pump to suck the oil correctly.
f) Is the pump flow not f-1) Check the hydraulic circuit and the main
going somewhere else? sequences. Doing so, you will check if all the valves
are set or work properly.
51
IV -1 TROUBLESHOOTING TABLE FOR PUMPS (continuation)
IV-1-1 - No flow, f) Is the pump flow not f-2) Check if the main relief valve is not set at an
no pressure going somewhere else ? extremely low pressure and therefore bringing all the
(continuation) (continuation) flow back to the tank.
f-3) Check if in the directional valves the spools are
not sticking in a position that brings the flow back to
the tank.
f-4) check if the check valve is not mounted "upside
down".
g) Is the receptor wor- g-1) Check if the motor does not let all the flow leak
king correctly? internally.
g-2) Check if the cylinder inner seals are not ruined.
h) Is the speed high h-1) Check if the minimum speed is reached.
enough? Mobile pumps require 400 rpm and industrial
pumps require 600 rpm.
IV-1-2 - a) Are the components a-1) Check the displacement of the pump.
Not enough flow OK? a-2) Check if the speed of the pump is not too low or
(or not the flow too high (E motor or thermic engine sized too small so
required) dropping the speed too low...).
a-3) Check if the main relief valve is not set at an
extremely low pressure and therefore venting some
flow back to the tank.
a-4) Check if in the directional valves the spools are
not sticking in a position that brings part of the flow
back to the tank.
a-5) Check if the hydraulic motor is not leaking inter-
nally due to a bad efficiency, low viscosity...
a-6) Check if the cylinder inner seals are not ruined
and therefore allow internal leakage.
b) Is the connection from b-1) Check if there is no air intake between the pump
the tank to the pump cor- and the inlet pipe (bad seals for example).
rect? b-2) Check if the inlet hose is convenient for the requi-
red velocity (0,5 < V < 1,9 m/s).
52
IV-1-2 - b) Is the connection from b-3) Check if the pump is not too high compared to
Not enough flow the tank to the pump cor- the oil level or if the pump is not too far from the tank
(or not the flow rect? (continuation) (check the inlet absolute pressure with the catalog
required) values).
(continuation) b-4) Check if the gate valve is not semi-open.
b-5) Check if the inlet strainer is sized correctly (250
m mesh mini.) or not clogged.
c) Is the tank design cor- c-1) Check if the oil level is correct.
rect? c-2) Check if the suction pipe is under the oil level
during the complete cycle of the machine.
c-3) Check if the inlet hose fitted in the tank is cut
with an angle wider than 45°.
c-4) Check if this inlet hose is not too close to the tank
wall or to the bottom of the tank and therefore limits
the "vein flow".
c-5) Check if the suction hose is not located near the
return line and therefore sucking a lot of air coming
from these turbulences.
c-6) Check if baffles are required to allow correct dea-
reation of the fluid.
c-7) Check if the air filter is not clogged or under sei-
zed (not well dimensioned).
c-8) Check if the tank is not fully tight, not allowing
the atmospheric pressure to apply.
d) Is the oil convenient? d-1) Check if the oil characteristics are not incompa-
tible with the pumps requirements.
d-2) Check if the viscosity is not too high, therefore
"sticking" some vanes in the rotor or blocking the vein
fluid.
d-3) Check if the high temperature does not destroy
the viscosity of the fluid. Doing so, the internal leaka-
ge will "consume" the flow.
53
IV-1-3- a) Is the hydraulic circuit a-1) Check the hydraulic circuit schematic.
No pressure correctly designed?
b) Is the circuit correctly b-1) Compare the schematic to the piped circuit.
piped?
c) Are the components c-1) Check the main sequences. Doing so, you will
working properly? check if all the valves are set or work properly.
c-2) Check if the main relief valve is not set at an
extremely low pressure and therefore bringing all the
flow back to the tank.
c-3) Check if in the directional valves the spools are
not sticking in a position that brings the flow back to
the tank.
IV-1-4 - a) Check as when "no

Not enough pressure" IV-1-3.
pressure
b) Is the system well b-1) Check if the flow required is not over the avai-
dimensioned? lable flow and therefore cannot build-up pressure..
c) Is there an internal c-1) Check all the possible faulty components, from
leakage somewhere that the pump to all the receptors and intermediates (high
maintains a certain pres- pressure seals, mechanical wear...).
sure?
IV-1-5 - a) Is the noise coming a-1) Check the mechanical link of the shaft pump : ali-
Uncommon noise from the pump? gnment, balancing of the coupling or Universal joint,
level key properly fastened, ...
a-2) Check if the air bleed has been done correctly.
a-3) Check if there is no air intake from the tank to the
pump (nor through the shaft seal).
54
IV-1-5 - a) Is the noise coming a-5) Check if the hose strain force does not create this
Uncommon noise from the pump? noise.
level (continuation) a-6) Check if the oil level is correct.
(continuation) a-7) Check if the oil in the tank is not aerated.
a-8) Check if the strainer is not clogged or under-
dimensioned.
a-9) Check if the inlet pipe is under the oil level.
a-10) Check if the air filter is not clogged or too small.
a-11) Check if the speed is not incompatible with the
catalog values.
a-12) Check if the oil is compatible with the catalog
recommendations.
a-13) Check if the inlet pressure is not higher than the
outlet pressure.
b) Is the noise coming b-1) Check the hoses and see if the noise in not
from the surroundings? coming back to the pump this way.
b-2) Check the pressure piping and see if its length
dumps or amplifies the noise.
b-3) Check if the structure of the tank is stiff enough
to avoid amplification/resonance.
b-4) Check the E motor fan.
b-5) Check the balancing of the E motor.
b-6) Check the water cooler and its theoretical limits.
b-7) Check the filtration unit, its capacity and if the
noise does not come from the opened by-pass valve.
IV-1-6 - a) Does the heat appear a-1) Check the oil level and the suction pipe. Is the oil
Unusual heat when the pump is run- coming to the pump (check the length of the pipe, its
level ning without pressure? internal diameter, all that could influence the inlet
pressure)?
a-2) Check if the air bleed has been done correctly.
a-3) Check if the flow versus the volume of oil in the
tank is correct to obtain a good cooling effect.
55
IV-1-6 - a) Does the heat appear a-4) Check if a cooler is required or, if there is one, if
Unusual heat when the pump is run- it is well dimensioned.
level ning without pressure? a-5) If there is a cooler, check if it is working
(continuation) (continuation) (example for water cooler: is the water flow open or
sufficient).
a-6) Check if the hydraulic circuit is not bringing back
the flow directly to the inlet port. Doing so, it would
create a very small closed circuit not able to cool
down the fluid.
a-7) Check the quality of the fluid.
a-8) Check the velocity of the fluid.
a-9) Check the filtration unit, its capacity and if the
heat does not come from the open by-pass valve or if
it is under-dimensioned (bigger delta P).
b) Does the heat appear b-1) Check the viscosity.

when the pump is run- b-2) Check the pressure rating.
ning with pressure? b-3) Check if the cooler is working correctly or well
dimensioned.
b-4) Check if the relief valve is not creating this heat
because always open.
b-5) Check if any other component in the system is
not creating this heat due to an internal defect.
b-6) Check if there is a big temperature differential
between the inlet and the outlet.
IV-1-7 - a) Is the seal destroyed? a-1) Check the alignment and the correct power trans-
Shaft seal leakage mission (non homokinetic movement, high radial
force as examples).
a-2) Check the inlet pressure and compare it to the
catalog values.
a-3) Check if the bad suction conditions do not create
a vacuum that could even reverse the seal lip.
56
IV-1-7 - a) Is the seal destroyed? a-4) Check if the external environment is not too dirty
Shaft seal leakage (continuation) and therefore ruining the seal.
(continuation)
b) Is the seal only lea- b-1) Check the alignment of the front shaft and check
king? if there is not any radial load.
b-2) Check if seal lip has not been cut during a main-
tenance operation.
b-3) Check if the inlet pressure is not over or under the
catalog values. This has to be done for the whole cycle
because the inlet pressure can vary from time to time.
b-4) Check if the seal material has not been modified
due to a too warm environment. The seal can vulcani-
ze and stop sealing correctly.
b-5) Check the acidity of the oil that can "burn" the
seals material. It will therefore destroy the elasticity of
the sealing.
b-6) Check if the chosen seal (high pressure seal for
example) is not too stiff for the use. If the environment
requires some elasticity due to a gentle misalignment,
a high pressure seal will not be able to follow the
movement and therefore leak.
57
IV -2 TROUBLESHOOTING TABLE FOR MOTORS
IV-2-1 - a) Is the flow coming to a-1) Check the circuit and the hydraulic schematic. Is
No rotation the motor? the piping OK?
a-2) Check the setting of the main pressure relief valve.
Check if it not settled at an extremely low pressure.
a-3) Check if the pump is giving a flow.
a-4) Check if the directional valve(s) allowing the
flow to go to the motor is energized. If it is, check if
the spool is in its correct position and not sticking in a
position that would deviate the flow somewhere else.
a-5) Check if a check valve would not have been
improperly mounted.
b) Is the torque required b-1) Check if the pressure settings are correct.
higher than the system b-2) Check if the load is not superior to the torque
settings? capabilities of the motor.
c) Is the pump OK? c-1) Check if the pump is working correctly.
d) Are the motors inter- d-1) Check if a failing check valve would not allow
nal drain check valves some flow to go back to the tank and therefore limit
working properly? the flow to the motor.
e) How is the motor e-1) Check the nature of the connectors. If, for
piped? example, the "self sealing couplings" type connectors
are well fitted into each other.
IV-2-2 - a) Is the load near the a-1) Check the relief valve setting and compare it to
Stalls easily limits of the system? the theoretical pressure required to deliver the conve-
nient torque.
b) Are the motors inter- b-1) Check if a failing check valve would not allow
nal drain check valves some flow to go back to the tank and therefore limit
working properly? the flow to the motor.
c) Is the flow going to c-1) Check the minimum flow required by the motor.
the motor sufficient? c-2) Check the flow of the pump or the valve feeding
the motor.
58
IV -2 TROUBLESHOOTING TABLE FOR MOTORS (continuation)
IV-2-3 - a) Is the speed lower a-1) Check the theoretical displacement of the motor
Not enough speed than desired? versus the theoretical flow of the pump.
a-2) Check that the flow of the pump is really coming
to the motor.
a-3) Check that the working pressure & speed are not
incompatible with the catalog values of the motor.
a-4) Check the oil temperature. Check then that the
low viscosity of the oil is not having a big effect on the
internal leakage of the motor.
a-5) Check the air bleed-off.
IV-2-4 - Erratic a) Is the motor loosing a-1) Check if the limit of the allowable torque is not
speed speed erratically? reached once a while.
a-2) Check if the driven load does not transmit some
inconstant load (high pressure piston water pumps
with an unbalanced technology).
a-3) Check if the flow coming from the pump is constant.
IV-2-5 - Unusual a) Is the motor running? a-1) Check if there is no air intake aerating the motor
noise level badly (through the front shaft seal for example).
a-2) Check if the motor is not cavitating. It could be
that the inertia of the load is such that it drives the
motor faster than the flow coming from the pump.
a-3) Check if the oil is not proper for the use.
a-4) Check if the air bleed has been done properly.
b) When the motor is b-1) Check the back pressure to see if the replenish-
breaking? ment pressure is not too low, leading to cavitation of
the motor.
IV-2-6 - a) Is the oil arriving to a-1) Check if a cooler is required or if there is one if
Unusual heat the motor already hot? it is well dimensioned.
a-2) If there is a cooler, check if it is working
(example for water cooler: is the water flow opened or
sufficient).
a-3) Check if the hydraulic circuit is not bringing back
the flow directly to the inlet port. Doing so, it would
create a very small closed circuit not able to cool
down the fluid.
59
IV -2 TROUBLESHOOTING TABLE FOR MOTORS (continuation)
IV-2-6 - a) Is the oil arriving to a-4) Check the quality of the fluid.
Unusual heat the motor already hot? a-5) Check the velocity of the fluid (5 to 6
(continuation) (continuation) meters/second max.).
a-6) Check the filtration unit, its capacity.
a-7) Check if the heat does not come from an open by-
pass valve.
b) Is the oil heating up b-1) Check the speed of rotation versus the catalog values.
when going through the b-2) Check the pressure rating.
motor? b-3) Check the fluid.
b-4) Check the viscosity.
IV-2-7 - a) Is the seal leaking a-1) Check if the lips of the seal are not ruined (lack
Shaft seal leakage when pressurized? of lubricity leading to vulcanization of the rubber,
external pollution...).
a-2) Check if the shaft is not marked by a groove in
the usual seal lip contact area.
a-3) Check the shuttle valves.
a-4) Check the pressure in the drain line on the motor.
Long piping, elbows, small diameter, too high oil vis-
cosity, other common drain flows in the same pipe can
lead to high drain pressures.
a-5) Check if there is no high overshoot at start-up that
would create a high instant internal leakage.
a-6) Check, when using a "rapid connector", if it is
well locked.
a-7) Check the alignment of the shafts.
a-8) Check if there is no unbalanced driven load that
could create a gap between the shaft and the seal.
a-9) Check if the radial force is not too high (belt
drives for example).
b) Is the seal leaking a-1) Check if the seal is not damaged.

when standing still? a-2) Check if the shaft does not have any scratches.
a-3) Check if the ball bearing is not ruined.
a-4) Check if the drain line does not create a back pressure.
60
SALES & SERVICES WORLDWIDE
International Distributors Australia Germany Spain

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Other sales offices :
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INTERNET: http ://www.denisonhydraulics.com

Your local DENISON representative
DENISON Hydraulics
Printed in France IRO - La Rochelle Change without notice reserved
Axial Piston Variable Pump RA-A 92703/12.11 1/60
Replaces: 11.07
RE 92708/03.08
A10VO (US-Version) and RE 92707/11.10
Data sheet
Series 52/53
Size NG10 to 100
Nominal pressure 3600 psi (250 bar)
Peak pressure 4600 psi (315 bar) Series 52 Series 53
Open circuits
Contents Features
Type code for standard program 2 –– Variable pump in axial piston swashplate design for
hydrostatic drives in an open circuit
Technical data 5
–– The flow is proportional to the drive speed and the displace-
Permissible radial and axial forces on the drive shaft 10
ment. The flow can be steplessly varied by adjusting the
DR – Pressure control 12 swashplate angle.
DRG – Pressure control remotely operated 13 –– Stable storage for long service life
DRF (DFR) DRS (DFR1) – Pressure and flow control 14 –– High permissible drive speed
LA... – Pressure, flow and power control 15 –– Favorable power-to-weight ratio - compact dimensions
EP – Electro-proportional control 16 –– Low noise
EK – Electro-proportional control with controller cut-off 17 –– Excellent suction characteristics
ED – Electro-hydraulic pressure control 20 –– Axial and radial load capacity of drive shaft
ER – Electro-hydraulic pressure control 21 –– Pressure and flow control
Dimensions, size 10 to 100 22 –– Electro-hydraulic pressure control
Dimensions through drive 50 –– Power control
Combination pumps A10VO + A10VO 54 –– Electro-proportional swivel angle control
Connector for solenoids 55 –– Short response times
Installation instructions 56
General instructions 60
VL113
2/60 Bosch Rexroth Corp. A10VO Series 52/53 RA-A 92703/12.11
Type code for standard program

A10V(S) O / 5 – V
01 02 03 04 05 06 07 08 09 10 11 12
Axial piston unit 10 18 28 45 601) 63 85 100

Swashplate design, variable, l – – – – – – – A10VS
01
nominal pressure 3600 psi (250 bar), maximum pressure 4600 psi (315 bar) – l l l l l l l A10V
Operation mode
02 Pump, open circuit O
Size (NG)
03 Geometric displacement, see table of values on page 7 10 18 28 45 601) 63 85 100
Control device
Pressure control l l l l l l l l DR
with flow control, hydraulic
X-T open l – l l l – l3) – DFR
– l – – – l l2) l DRF
X-T plugged l – l l l – l3) – DFR1
– l – – – l l2) l DRS
Electrically overridable (negative characteristic) – m m m – l l m EF.D.4)
with pressure cut-off, remotely operated
hydraulic l l l l l l l l DRG
electrical negative characteristic U = 12 V – l l l l l l l ED71
U = 24 V – l l l l l l l ED72
04
positive characteristic U = 12 V – l l l l l l l ER715)
U = 24 V – l l l l l l l ER725)
Power control with pressure cut-off
Start of control 145 to 510 psi (10 to 35 bar) – l l l – l l l LA5D
520 to 1015 psi (36 to 70 bar) – l l l – l l l LA6D
remotely operated Start of control see LA.D – l l l – l l l LA.DG
Flow control, X-T plugged Start of control see LA.D – l l l – l l l LA.DS
Flow control, electrically overridable Start of control see LA.D
– l l l – l l l LA.S
(negative characteristic), X-T plugged
1) Series 52 units are delivered as standard with 3.66 in3 (60 cm3). Higher values on request.
2) Series 53 only with D flange
3) Series 52 only with C flange
4) See RE 92709
5) The following must be taken into account during project planning:
Excessive current levels (I > 1200 mA with 12 V or I > 600 mA with 24 V) to the ER solenoid can result in undesired increase
of pressure which can lead to pump or system damage:
- Use Imax current limiter solenoids.
- An intermediate plate pressure controller can be used to protect the pump in the event of overflow.
An accessory kit with intermediate plate pressure controller can be ordered from Bosch Rexroth under part number R902490825.
= available m = on request – = not available
RA-A 92703/12.11 A10VO Series 52/53 Bosch Rexroth Corp. 3/60

A10V(S) O / 5 – V
01 02 03 04 05 06 07 08 09 10 11 12
10 18 28 45 601) 63 85 100
Electro-proportional control (positive characteristic) with
pressure control U = 12 V – l l l – l l m EP1D
U = 24 V – l l l – l l m EP2D
Pressure and flow control, U = 12 V – l l l – l l m EP1DF
X-T open (load sensing) U = 24 V – l l l – l l m EP2DF
Pressure and flow control, U = 12 V – l l l – l l m EP1DS
X-T plugged (load sensing) U = 24 V – l l l – l l m EP2DS
Electrohydraulic pressure control U = 12 V – l l l – l l m EP1ED
04
U = 24 V – l l l – l l m EP2ED
Pressure and flow control with control- U = 12 V – l l l – l l m EK1DF
ler cut-off, X-T open (load sensing) U = 24 V – l l l – l l m EK2DF
Pressure and flow control with control- U = 12 V – l l l – l l m EK1DS
ler cut-off, X-T plugged (load sensing)
U = 24 V – l l l – l l m EK2DS
Electrohydraulic pressure control with U = 12 V – l l l – l l m EK1ED
controller cut-off U = 24 V – l l l – l l m EK2ED
Series
Series 5, index 2 l – l l l – l – 522)
05
Series 5, index 3 – l l l – l l l 533)4)
Direction of rotation
With view on drive shaft clockwise R
06
counter clockwise L
Seals
07 FKM (fluor-caoutchouc) V
Drive shaft 10 18 28 45 601) 63 85 100

Splined shaft standard shaft l l l l l l l l S
ANSI B92.1a similar to shaft „S“ however for higher input torque – l l l l l – – R
reduced diameter, not for through drive l l – l l l l l U
08
similar to shaft "U", however for higher torque – – – l l l l l W
Parallel shaft SAE with key, not for through drive l – l l l – – – K7)
Tapered with Woodruff key – – l l l – – – C7)
2) Control DR, DFR, DFR1, DRG, ED and ER: delivery with size 10, 28, 45, 60 and 856) only in series 52
3) Control DR, DRF, DRS, DRG, ED and ER: delivery with size 18, 63, 855) and 100 only in series 53
4) Control EF., LA.., EP.. and EK.. Delivery with size 18 to 100 only in series 53
5) Control DRF and DRS: delivery with size 85 only with D flange in series 53
6) Control DFR, DFR1: delivery with size 85 only with C flange in series 52
7) only series 52

A10V(S) O / 5 – V
01 02 03 04 05 06 07 08 09 10 11 12
Mounting flange 10 18 28 45 601) 63 85 100

ISO 3019-1 (SAE) 2-bolt l l l l l l l l C
4-bolt – – – – l l l2) l D
Service line port 10 18 28 45 601) 63 85 100

SAE flange port at rear, UNC fixing thread
– l l l l l l l 61
(not for through drive)
10 SAE flange port on opposite side, UNF fixing thread
– l l l l l l l 62
(for through drive)
UNF threaded ports, rear (not for through drive) l – – – – – – – 64
Through drive 10 18 28 45 601) 63 85 100

Without through drive, standard for versions 61 and 64 l l l l l l l l N00
SAE J744 flange coupling for splined shaft3 )
Diameter diameter
82-2 (A) 5/8 in 9T 16/32DP – l l l l l l l K01
3/4 in 11T 16/32DP – l l l l l l l K52
11 101-2 (B) 7/8 in 13T 16/32DP – – l l l l l l K68
1 in 15T 16/32DP – – – l l l l l K04
127-4 (C) 1 1/4 in 14T 12/24DP – – – – l l l l K15
1 1/2 in 17T 12/24DP – – – – – – l l K16
127-2 (C) 1 1/4 in 14T 12/24DP – – – – – – l l K07
1 1/2 in 17T 12/24DP – – – – – – l l K24
Connector for solenoids 10 18 28 45 601) 63 85 100

12 DEUTSCH molded connector, 2-pin – without suppressor diode – l l l l l l l P
2) Only available in series 53. For controller designation and series assignment, please refer to positions 04, 05,
including footnotes.
3) Coupling for splined shaft as per ANSI B92.1a

Technical data
Hydraulic fluid Notes on the selection of the hydraulic fluid
Prior to project design, please see our data sheets RE 90220 In order to select the correct hydraulic fluid, it is necessary to
(mineral oil) and RE 90221 (environmentally acceptable hyd- know the operating temperature in relation to the ambient tem-
raulic fluids) for detailed information regarding the choice of perature. In an open circuit this is the reservoir temperature.
hydraulic fluid and application conditions. The fluid should be selected so that within the operating
When using environmentally acceptable hydraulic fluids, temperature range, the viscosity lies within the optimum range
the limitations regarding technical data and seals must be (nopt), see shaded section of the selection diagram. We recom-
observed. Please contact us. When ordering, indicate the mend to select the higher viscosity grade in each case.
hydraulic fluid that is to be used. Example: at an ambient temperature of X °F (°C) the operating
Operating viscosity range temperature in the reservoir is 140 °F (60 °C) . In the optimum
operating viscosity range (nopt; shaded area) this corresponds
For optimum efficiency and service life we recommend that the to viscosity grades VG 46 resp. VG 68; VG 68 should be
operating viscosity (at operating temperature) be selected the selected.
range
Important
nopt = opt. operating viscosity 80 to 170 SUS The case drain temperature is influenced by pressure and input
(16 to 36 mm2/s) speed and is always higher than the reservoir temperature.
However, at no point in the component may the temperature
referred to reservoir temperature (open circuit).
exceed 239 °F (115 °C). The temperature difference specified
Limits of viscosity range on the left is to be taken into account when determining the
viscosity in the bearing.
For critical operating conditions the following values apply:
Please contact us if the above conditions cannot be met due to
nmin = 60 SUS (10 mm2/s)
extreme operating parameters.
for short periods (t ≤ 1 min)
at max. perm. case drain temperature of Filtration of the fluid
239 °F (115 °C).
The finer the filtration the better the fluid cleanliness class and
Please note that the max. case drain temperature of 115 °C is the longer the service life of the axial piston unit.
also not exceeded in certain areas (for instance bearing area).
In order to guarantee the functional reliability of the axial piston
The fluid temperature in the bearing area is approx. 7 °F (5 K)
unit it is necessary to carry out a gravimetric evaluation of the
higher than the average case drain temperature.
fluid to determine the particle contamination and the cleanli-
nmax = 7500 SUS (1600 mm2/s) ness class according to ISO 4406. A cleanliness class of at
for short periods (t ≤ 1 min) least 20/18/15 must be achieved.
on cold start
At very high hydraulic fluid temperatures (195 °F (90 °C) to ma-
(p ≤ 435 psi (30 bar), n ≤ 1000 rpm,
ximum 239 °F (115 °C)), a cleanliness class of at least 19/17/14
tmin -13 °F (-25 °C))
according to ISO 4406 is necessary.
Depending on the installation situation, special measures are
Please contact us if the above classes cannot be observed.
necessary at temperatures between -40 °F (-40°C) and -13 °F
(-25°C). Please contact us.
For detailed information on operation with low temperatures
see data sheet RE 90300-03-B.
Selection diagram
-40° -4° 32° 68° 104° 140° 176° 212° °F
-40° -20° 0° 20° 40° 60° 80° 100° °C
7400 1600 1600 7400
4600 1000
3000 600
2000 400
VG 68
1000
VG
VG 22
VG 32
VG 46
200
10
500 100
0
Viscosity n
300 60
200 40 36 170
100 20
80 16 80
60 10
SUS mm 2/s mm 2/s SUS

42 5 5 42
-40° -25° 10° 0° 10° 30° 50° 70° 90° 115° °C
-40° -13° 14° 32° 50° 86° 122° 158° 194° 240° °F
Temperature t
t min = -40°F (-40°C) Fluid temperature range t max = 240°F (115°C)
Technical data
Operating pressure range
Pressure at service line port B Definition

Nominal pressure pnom ________ 3600 psi (250 bar) absolute Nominal pressure pnom
The nominal pressure corresponds to the maximum design
Maximum pressure pmax _ ______ 4600 psi (315 bar) absolute
pressure.
Single operating period____________________________ 2.5 ms
Total operating period _____________________________ 300 h Maximum pressure pmax
The maximum pressure corresponds to the operating pressure
Minimum pressure (high-pressure side) ____145 psi (10 bar)
within the single operating period. The total of the single opera-
Rate of pressure change RA max__ 235000 psi/s (16000 bar/s) ting periods must not exceed the total operating period.
Minimum pressure (high-pressure side)
pnom Minimum pressure on the high-pressure side (B) that is requi-
Pressure p
Dt red in order to prevent damage to the axial piston unit.

Minimum pressure (inlet) open circuit
Minimum pressure at suction port S (inlet) that is required to
Dp prevent damage to the axial piston unit. The minimum pressure
depends on the speed and displacement of the axial piston
unit.
Rate of pressure change RA
Maximum permissible pressure build-up and pressure reduc-
Time t tion speed with a pressure change over the entire pressure
range.
Pressure at suction port S (inlet)
Minimum pressure pS min____________ 10 psi (0.8 bar) absolute t2
Single operating period t1 tn
Maximum pressure pS max _____________75 psi (5 bar) absolute
Pressure p
Maximum pressure pmax

Case drain pressure Nominal pressure pnom
Maximum permissible case drain pressure
(at port L, L1):
Maximum 7.5 psi (0.5 bar) higher than the inlet pressure at port
S, however not higher than 30 psi (2 bar) absolute.
pL max abs ___________________________________ 30 psi (2 bar)
Minimum pressure (high-pressure side)

Maximum permissible speed (limit speed)
Permissible speed by increasing inlet pressure pabs at suction Time t
opening S or at Vg ≤ Vg max .
Total operating period = t1 + t2 + ... + tn
1.2
Speed n/no max [rpm (min-1)]
Inlet pressure pabs [psi (bar)]
23 (1.6)
20 (1.4)
1.1
17.5 (1.2)
1.0 14.5 (1.0)
13 (0.9)
0.9 11.5 (0.8)

0.7 0.8 0.9 1.0
Displacement Vg/Vg max [%]
Notes
Technical data
Table of values (theoretical values, without efficiencies and tolerances: values rounded)
Size NG 10 18 28 45 601) 632) 85 100
Geometrical displacement Vg max in3 0.64 1.10 1.75 2.75 3.66 3.84 5.18 6.10
per revolution
(cm3) (10.5) (18) (28) (45) (60) (63) (85) (100)
Speed3)
maximum at Vg max nnom rpm 3600 3300 3000 26004) 2600 2600 2500 2300
maximum at Vg < Vg max nmax perm rpm 4320 3960 3600 3120 3140 3140 3000 2500
Flow
at nnom and Vg max qv max gpm 9.7 15.6 22 31 41 43 55 60
(l/min) (37) (59) (84) (117) (156) (163) (212) (230)
at nE = 1500 rpm qvE max gpm 4 7.1 1.1 18 24 25.1 34 39
and Vg max
(l/min) (15) (27) (42) (68) (90) (95) (128) (150)
Power at Dp = 3600 psi (250 bar)
at nnom, Vg max Pmax HP (kW) 22 (16) 34 (25) 47 (35) 65 (49) 88 (65) 90 (68) 119 (89) 130 (96)
at nE = 1500 rpm PE max HP 9.4 15 24 38 50 52 71 84
and Vg max
(kW) (7) (11) (18) (28) (37) (39) (53) (62)
Torque
at Vg max ∆p = 3600 psi Tmax lb-ft 31 52 82 132 175 184 247 293
and (250 bar)
(Nm) (42) (71) (111) (179) (238) (250) (338) (398)
∆p = 1440 psi T lb-ft 13 21 33 53 70 74 102 117
(100 bar) (Nm) (17) (29) (45) (72) (95) (100) (135) (159)
Rotary S c lb-ft/rad 6760 8082 16400 37500 48100 48100 105100 105100
stiffness, (Nm/rad) (9200) (11000) (22300) (37500) (65500) (65500) (143000) (143000)
drive c
R lb-ft/rad – 10870 19400 30240 51200 51200 – –
shaft
(Nm/rad) – (14800) (26300) (41000) (69400) (69400) – –
U c lb-ft/rad 5020 5870 – 22130 36290 36390 75900 75900
(Nm/rad) (6800) (8000) – (30000) (49200) (49200) (102900) (102900)
W c lb-ft/rad – – – 25370 39830 39830 86960 86960
(Nm/rad) – – – (34400) (54000) (54000) (117900) (117900)
K/C c lb-ft/rad 7965 – 19770 32380 54506 – – –
(Nm/rad) (10800) – (26800) (43900) (73900) – – –
Moment of inertia rotary JTW lbs-ft2 0.0142 0.2207 0.0403 0.0783 0.1329 0.1329 0.2848 0.2848
group (kgm2) (0.0006) (0.00093) (0.0017) (0.0033) (0.0056) (0.0056) (0.012) (0.012)
Angular accel., max.5) a rad/s2) 8000 6800 5500 4000 3300 3300 2700 2700
Filling capacity V gal 0.05 0.06 0.08 0.13 0.21 0.21 0.26 0.26
(L) (0.2) (0.25) (0.3) (0.5) (0.8) (0.8) (1) (1)
Weight (without through m
lbs (kg) 17 (8) 25 (11.5) 31 (14) 40 (18) 48.5 (22) 48.5 (22) 75 (34) 75 (34)
drive) approx.
1) Only series 52
2) Only series 53
3) The values are applicable:
- for absolute pressure pabs = 15 psi (1 bar) at the suction port S
- for the optimum viscosity range of nopt = 80 to 170 SUS (16 to 36 mm2/s)
- for mineral-based operating materials with a specific mass of 0.88 kg/l.
4) Please contact us regarding higher speeds
5) The scope of application lies between the minimum necessary and the maximum permissible drive speeds.
Valid for external excitation (e.g. diesel engine 2- to 8-fold rotary frequency, cardan shaft 2-fold rotary frequency). The limiting
value is only valid for a single pump. The loading capacity of the connecting parts must be taken into account.
Technical data
Note
Exceeding the maximum or falling below the minimum permissible values on page 8 can lead to a loss of function, a reduction in
operational service life or total destruction of the axial piston unit. We recommend checking the loading with tests or calculations /
simulations and comparison with the permissible values.
Determination of size
Vg • n • hV Vg = Geometric displ. per revolution in in3 (cm3)

Flow qV = [gpm (l/min)]
231 (1000) Dp = Differential pressure in psi (bar)
Vg • Dp n = Speed in rpm
Torque T = [lb-ft (Nm)]
24 (20) • p • hmh hV = Volumetric efficiency
2p • T • n qV • Dp hmh = Mechanical-hydraulic efficiency
Power P = = [HP (kW)]
33.000 (60000) 1.714 (600) • ht ht = Total efficiency (ht = hV • hmh)
Technical data
Permissible radial and axial forces on the drive shaft
Size NG 10 18 28 45 60/63 85 100

Radial force maximum
at a/2
Fax lbf 56 78 270 337 382 450 450
Fq max
(N) (250) (350) (1200) (1500) (1700) (2000) (2000)
Axial force maximum Fq
lbf 90 157 225 337 450 675 675

+ Fax max
a/2 a/2 (N) (400) (700) (1000) (1500) (2000) (3000) (3000)
a
Permissible input and through-drive torques

Size NG 10 18 28 45 60/63 85 100
Torque at Vg max and
T lb-ft (Nm) 31 (42) 52 (71) 82 (111) 132 (179) 184 (250) 293 (338) 293 (398)
Dp = 3600 psi (250 bar)1) max
Input torque for drive shaft, maximum2)
S TE max lb-ft (Nm) 93 (126) 91 (124) 198 319 630 1157 1157
DIA in 3/4 3/4 7/8 1 1 1/4 1 1/2 1 1/2
R TE max lb-ft (Nm) – 110 (150) 166 (225) 295 (400) 479 (650) – –
DIA in – 3/4 7/8 1 1 1/4 – –
U TE max lb-ft (Nm) 44 (60) 43 (59) – 139 (188) 226 (306) 463 (628) 463 (628)
DIA in 5/8 5/8 – 7/8 1 1 1/4 1 1/4
W TE max lb-ft (Nm) – – – 162 (220) 292 (396) 447 (650) 447 (650)
DIA in – – – 7/8 1 1 1/4 1 1/4
K TE max lb-ft (Nm) 78 (106) – 107 (145) 156 (212) 325 (441) – –
0.750 0.8750 1.000 1.2500
DIA in (mm) – – –
(19.05) (22.225) (25.4) (31.75)
C3) TE max lb-ft (Nm) – – 107 (145) 156 (212) 325 (441)4)
Maximum through-drive torque for drive shaft
S TD max lb-ft (Nm) – 80 (108) 118 (160) 235 (319) 357 (484) 515 (698) 515 (698)
R TD max lb-ft (Nm) – 89 (120) 130 (176) 270 (365) 357 (484) – –
1) Without considering efficiency
2) For drive shafts free of radial load
3) only series 52
4) only size 60
Distribution of torques
T1 T2
TE
1. Pumpe
Pump 1 Pump
2. Pumpe2
TD
Technical data
Drive power and flow Size 60/63
n = 1500 rpm
Operating material: n = 2600 rpm
Hydraulic fluid ISO VG 46 DIN 51519, t = 50 °C
gpm (L/min) (kW) HP
Size 10 (160) (80)
40 100
n = 1500 rpm (140) (70)
Drive power Pqv

Flow q v
35
n = 3600 rpm (120) qv (60) 80
30
gpm (L/min) (kW) HP (100) Pqv max (50)
30 25 60
10 (40)
20 (80)
Drive power P qV
(35) (20) 25
7.5 qV 15 (60) (30) 40
(15) 20
Flow qV
(25) pqV max

5 (20)
(15) (10) 15 10 (40) Pqv min 20
10 (10)
2.5 (5) pqV min (5) 5 (20)
5
0 0 0
(50) (100) (150) (200) (250) (bar)
0 (50) (100) (150) (200) (250) (bar)
0 1000 2000 3000 3625 psi
1000 2000 3000 3625 psi Operating pressure p
Operating presure p
Size 85
Size 18 n = 1500 rpm
n = 1500 rpm n = 2500 rpm
n = 3300 rpm
gpm (L/min) (kW) HP
gpm (L/min) (kW) HP 58 (220) (110) 146
140
(60) (40) 50 55 (200)
Drive power P qV
15 (100)
(50) qV (30) 40 50 qV
Flow qV
(180) (90) 120

10 (40) (20) 45
pqV max 20 (160) (80)
(30) pqV min (10) 40 100
Drive power P qV
(140) (70)
Flow qV
5 (20) (0) 0 35
0 (50) (100) (150) (200) (250) (bar) (120) (60) 80
30
1000 2000 3000 3625 psi (100) (50)
25 pqV max
Operating presure p 60
(80) (40)
20
Size 28 (60) (30)
15 40
n = 1500 rpm (40) (20)
10 pqV 0
n = 3000 rpm 20
5 (20) (10)
gpm (L/min) (kW) HP
23.8 (90) 60 0 0
(40) (50) (100) (150) (200) (250) (bar)
20 (80)
qv
Flow qv
0
Drive power Pqv
(30) 40 1000 2000 3000 3625 psi

15 (60) Pqv max
Operating pressure
10 (40) (20)
20 Size 100
5 (20) Pqv min (10)
n = 1500 rpm
0 0 n = 2300 rpm
(50) (100) (150) (200) (250) (bar)
0 1000 2000 3000 3625 psi gpm (L/min)
Operating pressure p (kW) HP
60 (230)
(110) 146
Size 45 58 (220)
140
55 (200) qV (100)
n = 1500 rpm
50 (180) (90) 120
n = 2600 rpm 45
(160) (80)
gpm (L/min) (kW) HP 40 100
Drive power P qV
(120) (60) 80 (140) (70)

Flow qV
30 35
(100) qv (50) (120) (60) 80
25 30
Drive power Pqv
Flow q v
60 pqV max
(40) (100) (50)
20 (80) Pqv max 25
60
15 (60) (30) 40 20
(80) (40)
10 (40) (20) 15 (60) (30) 40

Pqv min 20 pqV 0
5 (20) (10) 10 (40) (20)
0 20
0 5 (20) (10)
(50) (100) (150) (200) (250)(bar)
0 0
0 1000 2000 3000 3625 psi (50) (100) (150) (200) (250) (bar)
Operating pressure p
0 1000 2000 3000 3625 psi
Operating pressure
DR – Pressure control
The pressure control limits the maximum pressure at the pump Circuit diagram
output within the pump control range. The variable pump only
supplies as much hydraulic fluid as is required by the consu-
mers. If the operating pressure exceeds the target pressure set
at the pressure valve, the pump will regulate towards a smaller
displacement. The pressure can be set steplessly at the control
valve. L L1 B
Static characteristic
(at n1 = 1500 rpm; tfluid = 120 °F (50 °C))
Hysteresis / pressure rise ∆pmax

psi (bar)
3600 (250)
Operating pressure pB
Setting range1)
290 (20) L2 S
Flow qv [gal (l/min)]

Port for
B Service line
1) In order to prevent damage to the pump and the system, this S Suction line
setting range is the permissible setting range and it is not L, L1,2 Case drain fluid (L1,2 plugged)
allowed to exceeded.
The range of possible settings at the valve are greater.
Controller data
Hysteresis and repeatability ∆p_______ maximum 45 psi (3 bar)
Pressure rise, maximum
NG 10 18 28 45 60/63 85 100
∆p psi 90 90 90 90 115 175 200
(bar) (6) (6) (6) (6) (8) (12) (14)
Control fluid consumption______ max. approx. 0.8 gpm (3 l/min)
Flow losses at qVmax see page 11.
DRG – Pressure control remotely operated

The DRG control valve overrides the function of the DR pres- Circuit diagram
sure controller (see page 12).
Not included in the delivery contents
A pressure relief valve can be externally piped to port X for
remote setting of pressure below the setting of the DR control
valve spool. This relief valve is not included in the delivery
contents of the pump. X
The differential pressure at the control valve is set as stan-
dard to 290 psi (20 bar). The control fluid volume at port X is
approx. 0.4 gpm (1.5 l/min). If another setting is required (range
from 145 to 320 psi (10 to 22 bar)) please state this in clear
text.
As a separate pressure relief valve we can recommend:
DBDH 6 (hydraulic) to RE 25402 or L L1 B
DBETR-SO 381 with orifice dia. 0.03 in (0.8 mm) in P
(electric) to RE 29166.
The max. length of piping should not exceed 6.6 ft (2 m).
(at n1 = 1500 rpm; tfluid = 120 °F (50 °C))
psi (bar)
3600 (250) S
L2
Setting range1)
Port for
B Service line
S Suction line
L, L1,2 Case drain fluid (L1,2 plugged)
290 (20) X Pilot pressure
Flow qv [gpm (l/min)]
Controller data
Hysteresis and repeatability ∆p_______ maximum 45 psi (3 bar)
Pressure rise, maximum
1) In order to prevent damage to the pump and the system, this
setting range is the permissible setting range and it is not NG 10 18 28 45 60/63 85 100
allowed to be exceeded. ∆p psi 90 90 90 90 115 175 200
The range of possible settings at the valve is higher. (bar) (6) (6) (6) (6) (8) (12) (14)
Control fluid consumption_____max. approx. 1.2 gpm (4.5 l/min)
Flow losses at qVmax see page 11.
DRF (DFR) DRS (DFR1) – Pressure and flow control

In addition to the pressure control function (see page 12), a variable Circuit diagram
orifice (e.g. directional valve) is used to adjust the differential pres-
sure upstream and downstream of the orifice. This is used to control Plugged in DRS (DFR1) valve
Not included in the delivery contents

the pump flow. The pump flow is equal to the actual required flow
by the consumer, regardless of changing pressure levels.
X
The pressure control overrides the flow control function.
Note
The DRS (DFR1) valve version has no connection between X
and the reservoir. Unloading the LS-pilot line must be possible
in the valve system.
Because of the flushing function sufficient unloading of the L L1
X-line must also be provided. B
Flow control at n1 = 1500 rpm; tfluid = 120 °F (50 °C))
psi (bar)
3625 (250)
Setting range1)
L2 S
290 (20)
Port for
B Service line
Flow qv [gpm (l/min)]
S Suction line
1) In order to prevent damage to the pump and the system, this L, L1,2 Case drain fluid (L1,2 plugged)
setting range is the permissible setting range and it is not X Pilot pressure
allowed to be exceeded.
The range of possible settings at the valve is higher.
Differential pressure ∆p
Static characteristic at variable speed Standard setting: 200 to 320 psi (14 to 22 bar).
If another setting is required, please state in clear text.
Relieving the load on port X to the reservoir results in a zero

stroke ("standby") pressure which lies about 15 to 30 psi (1 to
2 bar) higher than the differential pressure ∆p). No account is
taken of system influences.
Flow qv [l/min]
Controller data
Data pressure control DR, see page 12.
Maximum flow deviation measured with drive speed
n = 1500 rpm.
Speed n [rpm]
NG 10 18 28 45 60/ 85 100
63
Possible connections at port B
(not included in the delivery, order separately) gpm 0.13 0.24 0.26 0.48 0.66 0.83 0.83
∆qv max
LS mobile control blocks (l/min) (0.5) (0.9) (1.0) (1.8) (2.5) (3.1) (3.1)
Mobile control blocks M4 - 12 (RE 64276)
Mobile control blocks M4 - 15 (RE 64283) Control fluid consumption
DRF (DFR)___ maximum approx. 0.8 to 1.2 gpm (3 to 4.5 l/min)
LUDV mobile control blocks DRS (DFR1) ____________ maximum approx. 0.8 gpm (3 l/min)
Mobile control blocks M6 - 15 (RE 64284) Volume flow loss at qVmax, see page 11.
Mobile control blocks M7 - 22 (RE 64295)
LA... – Pressure, flow and power control

Pressure control equipped as DR(G), see page 12 (13). When ordering please state the power characteristics to be set
Flow control equipped as DRF, DRS, see page 14. ex works in clear text, e.g. 27 HP (20 kW) at 1500 rpm.
In order to achieve a constant drive torque with varying opera- Controller data
ting pressures, the swivel angle and with it the output flow from
For pressure controller DR data, see page 12.
the axial piston pump is varied so that the product of flow and
For flow control FR data, see page 13.
pressure remains constant.
Controller data
Flow control is possible below the power control curve.
Maximum control fluid consumption, see page 14
Volume flow loss at qVmax, see page11.
Start of Torque T [lb-ft (Nm)] for size Order code

control
[psi ((bar)] 18 28 45 63 85 100
145 to 510 2.80 - 8.92 4.4 - 14 7.4 - 22.1 11 - 32 15 - 42 18 - 49.5 LA5
(10 to 35) (3.8 - 12.1) (6 - 19) (10 - 30) (15 - 43) (20 - 57) (24 - 68)
520 to 1015 8.92 - 17.2 14 - 26.5 22.2 - 43.5 32 - 61 42 - 83 49.5 - 97.1 LA6
(36 to 70) (12.2 - 23.3) (19.1 - 36) (30.1 - 59) (43.1 - 83) (57.1 - 112) (68.1 - 132)
1030 to 1520 17.2 - 24.9 26.6 - 38.4 43.6 - 62 61 - 88 83 - 118) 97.1 - 139.4 LA7
(71 to 105) (23.4 - 33.7) (36.1 - 52) (59.1 - 84) (83.1 - 119) (112.1 - 160) (132.1 - 189)
1535 to 2030 24.9 - 33.2 38.4 - 51.6 62 - 83 88 - 116 118 - 156 139.4 - 183.6 LA8
(106 to 140) (33.8 - 45) (52.1 - 70) (84.1 - 112) (119.1 - 157) (160.1 - 212) (189.1 - 249)
2045 to 3335 33.2 - 55.2 51.7 - 86.3 83 - 139 116 - 195 156 - 263 183.3 - 309 LA9
(141 to 230) (45.1 - 74.8) (70.1 - 117) (112.1 - 189) (157.1 - 264) (212.1 - 357) (249.1 - 419)
Conversion of the torque values in power [kW]:
T 2p • T • n
P= [HP (kW)] ( at 1500 rpm) or P= [HP (kW)] (for speeds, see table on page 8)
3.5 (6.4) 33.000 (60000)
Static curves and torque characteristic Circuit diagram (LAXD) with pressure cut-off
psi (bar)
4350 (300)
3620 (250)
2900 (200) LA9 Circuit diagram (LAXDG) with pressure cut-off, remotely operated
2175 (150) LA8

X
1450 (100) LA7 X
725 (50) LA6 Not included

0 (0) LA5
in the delivery
0 100 contents
∆qV (see table

on page 14)
LA9 Circuit diagram (LAXDS) with pressure and flow control
Torque T [lb-ft (Nm)]
LA8 X X Not included

in the delivery
LA7 contents
LA6
L L1 B
LA5
0 100
Volume flow qv [%]
L2 S
EP – Electro-proportional control
Electro-proportional control makes a stepless and reproducib- Technical data, solenoid EP1 EP2
le setting of the pump displacement possible directly via the
swashplate. The control force of the control piston is applied Voltage 12 V (±20 %) 24 V (±20 %)
by a proportional solenoid. The control is proportional to the Control current
current (for start of control, see table right). Start of control at Vg min 400 mA 200 mA
In a depressurized state, the pump is swiveled to its initial po- End of control at Vg max 1200 mA 600 mA
sition (Vg max) by an adjusting spring. If the operating pressure Limiting current 1.54 A 0.77 A
exceeds 200 psi (14 bar), the pump will swivel from Vg max to
Nominal resistance (at 68 °F
Vg min without control by the solenoid (control current < start of 5.5 Ω 22.7 Ω
(20 °C))
control). A PWM signal is used to control the solenoid.
Dither frequency 100 to 100 to
EP.D: The pressure control regulates the pump displacement 200 Hz 200 Hz
back to Vg min after the set target pressure has been reached. Actuated time 100 % 100 %
A minimum operating pressure of 200 psi (14 bar) is needed For protection rating, please refer to "Socket version"
for control. The necessary control fluid is taken from the high on page 55
pressure.
Operating temperature range at valve -4 °F to 239 °F
Circuit diagram EP.D (-20 °C to +115 °C)
Characteristic EP1/2
Hysteresis < 5 %
L1 L B
1400
1200
1000
Control current I [mA]
EP1
800
L2 S
600
EP2
400
Port for
200
B Service line
S Suction line
0 0,5 1,0
Displacement [%]
X Control pressure Vg min Vg max
Note
The spring return at the controller is not a safety device
Dirt contamination (contaminated hydraulic fluid, wear or resi-
dual dirt from system components) could cause the controller
to stick in an undefined position. The volume flow of the axial
piston unit will then no longer follow the commands of the
operator.
Check whether remedial measures for your application are
needed on your machine in order to put the driven consumer
in a safe state (e.g. immediate stop).
EK – Electro-proportional control with controller cut-off

The variant EK... is based completely on the variant EP... Technical data, solenoid EK1 EK2
(see page 16).
Voltage 12 V (±20 %) 24 V (±20 %)
In addition to the electro-proportional control function, a cont-
Control current
roller cut-off is integrated in the electric characteristic.
The pump then swivels to Vg max if the control signal is lost (e.g. Start of control at Vg min 400 mA 200 mA
cable break) and then works with the DRF settings (see page End of control at Vg max 1200 mA 600 mA
14). The controller cut-off is only intended for short-term use Limiting current 1.54 A 0.77 A
and not for permanent use if the control signal is lost. If the
control signal is lost, the pump swivel times will be reduced by 5.5 Ω 22.7 Ω
(20 °C))
the EK valve.
A PWM signal is used to control the solenoid. Dither frequency 100 to 100 to
200 Hz 200 Hz
A minimum operating pressure of 200 psi (14 bar) is needed Actuated time 100 % 100 %
for control. The necessary control fluid is taken from the high
For protection rating, please refer to "Socket version"
pressure.
on page 55
The Vg max position is maintained by the force of the adjusting
spring. To overcome the force of this spring, the solenoid must
(-20 °C to +115 °C)
be subjected to excessive current (Ires).
Observe the instructions regarding the project design on
page 2 Characteristic EK
Hysteresis < 5 %
Circuit diagram EK.DF
1400
X 1200 Ires
Control current I [mA]
1000
EK1
L1 L B 800
600 Ires
EK2
Imin
400
Ioff
Imin
200
L2 S
Ioff
0 0,5 1,0
Port for Displacement [%]
Vg min Vg max
B Service line
S Suction line
EK1. EK2.
X Control pressure
Imin [mA] 400 200
Imax [mA] 1200 600
Note
Ioff [mA] < 300 < 150
The spring return at the controller is not a safety device
Ires [mA] > 1200 > 600
Dirt contamination (contaminated hydraulic fluid, wear or resi-
dual dirt from system components) could cause the controller For changes in current, ramp times of > 200 ms must be
to stick in an undefined position. The volume flow of the axial observed.
piston unit will then no longer follow the commands of the
operator.
Check whether remedial measures for your application are
needed on your machine in order to put the driven consumer
in a safe state (e.g. immediate stop).
EP(K).DF / EP(K).DS – EP(K) with pressure and flow control

A hydraulic pressure flow control is superimposed on the
electro-proportional control.
Circuit diagram EP.DF
The pressure control regulates the pump displacement back to
Vg min after the set target pressure has been reached. X Not included
This function is super-imposed on the EP or EK control, i.e. in the delivery
the control-current dependent function is executed below the contents
target pressure.
Setting range from 290 to 3600 psi (20 to 250 bar). For the
pressure flow control, see page 14. L1 L B
Pressure control has priority over electro-proportional control
and flow control.
With flow control, the pump flow can be influenced in addition
to pressure control. The pump flow is thus equal to the actual
amount of hydraulic fluid required by the consumer. This is
achieved using the differential pressure at the consumer
(e.g. orifice).
The EP.DS or EK.DS version has no connection between X L2 S
and the reservoir (load sensing). Please refer to the notes on
page 14.
Port for
Circuit diagram EP.D B Service line
S Suction line
X Control pressure
L1 L B
Circuit diagram EP.DS
X Not included
in the delivery
contents
L2 S
L1 L B
Port for
B Service line
S Suction line
L2 S
Port for
B Service line
S Suction line
X Control pressure
EP(K).ED – EP(K) with electro-hydraulic pressure control

The ED valve is set to a certain pressure by a specified variable Circuit diagram EP.ED
solenoid current.
X
When a change is made at the consumer (load pressure), the
position of the control piston will shift.
This causes an increase or decrease in the pump swivel angle
(flow) in order to maintain the electrically set pressure level.
The pump thus only delivers as much hydraulic fluid as the
consumers can take. The pressure can be set steplessly by the
L1 L B
solenoid current.
As the solenoid current signal drops towards zero, the pres-
sure will be limited to pmax by an adjustable hydraulic pressure
cut-off (negative characteristic, e.g. for fan drives ). A PWM
signal is used to control the solenoid.
For further information and technical data of the solenoids for
ED(ER) control please refer to pages 20 and 21.
Static current-pressure characteristic ED
(negative characteristic) L2 S
(measured with pump in zero stroke)
Port for
psi (bar)
3600 (250) B Service line
S Suction line
Max. adjustable
Operating pressure P
control pressure X Control pressure

2000 (140)
Circuit diagram EK.ED

Min. adjustable control pressure X
0 (0)
0 Amperage 1
I/ I max
Hysteresis static current-pressure characteristic
< 45 psi (3 bar).
Static flow-pressure characteristic
L1 L B
(at n= 1500 rpm; tfluid = 120 °F (50 °C))
psi (bar)
3600 (250)
Setting range
L2 S
290 (20) Port for

B Service line
Flow qv [gpm (l/min)] S Suction line
Controller data L, L1,2 Case drain fluid (L1,2 plugged)
Standby standard setting: 290 psi (20 bar). Other values on X Control pressure
request. Hysteresis / pressure rise ∆p 60 psi (4 bar)
ED – Electro-hydraulic pressure control

The ED valve is set to a certain pressure by a specified variable Circuit diagram ED..
solenoid current.
consumers can take. The desired pressure level can be set L B
steplessly by varying the solenoid current.
As the solenoid current signal drops towards zero, the pres-
sure will be limited to pmax by an adjustable hydraulic pressure
cut-off (secure fail safe function in case of a loss of power, e.g.
for fan drives ).
The response time characteristic of the ED-control was opti-
mized for the use as a fan drive system.
When ordering, state the type of application in clear text.
L1 S
Static current-pressure characteristic ED

(measured at pump in zero stroke – negative characteristic)
psi (bar)
Port for
3600 (250)
B Service line
S Suction line
Max. adjustable
control pressure L, L1 Case drain (L1 plugged)
2000 (140)
Technical data, solenoid ED71 ED72

Voltage 12 V (±20 %) 24 V (±20 %)
Min. adjustable control pressure Control current
0 (0)
0 Amperage 1 Control begin at qv min 100 mA 50 mA
I/ I max
End of control at qv max 1200 mA 600 mA
Hysteresis static current-press. characteristic < 45 psi (3 bar) Limiting current 1.54 A 0.77 A
5.5 Ω 22.7 Ω
(20 °C))
Static flow-pressure characteristic Dither frequency 100 to 100 to
(at n= 1500 rpm; tfluid = 120 °F (50 °C)) 200 Hz 200 Hz
Actuated time 100 % 100 %
Hysteresis / pressure rise ∆p
psi (bar) max

3600 (250)
For protection rating, please refer to "Socket version"
on page 55
Setting range

(-20 °C to +115 °C)
2000 (140)
min
Flow qv [l/min]
min max
Controller data
Standby standard setting 290 psi (20 bar), other values on
request.
Hysteresis and pressure rise_ ___________ ∆p < 60 psi (4 bar).
Control flow consumption______ 0.8 to 1.2 gpm (3 to 4.5 l/min).
ER – Electro-hydraulic pressure control

The ER valve is set to a certain pressure by a specified variable Circuit diagram ER..
solenoid current.
consumers can take. The desired pressure level can be set
steplessly by varying the solenoid current.
L B
As the solenoid current signal drops towards zero, the pressu-
re will be limited to pmin (stand by).
Observe the project planning notes on page 2.
Static current-pressure characteristic ER

(measured with pump in zero stroke – positive characteristic)
psi (bar)
5100 (350)
L1 S
3600 (250)
Max. adjustable
2200 (150) control pressure
Min. Port for
adjustable Service line
B
725 (50) control
pressure S Suction line
0 (0)
0 1 L, L1 Case drain (L1 plugged)
Amperage I/Imax
Hysteresis static current-pressure characteristic < 45 psi

(3 bar)
Influence of pressure setting on stand by ± 30 psi (2 bar) Technical data, solenoid ED71 ED72
Static flow-pressure characteristic Voltage 12 V (±20 %) 24 V (±20 %)
(at n= 1500 rpm; tfluid = 120 °F (50°C)) Control current
Control begin at qv min 100 mA 50 mA
Hysteresis / pressure rise ∆p
psi (bar) max End of control at qv max 1200 mA 600 mA

3600 (250)
Limiting current 1.54 A 0.77 A

Setting range
5.5 Ω 22.7 Ω
(20 °C))
Dither frequency 100 to 100 to
200 Hz 200 Hz
2000 (140) For protection rating, please refer to "Socket version"
min on page 55
Flow qv [l/min] Operating temperature range at valve -4 °F to 239 °F
min max (-20 °C to +115 °C)
Controller data
Standby standard setting 200 psi (14 bar), other values on
request.
Hysteresis and pressure rise_ ___________ ∆p < 60 psi (4 bar).
Control flow consumption______ 0.8 to 1.2 gpm (3 to 4.5 l/min).
Dimensions, size 10 Before finalizing your design request a certified

installation drawing.
Dimensions in inches and (mm).
DR – Hydraulic pressure controller
Centering flange SAE version; series 52
max. 4.33 (110)

2.87 (73)
)6
(5
0.43 (11)
L
20
0.25 (6.4)
2.
Flange
ISO 3019-1
45°
DIA 0.43
0. )
35
(9
)
2.11 (53.5) (ø 11)

(ø 82.55 -0.054
DIA 3.250
3.248
45°
0
2.20 (56)
L1
0.94 (24) 4.19 (106.4)
5.83 (148) 5.28 (134)
7.09 (180)
View Y clockwise rotation View Y counter-clockwise rotation
S B B S
1.13 1.13 1.13 1.13
(28.6)(28.6) (28.6)(28.6)
2.00 (51) 2.00 (51) 2.00 (51) 2.00 (51)
DRG DFR / DFR1

Pressure and flow control, remote controlled Pressure and flow control
max. 4.33 (110) max. 4.33 (110)

5.75 (146) 1.57 5.75 (146) 1.57
(40) X (40) X
X X
L L
4.02 (102)
4.02 (102)
3.74 (95)
3.74 (95)
L1 L1
7.05 (179) 7.05 (179)
For details of connection options and drive shafts, please refer to page 23

Drive shaft
S Splined shaft 3/4 in U Splined shaft 5/8 in K Parallel shaft key
11T 16/32DP1) (SAE J744) 9T 16/32DP1) (SAE J744)
1.18 (30)
1/4-20UNC-2B2) 3)
0.188 (4.76 +0.025 )

0.94 (23.8) 0.187
0.35 (14) 0.01(2.5) 1.13
0.19 (5)
+0.05
(28.6)
(ø19.05-0.02)
0.827 21.1 -0.1

0.750
0.749
0.833
DIA
Centering4)
0.87 R12 x 0.26 0.62 Centering4)
(21) DIN 332 (15.8) R 0.12x0.26 1.30 (33)
DIN 332 0.31 (8)
1.50 (38) 1.61(41)
1.25 (31.8)
Ports
Designation Port for Standard Size3) Maximum pressure State
[psi (bar)]5)
B Service line ISO 11926 1 1/16-12UNF-2B; 0.79 (20) deep 4600 (315) O
S Suction line ISO 11926 1 1/16-12UNF-2B; 0.79 (20) deep 75 (5) O
L Case drain fluid ISO 119266) 9/16-18UNF-2B; 0.47 (12) deep 30 (2) O7)
L1 Case drain fluid ISO 119266) 9/16-18UNF-2B; 0.47 (12) deep 30 (2) X7)
X Pilot pressure ISO 119265) 7/16-20UNF-2B; 0.45 (11.5) deep 4600 (315) O
1) ANSI B92.1a, 30° pressure angle, flat root, side fit, tolerance class 5
2) Thread according to ASME B1.1
3) For the maximum tightening torques the general instructions on page 60 must be observed.
4) Coupling axially secured, e.g. with a clamp coupling or radially mounted clamping screw
5) Depending on the application, momentary pressure spikes can occur. Consider this when selecting measuring equipment and
fittings.
6) The spot face can be deeper than as specified in the standard.
7) Depending on the installation position, L or L1 must be connected (please refer to pages 56 and 57)
O = Must be connected (plugged on delivery)
X = Plugged (in normal operation)
Dimensions, size 181) Before finalizing your design request a certified

Clockwise rotation, series 53
Port plate 61
3.27 (83)
0.31 (7.8) 0.39 (10)
0.96 (24.5)
L1
Flange L1
4.80 (122)
ISO 3019-1
L
0.
09
2.83 (72)
(2
.5
L 45°
)
(Ø82.55 - 00.054 )
DIA 3.250
3.248
5)
5)
1.
1.
(6
X
(6
42
42
2.
0.43 (11)
2.
2.48 (63)
45°
L2
3.27 (83) 4.19 (106.4)
6.14 (156) 5.35 (136)
max. 7.20 (183)
View X
DIA 0.79
(Ø20)
2.31 (58.7)
1.87 (47.6)
DIA 1.26
(Ø32)
S B
1.19 (30.2) 0.87 (22.2)

1.26 1.30
Port plate 62 Detail Z
(32) (33)
3.27 (83)
1.87 (47.6)
DIA 0.79
0.31 (7.8) 0.39 (10)

(Ø20)
0.96 (24.5) View Y
Flange L1
ISO 3019-1 B 0.87
(22.2)
L
(Ø82.55 - 00.054 )
DIA 3.250
3.248
2.31 (58.7)
DIA 1.26
(Ø32)
Y Z
S
1.19 2.22 (56.5) 2.22 (56.5)
5.63 (143) (30.2)
6.70 (170)
1)Dimensions of service line ports turned through 180° for counter-clockwise rotation

Drive shaft
S Splined shaft 3/4 in R Splined shaft 3/4 in U Splined shaft 5/8 in
11T 16/32DP1) (SAE J744) 11T 16/32DP1)2) (SAE J744) 9T 16/32DP1) (SAE J744)
1.18 (30)
1/4-20UNC-2B3) 4)
1/4-20UNC-2B3) 4)
0.55 (14) 0.94 (23.8)
0.35 (14)
0.20 (5) 0.20 (5)
Usable Centering5)
0.87 shaft length 0.83 (21) R 0.12 x 0.26 0.62
(21) DIN 332 (15.8)
1.50 1.50 (38)
(38) 1.25 (31.8)
Ports
Designation Port for Standard Size4) Maximum pres- State
sure [psi (bar)]6)
B Service line, SAE J518 3/4 in 4600 (315) O
fixing thread ASME B1.1 3/8-16UNC-2B; 0.75 (19) deep
S Suction line, SAE J518 1 1/4 in 75 (5) O
L1, L2 Case drain fluid ISO 119267) 3/4-16UNF-2B; 0.47 (12) deep 30 (2) X8)
X Pilot pressure ISO 119267) 7/16-20UNF-2A; 0.45 (11.5) deep 4600 (315) O
2) Splines according to ANSI B92.1a, run out of spline is a deviation from standard
4) For the maximum tightening torques the general instructions on page 60 must be observed
5) Coupling axially secured, e.g. with a clamp coupling or radially mounted clamping screw
6) Depending on the application, momentary pressure spikes can occur. Keep this in mind when selecting measuring equipment
and fittings
7) The spot face can be deeper than as specified in the standard
8) Depending on the installation position, L, L1 or L2 must be connected (please refer to installation instructions on pages 56, 57)

DRG EP.D. / EK.D.
Pressure controller, remote controlled, series 53 Electro-proportional control, series 53
max. 7.20 (183)

4.45 (113) 2.44 (62) 8.60 (218.5)
4.45 (113) 2.44 (62)
X L1
L1 X
4.80 (122) X
4.17 (106)
4.17 (106)
L
4.80 (122)
L
S
S L2 L2
DRF/DRS EP.ED / EK.ED

Pressure and flow control, series 53 Electro-proportional control, series 53
max. 7.20 (183)

4.45 (113) 2.44 (62)
8.66 (220)
X L1
L1 X
4.33 (110)
4.80 (122)
4.17 (106)
L L
4.80 (122)
L2
S L2
LA.D. ED7. / ER7.

Pressure, flow and power control, series 53 Electro-hydraulic pressure control, series 53
8.86 (225) 8.42 (214)

4.45 (113) X 2.44 (62)
L1 L1
1)
4.80 (122)
4.80 (122)
4.45 (113)
4.17 (106)
L L
L2
S L2
S
1) ER7.: 6.18 inches (157 mm) if using an intermediate plate pressure controller.
Dimensions, size 281)2)

Before finalizing your design request a certified

Port plate 61/64

3.54 (90)
0.37 (9.5) 0.47 (12)
45°
0.25 (6.3)
4.86 (123.5)
Flange
ISO 3019-1 L
0.56 (14.3)
L
(ø101.6 -0.054 )
4.000
3.998
9)
X
0
(6
72
DIA
2.
2.60 (66)
2.87 (73)
L1
0.31 (7.9) 1.06 (27) 6.79 (170) 5.75 (146)
6.77 (172)
max. 8.25 (209.5)
View X View X
Port plate 64 Port plate 61
DIA 0.79 (ø20)

1.87 (47.6)
DIA 1.26 (ø32)
2.31 (58.7)
S B S B
1.30 1.30 1.19 (30.2) 0.87 (22.2)

(33) (33) 1.30 1.30
Port plate 62 (33) (33)
Detail Z
max. 8.25 (209.5)
DIA 0.79 (ø20)
1.87 (47.6)
3.54 (90) View Y

0.47 (12)
0.37 (9.5)
0.25 6.3)
Flange B
ISO 3019-1 0.87 (22.2)
L
(ø101.6 -0.054 )
DIA 4.000
3.998
2.31 (58.7)
DIA 1.26
Y Z
(ø32)
0
S B
S
1.19
1.06 (27) L1 (30.2) 2.60 (66) 2.60 (66)
6.30 (160)
1) Dimensions of service line ports turned through 180° for counter-clockwise rotation (please refer to page 28)
2) Primary dimensions for pump apply for series 52 and 53

Drive shaft
S Splined shaft 7/8 in R Splined shaft 7/8 in K5) Parallel keyed shaft
13T 16/32DP1) (SAE J744) 13T 16/32DP1)2) (SAE J744)
(25 -0.2) (ø22.225 - 0.02 )

0.10 1.31 (33.3)
DIA 0.8750
0.8742
1.30 (33.1)
1/4-20UNC-2B3) 4)
(2.5) 1.13 (28.6)
1/4-20UNC-2B3) 4)
0.63 (16) 0.259 (6.35+0.25 )
0.63 (16) 0.250
1/4-20UNC-2B3)4)
0.20(5) 0.20(5)
DIA 0.98
0.9843
0.9764
(ø25)
Usable
0.99 shaft length 0.99 (25) 0.63 (16)
(25.1)
1.61 (41) 1.62 (41.3)
1.61 (41)
C5) Tapered with woodruff key

(ISO 3019-1)
0.75
DIA 0.749
(19)
(19.024)
0.118 0.87 Section A-B

5/8-18UNF-2A3)
0.110 (22)
(3-0,2) 0.251(6.35+0.025)
0.250
A
— 0.006 ) DIA 0.863
0.251(6.35+0.025)
(21.91)
0.130(3.2+0.1)
B
0.250
0.126
0.16 (4)
(21.774 +0.006
0.57
DIA 0.8575
0.8570
(14.4)
2.19 (55.6)
Taper
125:1000
Ports
sure [psi (bar)]6)
B; Port plate 61/62 Service line, SAE J518 3/4 in 4600 (315) O
fixing thread ASME B1.1 3/8-16UNC-2B; 075 (19) deep
B; Port plate 64 threaded ISO 119267) 1 1/16-12UNF-2B; 079 (20) deep 4600 (315) O
S; Port plate 61/62 Suction line, SAE J518 1 1/4 in 75 (5) O
S; Port plate 64 threaded ISO 119267) 1 5/8-12UN-2B; 0.79 (20) deep 75 (5) O
L1, L28) Case drain fluid ISO 119267) 3/4-16UNF-2B; 0.47 (12) deep 30 (2) X9)
X Control pressure ISO 119267) 7/16-20UNF-2B; 0.45 (11.5) deep 4600 (315) O
2) Splines according to ANSI B92.1a, run out of spline is a deviation from standard.
5) Only series 52
6) Depending on the appl., momentary press. spikes can occur. Consider this when selecting measuring equipment and fittings.
8) Only series 53
Dimensions, size 28
DRG EP.D. / EK.D.

max. 8.25 (209.5) 8.82 (224)

5.49 (139.5) 5.51 (140) 2.48 (63)
2.48 (63)
L1
X
X
5.12 (130)
4.86 (123.5)
4.49 (114)
4.21 (107)
X L L
L
S S
L2
L1
DFR / DFR1 EP.ED / EK.ED

max. 8.25 (209.5)

5.49 (139.5) 9.45 (240)
2.48 (63)
L1
X
4.86 (123.5)
5.12 (130)
4.60 (117)
4.21 (107)
X L L
L
L2
S
L1
LA.D. ED7. / ER7.

9.09 (231)
5.51 (140) 2.48 (63)
9.45 (240)
X
L1
5.12 (130)
X
5.12 (130)1)
4.49 (114)
L L
S
S
L2
L1
1)ER7.: 6.26 inches (159 mm) if using an intermediate plate pressure controller.

Port plate 61
3.90 (99)
0.37 (9.5) 0.47 (12)
0.25 (6.3) 1.18 (30) 45°
L1
5.18 (131.5)
Flange
ISO 3019-1
0.56 (14.3)
L
3.03 (77)
(Ø101.6 -0.054 )
DIA 4.000
3.998
8)
X
(7
0
07
2.70 (68.5)
3.
7.44 (189)
max. 8.68 (220.5) 5.75 (146)
6.77 (172)
Port plate 62
max. 8.68 (220.5)
5.93 (150.5)
3.90 (99)
0.37 (9.5) 0.47 (12) View X
0.25 (6.3) 1.18 (30)
Flange L1
ISO 3019-1
DIA 1.50 (ø38)
S
.9 )
DIA 0.98
DIA 1.50 (69
(ø25)
(Ø101.6 -0.054 )
5
2.7
DIA 4.000
3.998
Y
69.9
0
ø38
(52 06
.4)
2.
S
1.4 1.0 B
1.41 (35.7) (26 3 30
7.01 (178) (35 1 .2) °
.7) 30°
8.31 (211) 1.50 1.50
(38) (38)
View Y
B
2.06 (52.4)
DIA 0.98 (Ø25)
1.03
(26.2) Z
S B
S B
1.50 1.50 3.54 (90) 3.54 (90)
(38) (38)
Dimensions of service line ports
turned through 180° for counter-clock-
wise rotation
1)Primary dimensions for pump apply for series 52 and 53
For details of connection options and drive shafts, please refer to page 31, 32

Drive shaft
S Splined shaft 1 in R Splined shaft 1 in U Splined shaft 7/8 in
1.49 (38) 1.30 (33.1)
1/4-20UNC-2B3) 4)
1/4-20UNC-2B3) 4)
1/4-20UNC-2B3) 4)
0.63 (16)
0.63 (16) 0.63 (16)
0.20 (5)
0.20 (5) 0.20 (5)
Usable 1.16
1.18 shaft length (29.5) 0.99
(30) (25.1)
1.81 (45.9)
1.81
(45.9) 1.61 (41)
W Splined shaft 7/8 in K5) Parallel keyed shaft

13T 16/32DP1)2) (SAE J744)
0.09 1.50 (38.1)
0.9988
DIA 1.0000
(28.2 -0.2) (ø25.4 - 0.03 )
1/4-20UNC-2B3) 4)
0.63 (16) (2.2) 1.37 (34.9) 0.259 (6.35+0.25 )

0.250
1/4-20UNC-2B3)4)
0.20 (5)
DIA 0.98
1.1024
1.1102
Usable (ø25)
shaft length 0.98 (25) 0.63 (16)
1.61 (41) 1.81 (46)

(ISO 3019-1)
DIA 1in 0.84(21.41)

(3.2) (28.6)
0.16 (4) 0.251(6.35+0.025)
0.250
A
3/4-16UNF-2B
0.251(6.35+0.025)
(25.4)
0.130 (3.2+0.1)
B
0.250
0.126
0.56 0.12 (3)

0.99(25.16)
(14.3) 0.75 1.18

(19) (30)
2.12(53.9) Taper
2.43 (61.8) 125:1000
5) Only series 52

Ports
sure [psi (bar)]2)
B Service line, SAE J518 1 in 4600 (315) O
Port plate 61/62 fixing thread ASME B1.1 3/8-16UNC-2B; 0.71 (18) deep
B; Port plate 64 Fixing thread ISO 11926 1 5/16-12UN-2B; 0.79 (20) deep 4600 (315) O
S; Port plate 64 Fixing thread ISO 11926 1 7/8-12UN-2B; 0.79 (20) deep 75 (5) O
L Case drain fluid ISO 119263) 7/8-14UNF-2B; 13 deep 30 (2) O5)
L1, L24) Case drain fluid ISO 119263) 7/8-14UNF-2B; 13 deep 30 (2) X5)
X Control pressure ISO 119263) 7/16-20UNF-2A; 11.5 deep 4600 (315) O
fittings.
4) Only for series 53

DRG EP.D. / EK.D.
max. 8.68 (220.5) 8.98 (228) 2.68 1.38

5.93 (150.5) 2.68 (68) 5.75 (146) (68) (35)
L1
X
5.22 (132.5)
5.18 (131.5)
L1 X X
4.53 (115)
4.57 (116)
L
S
L
S
L2

max. 8.68 (220.5)

5.93 (150.5) 2.68 (68) 9.68 (246) 3.35 (85) 1.42
(36)
X L1
5.18 (131.5)
L1 X
4.53 (115)
4.68 (119)
L
5.24 (133)
L S
S
L2
LA.D. ED7. / ER7.

9.25 (235)
5.75 (146) 2.68 (68) 9.84 (250)
L1
X X L1
5.24 (133)
X
4.57 (116.4)
(132)1)
L
5.20
L L
S L
L2

Mounting flange C, clockwise rotation, series 52
Port plate 61
max. 8.68 (220.5)
4.61 (117)
0.37 1.57 (40)
(9.5) X L1
L
5.39 (137)
Flange
ISO 3019-1
3.42 (87)
0.56 (14.3)
45°
(Ø101.6 -0.054 )
DIA 5.0000
4.9975
.5
0
78
X
2.99 (78)
0.59 (15) 5.75 (146)
8.19 (208) 6.77 (172)
View X
0.98 (Ø25)
S B
3.06 (77.8)
DIA 1.97
(Ø50)
(52.4)
2.06
B
S
1.67 (42.9) 1.03 (26.2)

Port plate 62 1.30 1.81
Detail Z
(33) (46)
max. 8.68 (220.5)

2.06 (52.4)
0.98 (Ø25)
4.61 (117)
0.37 (9.5) View Y
1.57 (40)
0.25 (6.3) X
B
1.11 (26.2)
Flange
ISO 3019-1
DIA 1.97 (Ø50)
(Ø101.6 -0.054 )
3.06 (77.8)
DIA 5.0000
4.9975
0
Y Z
B
S
S
1.69
0.59 (15) (42.9)
7.93 (201.5) 2.83 (72) 2.83 (72)
9.43 (239.5)

Mounting flange D, clockwise rotation, series 52
Port plate 61
max. 8.68 (220.5)
4.61 (117)
0.50 (12.7) 1.57 (40) X L1
0.24 (6) L
5.41 (137.4)
Flange
ISO 3019-1
14
.3
3.43 (87)
45°
(Ø127 -0.063 )
4.9975
DIA 5.000
5.83 (148)
5)
0
8.
(7
114.5
X
09
3.
3.07 (78)
4.51 (114.5)
0.59 (15) 5.75 (146)
8.19 (208)
View X
2.96 (52.4)
0.98 (Ø25)
1.97 (Ø50)
3.06 (77.8)
B
1.67 (42.9) 1.03 (26.2)
1.30 1.81
(33) (46)
DIA 0.98 (Ø25)
max. 8.68 (220.5)

2.06 (52.4)
4.61 (117) View Y

0.50
(12.7) 1.57 X
(40)
Flange B
ISO 3019-1 1.11
(26.2)
DIA 1.97 (Ø50)
(Ø127 -0.063 )
4.9975
DIA 5.000
3.06 (77.8)
0
Y Z
B
S
S
1.67
(42.9)
0.59 (15) 2.83 (72) 2.83 (72)
7.93 (201.5)
9.43 (239.5)

Port plate 61
max. 8.68 (220.5)
4.55 (115.5)
L1
L1
L
5.53 (140.4)
Flange
4.37 (111)
3.50 (89)
ISO 3019-1 43°
(Ø101.6 -0.054 )
14.3
DIA 5.0000
4.9975
9)
(7
0
)
X
7.5
1
3.1
(7
05
3.46 (88)
45°
3.
L2
8.19 (208.2) 5.75 (146)
6.77 (172)
View X
DIA 0.98 (Ø25)

S B
2.06 (52.4)
3.06 (77.8)
DIA 1.97
(Ø50)
S B
1.67 (42.9) 1.03 (26.2)

1.30 1.81
DIA 0.98 (Ø25)
(33) (46)
2.06 (52.4)
max. 8.68 (220.5)

4.55 (115.5)
View Y
0.37 (9.5) 1.54 (39)
0.25 (6.3) B
1.03
Flange
(26.2)
ISO 3019-1
DIA 1.97 Ø50
(Ø101.6 -0.054 )
DIA 5.0000
4.9975
3.06 (77.8)
0
Y Z
B
S
S
0.59 (15) 1.69
(42.9)
2.83 (72) 2.83 (72)
7.93 (201.5)
9.43 (239.5)

Port plate 61
max. 8.68 (220.5)
4.55 (115.5)
0.50 (12.7) 1.54 (39)
0.25 (6.3) L1 X L1
Flange L
)
5.51 (140)
(14
ISO 3019-1
4.37 (111)
55
0.
3.50 (89)
43°
4 5 ° 4 5 °
)
DIA 5.0000
(Ø127 -0.063
4.9975
4.51 (114.5)
9)
5.75 (146)
(7
)
0
7.5
X
1
3.1
(7
05
3.46 (88)
45°
3.
0.59 (15) L2
8.19 (208) 4.51 (114.5)
5.75 (146)
5.91 (150)
View X
DIA 0.98 (Ø25)

2.06 (52.4)
DIA 1.97 (Ø50)
3.06 (77.8)
B
S
1.67 1.03
(42.9) 1.81 (26.2)
1.30 (46)
Port plate 62 (33)
DIA 0.98 (Ø25)
max. 8.68 (220.5) Detail Z

4.55 (115.5)
2.06 (52.4)
View Y
0.50 (12.7) 1.54 (39) X
0.25 (6.3) L1
Flange
ISO 3019-1 B
1.03
DIA 1.97 (Ø50)
(26.2)
DIA 5.0000
)
4.9975
(Ø127 -0.063
3.06 (77.8)
0
Y Z
B
S
0.59 (15) 1.69

(42.9) 2.83 (72) 2.83 (72)
7.93 (201.5)
9.43 (239.5)
Dimensions, size 60 / 63 Before finalizing your design request a certified

Drive shaft
S Splined shaft 1 1/4 in R Splined shaft 1 1/4 in U Splined shaft 1 in
1.87 (47.5) 1.30 (33.1)
5/16-18UNC-2B3) 4)
5/16-18UNC-2B3) 4)
1/4-20UNC-2B3) 4)
0.75 (19)
0.75 (19) 0.63 (16)
0.20 (5)
0.20 (5) 0.20 (5)
Usable
1.56 shaft length 1.50 (38) 0.98
(39.5) (25)
2.18 (55.4)
2.18 1.81
(55.4) (45.9)
W Splined shaft 1 in K5) Parallel keyed shaft

15 T 16/32DP1)2) (SAE J744)
0.12 1.87 (47.5)
(35.3 -0.2) (ø31.75 - 0.03 )
DIA 1.2500
1.2488
(3)
1/4-20UNC-2B3) 4)
0.63 (16) 1.63 (41.3)

0.3136 (7.94 +0.25)
5/16-18UNC-2B3)4)
0.3126
0.20 (5) DIA 1.37
1.3898
(ø34.91)
1.3819
Usable 1.14
shaft length (29) 0.75 (19)
1.81 (45.9) 2.18 (55.4)

(ISO 3019-1)

(3.2) (28.6)
(21.41)
DIA 1.0715 0.84
0.16 (4) 0.3136(7.94+0.025)

0.3126
A
3/4-16UNF-2B
0.3136(7.94+0.025)
DIA 1.25
(31.75)
0.1394(3.54—0.1)
(25.4)
B
0.3126
0.1354
0.56 0.12
(14.1) (3)
(25.16)
0.99
1.18 Taper
(30) 125:1000
0.93 1.37
(23.6) (34.9)
2.61 (66.4)
5) Only series 52

Ports
sure [psi (bar)]2)
B Service line, SAE J518 1 in 4600 (315) O
S Suction line, SAE J518 2 in 75 (5) O
L1, L24) Case drain fluid ISO 119263) 7/8-14UNF-2B; 0.51 (13) deep 30 (2) X5)
X Control pressure ISO 119263) 7/16-20UNF-2A; 0.45 (11.5) deep 4600 (315) O
fittings.

DRG EP.D. / EK.D.
max. 8.68 (220.5) 9.49 (241)

5.94 (151) 2.55 1.40
5.93 (150.5) X 2.56 (65)
4.55 (115.5) X (64.8)(35.6)
L1 L1 L1
X X
5.39 (137)
5.53 (140.4)
L
4.88 (123.9)
4.92 (125)
4.76 (121)
L
S L2
S
DFR / DFR1 (DRF/DRS) EP.ED / EK.ED

Pressure and flow control, series 52 (series 53) Electro-proportional control, series 53
max. 8.68 (220.5) 1.42

5.93 (150.5) X 2.56 (65) 9.86 (250.5)
4.55 (115.5) 3.23 (82)(36)
L1 L1 L1
X X
5.39 (137)
5.53 (140.4)
L
4.76 (121)
4.92 (125)
L
S L2
LA.D. ED7. / ER7.

9.72 (247)
5.91 (150) 2.56 (65) 9.88 (251)
X
L1 L1
5.51 (140)
X
5.04 (128)
4.88 (124)
(137)1)
5.391)
L L1 L
L S
S
L2

Port plate 61
max. 9.53 (242)
5.12 (130) L1
0.50 (12.7) 1.57 (40)
X L
Flange
6.14 (156)
ISO 3019-1
3.68 (93.5)
45°
(Ø127 -0.063 )
DIA 5.0000
4.9975
95
0
3.42 (87)
0.69 (17.5)
0.79 (20)
7.13 (181)
9.65 (245) 8.26 (210)
View X
DIA 1.26 (Ø32)

S
DIA 2.36 (Ø60)
3.50 (88.9)
(66.7)
2.63
B
2.00 (50.8) 1.25 (31.8)

Port plate 62 1.97 1.77
Detail Z (50) (45)
DIA 1.26 (Ø32)
max. 9.53 (242)

2.63 (66.7)
5.12 (130)
View Y
0.50 (12.7) 1.57 (40)
X
Flange
B
ISO 3019-1 1.25
(31.8)
DIA 2.36 (Ø60)
)
3.50 (88.9)
(Ø127 -0.063
DIA 5.0000
4.9975
0
Y Z
S
S
0.79 (20) 2.00 (50.8) 3.74 (95) 3.35 (85)
9.27 (235.5)
10.90 (277)

Port plate 61
max. 9.90 (251.5)
5.63 (143)
L1
0.50 (12.7) 1.42 (36) X
L
Flange
5.91 (150)
4.96 (126)
ISO 3019-1
0.1
4.04 (102.5) 3.98 (101)

6
(4
45°
)
(Ø127 -0.063 )
4.51 (114.5)
5.0000
4.9975
5)
5)
(9
0
(9
X
74
74
3.
3.
DIA
45°
0.1
6
(14 .56
(4
)
.3
0
)
5.12 (130) L2
9.65 (245) 4.51 (114.5)
5.75 (146)
View X
DIA 1.26 (Ø32)

DIA 2.36 (Ø60)
3.50 (88.9)
(66.7)
2.63
S B
2.00 (50.8) 1.25 (31.8)

DIA 1.26 (Ø32)
1.97 1.77
Port plate 62
(50) (45)
Detail Z
max. 9.90 (251.5)
5.63 (143)
2.63 (66.7)
0.50 (12.7) 1.42 (36) View Y

X
Flange
B
ISO 3019-1 1.25
DIA 2.36 (Ø60)
(31.8)
(Ø127 -0.063 )
3.50 (88.9)
5.0000
4.9975
0
Y Z
S
B
DIA
0.79 (20) 2.00 S

5.12 (130) (50.8) 3.74 (95) 3.35 (85)
9.25 (235)
10.91 (277)

Drive shaft
S Splined shaft 1 1/2 in U Splined shaft 1 1/4 in W Splined shaft 1 1/4 in
17T 12/24DP1) (SAE J744) 14T 12/24DP1) (SAE J744) 14T 12/24DP1)2) (SAE J744)
1.87 (47.5)
5/16-18UNC-2B3) 4)
2.12 (54)
5/16-18UNC-2B3) 4)
7/16-14UNC-2B3) 4) 0.75 (19)
1.10 (28) 0.75 (19)
0.20 (5)
0.20 (5) 0.20 (5)
Usable
1.71 1.38 shaft length 1.30 (33)
(43.5) (35)
2.18 (55.4)
2.44 2.18
(61.9) (55.4)
Ports
Designation Port for Standard Size4) Maximum pressure State
[psi (bar)]5)
B Service line, SAE J518 1 1/4 in 4600 (315) O
L Case drain fluid ISO 119266) 1 1/16-12UNF-2B; 0.59 (15) deep 30 (2) O8)
L1, L27) Case drain fluid ISO 119266) 1 1/16-12UNF-2B; 0.59 (15) deep 30 (2) X8)
2) Splines according to ANSI B92.1a, run out of spline is a deviation from standard
fittings.
Dimensions, size 85, mounting flange C Before finalizing your design request a certified
DRG EP.D. / EK.D.
max. 9.51 (241.5)

10.51 (267)
6.75 (171.5) X 2.91 (74)
L1
7.15 (181.5) X 2.91 (74) 1.42 (36)
X L1
6.14 (156)
X
L
5.49 (139.5)
5.91 (150)
5.59 (142)
5.24 (133)
L
S S L2

max. 9.51 (241.5)

11.06 (281)
6.75 (171.5) X 2.91 (74) 7.15 (181.5) X 2.91 (74)
L1 L1
X
6.14 (156)
X
L
5.49 (139.5)
5.91 (150)
L
5.24 (133)
S S L2
LA.D. ED../ ER..

10.67 (271) 10.68 (271.4)

X 2.91 (74) 2.17 (55)
7.15 (181.5) 0.76 (19.4)
L1
X L1 X
5.90 (149.9)
6.14 (156)1)
5.25 (133.4)
L
5.71 (145)
S
S L2
1) ER7.: 191 mm if using an intermediate plate pressure controller.

Dimensions, size 85, mounting flange D Before finalizing your design request a certified
DRF/DRS EP.D. / EK.D.
max. 9.90 (251.5) 10.51 (267)

7.15 (181.5) X 2.91 (74) 7.15 (181.5) 2.91 (74) 1.42 (36)
L1 L1
X
5.91 (150)
5.59 (142)
5.91 (150)
5.24 (133)
5.24 (133)
4.96 (126)
L L
S S L2
L2
LA.D. EP.ED / EK.ED

Pressure, flow and power control, series 53 Electro-proportional control, series 53
10.75 (273) 2.91 (74)

7.15 (181.5) 11.06 (281) X
L1 L1
X X
5.91 (150)
5.91 (150)
5.71 (145)
5.24 (133)
5.59 (142)
L L
S L2 S L2

Port plate 61
max. 9.90 (251.5)

5.63 (143) L1
0.50 (12.7) 1.42 (36)
X
Flange
0.1
5.91 (150)
6
3019-1
(4
3.98 (101)
)
45° L
(Ø127 -0.063 )
DIA 5.0000
4.9975
5)
5)
(9
(9
0
74
4
3.7
3.
4.03 (102.5)
0.69 (17.5)
45°
L2
0.1
6
5.12 (130)
(4
)
9.65 (245) 7.13 (181)
8.27 (210)
View X
DIA 1.26 (Ø32)

DIA 2.36 (Ø60)
3.50 (88.9)
(66.7)
2.62
S B
2.00 (50.8) 1.25 (31.8)

DIA 1.26 (Ø32)
1.97 1.77
Port plate 62
(50) (45)
Detail Z
max. 9.90 (251.5)
5.63 (143)
2.63 (66.7)
0.50 (12.7) 1.42 (36) View Y

X
Flange
3019-1 B
1.25
DIA 2.48 (Ø63)
(31.8)
(Ø127 -0.063 )
3.50 (88.9)
DIA 5.0000
4.9975
0
Y Z
S
0.79 (20) 2.00 S

5.12 (130) (50.8) 3.74 (95) 3.35 (85)
9.25 (235)
10.91 (277)


Port plate 61
max. 9.90 (251.5)
5.63 (143)
L1
0.50.(12.7) 1.42 (36) X
L
Flange
5.91 (150)
4.96 (126)
3019-1
0.1
4.03 (102.5) 3.98 (101)

6
(4
45°
)
5.0000
-0.063 )
4.9975
4.51 (114.5)
5)
5)
(9
(9
0
X 4
74
3.7
(Ø127
3.
DIA
45°
0.1
6
3)
(4
.
(14
)
56
5.12 (130) L2
0.
9.65 (245) 4.51 (114.5)
5.75 (146)
View X
DIA 1.26 (Ø32)

DIA 2.36 (Ø60)
3.50 (88.9)
(66.7)
2.62
S B
2.00 (50.8) 1.25 (31.8)

DIA 1.26 (Ø32)
Port plate 62
1.97 1.77
(50) (45)
Detail Z
max. 9.90 (251.5)
5.63 (143)
2.63 (66.7)
0.50 (12.7) 1.42 (36) View Y

X
Flange
3019-1 B
1.25
DIA 2.48 (Ø63)
(31.8)
5.0000
-0.063 )
4.9975
3.50 (88.9)
0
Y Z
S
B
(Ø127
DIA
0.79 (20) 2.00 S

5.12 (130) (50.8) 3.74 (95) 3.35 (85)
9.25 (235)
10.91 (277)

DRG ED../ ER..
Pressure controller, remote controlled, series 53 Electro-hydraulic pressure control, series 53
max. 9.90 (251.5)

7.15 (181.5) X 2.91 (74) 10.71 (272)
L1
L1
5.91 (150)
X
6.14 (156)1)
X
L
5.24 (133)
L
S L2 S L2
DRF/DRS
Pressure and flow control, series 53
max. 9.90 (251.5)

7.15 (181.5) X 2.91 (74)
L1
5.91 (150)
L
5.24 (133)
S L2
LA.D.
Pressure, flow and power control, series 53
10.67 (271)
X 2.91 (74)
7.15 (181.5)
L1
X
5.90 (149.9)
5.25 (133.4)
L
5.71 (145)
S L2
Dimensions, size 100

Drive shaft
S Splined shaft 1 1/2 in U Splined shaft 1 1/4 in W Splined shaft 1 1/4 in
17T 12/24DP1) (SAE J744) 14T 12/24DP1) (SAE J744) 14T 12/24DP1)2) (SAE J744)
1.87 (47.5)
5/16-18UNC-2B3) 4)
2.12 (54)
5/16-18UNC-2B3) 4)
7/16-14UNC-2B3) 4)
0.75 (19)
1.10 (28) 0.75 (19)
0.20 (5)
0.20 (5) 0.20 (5)
Usable
1.38 shaft length 1.30 (33)
1.71
(43.5) (35)
2.18 (55.4)
2.44 2.18
(61.9) (55.4)
Ports
Designation Port for Standard Size4) Maximum State
pressure
[bar]5)
B Service line, SAE J518 1 1/4 in 4600 (315) O
L Case drain fluid ISO 119266) 1 1/16-12UNF-2B; 0.59 (15) deep 30 (2) O8)
L1, L2 Case drain fluid ISO 119266) 1 1/16-12UNF-2B; 0.59 (15) deep 30 (2) X8)
fittings.
6) Metric fixing thread is a deviation from standard.
Dimensions through drive Before finalizing your design request a certified

K01 flange SAE J744 - 82-2 (A)
Coupling for splined shaft in accordance with ANSI B92.1a-1996 5/8 in 9T 16/32 DP1) (SAE J744 - 16-4 (A))
Cut A - B NG A1 A2 A3 A42)
18 7.17 0.37 1.70 M10 x 1.5,
Omitted for NG28 A3
(182) (9.3) (43.3) 0.57 (14.5) deep
A2
28 8.03 0.39 1.85 M10 x 1.5,
(204) (9.9) (47) 0.63 (16) deep
45 9.02 0.42 2.09 M10 x 1.5,
45°
(229) (10.7) (53) 0.63 (16) deep
+0.020 )
A B
(ø82.55 +0.050
3.2508
DIA 3.2520
60/ 10.03 0.37 2.32 M10 x 1.5,
4.19 63 (255) (9.5) (59) 0.63 (16) deep
(106
.5) 85 11.89 0.53 2.68 M10 x 1.5,
(302) (13.4) (68) 0.79 (20) deep
A4 100 11.89 0.53 2.68 M10 x 1.5,
0.39 (302) (13.4) (68) 0.79 (20) deep
to mounting flange A1 (10)
Omitted for NG28
K52 flange SAE J744 - 82-2 (A)

Coupling for splined shaft in accordance with ANSI B92.1a-1996 3/4 in 11T 16/32 DP1) (SAE J744 - 19-4 (A-B))
Cut A - B NG A1 A2 A3 A4 A52)
Omitted for NG28 A4
18 7.17 0.37 1.70 M10 x 1.5,
A3
(182) (9.3) (43.3) 0.57 (14.5) deep
28 8.03 1.54 0.74 1.85 M10 x 1.5,
(204) (39.3) (18.8) (47) 0.63 (16) deep
45°
45 9.02 1.55 0.75 2.09 M10 x 1.5,

)
+0.050
+0.020
A B
3.2508
DIA 3.2520
(229) (39.4) (18.9) (53) 0.63 (16) deep

(ø82.55
4.1 60/ 10.03 1.55 0.75 2.40 M10 x 1.5,

10 9
6.5 63 (255) (39.4) (18.9) (61) 0.63 (16) deep
85 11.89 1.74 0.93 2.56 M10 x 1.5,
A5 (302) (44.1) (23.6) (65) 0.79 (20) deep
0.39 100 11.89 1.74 0.93 2.56 M10 x 1.5,
A2 (10) (302) (44.1) (23.6) (65) 0.79 (20) deep
Omitted for NG28
to mounting flange A1
K68 flange SAE J744 - 101-2 (B)

Coupling for splined shaft in accordance with ANSI B92.1a-1996 7/8 in 13T 16/32 DP1) (SAE J744 - 22-4 (B))
Cut A - B
Omitted for NG28, 45 A4 NG A1 A2 A3 A4 A52)
A3
28 8.03 1.66 0.70 1.85 M12 x 1.75,
(204) (42.3) (17.8) (47) 0.71 (18) deep
45 9.02 1.67 0.71 2.09 M12 x 1.75,
45
(229) (42.4) (17.9) (53) 0.71 (18) deep

°
A B
(ø101.6 +0.020 )
DIA 4.0008
4.0020
+0.050
60/ 10.03 1.67 0.71 2.32 M12 x 1.75,

5.7 63 (255) (42.4) (17.9) (59) 0.71 (18) deep
(14 5
6) 85 11.89 1.83 0.87 2.72 M12 x 1.75,
(302) (46.5) (22) (69) 0.79 (20) deep
A5 100 11.89 1.83 0.87 2.72 M12 x 1.75,
(302) (46.5) (22) (69) 0.79 (20) deep
0.39
Omitted for NG28, 45 A2 (10)
1) 30° pressure angle, flat base, flank centering, tolerance class 5
2) Thread according to DIN 13, observe the general instructions on page 60 for the maximum tightening torques.

K04 flange SAE J744 - 101-2 (B)
Coupling for splined shaft in accordance with ANSI B92.1a-1996 1 in 15T 16/32 DP1) (SAE J744 - 25-4 (B-B))
Cut A - B NG A1 A2 A3 A4 A52)
Omitted for NG45 A4
A3 45 9.02 1.88 0.74 2.10 M12 x 1.75,
(229) (47.9) (18.9) (53.4) 0.71 (18) deep
60/ 10.03 1.87 0.72 2.32 M12 x 1.75,
45°
63 (255) (47.4) (18.4) (58.9) 0.71 (18) deep
A B 85 11.89 2.01 0.87 2.72 M12 x 1.75,
+0.020 )
4.0008
DIA 4.0020
(ø101.6 +0.050
(302) (51.2) (22.2) (69) 0.79 (20) deep
5.7
(14 5 100 11.89 2.01 0.87 2.72 M12 x 1.75,
6) (302) (51.2) (22.2) (69) 0.79 (20) deep
A5
0.39
Omitted for NG45 A2 (10)
K15 flange SAE J744 - 127-4 (C)

Coupling for splined shaft in accordance with ANSI B92.1a-1996 1 1/4 in 14T 12/24 DP1) (SAE J744 - 32-4 (C))
A4 60/ 10.03 0.31 2.32 M12 x 1.75,
A3 63 (255) (8) (59) 0.63 (16) deep
A
85 11.87 0.51 2.67 M12 x 1.75,
(301.5) (13) (67.9) through
100 11.87 0.51 2.67 M12 x 1.75,
(301.5) (13) (67.9) through
+0.050
ø127 +0.020
114.5
114.5 A5 13
B to mounting flange A1
K16 flange SAE J744 - 127-4 (C)

A4 85 11.87 0.51 2.67 M12 x 1.75,
A3 (301.5) (13) (67.9) through
A
100 11.87 0.51 2.67 M12 x 1.75,
(301.5) (13) (67.9) through
+0.020 )
4.51 (114.5)
(ø127 +0.050
DIA 5.0020
5.0008
4.51 (114.5) A5 0.53

B to mounting flange A1 (13.4)

K07 flange SAE J744 - 127-2 (C)
45 A4 85 11.87 0.51 2.67 M12 x 1.75,
A
A3 (301.5) (13) (67.9) through
100 11.87 0.51 2.67 M12 x 1.75,
(301.5) (13) (67.9) through
A5
+0.020 )
7.13 )
(Ø127 +0.050
5.0008
DIA 5.0020
81
(Ø1
A5
B 0.51
A2 (13)
K24 flange SAE J744 - 127-2 (C)

Coupling for splined shaft in accordance with ANSI B92.1a-1996 1 1/2 in 17T 12/24 DP1) (SAE J744 - 38-4 (C-C))
45° A4 85 11.89 0.31 2.68 M16 x 2,
A (302) (8) (68) 0.94 (24) deep
A3
100 11.89 0.31 2.68 M16 x 2,
(302) (8) (68) 0.94 (24) deep
(ø127 +0.020 )
7.13
DIA 5.0008
5.0020
+0.050
1)
(ø18
A5
B
0.51
to mounting flange A1 (13)

Summary mounting options

Through-drive1) Mounting option – 2nd pump
Flange Through
Coupling
Short A10V(S)O/5x A10VO/31 Gear pump drive
for splined
des. NG (shaft) NG (shaft) design (NG) available for
shaft
NG
82-2 (A) 5/8 in K01 10 (U) 18 (U) F (5 to 22) 18 to 100
3/4 in K52 10 (S) 18 (S, R) – 18 to 100
18 (U)
18 (S, R)
101-2 (B) 7/8 in K68 28 (S, R) 28 (S, R) N/G (26 to 49) 28 to 100
45 (U, W)1) 45 (U, W)
1 in K04 45 (S, R) 45 (S, R) – 45 to 100
60, 63 (U, W) 2) –
127-4 (C) 1 1/4 in K15 60, 63 (S, R) – – 63 to 100
1 1/2 in K16 85 (S) – – 85 to 100
100 (S)
127-2 (C) 1 1/4 in K07 85 (U, W) 71 (S, R) – 85 to 100
100 (U, W)
1 1/2 in K24 85 (S) – – 85 to 100
100 (S)
1) Not for NG28 with K68
2) Not for NG28 with K04
Combination pumps A10VO + A10VO Before finalizing your design request a certified
When using combination pumps it is possible to have multiple, mutually independent circuits without the need for a splitter
gearbox.
When ordering combination pumps the model codes for the first and the second pump must be joined by a "+".
Order example:
A10VO85DRS/53R-VSC12K04+
A10VO45DRF/53R-VSC11N00
The tandem pump comprising two identical sizes is permissible without additional supports taking into account a maximum
dynamic mass acceleration of 10 g (= 98.1 m/s2).
For combination pumps comprising more than two pumps, the mounting flange must be calculated for the permissible moment of
inertia.
Permissible moment of inertia
NG 10 18 28 45 60/63 85 100
Permissible moment of inertia
static Tm lb-ft – – 656 664 1010 2270 2270
(Nm) – – (890) (900) (1370) (3080) (3080)
dynamic at 10 g (98.1 m/s2) T lb-ft – – 65 66 101 227 227
(Nm) – – (89) (90) (137) (308) (308)
Mass with through-drive plate m1 lbs – – 37.5 53 62 99 99
(kg) – – (17) (24) (28) (45) (45)
Mass without through drive (e.g. 2nd m lbs 18 25 31 40 48.5 75 75
pump) (kg) (8) (11.5) (14) (18) (22) (34) (34)
Distance center of gravity l1 in – 3.23 3.19 3.74 3.94 4.80 4.80
(mm) – (82) (81) (95) (100) (122) (122)
m1, m2, m3 Mass of pumps [lbs (kg)]
A10VO m1 A10VO m2
(1st pump) (2nd pump) Distance center
l1, l2, l3 [in (mm)]
of gravity
1
l1 Tm = (m1 • l1 + m2 • l2 + m3 • l3) •
l2 12 (102) [lb-ft (Nm)]
Connector for solenoids

DEUTSCH DT04-2P-EP04, 2-pin Changing connector position
Molded, without bidirectional suppressor diode ___________ P If necessary, you can change the position of the connector by
Protection according to DIN/EN 60529 _______________ IP67 turning the solenoid.
Protection according to DIN 40050-9_ _______________IP69K To do this, proceed as follows:
Circuit symbol 1. Loosen the mounting nut (1) of the solenoid. To do this, turn
the mounting nut (1) one revolution counter-clockwise.
Without bidirectional suppressor diode
2. Turn the solenoid body (2) to the desired position.
3. Retighten the mounting nut of the solenoid. Tightening
torque: 3.7+0.7 lb-ft (5+1 Nm) (size WAF 26, 12kt DIN 3124).
On delivery, the position of the connector may differ from that
shown in the brochure or drawing.
Mating connector
DEUTSCH DT06-2S-EP04
Bosch Rexroth Mat. No. R902601804
Consisting of: DT designation
–– 1 case _ _______________________________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.
1.44 (36.7)
(2)
1.44 (36.7)
(1)
DIA 1.46
(Ø37)
1.97 (50)
2.70 (68.5)
Electronic controls
Control Electronics function Electronics Further information

Electric pressure control Controlled power outlet RA analog RE 95230
RC2-2/21 1) Digital RE 95201
1) Power outlets for 2 valves, can be actuated separately
2) only 24V nominal voltage
Installation instructions
General Below-reservoir installation (standard)
The axial piston unit must be filled with hydraulic fluid and air Below-reservoir installation means the axial piston unit is ins-
bled during commissioning and operation. This must also be talled outside of the reservoir below the minimum fluid level.
observed following a longer standstill as the axial piston unit
empty via the hydraulic lines.
Especially with the installation position "drive shaft upwards" 1 2
or "drive shaft downward", attention must be paid to a comple-
amin amin
te filling and air bleeding since there is a risk, for example,
of dry running.
SB SB
The case drain fluid in the case interior must be directed to the ht min ht min
reservoir via the highest case drain port (L1, L2, L3). h min h min
L1
For combinations of multiple units, make sure that the respec- L1 L X
tive case pressure in each unit is not exceeded. In the event of L

S
pressure differences at the drain ports of the units, the shared S
drain line must be changed so that the minimum permissible
X
case pressure of all connected units is not exceeded in any
situation. If this is not possible, separate drain lines must be
laid if necessary.
To achieve favorable noise values, decouple all connecting 3 4
lines using elastic elements and avoid above-reservoir installa-
tion. amin amin
In all operating conditions, the suction line and case drain line
SB SB
must flow into the reservoir below the minimum fluid level. The ht min ht min
permissible suction height hS is a result of the overall pressure h min h min
loss, but may not be greater than hS max = 31.50 in (800 mm).
The minimum suction pressure at port S must also not fall
L2 S S
below 12 psi (0.8 bar) absolute during operation.
Installation position L L1
See the following examples 1 to 12. L1 L
Additional installation positions are available upon request.
Recommended installation positions: 1 and 3.
Installation Air bleed Filling
position
1 L S+L
2 L1 S + L1
31) L2 S + L2
4 L S+L
Key, see page 57
1) Only series 53
Installation instructions
Above-reservoir installation Inside-reservoir installation
Above-reservoir installation means the axial piston unit is Inside-reservoir installation means the pump is installed within
installed above the minimum fluid level of the reservoir. the minimum reservoir fluid level.
Axial piston units with electrical components (e.g. electric
To prevent the axial piston unit from draining, a height diffe-
control, sensors) may not be installed in a reservoir below the
rence hES min of at least 0.98 in (25 mm) is required in installati-
fluid level.
on position 6.
Observe the maximum permissible suction height 9 10
hS max = 31.50 in (800 mm). amin amin
A check valve in the case drain line is only permissible in indivi-
dual cases. Consult us for approval. L1
L1 L X
LSB
5 6 F SB ht min ht min
F hES min
L1 L
X
S
X
L1 h min S h min
X L
S S
hs max
11 12
hs max
amin amin
ht min SB ht min SB L2 S
h min h min S
ht min ht min
amin amin
SB
L1 L L
7 8 h min L1 SB h min
F F
L2 S S
Installation Air bleed Filling
L position
L1 L L1
9 L1 L, L1
hs max
hs max 10 L1 L, L1
111) L2 S
ht min SB ht min SB
h min h min 12 L S+L
amin amin
S Suction port
Installation Air bleed Filling F Filling / air bleeding
position L, L1 Case drain port
5 F L, L1 (F) SB Baffle (baffle plate)
6 F L1 (F) ht min Minimum necessary immersion depth (7.87 in
71) F S + L2 (F) (200 mm))
8 F S + L (F) hmin Minimum necessary spacing to reservoir base
(3.94 in (100 mm))
hES min
Minimum necessary height needed to protect the
1) Only series 53 axial piston unit from draining (0.98 in (25 mm)).
hS max Maximum permissible suction height (21.50 in
(800 mm))
amin When designing the reservoir, ensure adequate
distance between the suction line and the case
drain line. This prevents the heated, return flow
from being drawn directly back into the suction
line.
Notes
Notes
General instructions
–– The A10VO pump is designed to be used in open circuit.
–– Project planning, installation and commissioning of the axial piston unit require the involvement of qualified personnel.
–– Before operating the axial piston unit, please read the appropriate instruction manual thoroughly and completely. If necessary,
request these from Bosch Rexroth.
–– During and shortly after operation, there is a risk of burns on the axial piston unit and especially on the solenoids.
Take appropriate safety measures (e.g. by wearing protective clothing).
–– Depending on the operating conditions of the axial piston unit (operating pressure, fluid temperature), the characteristics may
shift.
–– Service line ports:
-- The ports and fixing threads are designed for the specified maximum pressure. The machine or system manufacturer must en-
sure that the connecting elements and lines correspond to the specified application conditions (pressure, flow, hydraulic fluid,
temperature) with the necessary safety factors.
-- The service line ports and function ports are only designed to accommodate hydraulic lines.
–– Pressure cut-off and pressure control do not provide security against pressure overload. A separate pressure relief valve
is to be provided in the hydraulic system.
–– The data and notes contained herein must be adhered to.
–– The product is not approved as a component for the safety concept of a general machine according to DIN EN ISO 13849.
–– The following tightening torques apply:
-- Fittings:
Observe the manufacturer's instruction regarding the tightening torques of the used fittings.
-- Fixing screws:
For fixing screws with metric ISO thread according to DIN 13 or thread according to ASME B1.1, we recommend checking the
tightening torque individually according to VDI 2230.
-- Female threads in axial piston unit:
The maximum permissible tightening torques MG max are maximum values for the female threads and must not be exceeded.
For values, see the following table.
-- Threaded plugs:
For the metal threaded plugs supplied with the axial piston unit, the required tightening torques of the threaded plugs MV
apply. For values, see the following table.
Ports Maximum permissible Required Size of
tightening torque for tightening torque for hexagon socket of
Standard Thread size female threads MG max threaded plugs MV threaded plugs
ISO 11926 7/16-20UNF-2B 40 Nm 18 Nm 3/16 in

9/16-18UNF-2B 80 Nm 35 Nm 1/4 in
3/4-16UNF-2B 160 Nm 70 Nm 5/16 in
7/8-14UNF-2B 240 Nm 110 Nm 3/8 in
1 1/16-12UN-2B 360 Nm 170 Nm 9/16 in
Bosch Rexroth Corporation Bosch Rexroth Corporation Bosch Rexroth Corporation

Hydraulics Hydraulics All rights reserved. Neither this document, nor any part of it, may be reproduced,
Axial & Radial Piston Units Axial & Radial Piston Units duplicated, circulated or disseminated, whether by copy, electronic format or any
8 Southchase Court 2315 City Lane Road other means, without the prior consent and authorization of Bosch Rexroth Corp.
Fountain Inn, SC 29644-9018 Bethlehem, PA 18017-2131 The data and illustrations in this brochure/data sheet are intended only to descri-
USA USA be or depict the products. No representation or warranty, either express or im-
Telephone (864) 967-2777 Telephone (610) 694-8300 plied, relating to merchantability or fitness for intended use, is given or intended
Facsimile (864) 967-8900 Facsimile (610) 694-8467 by virtue of the information contained in this brochure/data sheet. The information
www.boschrexroth-us.com www.boschrexroth-us.com contained in this brochure/data sheet in no way relieves the user of its obligation
to insure the proper use of the products for a specific use or application. All
products contained in this brochure/data sheet are subject to normal wear and
tear from usage.
Subject to change.
Electric Drives Linear Motion and
and Controls Hydraulics Assembly Technologies Pneumatics Service
Axial Piston RE 93 100/05.06

Replace: 07.03
/16
Variable Double Pump A20VO
Technical data sheet
Series 1
Sizes Nominal pressure/ Peak pressure
60 250/315 bar
95...520 350/400 bar
for open circuits
Contents Features
Ordering Code / Standard Program 2 – Variable pump with two axial piston rotary groups in swash-
plate design for use in open circuit hydrostatic drives
Technical Data 3
– For use in mobile and stationary applications
Through Drive 3
– The pump consists of proven components from the A11VO
Control Devices 4
(RE 92500), A10VO/53 (RE 92703) or A4VSO (RE 92050)
Unit Dimensions, Size 60 6 variable pumps
Unit Dimensions, Size 95 8 – The pump operates under self-priming condition, with tank
pressurisation or with charge pump (sizes 190...260)
Unit Dimensions, Size 190 (with impeller) 10
– A wide variety of controls are available
Unit Dimensions, Size 260 (with impeller) 12
– Setting of the constant power control is possible via
Unit Dimensions, Size 520 14
external adjustments, even when the unit is operating (only
General Notes 16 with power contol).
– The pump is available with a through drive to mount a gear
pump or a second axial piston pump
– Output flow is proportional to drive speed and pump
displacement and is steplessly variable between maximum
and zero displacement
VL114
/16 Bosch Rexroth AG A20VO RE 93 100/05.06
Ordering Code / Standard Program

A20V O / 10 –
01 02 03 04 05 06 07 08 09 10 11 12
Axial piston unit

01 Swashplate design, variable (Back to back - design) A20V
Charge pump (impeller) 60 95 190 260 520
without charge pump (no code) ● ● – – ●
02
with charge pump – – ● ● – L
Operation
03 Double pump, open circuit O
Size
04 ≈ Displacement Vg max in cm3 (per rotary group) 60 95 190 260 520
Control devices 60 95 190 260 520
see RE 92703 (A10VO/53) ● – – – –
05 see RE 92500 (A11VO) – ● ●  –
see RE 92050 (A4VSO) and RE 92060, RE 92064, RE 92076 – – – – 
Series
06 Series 1, Index 0 10
viewed on shaft end clockwise R
07
counter-clockwise L
Seals
NBR (nitril-caoutchouc), shaft seal ring in FKM (fluor-caoutchouc) ● ● ● ● – N
08
FKM (fluor-caoutchouc) – – – – ● V
Shaft end 60 95 190 260 520
Splined shaft DIN 5480 – ● ● ● ● Z
Splined shaft, ANSI B92.1a-1976 ● ● – – – S
10
– – ● ● – T
Parallel keyed shaft, DIN 6885 – – – – ● P
Mounting flange 60 95 190 260 520
SAE J744 – 4-hole ● ● ● ● – D
To fit flywheel housing (conformin to SAE J617)
09 – ● ● – – G
of internal combustion engine (details on request)
ISO 3019-2 – 8-hole – – – – ● H
Service line ports 60 95 190 260 520
Two service line ports and one scution port at site,
● ● ● ● – 24
opposite (fastening thread metric)
11
At the site two service line ports each, opposite and one suction port displaced
– – – – ● 26
by 90° (fastening thread metric)
Boost pump and through drive1) 60 95 190 260 520

without boost pump, without through drive ● ● ● ● – N00
without boost pump, with through drive
Flange SAE J744 Splined shaft hub
12
82-2 (A) 5/8 in 9T 16/32DP (A) m m m m – K01
127-2 (C) 1 1/4in 14T 12/24DP (C) – – – – ● K07
with through drive shaft, without hub, without intermediate flange, closed by a cover – – – – ● K99
l = available m = available on request – = not available
1) Please contact us
RE 93 100/05.06 A20VO Bosch Rexroth AG /16
Technical Data
Table of values (theoretical values, without efficiencies ηmh and ηv; values rounded)
without charge pump 60 95 520
Size
with charge pump 190 260
Displacement Vg max cm3 60 93,8 192,7 260 520
(per rotary group) Vg min cm3 0 0 0 0 0
Speed
maximal 1) at Vg max nmax min–1 2700 2350 2500 2) 2300 2) 1450
Speed max. 3)
at Vg ≤ Vg max nmax min–1 3200 2780 2500 2300 1720

Flow
at nmax and Vg max qv max L/min 2x162 2x220 2x482 2x598 2x754
Power at qV max
and Dp = 350 bar Pmax kW 1354) 257 562 698 880
Torque at Vg max
at long-term (Δp = 350 bar) Tmax Nm 477 4) 1045 2147 2897 5793
max. perm., short term (Δp = 400 bar) Tmax Nm 602 4) 1194 2454 3310 6621
Moment of inertia
J kgm2 0,0113 0,0346 0,0604 0,0912 0,696
(of the rotating parts)
Mass approx. m kg 44 640
1) The values are quoted for an absolute pressure (pabs) of 1 bar at suction port S and mineral operating fluid.
2) The values are quoted for an absolute pressure (pabs) of at least 0.8 bar at suction port S and mineral operating fluid.
3) The values are quoted for V < V
g g max or increase of the input pressure pabs at suction port S.
4) Δp = 250 bar (long-term operation) or rather 315 bar (short term).
Through Drive
Please contact us.
Control Devices
Example circuit diagram Size 60: DFR
X1 X2
B1 B2
S L2 L1 L4 L3
Example circuit diagram Size 95...260: HD1D
Y Y
MA A G B MB
Vg max Vg min Vg min Vg max
M 1A R T1 T 2 S T2 T1 R M 1B
Control Devices
Example circuit diagram Size 520: LR2DN
Pst1 Pst2
(P2) (P4)
Mst1 Mst2
P1 MB1 MB3 P3
M1 MB2 B1B2 B4B3 MB4 M3
M2 M4
U1 K1 K2 T1 R(L)1 S MS R(L)2 T2 K3 K4 U2
Further technical datas as soon as control devices see

for size 60_____________________ RE 95703 (A10VO/53)
for sizes 95 ... 260______________ RE 92500 (A11VO)
for size 520_ __________________ RE 92050 (A4VSO), RE 92060, RE 92064, RE 92076
Unit Dimensions, Size 60 Before finalizing your design, please request a

approved installation drawing.
Dimensions in mm
For controller selection see RE 92703 (A10VO/53)
304 45° 45°

117
L1 L3
14
L2 L4
.3
137
87
2
ø16
114.5
148
210.5 114.5
434 15.5 146
90 90
X
381
40
View Z
88.9
ø127
ø69
S
12.7 50.8
15
Y
View Y
ø25
B1
31 31
26.2
B2
52.4

Dimensions in mm
Shaft end
S Splined shaft
1 1/4in 14T 12/24DP 1)
(SAE J744 – 32-4 (C))
19
6
ø34.9
5/16-18UNC-2B
8
47.5
55.4
Ports
B1, B2 Service ports (High pressure series) SAE J518 1in
Fastening thread DIN 13 M10x1,5; 17 deep 2)
S Suction port SAE J518 2 1/2 in
Fastening thread DIN 13 M12x1,75; 20 deep 2)
L1,2,3,4 Case drain DIN 3852 7/8-14UNF-2B 240 Nm 2)
1) ANSI B92.1a-1976, pressure angle 30°, flat rood, side fit, tolerance class 5
2) please observe the general notes for the max. tightening torques on page 16

Dimensions in mm
For controller selection see RE92500 (A11VO)
508
492 View W
246.5
T1 B T1 106.4
20
13
50 50
W
ø161.6
152.4
135
R
R 155 T2 G T2 MB M1B G M1A MA
211
A R
338
X
246.5
T2 S T1 View Z
98
120.7
ø90
102
69.9
T1 B; A T2
Y View Y
B
38 38
A
27.8
ø25
57.2

Dimensions in mm
Shaft ends
Z Splined shaft DIN 5480 S Splined shaft
W45x2x30x21x9g 1 3/4in 13T 8/16DP 1)
(SAE J744 – 44-4 (D))
36 36
12 12
ø101
ø101
ø50
ø50
M16x22)3)
5/8-11UNC-2B
8 12
50 67
60 75
Ports
A, B Service ports (High pressure series) SAE J518 1in
Fastening threads DIN 13 M12x1,75; 17 deep 3)
S Suction port (standard series) SAE J518 3 1/2 in
Fastening threads DIN 13 M16x2; 24 deep 3)
T1, T2 Case drain DIN3852 M26x1,5; 14 deep 230 Nm 3)
MA, M B Gauge point positioning chamber DIN3852 M12x1,5; 12 deep 50 Nm 3)
MA1, M B1 Gauge point for service port DIN3852 M12x1,5; 12 deep 50 Nm 3)
R Air bleed, drain port DIN3852 M26x1,5; 14 deep 230 Nm 3)
G Control pressure port (controller) 4) DIN3852 M14x1,5; 12 deep 80 Nm 3)
2) Center bore according to DIN 332 (thread according to DIN13)
4) At design with stroke limiter (H..., U2), HD and EP with fitting GE10-PLM (in other case is port G plugged)
10/16 Bosch Rexroth AG A20VO RE 93 100/05.06
Unit Dimensions, Size 190 (with impeller) Before finalizing your design, please re-
quest a approved installation drawing.
Dimensions in mm
700.5
684.6
404.3
280.3
27
15.9 View W
T1 B1 B2 T2
224.5
66
W B S
ø165.1
66
164
R T2 G1 G2 T1 R R
190.3
282.3 MB1 M M
1 2 MB2
402.3
494.3
342 Z
T2 S T1
View Z
132
134
112
S
152.4
ø125
112
116
134
92.1
T1 B1 G1 G2 B2 T2
Y
View Y
36.5
B1;B2
ø38
79.4
RE 93 100/05.06 A20VO Bosch Rexroth AG 11/16
Unit Dimensions, Size 190 (with impeller) Before finalizing your design, please
request a approved installation drawing.
Dimensions in mm
Shaft ends
Z Splined shaft DIN 5480 T Splined shaft
W50x2x30x24x9g 2in 15T 8/16DP 1)
(SAE J744 – 50-4 (F))
36 36
12 12
ø126
ø126
ø60
ø60
M16x22)3)
5/8-11UNC-2B
11 14
55 80
65 88
Connections
B1, B2 Service ports (High pressure series) SAE J518 1 1/2 in
Fastening threads DIN 13 M16x2; 21 deep
S Suction port (standard series) SAE J518 5 in
Fastening threads DIN 13 M16x2; 23 deep
T1, T2 Case drain DIN3852 M33x2; 18 deep 540 Nm 4)
M1, M2 Gauge point positioning chamber DIN3852 M12x1,5; 12 deep 50 Nm 4)
M B1, M B2 Gauge point for service port DIN3852 M12x1,5; 12 deep 50 Nm 4)
R Air bleed, drain port DIN3852 M33x2; 16 deep 540 Nm 4)
G1, G2 Control pressure port (controller) 4) DIN3852 M14x1,5; 12 deep 80 Nm 4)
Dimensions in mm
766
750
442
308
30 View W
15.9
B1 B2 T2
T1
72 72
W B S
224.5
ø165.1
T2
T1
174
G1 M B1 M1 M 2 M B2 G 2 R R
214
311
439
536
Z
375
T2 S T1 View Z
149
126
152.4
ø125
S
126
130
152
92.1
T1 B1 G1 G 2 B2 T2
Y
View Y
36.5
B2
ø38
79.4
Dimensions in mm
Shaft ends
Z Splined shaft DIN 5480 T Splined shaft
W60x2x30x28x9g 2 1/4in 17T 8/16DP 1)
42 42
15 15
ø131
ø131
ø70
ø70
M20x2.52)3)
3/4-10UNC-2B
11 14
58 80
66 88
Connections
B1, B2 Service ports (High pressure series) SAE J518 1 1/2 in
T1, T2 Case drain DIN3852 M33x2; 18 deep 540 Nm 3)
M1, M2 Gauge point positioning chamber DIN3852 M12x1,5; 12 deep 50 Nm 3)
M B1, M B2 Gauge point for service port DIN3852 M12x1,5; 12 deep 50 Nm 3)
R Air bleed, drain port DIN3852 M33x2; 16 deep 540 Nm 3)
G1, G2 Control pressure port (controller) 3) DIN3852 M14x1,5; 12 deep 80 Nm 3)
Unit Dimensions, Size 520 Before finalizing your design, please

Dimensions in mm
For controller selection see RE92064 (A4VS)
Picture for counter-clockwise
15 15 510
Pst1 B1 B3 Pst2
392
392
306
306
ø24
190
K2,K4
ø3
05
190
60
ø4
8x4
45
=3
5
R(L)
°
K1 K3 22°30'
°(
S T 60 K1,K3
°)
47
16+5 MB1(MB2) X MB3(MB4) 155 155
155 190 190
497.5
920
1054
16 Y
U View Z
44.5
189
015°
015°
ø315
ø225
ø233
96.8
ø50
15°
15°
R
L
60 60
B1, B3 (offen)
30 B2, B4 (verschlossen)
140 279 50 Y
716
View Y
152.4
ø125
92.1
S MS
Unit Dimensions, Size 520 Before finalizing your design, please

Dimensions in mm
Shaft ends
Z Splined shaft DIN 5480 P Parallel keyed shaft
W80x3x30x25x9g DIN 6885
42 42
15 15
ø80 m6
ø100
ø100
85
M20x2.52)3)
M20x2.52)3)
14
90 130
Connections
B1 - B4 Service line ports (High pressure series) SAE J518 2 in
Fastening threads DIN 13 M20x2,5; 24 deep 3)
K1 - K4 Flush ports M48x2; 22 deep 960 Nm 3)
M B1, M B4 Gauge point for operating pressure DIN3852 M18x1,5; 12 deep 140 Nm 3)
MS Gauge point for suction port DIN3852 M18x1,5; 12 deep 140 Nm 3)
Pst1, Pst2 Pilot pressure port M14x1,5; 12 deep 80 Nm 3)
R (L) Air bleed, drain port DIN3852 M48x2; 22 deep 960 Nm 3)
T Case drain DIN3852 M48x2; 22 deep 960 Nm 3)
U Flush port DIN3852 M18x1,5; 12 deep 140 Nm 3)
4) At design with stroke limiter (H1) with fitting GE10-PLM (in other case is port G plugged)
General Notes
– The pump A20VO is designed to be used in open circuits.
– Project planning, assembly and commissioning of the pump require the invovement of trained personnel.
– The working and functional ports are only designed to accommadate hydraulic piping.
– There is a danger of burns from the pump and especially the solenoids during and shortly after operation. Suitable safety
precautions, e.g. protective clothing plan.
– The characteristic curve may shift depending on the operating status (operating pressure, fluid temperature) of the pump.
– Tightening torques:
- The tightening torques specified in this data sheet are maximum values and may not be exceeded (maximum value for screw
thread). Manufacturer specifications for the max. permissible tightening torques of the used fittings must be observed!
- For DIN 13 fastening screws we recommend checking the tightening torque individually according to VDI 2230
Edition 2003.
– The data and information contained herein must be adhered to.
Bosch Rexroth AG © This document, as well as the data, specifications and other information
Hydraulics set forth in it, are the exclusive property of Bosch Rexroth AG. It may not be
Product Segment Axial Piston Units reproduced or given to third parties without its consent.
Elchingen Plant Horb Plant The data specified above only serve to describe the product. No statements
Glockeraustrasse 2 An den Kelterwiesen 14 concerning a certain condition or suitability for a certain application can be
89275 Elchingen, Germany 72160 Horb, Germany derived from our information. The information given does not release the user
from the obligation of own judgment and verification. It must be remembered that
Phone +49 (0) 73 08 82-0 Phone +49 (0) 74 51 92-0
our products are subject to a natural process of wear and aging.
Facsimile +49 (0) 73 08 72 74 Facsimile +49 (0) 74 51 82 21
Subject to change.
[email protected]
www.boschrexroth.com/brm
Electric Drives Linear Motion and
and Controls Hydraulics Assembly Technologies Pneumatics Service
Axial Piston Variable Pump RE 92500/10.09 1/64

Replaces: 06.09
A11VO
Data sheet
Series 1
Size NG40 to 260
Nominal pressure 350 bar
Maximum pressure 400 bar
Open circuit
Contents Features
Ordering Code / Standard Program 2 – Variable axial piston pump of swashplate design for hydrosta-
tic drives in open circuit hydraulic system.
Technical Data 5
– Designed primarily for use in mobile applications.
LR – Power Control 9
– The pump operates under self-priming conditions, with tank
DR – Pressure Control 20
pressurization, or with an optional built-in charge pump
HD – Hydraulic Control, Pilot-Pressure Related 24 (impeller).
EP – Electric Control with Proportional Solenoid 26 – A comprehensive range of control options is available
matching any application requirement.
Dimensions, Size 40 28
– Power control option is externally adjustable, even when the
pump is running.
– The through drive is suitable for adding gear pumps and axial
Dimensions, Size 95 40 piston pumps up to the same, i.e. 100% through drive.
Dimensions, Size 130/145 44 – The output flow is proportional to the drive speed and
infinitely variable between qV max and qV min = 0.
Through Drive Dimensions 56
Overview of Attachments for A11V(L)O 58
Combination Pumps A11VO + A11VO 58
Swivel Angle Indicator 59
Connector for Solenoids 60
Installation Notes 61
General Notes 64
VL115
2/64 Bosch Rexroth AG A11VO Series 1 RE 92500/10.09

A11V O / 1 – N
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16
Axial piston unit

01 Swashplate design, variable, nominal pressure 350 bar, maximum pressure 400 bar A11V
Charge pump (impeller) 40 60 75 95 130 145 190 260

without charge pump (no code) ● ● ● ● ● ● ● ●
02
with charge pump – – – – ● ● ● ● L
Operation
03 Pump, open circuit O
Size
04 ≈ Displacement Vg max in cm3 40 60 75 95 130 145 190 260
Control unit
Power control LR ● ● ● ● ● ● ● ● LR
with override cross sensing negative LR C ● ● ● ● ● ● ● ● LR .C
high-pressure related negative LR3 ● ● ● ● ● ● ● ● LR3
pilot-pressure related negative LG1 ● ● ● ● ● ● ● ● LG1
positive LG2 ● ● ● ● ● ● ● ● LG2
electric U = 12 V negative LE1 ❍ ❍ ❍ ● ● ● ● ● LE1
U = 24 V negative LE2 ❍ ● ● ● ● ● ● ● LE2
with pressure cut-off D ● ● ● ● ● ● ● ● L . D. .
hydraulic, 2-stage E ● ● ● ● ● ● ● ● L . E. .
hydraulic, remote controlled G ● ● ● ● ● ● ● ● L . . G.
with load sensing S ● ● ● ● ● ● ● ● L . . .S
electric, prop. override, 24 V S2 ❍ ❍ ❍ ● ● ● ● ● L . . .S2
hydraulic, prop. override S5 ❍ ❍ ❍ ● ● ● ● ● L . . .S5
with stroke limiter negative Δp = 25 bar H1 ● ● ● ● ● ● ● ● L . . .H1
characteristic Δp = 10 bar H5 ● ● ● ● ● ● ● ● L . . .H5
05 positive Δp = 25 bar H2 ● ● ● ● ● ● ● ● L . . .H2
characteristic Δp = 10 bar H6 ● ● ● ● ● ● ● ● L . . .H6
U = 12 V U1 ● ● ● ● ● ● ● ● L . . .U1
U = 24 V U2 ● ● ● ● ● ● ● ● L . . .U2
Pressure control DR ● ● ● ● ● ● ● ● DR
with load sensing DRS ● ● ● ● ● ● ● ● DRS
remote controlled DRG ● ● ● ● ● ● ● ● DRG
for parallel operation DRL ● ● ● ● ● ● ● ● DRL
Hydraulic control, Δp = 10 bar HD1 ● ● ● ● ● ● ● ● HD1
pilot-pressure (positive characteristic) Δp = 25 bar HD2 ● ● ● ● ● ● ● ● HD2
related with pressure cut-off D ● ● ● ● ● ● ● ● HD.D
with pressure cut-off, remote controlled G ❍ ● ❍ ❍ ❍ ❍ ● ● HD. G
Electric control U = 12 V EP1 ● ● ● ● ● ● ● ● EP1
with (positive characteristic) U = 24 V EP2 ● ● ● ● ● ● ● ● EP2
proportional with pressure cut-off D ● ● ● ● ● ● ● ● EP. D
solenoid
with pressure cut-off, remote control G ● ● ● ● ● ● ● ● EP. G
In case of controls with several additional functions, observe the order of the columns, only one option per column is possible
(e.g. LRDCH2). The following combinations are not available for the power control: LRDS2, LRDS5, L...GS, L...GS2, L...GS5,
L...EC and the combination L...DG in conjunction with the stroke limiters H1, H2, H5, H6, U1 and U2.
RE 92500/10.09 A11VO Series 1 Bosch Rexroth AG 3/64

A11V O / 1 – N
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16
Series
06 1
Index
Size 40 ... 130 0
07
Size 145 ... 260 1
Viewed from shaft end clockwise R
08
counter-clockwise L
Seals
09 NBR (nitrile-caoutchouc), shaft seal ring in FKM (fluor-caoutchouc) N
Shaft end (see page 8 for permissible input and through drive torques) 40 60 75 95 130 145 190 260
Splined shaft DIN 5480 for single and combination pump ● ● ● ● ● ● ● ● Z
Parallel keyed shaft DIN 6885 ● ● ● ● ● ● ● ● P
10
Splined shaft ANSI B92.1a–1976 for single pump ● ● ● ● ● ● ● ● S
for combination pump ● ● ● –1) –1) –1) ● ● T
Mounting flange 40 60 75 95 130 145 190 260

SAE J744 – 2-hole ● ● – – – – – – C
11 SAE J744 – 4-hole – – ● ● ● ● ● ● D
SAE J617 2) (SAE 3) – – – ● ● ● ● – G
Service line ports 40 60 75 95 130 145 190 260

Pressure and suction port SAE, at side, opposite side
12 ● ● ● ● ● ● ● ● 12
(with metric fastening threads)
Through drive (see page 58 for attachments) 40 60 75 95 130 145 190 260
Flange SAE J744 3) Coupler for splined shaft
– – ● ● ● ● ● ● ● ● N00
82-2 (A) 5/8in 9T 16/32DP (A) ● ● ● ● ● ● ● ● K01
3/4in 11T 16/32DP (A-B) ❍ ● ❍ ● ● ● ❍ ❍ K52
101-2 (B) 7/8in 13T 16/32DP (B) ● ● ● ● ● ● ● ● K02
1 in 15T 16/32DP (B-B) ● ● ● ● ● ● ● ● K04
W35 2x30x16x9g ● ● ● ● ● ● ● ● K79
127-2 (C) 4) 1 1/4in 14T 12/24DP (C) – ● ● ● ● ● ● ● K07
1 1/2in 17T 12/24DP (C-C) – – – ● ● ● ● ● K24
13 W30 2x30x14x9g – ● ● ● ● ● ● ● K80
W35 2x30x16x9g – ● ● ● ● ● ● ● K61
152-4 (D) 1 1/4in 14T 12/24DP (C) – – ● ● ● ● ● ● K86
1 3/4in 13T 8/16DP (D) – – – – ● ● ● ● K17
W40 2x30x18x9g – – ● ● ● ● ● ● K81
W45 2x30x21x9g – – – ● ● ● ● ● K82
W50 2x30x24x9g – – – – ● ● ● ● K83
165-4 (E) 1 3/4in 13T 8/16DP (D) – – – – – – ● ● K72
W50 2x30x24x9g – – – – – – ● ● K84
W60 2x30x28x9g – – – – – – – ● K67

A11V O / 1 – N
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16
Swivel angle indicator (page 59) 40 60 75 95 130 145 190 260

without swivel angle indicator (no symbol) ● ● ● ● ● ● ● ●
14 with optical swivel angle indicator ● – ● ● ● ● ● ● V
with electric swivel angle sensor ● – ● ● ● ● ● ● R
Connector for solenoids (page 60) 40 60 75 95 130 145 190 260

15 DEUTSCH connector molded, 2-pin – without suppressor diode ● ● ● ● ● ● ● ● P
Standard / special version

Standard version without symbol
combined with attachment part or attachment pump -K
16
Special version -S
combined with attachment part or attachment pump -SK
1) S-shaft suitable for combination pump!
2) To fit the flywheel case of the combustion engine
3) 2 2-hole; 4 4-hole
4) Size 190 and 260 with 2 + 4-hole flange
= available ❍ = on request – = not available = preferred program

Technical Data
Hydraulic fluid Selection diagram
Before starting project planning, please refer to our data -40° -20° 0° 20° 40° 60° 80° 100°
1600 1600
sheets RE 90220 (mineral oil), RE 90221 (environmentally 1000
acceptable hydraulic fluids) and RE 90223 600
400
(HF hydraulic fluids) for detailed information regarding the choi-
200
VG 6 8
VG
VG 32
VG 46
VG 2
ce of hydraulic fluid and operating conditions.
10
2
100
0
The variable pump A11VO is not suitable for operating with
60
HFA, HFB and HFC. If HFD or environmentally acceptab-
40 36
le hydraulic fluids are being used, the limitations regarding
technical data and seals mentioned in RE 90221 and νopt.
Viscosity ν in mm2/s
20
RE 90223 must be observed. 16
When ordering, please indicate the used hydraulic fluid. 10
Operating viscosity range

For optimum efficiency and service life, select an operating vis- 5 5
-40° -25° -10° 0° 10° 30° 50° 70° 90° 115°
cosity (at operating temperature) within the optimum range of Temperature t in °C
νopt = optimum operating viscosity 16 to 36 mm2/s tmin = -40°C tmax = +115°C
Hydraulic fluid temperature range
depending on the tank temperature (open circuit).
Details regarding the choice of hydraulic fluid
Limits of viscosity range
The correct choice of hydraulic fluid requires knowledge of the
The limiting values for viscosity are as follows: operating temperature in relation to the ambient temperature: in
νmin = 5 mm2/s an open circuit the tank temperature.
Short-term (t < 3 min) The hydraulic fluid should be chosen so that the operating vis-
At max. perm. temperature of tmax = +115°C. cosity in the operating temperature range is within the optimum
νmax = 1600 mm2/s range (νopt.) – see the shaded area of the selection diagram.
Short-term (t < 3 min) We recommended that the higher viscosity class be selected
At cold start (p ≤ 30 bar, n ≤ 1000 rpm, tmin = -40°C). in each case.
Only for starting up without load. Optimum operating Example: At an ambient temperature of X°C an operating tem-
viscosity must be reached within approx. 15 minutes. perature of 60°C is set. In the optimum operating viscosity range
Note that the maximum hydraulic fluid temperature of 115°C (νopt; shaded area) this corresponds to the viscosity classes VG
must not be exceeded locally either (e.g. in the bearing area). 46 and VG 68; to be selected: VG 68.
The temperature in the bearing area is – depending on pressu- Please note:
re and speed – up to 5 K higher than the average case drain The case drain temperature, which is affected by pressure and
temperature. speed, is always higher than the tank temperature. At no point
Special measures are necessary in the temperature range from in the system may the temperature be higher than 115°C.
-40°C and -25°C (cold start phase), please contact us. If the above conditions cannot be maintained due to extreme
For detailed information about use at low temperatures, operating parameters, please contact us.
see RE 90300-03-B.
Filtration
The finer the filtration, the higher the cleanliness level of the hyd-
raulic fluid and the longer the service life of the axial piston unit.
To ensure functional reliability of the axial piston unit, the hyd-
raulic fluid must have a claenliness level of at least
20/18/15 according to ISO 4406.
At very high hydraulic fluid temperatures (90°C to max. 115°C,
not permitted for sizes 250 to 1000) at least cleanliness level
19/17/14 according to ISO 4406 is required.
If the above classes cannot be observed, please contact us.
Technical Data
Operating pressure range Case drain pressure
The case drain pressure at the ports T1 and T2 may
Inlet
be a maximum of 1.2 bar higher than the inlet pressure at the
Absolute pressure at port S (suction port) port S but not higher than
Version without charge pump
pL abs. max ________________________________________ 2 bar.
pabs min _________________________________________ 0.8 bar
An unrestricted, full size case drain line directly to tank is
pabs max_________________________________________ 30 bar
required.
If the pressure is > 5 bar, please ask.
Version with charge pump Temperature range of the shaft seal ring
pabs min _________________________________________ 0.6 bar The FKM shaft seal ring is permissible for case drain tempera-
pabs max___________________________________________2 bar tures of -25°C to +115°C.
Note:
Maximum permissible speed (speed limit)
For applications below -25°C, an NBR shaft seal ring is neces-
Permissible speed by increasing the inlet pressure pabs at the sary (permissible temperature range: -40°C to +90°C).
suction port S or at Vg ≤ Vg max State NBR shaft seal ring in clear text in the order.
1,2
Flushing the case
pabs = 1.5 bar
1,1 If a variable pump with control unit EP, HD, DR or stroke limiter
Speed nmax /nmax1
(H., U., ) is operated over a long period (t > 10 min) with flow
pabs = 1 bar zero or operating pressure < 15 bar, flushing of the case via
1,0 ports "T1", "T2" or "R" is necessary.
Size 40 60 75 95 130 145 190 260

0,9
0,8 0,9 1,0 qV flush(l/min) 2 3 3 4 4 4 5 6
Displacement Vg / Vg max Flushing the case is unnecessary in versions with charge pump
(A11VLO), since a part of the charge flow is directed to the
Outlet case.
Pressure at port A or B
Nominal pressure pN ____________________________ 350 bar Charge pump (impeller)
Maximum pressure pmax __________________________ 400 bar The charge pump is a circulating pump with which the A11VLO
Nominal pressure: Max. design pressure at which fatigue (size 130...260) is filled and therefore can be operated at
strength is ensured. higher speeds. This also simplifies cold starting at low tempe-
ratures and high viscosity of the hydraulic fluid. Tank charging
Maximum pressure: Max. operating pressure which is is therefore unnecessary in most cases. A tank pressure of a
permissible for short-term (t < 1s). max. 2 bar is permissible with charge pump.
Minimum operating pressure T1 GM A
A minimum operating pressure pB min is required in the pump

service line depending on the speed, the swivel angle and the
displacement (see diagram). Vg max Vg min
pB (bar)
20
18 n (w R T2 M1 S
16 n (w ith ch
itho arge
14 ut c p
har ump)
12 ge
pum
10 p )
8
6
0 0,5 1,0 Vg max
Technical Data
Table of values (theoretical values, without efficiency and tolerances; values rounded)
Size A11VO 40 60 75 95 130 145 190 260
Displacement Vg max cm3 42 58.5 74 93.5 130 145 193 260
Vg min cm3 0 0 0 0 0 0 0 0
Speed
maximum at Vg max 1) nmax rpm 3000 2700 2550 2350 2100 2200 2100 1800
maximum at Vg ≤ Vg max 3) nmax1 rpm 3500 3250 3000 2780 2500 2500 2100 2300
Flow
qv max l/min 126 158 189 220 273 319 405 468
at nmax and Vg max
Power at
Pmax kW 74 92 110 128 159 186 236 273
qv max and Δp = 350 bar
Torque at
Tmax Nm 234 326 412 521 724 808 1075 1448
Vg max and Δp = 350 bar
Rotary stiffness Z shaft Nm/rad 88894 102440 145836 199601 302495 302495 346190 686465
P shaft Nm/rad 87467 107888 143104 196435 312403 312403 383292 653835
S shaft Nm/rad 58347 86308 101921 173704 236861 236861 259773 352009
T shaft Nm/rad 74476 102440 125603 – – – 301928 567115
Moment of inertia for
JTW kgm2 0.0048 0.0082 0.0115 0.0173 0.0318 0.0341 0.055 0.0878
rotary group
Angular acceleration, max. 4)
α rad/s2 22000 17500 15000 13000 10500 9000 6800 4800
Filling capacity V l 1.1 1.35 1.85 2.1 2.9 2.9 3.8 4.6
Mass (approx.) m kg 32 40 45 53 66 76 95 125
Size A11VLO
130 145 190 260
(with charge pump)
Displacement Vg max cm3 130 145 193 260
Vg min cm3 0 0 0 0
Speed
maximum at Vg max 2) nmax rpm 2500 2500 2500 2300
maximum at Vg ≤ Vg max 3) nmax1 rpm 2500 2500 2500 2300
Flow
qv max l/min 325 363 483 598
at nmax and Vg max
Power at
Pmax kW 190 211 281 349
qv max and Δp = 350 bar
Torque at
Tmax Nm 724 808 1075 1448
Vg max and Δp = 350 bar
Rotary stiffness Z shaft Nm/rad 302495 302495 346190 686465
P shaft Nm/rad 312403 312403 383292 653835
S shaft Nm/rad 236861 236861 259773 352009
T shaft Nm/rad – – 301928 567115
Moment of inertia for
JTR kgm2 0.0337 0.036 0.0577 0.0895
rotary group
Angular acceleration, max. 4)
α rad/s2 10500 9000 6800 4800
Filling capacity V l 2.9 2.9 3.8 4.6
Mass (approx.) m kg 72 73 104 138
1) The values apply at absolute pressure (pabs) 1 bar at the suction port S and mineral hydraulic fluid.
2) The values apply at absolute pressure (pabs) of at least 0.8 bar at the suction port S and mineral hydraulic fluid.
3) The values apply at Vg ≤ Vg max or in case of an increase in the inlet pressure pabs at the suction port S (see diagram page 6)
4) – The area of validity is situated between 0 and the maximum permissible speed.
It applies for external stimuli (e.g. engine 2-8 times rotary frequency, cardan shaft twice the rotary frequency).
– The limit value applies for a single pump only.
– The loading on the connection parts has to be considered.
Caution:
Exceeding the permissible limit values could cause a loss of function, reduced service life or the destruction of the axial piston
unit. The permissible values can be determined by calculation.
Technical Data
Permissible radial and axial loading on drive shaft
The values stated are maximum data and not permissible for continuous operation
Size Size 40 60 75 95 130 145 190 260
Radial force, max. Fq max N 3600 5000 6300 8000 11000 11000 16925 22000
at distance a, b, c Fq a mm 17.5 17.5 20 20 22.5 22.5 26 29
(from shaft collar)
Fq max N 2891 4046 4950 6334 8594 8594 13225 16809
B mm 30 30 35 35 40 40 46 50
a, b, c
Fq max N 2416 3398 4077 5242 7051 7051 10850 13600
c mm 42.5 42.5 50 50 57.5 57.5 66 71
Axial force, max. -
Fax ± Fax max N 1500 2200 2750 3500 4800 4800 6000 4150
+
Permissible input and through drive torques

Size Size 40 60 75 95 130 145 190 260
Torque
Tmax Nm 234 326 412 521 724 808 1075 1448
(at Vg max and Δp = 350 bar 1))
Input torque, max. 2)
at shaft end P 468 648 824 1044 1448 1448 2226 2787
TE perm. Nm
Shaft key DIN 6885 ø32 ø35 ø40 ø45 ø50 ø50 ø55 ø60
at Z shaft end 912 912 1460 2190 3140 3140 3140 5780
TE perm. Nm
DIN 5480 W35 W35 W40 W45 W50 W50 W50 W60
at S shaft end 314 602 602 1640 1640 1640 1640 1640
TE perm. Nm
ANSI B92.1a-1976 (SAE J744) 1 in 1 1/4 in 1 1/4 in 1 3/4 in 1 3/4 in 1 3/4 in 1 3/4 in 1 3/4 in
at T shaft end 602 970 970 — — – 2670 4070
TE perm. Nm
ANSI B92.1a-1976 (SAE J744) 1 1/4 in 1 3/8 in 1 3/8 in — — – 2 in 2 1/4 in
Through drive torque, max. 3) TD perm. Nm 314 521 660 822 1110 1110 1760 2065
1) Efficiency not considered
2) For drive shafts with no radial force
3) Observe max. input torque for shaft S!
Torque distribution Determining the nominal value
T1 T2 Flow qv =
Vg • n • ηv
l/min
1000
Vg • Δp Nm
Torque T =
20 • π • ηmh
TE
1. Pumpe 2π•T•n = qv • Δp
1st pump 2nd
2. pump
Pumpe Power P = kW
60,000 600 • ηt
TD
Vg = Displacement per revolution in cm3
Δp = Differential pressure in bar
n = Speed in rpm
ηv = Volumetric efficiency
ηmh = Mechanical-hydraulic efficiency
ηt = Overall efficiency (nt = nv • nmh)
LR – Power Control
The power control regulates the displacement of the pump de- Circuit diagram LR
pending on the operating pressure so that a given drive power
Size 40 ... 145
is not exceeded at constant drive speed.
pB = operating pressure
pB • Vg = constant
Vg = displacement
T1 M A
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
Vg max Vg min
piston. An externally adjustable spring force counteracts this, it
determines the power setting.
If the operating pressure exceeds the set spring force, the
control valve is actuated by the rocker, the pump swivels back
(direction Vg min). The lever length at the rocker is shortened R T2 M1 S
and the operating pressure can increase at the same rate as
the displacement decreases without the drive powers being Size 190 ... 260
exceeded (pB • Vg = constant).
The hydraulic output power (characteristic LR) is influenced by
the efficiency of the pump.
T1 M A
State in clear text in the order:
– drive power P in kW
– drive speed n in rpm Vg max Vg min
– max. flow qV max in l/min
After clarifying the details a power diagram can be created by
our computer.
R T2 M1 S
Characteristic LR
320 bar
Operating pressure pB in bar
Setting range
Start of control
50 bar
Vg min Displacement Vg max

LRC Override with cross sensing LR3 High-pressure related override
Cross sensing control is a summation power control system, The high-pressure related power override is a total power
whereby the total power, of both the A11VO and of a same control in which the power control setting is piloted by the load
size A11VO power controlled pump mounted onto the through pressure of an attached fixed pump (port Z).
drive, are kept constant.
As a result the A11VO can be set to 100% of the total drive
If a pump is operating at pressures below the start of the power. The power setting of the A11VO is reduced proporti-
control curve setting, then the surplus power not required, in a onal to the load-dependent rise in operating pressure of the
critical case up to 100%, becomes available to the other pump. fixed pump. The fixed pump has priority in the total power
Total power is thus divided between two systems as demand setting.
requires.
The measuring area of the power reduction pilot piston is desi-
Any power being limited by means of pressure cut-off or other gned as a function of the size of the fixed pump.
override functions is not taken into account.
Circuit diagram LR3
Half side cross sensing function
Size 40 ... 145
When using the LRC control on the 1st pump (A11VO) and
PHD
a power-controlled pump without cross sensing attached to Z
the through drive, the power required for the 2nd pump is
deducted from the setting of the 1st pump. The 2nd pump has
priority in the total power setting.
T1 M A
The size and start of control of the power control of the 2nd
pump must be specified for rating the control of the 1st pump.
Circuit diagram LRC Vg max Vg min
Size 40 ... 145

pHD
Z
R T2 M1 S
T1 M A Size 190 ... 260

PHD
Z
Vg max Vg min LR
T1 M A
R T2 M1 S
Vg max Vg min
Size 190 ... 260
Z
R T2 M1 S
T1 M A
Vg max Vg min
R T2 M1 S
LG1/2 Pilot-pressure related override
This power control works by overriding the control setting with
an external pilot pressure signal. This pilot pressure acts on the
adjustment spring of the power regulator via port Z.
The mechanically adjusted basic setting can be hydraulically
adjusted by means of different pilot pressure settings, enabling
different power mode settings.
If the pilot pressure signal is then adjusted by means of an
external power limiting control, the total hydraulic power
consumption of all users can be adapted to the available drive
power from the engine.
The pilot pressure used for power control is generated by an
external control element that is not a component part of the
A11VO (e.g. see also data sheet RE 95310, Electronic Load
Limiting Control, LLC).
LG1 Negative power override LG2 Positive power override

Power control with negative override, LG1: the force resulting Power control with positive override, LG2: the force resulting
from the pilot pressure is acting against the mechanical adjust- from the pilot pressure is additive the mechanical adjustment
ment spring of the power control. spring of the power control.
Increasing the pilot pressure reduces the power setting. An increase in pilot pressure increases the power output.
Circuit diagram LG1 Circuit diagram LG2

Size 40 ... 145 Size 40 ... 145
Z Z
T1 M A T1 M A
Vg max Vg min Vg max Vg min
R T2 M1 S R T2 M1 S
Size 190 ... 260 Size 190 ... 260

Z Z
T1 M A T1 M A
R T2 M1 S R T2 M1 S
LE1/2 Electric override (negative) Circuit diagram LE1/2
Contrary to hydraulic power control override, the basic power Size 40 ... 145
setting is reduced by an electric pilot current applied to a
proportional solenoid. The resulting force is acting against the
mechanical power control adjustment spring.
T1 M A
The mechanically adjusted basic power setting can be varied
by means of different control current settings.
Increase in current = decrease in power
Vg max Vg min
If the pilot current signal is adjusted by a load limiting control
the power consumption of all actuators will be reduced to
match the available power from the diesel engine.
A 12V (LE1) or 24V (LE2) supply is required for the control of
the proportion solenoid. R T2 M1 S
Technical data - Solenoids Size 190 ... 260
LE1 LE2
Voltage 12 V (±20 %) 24 V (±20 %)
Control current T1 M A
Start of control 400 mA 200 mA
End of control 1200 mA 600 mA
Limiting current 1.54 A 0.77 A Vg max Vg min
Nominal resistance (at 20°C) 5.5 Ω 22.7 Ω
Dither frequency 100 Hz 100 Hz
see connector version, R T M S
Type of protection
page 60
Overview of power overrides

Effect of power overrides at rising pressure or current
pHD I pSt
LG2
50
LRC LR3 LE1/2 LG1
LRD Power control with pressure cut-off LRE Power control with pressure cut-off,
2-stage
The pressure cut-off corresponds to a pressure control which
adjusts the pump displacement back to Vg min, when the pres- By connecting an external pilot pressure to port Y, the basic
sure setting is reached. value of the pressure cut-off can be increased by 50 +20 bar
and a 2nd pressure setting implemented.
This function overrides the power control, i.e. below the preset
This value is usually above the primary pressure relief valve
pressure value, the power function is effective.
setting and therefore disables the pressure cut-off function.
The pressure cut-off function is integrated into the pump cont- The pressure signal at port Y must be between 20 and 50 bar.
rol module and is preset to a specified value at the factory.
Characteristic LRE
Setting range from 50 to 350 bar
Characteristic LRD
390 Increased pressure cut-off with tolerance
max range (pressure cut-off deactivated)

350 370
Primary pressure relief valve

350
Basic value pressure cut-off
Setting range
320
50
min Vg min Displacement Vg max
Circuit diagram LRE
Circuit diagram LRD Size 40...145
Size 40...145 Y
T1 M A
T1 M A
Vg max Vg min
Vg max Vg min
R T2 M1 S
R T2 M1 S
Size 190...260 Size 190...260

Y
LRG Power control with pressure cut-off,

hydraulically remote controlled
See page 21 for description and characteristic
(pressure control remote controlled, DRG)
LRDS Power control with pressure cut-off Circuit diagram LRDS
and load sensing Size 40 ... 145
The load sensing control is a flow control option that operates
as a function of the load pressure to regulate the pump dis- X
placement to match the actuator flow requirement.
The flow depends here on the cross section of the external
sensing orifice (1) fitted between the pump outlet and the
actuator. The flow is independent of the load pressure below (1)
the power curve and the pressure cut-off setting and within the
control range of the pump.
The sensing orifice is usually a separately arranged load T1 M A
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.
Vg max Vg min
The load sensing control compares pressure before and after
the sensing orifice and maintains the pressure drop across
the orifice (differential pressure Δp) and with it the pump flow
constant.
R T2 M1 S
If the differential pressure Δp increases at the sensing orifice,
the pump is swivelled back (towards Vg min), and, if the differen-
Size 190 ... 260
tial pressure Δp decreases, the pump is swivelled out (towards
Vg max) until the pressure drop across the sensing orifice in the
X
valve is restored.
Δporifice = ppump – pactuator
The setting range for Δp is between 14 bar and 25 bar.
(1)
The standard differential pressure setting is 18 bar. (Please
state in clear text when ordering).
The stand-by pressure in zero stroke operation (sensing orifice T1 M A
plugged) is slightly above the Δp setting.
In a standard LS system the pressure cut-off is integrated in
the pump control. In a LUDV (flow sharing) system the pressu- Vg max Vg min
re cut-off is integrated in the LUDV control block.
(1) The sensing orifice (control block) is not included in the
pump supply.
R T2 M1 S
Characteristic LRDS
350
50

LRS2 Power control with load sensing, LRS5 Power control with load sensing,
electric override hydraulic override
This control option adds a proportional solenoid to override This control option adds an external proportional pilot pressure
to the mechanically set load sensing pressure. The pressure signal (to port Z) to override the mechanically set load sensing
differential change is proportional to the solenoid current. pressure.
Increasing current = smaller Δp-setting Increasing pilot pressure = smaller Δp-setting
See following characteristic for details (example). Please con- See following characteristic for details (example). Please con-
sult us during the project planning phase. sult us during the project planning phase.
For solenoid specification, see page 12 (LE2)
Characteristic LRS2 Characteristic LRS5

25 25
18 18
ΔpLS in bar
ΔpLS in bar
14 14
10 10
5 5
200 300 400 500 600 0 5 10 15 20 25 30

Control current I in mA (at 24V) Pilot pressure pZ in bar
Circuit diagram LRS2 Circuit diagram LRS5

Size 40 ... 145 Size 40 ... 145
X Z X
T1 M A T1 M A
R T2 M1 S R T2 M1 S
Size 190 ... 260 Size 190 ... 260
X Z X
T1 M A T1 M A
R T2 M1 S R T2 M1 S
LR... Power control with stroke limiter
Note
The stroke limiter can be used to vary or limit the displacement
of the pump continuously over the whole control range. The The spring return feature in the controller is not a safety
displacement is set in LRH with the pilot pressure pSt (max. device
40 bar) applied to port Y or in LRU by the control current ap- The spool valve inside the controller can get stuck in an
plied to the proportional solenoid. A DC current of 12V (U1) or undefined position by internal contamination (contamina-
24V (U2) is required to control the proportional solenoid. ted hydraulic fluid, abrasion or residual contamination from
The power control overrides the stoke limiter control, i.e. below system components). As a result, the axial piston unit can no
the hyperbolic power characteristic, the displacement is cont- longer supply the flow specified by the operator.
rolled by the control current or pilot pressure. When exceeding Check whether your application requires that remedial mea-
the power characteristic with a set flow or load pressure, the sures be taken on your machine in order to bring the driven
power control overrides and reduces the displacement follo- consumer into a safe position (e.g. immediate stop).
wing the hyperbolic characteristic.
To permit operation of the pump displacement control from its
starting position Vg max to Vg min, a minimum control pressure of
30 bar is required for the electric stroke limiter LRU1/2 and the
hydraulic stroke limiter LRH2/6.
The required control pressure is taken either from the load
pressure, or from the externally applied control pressure at the
G port.
To ensure functioning of the stroke limiter even at low operating
pressure, port G must be supplied with external control pressu-
re of approx. 30 bar.
Note:
If no external control pressure is connected at G, the shuttle
valve must be removed.
LRH1/5 Hydraulic stroke limiter Circuit diagram LRH1/5
(negative characteristic) Size 40 ... 145
Control from Vg max to Vg min Y
With increasing pilot pressure the pump swivels to a smaller
displacement.
Start of control (at Vg max), can be set _______ from 4 – 10 bar
State start of control in clear text in the order. T1 GM A
Starting position without control signal (pilot pressure): Vg max
Characteristic H1 Vg max Vg min

Increase in pilot pressure (Vg max – Vg min) ________Δp = 25 bar
35
30
25 R T2 M1 S
Pilot pressure pSt in bar
20
15 Size 190 ... 260
10 Y
Setting range
0 0,5 1,0
T1 G M A
Characteristic H5
Increase in pilot pressure (Vg max – Vg min) ________ Δp = 10 bar
Vg max Vg min
20
15
10
4
Setting range
R T2 M1 S
0 0,5 1,0
LRH2/6 Hydraulic stroke limiter Circuit diagram LRH2/6
(positive characteristic) Size 40 ... 145
Control from Vg min to Vg max Y
With increasing pilot pressure the pump swivels to a higher
displacement.
Start of control (at Vg min), can be set _________ from 4–10 bar
State start of control in clear text in the order. T1 G M A
Starting position without control signal (pilot pressure):
– at operating pressure and external control pressure
< 30 bar: Vg max Vg max Vg min
– at operating pressure or external control pressure

> 30 bar: Vg min
Characteristic H2 R T2 M1 S
Increase in pilot pressure (Vg min – Vg max) _______ Δp = 25 bar
Size 190 ... 260
35
30 Y
25
20
Setting range
15
10
T1 G M A
4
0 0,5 1,0
Vg min Displacement Vg max Vg max Vg min
Characteristic H6
Increase in pilot pressure (Vg min – Vg max) _______ Δp = 10 bar
20 R T2 M1 S
15
Setting range
10
4
0 0,5 1,0
LRU1/2 Electric stroke limiter Characteristic LRU1/2
(positive characteristic) 1400
Control from Vg min to Vg max
Control current I in mA
With increasing control current the pump swivels to a higher 1200
displacement.
1000
Technical data - solenoids
800 LRU1
LRU1 LRU2
Voltage 12 V (±20 %) 24 V (±20 %) 600
Control current LRU2
Start of control at Vg max 400 mA 200 mA 400
End of control at Vg min 1200 mA 600 mA
Limiting current 1.54 A 0.77 A 200
Dither frequency 100 Hz 100 Hz 0 0,5 1,0
Actuated time 100 % 100 % Vg min Displacement Vg max
Type of protection see connector version, page 60 Circuit diagram LRU1/2
Starting position without control signal (control current): Size 40 ... 145
– at operating pressure and external control pressure
< 30 bar: Vg max
> 30 bar: Vg min
T1 GM A
The following electronic controllers and amplifiers are available
for actuating the proportional solenoids (see also
www.boschrexroth.com/mobile-electronics):
– BODAS controller RC Vg max Vg min
Series 20 ______________________________ RE 95200
Series 21_______________________________ RE 95201
Series 22 ______________________________ RE 95202
Series 30 ______________________________ RE 95203
and application software R T2 M1 S
– Analog amplifier RA ______________________ RE 95230 Size 190 ... 260
T1 G M A
Vg max Vg min
R T2 M1 S
DR – Pressure Control
DR Pressure control Circuit diagram DR
The pressure control keeps the pressure in a hydraulic system Size 40 ... 145
constant within its control range even under varying flow condi-
tions. The variable pump only moves as much hydraulic fluid as
is required by the actuators. If the operating pressure exceeds
the setpoint set at the integral pressure control valve, the pump T1 M A
displacement is automatically swivelled back until the pressure
deviation is corrected.
Starting position in depressurized state: Vg max
Vg max Vg min
Setting range from 50 to 350 bar.
Characteristic: DR
max R T2 M1 S
350
Size 190 ... 260

max. 10 bar
Setting range
T1 M A
50
min Vg max Vg min
0
Flow qv in L/min
R T2 M1 S
DRS Pressure control with load sensing Circuit diagram DRS
The load sensing control is a flow control option that operates Size 40 ... 145
as a function of the load pressure to regulate the pump dis-
placement to match the actuator flow requirement. X
The flow depends here on the cross section of the external
sensing orifice (1) fitted between the pump outlet and the (1)
actuator. The flow is independent of the load pressure below
the pressure cut-off setting and within the control range of the
pump. T1 M A
The sensing orifice is usually a separately arranged load

sensing directional valve (control block). The position of the
directional valve piston determines the opening cross section Vg max Vg min
of the sensing orifice and thus the flow of the pump.
The load sensing control compares pressure before and after
the sensing orifice and maintains the pressure drop across
the orifice (differential pressure Δp) and with it the pump flow
R T2 M1 S
constant.
If the differential pressure Δp increases at the sensing orifice,
the pump is swivelled back (towards Vg min), and, if the differen- Size 190 ... 260
tial pressure Δp decreases, the pump is swivelled out (towards
Vg max) until the pressure drop across the sensing orifice in the X
valve is restored.
(1)
Δporifice = ppump – pactuator
The setting range for Δp is between 14 bar and 25 bar.
The standard differential pressure setting is 18 bar. (Please T1 M A
state in clear text when ordering).
The stand-by pressure in zero stroke operation (sensing orifice
plugged) is slightly above the Δp setting. Vg max Vg min
(1) The sensing orifice (control block) is not included in the

pump supply.
Characteristic: DRS R T2 M1 S
max
350
max. 10 bar
50
min
0
Flow qv in L/min
DRG Pressure control, remote controlled Circuit diagram DRG
The remote control pressure cut-off regulator permits the Size 40 ... 145
adjustment of the pressure setting by a remotely installed pres- (2) (1)
sure relief valve (1). Pilot flow for this valve is provide by a fixed
orifice in the control module.
max. 5m
Setting range from 50 to 350 bar.
X
In addition the pump can be unloaded into a standby pressure
condition by an externally installed 2/2-way directional valve
(2).
Both functions can be used individually or in combination (see
circuit diagram).
T1 M A
The external valves are not included in the pump supply.
As a separate pressure relief valve (1) we recommend:
DBDH 6 (manual control), see RE 25402 Vg max Vg min
Characteristic: DRG
max
350 R T2 M1 S
max. 10 bar
Setting range
Size 190 ... 260

(2) (1)
max.5m
50 X
min
0
Flow qv in L/min
Note: The remote controlled pressure cut-off is also possible in

combination with LR, HD and EP.
T1 M A
Vg max Vg min
R T2 M1 S
DRL Pressure control for parallel operation Circuit diagram DRL
The pressure control DRL is suitable for pressure control of se- Size 40 ... 145
veral axial piston pumps A11VO in parallel operation pumping
into a common pressure header. (2) (1)
The parallel pressure control has a pressure rise characteris- (3) (3)
tic of approx. 15 bar from qv max to qv min. The pump regulates
therefore to a pressure dependent swive angle. This results X
in stable control behavior, without the need of "staging" the
individual pump compensators.
With the externally installed pressure relief valve (1) the nominal T1 M A
pressure setting of all pumps connected to the system is adjus-
ted to the same value.
Setting range from 50 to 350 bar. Vg max Vg min
Each pump can be individually unloaded from the system by a
separately installed 3/2-way directional valve (2).
The check valves (3) in the service line (port A) or control line
(port X) must be provided generally. R T2 M1 S
The external valves are not included in the pump supply.
As a separate pressure relief valve (1) we recommend: Size 190 ... 260
DBDH 6 (manual control), see RE 25402
(2) (1)
Characteristic DRL
(3) (3)
max
350 X MD MA
MS
335
max. 15 bar
Setting range
T1 M A
165
150
65 Vg max Vg min
50
min
0
Flow qv in L/min
R T2 M1 S
HD – Hydraulic Control, Pilot-Pressure Related

With the pilot-pressure related control the pump displacement Characteristic HD1
is adjusted in proportion to the pilot pressure applied to port Y.
Increase in pilot pressure Vg min to Vg max _________ Δp = 10 bar
Maximum permissible pilot pressure pSt max = 40 bar

Control from Vg min to Vg max. 20
15
Setting range
With increasing pilot pressure the pump swivels to a higher
displacement. 10
Start of control (at Vg min), can be set _________ from 4–10 bar 4
State start of control in clear text in the order. 0 0,5 1,0

Starting position without control signal (pilot pressure):
– at operating pressure and external control pressure Characteristic HD2
< 30 bar: Vg max
Increase in pilot pressure Vg min to Vg max _________Δp = 25 bar
> 30 bar: Vg min 35

30
25
A control pressure of 30 bar is required to swivel the pump 20
from its starting position Vg max to Vg min. Setting range
15
The required control pressure is taken either from the load 10
pressure, or from the externally applied control pressure at the
4
G port.
0 0,5 1,0
To ensure the control even at low operating pressure < 30 bar
the port G must be supplied with an external control pressure Vg min Displacement Vg max
of approx. 30 bar.
Circuit diagram HD
Note:
If no external control pressure is connected at G, the shuttle Size 40 ... 260
valve must be removed.
Y
Note
The spring return feature in the controller is not a safety
device T1 G M A
The spool valve inside the controller can get stuck in an

undefined position by internal contamination (contamina-
ted hydraulic fluid, abrasion or residual contamination from Vg max Vg min
system components). As a result, the axial piston unit can no
longer supply the flow specified by the operator.
Check whether your application requires that remedial mea-
sures be taken on your machine in order to bring the driven
R T2 M1 S
consumer into a safe position (e.g. immediate stop).
HD – Hydraulic Control, Pilot-Pressure Related

HD.D Hydraulic control Circuit diagram HD.D
with pressure cut-off Size 40 ... 145
Y
adjusts the pump displacement back to Vg min when the pressu-
re setting is reached.
This function overrides the HD control, i.e. the pilot-pressure
related displacement control is functional below the pressure
setting. T1 GM A
The pressure cut-off function is integrated into the pump cont-
rol module and is preset to a specified value at the factory.
Setting range from 50 to 350 bar. Vg max Vg min
Pressure cut-off characteristic D
max
350
R T2 M1 S
max. 10 bar
Setting range
Size 190 ... 260

Y
50
min
0
Flow qv in L/min T1 G M A
Vg max Vg min
R T2 M1 S
EP – Electric Control with Proportional Solenoid

With the electric control with proportional solenoid, the pump Note
displacement is adjusted proportionally to the solenoid current,
resulting in a magnetic control force, acting directly onto the The spring return feature in the controller is not a safety
control spool that pilots the pump control piston. device
Control from Vg min to Vg max The spool valve inside the controller can get stuck in an
undefined position by internal contamination (contamina-
With increasing control current the pump swivels to a higher
ted hydraulic fluid, abrasion or residual contamination from
displacement.
system components). As a result, the axial piston unit can no
Starting position wthout control signal (control current): longer supply the flow specified by the operator.
– at operating pressure and external control pressure Check whether your application requires that remedial mea-
< 30 bar: Vg max sures be taken on your machine in order to bring the driven
consumer into a safe position (e.g. immediate stop).
> 30 bar: Vg min
Characteristic EP1/2
A control pressure of 30 bar is required to swivel the pump 1400
from its starting position Vg max to Vg min.
The required control pressure is taken either from the load Control current I in mA 1200
pressure, or from the externally applied control pressure at
port G. 1000
To ensure the control even at low operating pressure < 30 bar EP1
the port G must be supplied with an external control pressure 800
of approx. 30 bar.
Note: 600
If no external control pressure is connected at G, the shuttle EP2
valve must be removed. 400
Note:
Install pump with EP control in the oil tank only when using 200
mineral hydraulic oils and an oil temperature in the tank of
max. 80°C.
0 0,5 1,0
The following electronic control units and amplifiers are availab-
le for actuating the proportional solenoids (see also
www.boschrexroth.com/mobilelektronik):
Circuit diagram EP1/2
– BODAS controller RC
Series 20 ______________________________RD 95200 Size 40 ... 260
Series 21_______________________________ RD 95201
Series 22 ______________________________RD 95202
Series 30 ______________________________RD 95203
and application software T1 G M A
– Analog amplifier RA ______________________ RE 95230
Technical data, solenoid at EP1, EP2 Vg min

Vg max
EP1 EP2
Voltage 12 V (±20 %) 24 V (±20 %)
Control current
Start of control at Vg min 400 mA 200 mA R T2 M1 S
End of control at Vg max 1200 mA 600 mA
Limiting current 1.54 A 0.77 A
Dither frequency 100 Hz 100 Hz
see connector version,
Type of protection
page 60
EP – Electric Control with Proportional Solenoid

EP.D Electric control with Circuit diagram EP.D
pressure cut-off Size 40 ... 145
adjusts the pump displacement back to Vg min when the pressu-
re setting is reached.
This function overrides the EP control, i.e. the control current
related displacement control is functional below the pressure T1 G M A
setting.
The valve for the pressure cut-off is integrated in the cont-
rol case and is set to a fixed specified pressure value at the Vg max Vg min
factory.
Setting range from 50 to 350 bar
Pressure cut-off characteristic D

R T2 M1 S
max
350
Size 190 ... 260

max. 10 bar
Setting range
T1 G M A
50
min
0
Flow qv in L/min Vg max Vg min
R T2 M1 S
Dimensions, Size 40 Before finalizing your design, please request a

certified drawing. Dimensions in mm.
LRDCS
Power control LR with pressure cut-off D, cross sensing control C and load sensing control S
248 *) Center of gravity
183
View Y
123
clockwise rotation
122*) (counter-clockwise
rotation)
74 Z T1 M Z
15
9.7 X
146
T1
100
S
X 39 Y A (A)
ø101.6
A (S)
20*)
103
T2
M1
Flange SAE J744
R
101-2 (B)
W
111
X T2 S Detail X
28.3 12
0
14
S
D
110
21
75
45°
C LR
75
Z
6
A M
14
225
7
17
Detail W Detail V
50.8
S A
77.8
50
19
42.9 23.8

Shaft ends
Z Splined shaft DIN 5480 P Parallel keyed shaft DIN 6885,
W35x2x30x16x9g AS10x8x56
40
58
M12x1.75 1) 2)
28
M12x1.75 1) 2)
22
9.5
7.5 E1x0.2
ø32
DIN509
ø80.5
ø40
ø80.5
ø40
35
32
66
50
S Splined shaft SAE J744 T Splined shaft SAE J744

1 in 15T 16/32 3) 1 1/4 in 14T 12/24DP 3)
38 7/16-14UNC-2B 48
3/8-16UNC-2B
22 28
7.5 9.5
ø40
ø80.5
ø80.5
ø40
R1.6 R1.6
30 40
46 56
Ports
Max. pres- State
Designation Function Standard Size2) sure (bar) 4)
A Service line port SAE J518 3/4 in 400 O
Fixing thread DIN 13 M10x1.5; 16 deep
S Suction port SAE J518 2 in 30 O
T1, 5)
Tank port DIN 3852 M22x1.5; 14 deep 10
T2
R Air bleed DIN 3852 M22x1.5; 14 deep 10 X
M1 Measurement point, positioning chamber DIN 3852 M12x1.5; 12 deep 400 X
M Measurement point, service line port DIN 3852 M12x1.5; 12 deep 400 X
X Pilot pressure port DIN 3852 M14x1.5 12 deep 400 O
in version with load sensing (S)
and remote controlled pressure cut-off (G)
Y Pilot pressure port DIN 3852 M14x1.5; 12 deep 40 O
in version with stroke limiter (H...),
2-stage pressure cut-off (E) and HD
Z Pilot pressure port DIN 3852 M14x1.5; 12 deep O
in version with cross sensing (C) and
power override (LR3) 400
power override (LG1) 40
G Port for control pressure (controller) DIN 3852 M14x1.5; 12 deep 40 O
in version with stroke limiter (H.., U2),
HD and EP with screw union GE10 - PLM
(otherwise closed)
1) Center bore according to DIN 332 (thread acc. to DIN 13)
2) For max. tightening torque, please refer to general notes on page 64
3) ANSI B92.1a-1976, 30° pressure angle, flat root, side fit, tolerance class 5
4) Depending on adjustment data and operating pressure
5) Depending on installation position, T1 or T2 must be connected (see also page 61)
O = Open, must be connected (closed on delivery)

X = Closed (in normal operation)

LRDH1/LRDH5 LRDH2/LRDH6
Power control with pressure cut-off and hydraulic stroke limiter Power control with pressure cut-off and hydraulic stroke limiter
(negative characteristic) (positive characteristic)
248 248
206 206
58 60
5.5 Y G 21.5 Y G
153
153
131
131
106
106
Y Y
D D
21
21
78
78
H1/5 LR H2/6 LR
LRDU1/LRDU2 LR3DS
Power control with pressure cut-off and electric stroke limiter Power control with high-pressure related override,
(positive characteristic) pressure cut-off and load sensing control
248 290
206 228
29 G 52 Z
153
140
106
111 X
D
S
78
U1/2 LR D Z
110
21
LR3
LG1E LG2E
Power control with pilot-pressure related override Power control with pilot-pressure related override
(negative) and 2-stage pressure cut-off (positive) and 2-stage pressure cut-off
248
70.5
35 Z
Y
131
107.5
Y Z
E
115
21
56
LG1

HD1D/HD2D EP1D/EP2D
Hydraulic control, pilot-pressure related with Electric control with proportional solenoid and
pressure cut-off pressure cut-off
208 208
206 206
62 33
23 Y G
G
150.5
106
134
Y 106 D
78
D
21
78
HD1/2 EP1/2
DRS/DRG DRL
Pressure control with load sensing control Pressure control for parallel operation
Pressure control remote controlled
209 211.5
52 3
134
135
111 X 74 X
S/G
110
DR
81
75
DRL
LE1S/LE2S LE2S2/LE1S5/LE2S5
Power control with electric override (negative) Power control with electric override (negative)
and load sensing control and load sensing control, override
248
25.5
141.5
111 X
S
110
LE1/2

LRDCS
261.5 *) Center of gravity
View Y
198
clockwise rotation
rotation)
136
10*)
88 Z T1 M Z
41.5
X
12.7
T1
154
108
S
17
46 (A)
Y
ø127
A
15*)
A
111
(S) T2
M1
Flange SAE J744
127-2 (C)
R
181
124.5 213
W
19
X T2 S
S
D
112
23
82
C LR
82
Z T1 A M
242
V
Detail W Detail V
50.8
S A
77.8
50
19
42.9 23.8

Shaft ends
40
58
M12x1.75 1) 2)
28
M12x1.75 1) 2)
28
9.5
9.5 E1x0.2
ø35
DIN509
ø45
ø45
38
ø91
ø91
32
66
50

1 1/4 in 14T 12/24DP 3) 1 3/8 in 21T 16/32DP 3)
48 48
7/16-14UNC-2B
7/16-14UNC-2B
28 28
9.5 9.5
ø45
ø45
ø91
ø91
R1.6 R1.6
40 40
56 56
Ports
Max. pres- State
A Service line port SAE J518 3/4 in 400 O
T1, 5)
T2
(otherwise closed)


261.5 261.5
225 225
73.5 73.5
17 Y G 35 Y G
161
161
139
139
110.5
110.5
Y Y
D D
23
23
83
83
H1/5 LR H2/6 LR
LRDU1/LRDU2 LR3DS
261.5 312
225 241
2.5 G 65.5 Z
161
148
110.5
124.5 X
S
D D Z
112
83
23
LR
LR3
U1/2
LG1E LG2E
261,5
83.5
48 Z
Y
136
114
Y Z
E
117
23
58
LG1

HD1D/HD2D EP1D/EP2D
225 225
221.5 221.5
75.5 5.5
38 Y G
G
158.5
139
110.5
110.5
Y
D
D
83
23
83
HD1/2
EP1/2
DRS/DRG DRL
223.5 225
66.5 10.5
138.5
137
125.5 X 87.5 X
S/G
DR
112
76.5
DRL 83
261.5
39
150
124.5 X
S
112
LE1/2

LRDCS
*) Center of gravity
276
215
View Y
148 clockwise rotation
rotation)
105 Z T1 M
10*)
56 Z
12.7 X
T1
160
117
10*)
A
50 Y
ø152.4
A (S)
S
(A)
117
T2
Flange SAE J744 R M1 21

152-4 (D)
161.6
138.5 W 200
19 X T2 S
Z S
D
113.5
24.5
88.5
C LR
88.5
260 M
T1 A
V
Detail W Detail V
88.9
S A
57.2
63
25
50.8 28

Shaft ends
Z Splined shaft DIN 5480 P Parallel keyed shaft DIN 6885
45
82
36
M16x2 1) 2)
36
M16x2 1) 2)
12
12 E1x0.2
ø40
DIN509
ø45
ø45
ø96
43
ø96
37
90
55

1 1/4 in 14T 12/24DP 3) 1 3/8 in 21T 16/32DP 3)
48 48
7/16-14UNC-2B
7/16-14UNC-2B
28 28
9.5 9.5
ø45
ø45
ø96
ø96
R1.6 R1.6
40 40
56 56
Ports
Max. pres- State
A Service line port SAE J518 1 in 400 O
S Suction port SAE J518 2 1/2in 30 O
T1, 5)
T2
(otherwise closed)


276 276
239 239
87.5 87.5
31 Y G 49 Y G
167.5
145.5
167.5
145.5
109
109
Y Y
D D
24.5
24.5
89.5
89.5
H1/5 LR H2/6 LR
LRDU1/LRDU2 LR3DS
326.5
276
239 255.5
80 Z
15 G
154.5
167.5
109
138.5 X
S
D Z
89.5
24.5
D
113.5
LR LR3
U1/2
LG1E LG2E
276
97.5
62 Z
Y
142.5
120.5
Y Z
118.5
E
59.5
24.5
LG1

HD1D/HD2D EP1D/EP2D
239
239
235.5
235.5
89.5
20.5
50.5 Y G
G
145.5
165
109
109
Y
D
24.5
89.5
89.5
HD1/2
EP1/2
DRS/DRG DRL
238.5 240
80 25.5
142.5
144.5
138.5 X 102.5
X
S/G
DR
113.5
89.5
78
DRL
276
54
156.5
138.5 X
S
113.5
LE1/2

LRDCS
292
234 View Y
clockwise rotation
155
(counter-clockwise
142*) rotation)
113 10*)
Z T1 M Z
48
X
12.7
172.5
T1
139
10*)
50
ø152.4
A Y
A S
(S) (A)
125
T2
M
M1 161.6
Flange SAE J744 R
200
152-4 (D)
Flange SAE J617 287

150 (SAE 3) 16
20 W 10 15
X T2 S 12x
3
Z 0
S
D
115
26
96
ø1
LR
1
C
77
ø409.58 1)
ø428.62 1)
ø385
M
ø451
ø130
ø101
287
T1 A
V
Detail W Detail V
106.5
57.2
S A
25
75
61.9 27.8
1) Dimensions according to SAE J617-No. 3, for connection to the flywheel case of the combustion engine

Shaft ends
Z Splined shaft DIN 5480 P Parallel keyed shaft DIN 6885 –
50
82
36
M16x2 1) 2)
36
M16x2 1) 2)
12
12 E1x0.2
ø45
DIN509
ø50
ø101
48.5
ø101
ø50
42
90
60
S Splined shaft SAE J744

1 3/4 in 13T 8/16DP 3)
67
5/8-11UNC-2B
36
12
ø50
ø101
R2.5
55
75
Ports
Max. pres- State
A Service line port SAE J518 1 in 400 O
Fixing thread DIN 13 M16x2; 24 deep
T1, 5)
T2
(otherwise closed)


292 292
262 262
97.5 97.5
Y 58.5 Y G
180
180
155
155
115
115
Y Y
D D
97
26
97
26
H1/5 LR H2/6 LR
LRDU1/LRDU2 LR3DS
292 342.5
262 271.5
32 91 Z
166
180
115
150
X
S
D Z
D
97
115
26
LR
LR3
U1/2
LG1E LG2E
292
108.5
73 Y Z
157
132.5
Y Z
E
120
26
LG1
61

HD1D/HD2D EP1D/EP2D
262
262
252
252
101
31.5
62 Y G
G
174.9
155
115
114.8
Y
D D
97
26
97
HD1/2
EP1/2
DRS/DRG DRL
255 255
91 36.5
153
157
150 X 113.5 X
S/G
DR
115
79.5
97
DRL
293 293
62.5 62.5
169.5
169.5
Detail
LE.S5
233 X 233 X 110
S S2 S5
121
121
LE1/2 LE2 LE1/2

Dimensions, Size 130/145 Before finalizing your design, please request a

LRDCS
313 View Y
174 clockwise rotation
(counter-clockwise 29
170*)
rotation) 10*)
134 Z T1 Z X
21
12.7
M
181.5
T1
148
21
58
ø152.4
Y A S
A
(S) (A)
10*)
135
T2
M1
R 161.6
Flange SAE J744 204
152-4 (D)
305 (A11VO) / 353 (A11VLO) 2)
Flange SAE J617
W (SAE 3) 16
171 15
10 12x
69 X T2 S 3 0
S
D
118
ø1
104
1
C LR
ø409.58 1)
ø428.62 1)
104
ø385
ø451
ø106
ø130
M
Z 310 T1 A
V
without charge pump with charge pump
Detail W Detail V Detail W Detail V
310 310 358 358
255 255 287 244
106.4
106.4
66.7
57.2
S A S1
75
75
A1
25
32
61.9 27.8 61.9 31.8
2) The case or length dimension with flange SAE 3 is 5 mm shorter than the standard case.

Shaft ends
55
82
36
M16x2 1) 2)
36
M16x2 1) 2)
12
12 E1x0.2
ø50
DIN509
ø55
53.5
ø107
ø55
ø107
44
90
65
S Splined shaft SAE J744

1 3/4 in 13T 8/16DP 3)
67
5/8-11UNC-2B
36
12
ø55
ø107
R2.5
55
75
Ports
Max. pres- State
A Service line port SAE J518 1 in O
400
A1 Service line port SAE J518 1 1/4 in O
400
S, Suction port SAE J518 3 in 30 O
S1 Fixing thread DIN 13 M16x2; 24 deep 26)
T1, 5)
T2
(otherwise closed)
6) with charge pump


313
283 313
118.5 283
118.5
Y 79.5
Y
G G
189
189
164
164
115
115
Y Y
D D
105
105
28
28
LR H2/6 LR
H1/5
LRDU1/LRDU2 LR3DS
313 364
283 293
Z
48 112
175.5
189
115
171 X
D S Z
105
D
118
28
LR
LR3
U1/2
LG1E LG2E
313
129.5
94 Y Z
166
Y Z
E
123
28
LG1
63

HD1D/HD2D EP1D/EP2D
283 283
273 273
125 52.5
86 Y
G G
184
164
115
115
Y
D
105
D
105
28
HD1/2
EP1/2
DRS/DRG DRL
276 276
112 57.5
166
162
171 X 134.5 X
S/G
DR
105
118
82.5
DRL
316
316
83.5
83.5
178.5
178.5
Detail
LE.S5
254 X 254 X 131
S S2 S5
124
124
LE1/2 LE2 LE1/2


LRDCS
379 View Y *) Center of gravity
203.5 clockwise rotation
190.5 (counter-clockwise 34
Z T1 M rotation)
170*) 10*) Z
27 X
15.9
196
T1
156
10*)
66 A S
ø165.1
Y
A (S) (A)
T2
163.2
21
M1
R 224.5
Flange SAE J744
165-4 (E) W 262.5
318.8 Flange SAE J617 341.8 (A11VO) / 390 (A11VLO) 2)

139.8 X (SAE 3) 16
T2 Z S 10 15
12x
30
S
D
131
116
C LR
ø1
1
ø409.58 1)
ø428.62 1)
116
M
ø385
ø451
ø126
ø155
346.8 T1 A
without charge pump V with charge pump

346.8 346.8 395 395
281.3 281.3 319 272
120.7
120.7
S A1
79.4
A S1
79.4
38
90
38
90
69.9 36.5 69.9 36.5
2) The case or length dimension with flange SAE 3 is 5 mm shorter than the standard case.

Shaft ends
W50x2x30x24x9g AS16x10x100
55
105
36
M20x2.5 1) 2)
M16x2 1) 2)
42
12
15 E1x0.2
ø55
DIN509
ø60
ø126
ø60
ø126
59
44
113
65

1 3/4 in 13T 8/16DP 3) 2 in 15T 8/16DP 3)
67 80
5/8-11UNC-2B
5/8-11UNC-2B
36 36
12 12
ø60
ø60
ø126
ø126
R2.5 R4
55 66
75 88
Ports
Max. pres- State
A, A1 Service line port SAE J518 1 1/2 in O
400
S, Suction port SAE J518 3 1/2 in 30 O
S1 Fixing thread DIN 13 M16x2; 24 deep 26)
T1, 5)
Tank port DIN 3852 M33x2; 18 deep 10
T2
R Air bleed DIN 3852 M33x2; 18 deep 10 X
(otherwise closed)
6) with charge pump


379 379
321.5 321.5
148 148
91 109
Y
Y
G G
227.5
227.5
142.5
176
176
142.5
Y Y
D
118.5
118.5
34
34
H1/5 LR H2/6 LR
LRDU1/LRDU2 LR3DS
379 379
321.5 207
77.5
Z
178
227.5
142.5
319 X
S
Z D 131
118.5
34
D
U1/2 LR3
LR
LG1EH LG2EH
Power control with pilot-pressure related override (neg.), Power control with pilot-pressure related override (pos.),
2-stage pressure cut-off and hydr. stroke limiter 2-stage pressure cut-off and hydr. stroke limiter
392 442.5
148 365
109
Z2
Y 148 Z1
109
Y
227.5
200.5
227.5
176
176
242 Y 399
Z1 Z2 Z1
Y
Z2
E
118.5
E
34
118.5
H
69
H LG2
69
LG1
44
34

HD1D/HD2D EP1D/EP2D
379 379
321.5 321.5
148
109
77.5 G
Y G
187.5
183
178
142.5
142.5
Y
118.5
D
118.5
34
HD1/2 EP1/2
DRS/DRG DRL
379 315.5
223 79.5
178
178
161.5
319 X X
S/G
118.5
89.5
DR
131
DRL
383 383
156.5 156.5
192
192
Detail
LE.S5
321.5 X 321.5 X 198.5
S2 S5
S LE1/2
133
133
LE1/2 LE2

LRDCS
408,5 View Y *) Center of gravity
214 clockwise rotation 34
Z T1 M (counter-clockwise
185*) 10*) Z
rotation)
30 X
15.9
205.5
T1
168
10*)
72
Y A S
ø165.1
A (S) (A)
T2
176.2
21
M1 R
R
Flange SAE J744 224.5
165-4 (E) 262.5
W
346
166.5
T2 Z S X
S
D
130
137
C LR
130
372.1 T1 A
V
without charge pump with charge pump
372.1 372.1 428 428
307 307 346 329.5
130.2
79.4
120.7
79.4
100
S A S1 A1
38
38
90
69.9 36.5 77.8 36.5


Shaft ends
W60x2x30x28x9g AS18x11x100
58
105
M20x2.5 1) 2)
42
M20x2.5 1) 2)
42
15
15 E1x0.2
ø60
DIN509
ø70
ø131
ø70
64
ø131
47
113
66

1 3/4 in 13T 8/16DP 3) 2 1/4 in 17T 8/16DP 3)
67 80
5/8-11UNC-2B
3/4-10UNC-2B
36 42
12 15
ø70
ø70
ø131
ø131
R2.5 R4
55 66
75 88
Ports
Max. pres- State
A, A1 Service line port SAE J518 1 1/2 in O
400
S Suction port SAE J518 3 1/2 in O
30
S1 Suction port SAE J518 4 in O
26)
T1, 5)
Tank port DIN 3852 M33x2; 16 deep 10
T2
R Air bleed DIN 3852 M33x2; 16 deep 10 X
(otherwise closed)
6) with charge pump


408.5 408.5
351 351
174.5 174.5
116 Y 135.5 Y
G G
239
239
187.5
187.5
153
153
Y Y
132.5
132.5
H1/5 D
LR H2/6 LR
40
40
LRDU1/LRDU2 LR3DS
408.5 408.5
351 235
104.5
189.5
239
153
345.5 X
D S
132.5
U1/2 LR Z D
137
LR3
40
LG1EH LG2EH
Power control with pilot-pressure related override (neg.), Power control with pilot-pressure related override (pos.),
2-stage pressure cut-off and hydr. stroke limiter 2-stage pressure cut-off and hydr. stroke limiter
419.6 469.1
174.5 391.6 Z1
135.5 Z2 174.5
135.5 Y
Y
246
187.5
212
239
212
187.5
469.2
268.5 Z1 Y
Y
Z1 Z
Z2 2
132.5
E E
132.5
H LG2
75
H LG1
75
40
50
40

HD1D/HD2D EP1D/EP2D
408.5
408.5
351
351
174.5
104.5
135.5 G
Y G
187.5
199
152.5
194
152.8
Y
D
132.5
132.5
D EP1/2
HD1/2
40
DRS/DRG DRL
408.5 342
106
189.5
189.5
345.5 188
X X
S/G
132.5
DR
137
95.5
DRL
409.5 409.5
183 183
203.5
203.5
Detail
LE.S5
348 348 X 230.3

X
S2 S5
S LE1/2
137
137
LE1/2 LE2
Through Drive Dimensions

Flange SAE J744 – 82-2 (A) Coupler for splined shaft acc. to ANSI B92.1a-1976 5/8 in 9T 16/32 DP1) (SAE J744 – 16-4 (A) K01
3/4 in 11T 16/32 DP1) (SAE J744 – 19-4 (A-B)) K52
A2 A1 A2 A33)
Size K01 K52
40 240 240 8 M10x1.5; 15 deep
O-Ring2)
60 257 257 – M10x1.5; 15 deep
75 275 275 – M10x1.5; 15 deep
A3 95 306 306 – M10x1.5; 12.5 deep
ø82.5
130/145 329 329 – M10x1.5; 12.5 deep
130/145* 363 363 – M10x1.5; 12.5 deep
190 359.8 359.8 – M10x1.5; 13 deep
190* 394 394 – M10x1.5; 13 deep
260 385 385 – M10x1.5; 13 deep
106.4 A1 260* 427.3 427.3 – M10x1.5; 13 deep
130 up to mounting flange *) Version with charge pump
Flange SAE J744 – 101-2 (B) Coupler for splined shaft acc. to ANSI B92.1a-1976 7/8 in 13T 16/32 DP1) (SAE J744 – 22-4 (B)) K02
1 in 15T 16/32 DP1) (SAE J744 – 25-4 (B-B))K04
Coupler for splined shaft acc. to DIN 5480 W35x2x30x16x9g K79
Hole pattern on size 40 and 145 A2 A1 A2 A33)
Size K02 K04 K79
O-Ring2)
45 40 244 244 10 M12x1.75; 19 deep
60 261 261 261 10 M12x1.75; 19 deep
75 279 279 10 M12x1.75; 19 deep
A3
ø101.6
95 303 303 303 10 M12x1.75; 16 deep

ø14
6 130/145 326 326 326 10 M12x1.75; 16 deep
130/145* 360 360 360 10 M12x1.75; 16 deep
190 371.8 369.8 361.8 – M12x1.75; 15 deep
190* 404 404 394 – M12x1.75; 15 deep
146 A1 260 395 395 395 – M12x1.75; 15 deep
up to mounting flange 260* 437.5 437.5 437.5 – M12x1.75; 15 deep
*) Version with charge pump
In size 190 and 260 the hole template is turned 45° counter-clockwise.
Flange SAE J744 – 127-2 (C) Coupler for splined shaft acc. to ANSI B92.1a-1976 1 1/4 in 14T 12/24 DP1) (SAE J744 – 32-4 (C)) K07
1 1/2 in 17T 12/24 DP1) (SAE J744 – 38-4 (C-C)) K24
W35x2x30x16x9g K61
A2 A1 A2 A33)
Size K07 K24 K80 K61
O-Ring2)
60 272 – 265 265 13 M16x2; 20 deep
75 290 – 283 283 13 M16x2; 20 deep
A3 95 318 318 318 318 13 M16x2; 16 deep
130/145 330 330 330 330 13 M16x2; 20 deep
ø127
130/145* 364 364 364 364 13 M16x2; 20 deep

181
213 A1
up to mounting flange
Note:
The mounting flange may be turned through 90°. Standard position as illustrated. Please state in clear text if required.
1) 30° pressure angle, flat root, side fit, tolerance class 5
2) O-ring included in the delivery contents
3) DIN 13, for max. tightening torque, please refer to general notes on page 64
Through Drive Dimensions

Flange SAE J744–127-2+4 (A) Coupler for splined shaft acc. to ANSI B92.1a-19761 1/4 in 14T 12/24 DP1) (SAE J744 – 32-4 (C) K07
1 1/2 in 17T 12/24 DP1) (SAE J744 – 38-4 (C-C)) K24
W35x2x30x16x9g K61
A1 A2 A33)
A2 Size K07 K24 K80 K61
O-Ring2) 190 367.8 367.8 367.8 367.8 13 M16x2; 19 deep
190* 400 400 400 400 13 M16x2; 19 deep
260 391.5 391.5 391.5 391.5 13 M16x2; 19 deep
A3
260* 433.5 433.5 433.5 433.5 13 M16x2; 19 deep
ø127
115
115 A1
181 up to mounting flange
Flange SAE J744 – 152-4 (D) Coupler for splined shaft acc. to ANSI B92.1a-1976 1 1/4 in 14T 12/24 DP1) (SAE J744 – 32-4 (C)) K86
1 3/4 in 13T 8/16 DP1) (SAE J744 – 44-4 (D)) K17
W45x2x30x21x9g K82
W50x2x30x24x9g K83
A2
A1 A2 A33)
Size K86 K17 K81 K82 K83
A3 O-Ring2)
75 290 – 290 – – 13 M20x2.5; 28 deep
95 317 327 317 317 – 30 M20x2.5; 25 deep
130/145 340 350 340 340 340 30 M20x2.5; 25 deep
130/145* 374 384 374 374 374 30 M20x2.5; 25 deep
ø152.4
161.6
190 392 392 392 392 392 13 M20x2.5; 22 deep

190* 424 424 424 424 424 13 M20x2.5; 22 deep
260 417 417 417 417 417 13 M20x2.5; 22 deep
260* 459 459 459 459 459 13 M20x2.5; 22 deep
161.6 A1
Flange SAE J744 – 101-2 (E) Coupler for splined shaft acc. to ANSI B92.1a-1976 1 3/4 in 13T 16/32 DP1) (SAE J744 – 32-4 (C)) K72
Coupler for splined shaft acc. to DIN 5480 W50x2x30x24x9g) K84
W60x2x30x28x9g K67
A2 A1 A2 A33)
Size K72 K84 K67
A3
190 376.8 376.8 – 19 M20x2.5; 20 deep
O-Ring2)
190* 409 409 – 19 M20x2.5; 20 deep
260 417 400 400 19 M20x2.5; 20 deep
260* 459 442.5 442.5 19 M20x2.5; 20 deep
ø165.1
224.5

ø270
224.5 A1
Note:
The mounting flange may be turned through 90°. Standard position as illustrated. Please state in clear text if required.
1) 30° pressure angle, flat root, side fit, tolerance class 5
2) O-ring included in the delivery contents
3) DIN 13, for max. tightening torque, please refer to general notes on page 64
Overview of Attachments for A11V(L)O

Through Through
A11VO Attachment – 2nd pump
drive drive
Coupler A10V(S)
Flange A11VO A10V(S)O/31 A4FO A4VG A10VG External available
for splined Code O/53
gear pump
shaft Size (shaft) Size (shaft) Size (shaft) Size (shaft) Size (shaft) Size (shaft) for size
82-2 (A) 5/8 in K01 – 18 (U) 10 (U) – – – Frame size F 40...260
Size 4-22 1)
3/4 in K52 – 18 (S) 10 (S) – – – – 40...260
101-2 (B) 7/8 in K02 – 28 (S, R) 28 (S, R) 16, 22, 28 (S) – 18 (S) Frame size N 40...260
45 (U) 45 (U, W) Size 20-32 1)
Frame size G
Size 38-45 1)
45 (S, R)
1 in K04 40 (S) 45 (S, R) – 28 (S) 28, 45 (S) – 40...260
60 (U, W)
W35 K79 40 (Z) – – – – – – 40...260
71 (S, R) 60 (S) 2)
127-2 (C) 1 1/4 in K07 60 (S) – 40, 56, 71 (S) 63 (S) – 60...260
100 (U) 85 (U)
1 1/2 in K24 – 100 (S) 85 (S) – – – – 95...260
W30 K80 – – – – 40, 56 (Z) – – 60...260
40, 56 (A)
W35 K61 60 (Z) – – – – – 60...260
71 (Z)
152-4 (D) 1 1/4 in K86 75 (S) – – – – – – 75...260
1 3/4 in K17 95, 130, 145 (S) 140 (S) – – 90, 125 (S) – – 130...260
W40 K81 75 (Z) – – – 125 (Z) – – 75...260
W45 K82 95 (Z) – – – 90, 125 (A) – – 95...260
W50 K83 130, 145 (Z) – – – – – – 130...260
165-4 (E) 1 3/4 in K72 190, 260 (S) – – – 180, 250 (S) – – 190...260
W50 K84 190 (Z) – – – 180 (Z) – – 190...260
W60 K67 260 (Z) – – – – – – 260
1) Rexroth recommends special versions of the gear pumps. Please ask.
2) Only A10VO with 4-hole mounting flange can be mounted to A11V(L)O 190 and 260.
Combination Pumps A11VO + A11VO

Total length A 1)
A11VO 2nd pump
1st pump Size 40 Size 60 Size 75 Size 95 Size 130/145 Size 130/145 2) Size 190 Size 190 2) Size 260 Size 260 2)
Size 40 – – – – – – – – – –
Size 60 490 507 – – – – – – – –
Size 75 – 525 550 – – – – – – –
Size 95 528 560 577 604 – – – – – –
Size 130/145 551 572 600 627 650 698 – – – –
Size 130/145 2) 585 606 634 661 684 732 – – – –
Size 190 586.8 609.8 652 679 702 750 723.6 772.3 – –
Size 190 2) 619 642 684 711 734 782 755.8 804.5 – –
Size 260 620 633.5 677 704 727 775 746.8 795.5 772 828
Size 260 2) 662.5 675.5 719 746 769 817 789.3 838 814.5 870.5
1) Coupler
When using the Z shaft (splined shaft DIN 5480) for the attached pump (2nd pump)
2) Flange
Version with charge pump
When ordering combination pumps, the type designations of the

1st and 2nd pumps must be connected by a "+". A11VO A11VO
Ordering code 1st pump + Ordering code 2nd pump (1st pump) (2nd pump)
Ordering example:
A11VO130LRDS/10R-NZD12K61 + A11VO60LRDS/10R-NZC12N00
A
Swivel Angle Indicator

Optical swivel angle indicator, V
Parameters
With the optical swivel angle indicator, a mechanical pointer on Supply voltage Ub 10...30 V DC
the side of the pump case displays the position of the swivel
angle of the pump. 2.5 V 4.5 V
Output voltage Ua
(Vg min) (Vg max)
T1 GM A
Reverse-connect protection Short-circuit-proof
EMC stability Details on request
Operating temperature range -40°C...+125°C
Vg max Vg min
Vibration resistance
Sinusoidal vibration 10 g / 5...2000 Hz
EN 60068-2-6
Shock resistance:
R T2 Vg min M1 S Continuous shock 25 g
Vg max IEC 68-2-29
Resistance to salt spray
96 h
DIN 50021-SS
Type of protection DIN/EN
IP67 and IP69K
60529
Case material synthetic material
0
1
Mating connector
AMP Superseal 1.5; 3-pin,
Rexroth mat. no. R902602132
A
Consisting of: AMP no.
– 1 female connector case, 3-pin _____________ 282087-1
C
– 3 single wire seals, yellow __________________ 281934-2

– 3 female connector contacts 1.8–3.3 mm _____ 283025-1
Size A C The mating connector is not included in the delivery contents.
40 50.5 84.0 This can be delivered by Rexroth on request.
60 not available
75 60.7 97.0
95 63,5 104.0
130 70.9 112.0
190 87.6 123.5 Detail V
260 87.6 137.0 not to scale
Electric swivel angle sensor, R A

With the electric swivel angle indicator the swivel position of B Ground Ub
the pump is measured by an electric swivel angle sensor. It has
a robust, sealed case and integrated electronics designed for Output
automotive applications. voltage Ua
C
As an output the Hall effect swivel angle sensor supplies a

voltage signal proportional to the swivel angle (see technical V
parameters).
T1 GM A Size A B C
40 50.5 88.5 118.3
60 not available
75 60.7 98.7 131.3
Vg max Vg min
95 63.5 101.5 138.3
130 70.9 108.9 146.3
190 87.6 125.6 157.8
260 87.6 125.6 171.3
R T2 U
α
M1 S
Connector for Solenoids

DEUTSCH DT04-2P-EP04, 2-pin
molded, without bidirectional suppressor diode
(standard) __________________________________________ P
Type of protection according to DIN/EN 60529:
IP67 and IP69K
Circuit diagram symbol

without bidirectional
suppressor diode
Mating connector
DEUTSCH DT06-2S-EP04
Rexroth mat. no. R902601804
Consisting of: DT designation
– 1 case ________________________________DT06-2S-EP04
– 1 wedge _______________________________________W2S
– 2 female connectors ___________________ 0462-201-16141
The mating connector is not included in the delivery contents.
This can be delivered by Rexroth on request.
(2) (1)
36
Ø37
50
68.5
Note for round solenoids:

The position of the connector can be changed by turning the
solenoid body.
Proceed as follows:
– 1. Loosen fixing nut (1)
– 2. Turn the solenoid body (2) to the desired position.
– 3. Tighten the fixing nut
Tightening torque of fixing nut: 5+1 Nm
(width across the flats WAF 26, 12kt DIN 3124)
Installation Notes
General
During commissioning and operation, the axial piston unit must be filled with hydraulic fluid and air bled. This is also to be obser-
ved following a relatively long standstill as the system may empty via the hydraulic lines.
The case drain in the case interior must be directed to the tank via the highest tank port (T1, T2). The minimum suction pressure at
port S must not fall below 0.8 bar absolute (without charge pump) or 0.6 bar (with charge pump).
In all operational conditions, the suction line and case drain line must flow into the tank below the minimum fluid level.
Installation position
See examples below. Additional installation positions are available upon request.
Below-tank installation (standard) Above-tank installation

Pump below the minimum fluid level of the tank. Pump above the minimum fluid level of the tank.
Recommended installation positions: 1 and 2. Observe the maximum permissible suction height
hs max = 800 mm.
The version A11VLO (with charge pump) is not designed for
installation above the tank.
Recommendation for installation position 7 (shaft up): A check
valve in the case drain line (opening pressure 0.5 bar) can
prevent the case interior from draining.
For control options with pressure control, displacement limiters,
HD and EP control, the minimum displacement setting must be
Vg ≥ 5% Vg max.
1 2 5 6
SB SB L1 L1
ht min ht min L2 L2 T2 R
hmin hmin
amin amin T1 S T1
S
T2 R R T2
hS max SB SB hS max
T1 S S T1 ht min ht min
hmin hmin
R amin amin
3 4 7
SB SB L1
ht min ht min R
L2 T1
hmin hmin
amin amin
0.5 bar
T2
S
S
T2
SB hS max
R T1
T1 R ht min
T2
S hmin
amin
hs max = 800 mm, ht min = 200 mm, hmin = 100 mm, SB = Silencer plate (baffle plate)
When designing the tank, ensure adequate space amin between the suction line and the case drain line to prevent the heated,
returned fluid from being directly drawn back out.
Installation position Air bleeding Filling Installation position Air bleeding Filling
1 T1 S + T1 5 L1 + L2 L2 (S) + L1 (T1)
2 R S + T2 6 R + L2 L2 (S) + L1 (T2)
3 T1/T2 S + T1/T2 7 L1 + L2 L2 (S) + L1 (T1/T2)
4 R S + T1/T2
Installation Notes
Tank installation
Pump below the minimum fluid level in the tank.
8 9
R
T1
SB
SB
ht min ht min
T2
S S T1
amin hmin hmin amin
R
10
SB T2 R
ht min
S
hmin amin
T1
hs max = 800 mm, ht min = 200 mm, hmin = 100 mm,

SB = Silencer plate (baffle plate)
When designing the tank, ensure adequate space amin be-
tween the suction line and the case drain line to prevent the
heated, returned fluid from being directly drawn back out.
Installation position Air bleeding Filling
8 T1 automatically via all
open T1, T2, R and S
9 R ports, though position
below the hyraulic fluid
10 R level
Notice
General Notes
– The A11VO pump is designed to be used in open circuits.
– Project planning, assembly and commissioning of the axial piston unit require the involvement of qualified personnel.
– The service line ports and function ports are only designed to accommodate hydraulic lines.
– During and shortly after operation, there is a risk of burns on the axial piston unit and especially on the solenoids. Take
appropriate safety measures (e. g. by wearing protective clothing).
– Depending on the operational state of the axial piston unit (operating pressure, fluid temperature), the characteristic may shift.
– Pressure ports:
The ports and fixing threads are designed for the specified maximum pressure. The machine or system manufacturer must
ensure that the connecting elements and lines correspond to the specified operating conditions (pressure, flow, hydraulic fluid,
temperature) with the necessary safety factors.
– The data and notes contained herein must be adhered to.
– The following tightening torques apply:
- Threaded hole for axial piston unit:
The maximum permissible tightening torques MG max are maximum values for the threaded holes and must not be exceeded.
- Fittings:
Observe the manufacturer's instruction regarding the tightening torques of the used fittings.
- Fixing screws:
For fixing screws according to DIN 13, we recommend checking the tightening torque individually according to VDI 2230.
- Locking screws:
For the metal locking screws supplied with the axial piston unit, the required tightening torques of locking screws MV apply.
– The product is not approved as a component for the safety concept of a general machine according to DIN EN ISO 13849.
Max. permissible tightening

Required tightening torque WAF
Thread size torque of the screw thread
for locking screws MV Hexagon socket
MGmax
M12x1.5 DIN 3852 50 Nm 25 Nm 6 mm
M14x1.5 DIN 3852 80 Nm 35 Nm 6 mm
M22x1.5 DIN 3852 210 Nm 80 Nm 10 mm
M26x1.5 DIN 3852 230 Nm 120 Nm 12 mm
M33x2 DIN 3852 540 Nm 310 Nm 17 mm
Bosch Rexroth AG © This document, as well as the data, specifications and other information set
Hydraulics forth in it, are the exclusive property of Bosch Rexroth AG. Without their consent
Axial Piston Unit it may not be reproduced or given to third parties.
Glockeraustraße 2 The data specified above only serve to describe the product. No statements con-
89275 Elchingen, Germany cerning a certain condition or suitability for a certain application can be derived
Tel.: +49 (0) 73 08 82-0 from our information. The given information does not release the user from the
obligation of own judgement and verification. It must be remembered that our
Fax: +49 (0) 73 08 72 74
products are subject to a natural process of wear and aging.
[email protected]
Subject to change.
www.boschrexroth.com/brm

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Copyright © 2016 Joy Global 2 Seção 04-01-09 DOC C-r00

Tools mentioned in A and B cannot be bought

2 HN.25.F3.93 • Rev AC • Sep2010

Dismantling Counter 1 Unscrew plug with O-ring

2 Take out small spring (hook).

3 Take out ball (magnetic rod).

4 Take out piston.

HN.25.F3.93 • Rev AC • Sep2010 3

5 Take out spring.

6 Counter pressure valve shown dismantled.

7 Counter pressure valve with orifice shown

Removing Pressure Relief 8 Unscrew plug with washer

4 HN.25.F3.93 • Rev AC • Sep2010

9 Unscrew pressure relief valve

10 Take out washer (magnetic rod).

12 Pressure relief valve shown dismantled.

HN.25.F3.93 • Rev AC • Sep2010 5

Removing End Cover at 13 U

14 Remove end cover.

15 Remove stop and 2 springs.

6 HN.25.F3.93 • Rev AC • Sep2010

17 Remove plate and 6 O-rings.

18 Remove spring guide.

Removing End Cover at 19 U

20 Remove end cover.

HN.25.F3.93 • Rev AC • Sep2010 7

21 Remove stop and 2 springs.

22 Remove stop and spring.

23 Remove plate and 4 O-rings.

24 Remove spring guide.

8 HN.25.F3.93 • Rev AC • Sep2010

Removing Spools 25 Remove directional spool.

26 Remove amplifier spool.

27 Remove priority valve spool.

Removing Orifices and 28 U

HN.25.F3.93 • Rev AC • Sep2010 9

Removing Shock Valves 31 R

Overview of Dismantled 32 Housing and end cover with accessories.

10 HN.25.F3.93 • Rev AC • Sep2010

33 Spool with accessories.

35 Directional spool shown dismantled.

HN.25.F3.93 • Rev AC • Sep2010 11

Note: Avoid damage to the spring ring.

40 Carefully guide the spring ring back.

12 HN.25.F3.93 • Rev AC • Sep2010

Note: Avoid damage to the spring ring.

42 Press pin out gently with finger.

43 Take out plug.

44 Take out spring.

HN.25.F3.93 • Rev AC • Sep2010 13

45 Take out pin with 3 mm screwdriver.

46 Take out inner spool.

Note: Avoid damaging the spool surface.

14 HN.25.F3.93 • Rev AC • Sep2010

49 Amplifier spool shown dismantled.

Dismantling of Check 51 Check valve shown dismantled.

HN.25.F3.93 • Rev AC • Sep2010 15

Dismantling Counter 1 Unscrew plug with O-ring

7 Counter pressure valve with orifice shown

Removing Pressure Relief 8 Unscrew plug with washer

9 Unscrew pressure relief valve

59 S hock valve/suction valve shown

65 T ighten with torque wrench for 19

Assembly of Check Valve 70 Fit ball, spring and plug. Tightening

Assembly of Amplifier 71 Fit orifice in plug. Tightening

72 Fit check valve. Tightening

Note: void damaging spool surface.

Note: hen assembling OSQA 5 and OSQB

76 Push spring ring into position.

80 Push spring ring into position.

Assembly of Priority 81 Fit prop or throttle check valve.

Assembly of Directional 82 Screw in orifice. Tightening torque:

Installation of Orifice and 83 Fit orifice in housing. Tightening torque:

84 Fit orifice in LS-connection.

85 Fit throttle check valve in PP-connection.

Comments on Flow 1 ¼ BSP.F in PP-connection. Fit washer

88 S crew the adjustment screw so far in that

90 Fit pressure relief valve. Tightening

91 Fit plug washer. Tightening torque:

Installation of Back 92 First fit spring in position with vaseline.

94 Fit spring in plug with vaseline.

Installation of Spools 95 Fit directional spool. Fit priority valve

Note: S pring control must be placed

97 Fit amplifier spool. Note: the orifice

Installation of End Cover 98 Fit spring with vaseline on amplifier

Note: The spring must be fitted at the

104 F it stop (thickness: 5mm) in end cover

107 F it screw with spring washer.

109 F it large and small springs with