Industrial Electric Drives Linear Motion and Service Mobile

Hydraulics and Controls Assembly Technologies Pneumatics Automation Hydraulics

Drive and Control Systems

for Truck Mounted Equipment

From Gear Pump to Electronic Crane Control

2 System Expertise

Unique Variety
Permits Customised Systems
Rexroth supplies a unique variety of components and systems designed to provide custom solutions for the drive and control
systems of commercial vehicles. Rexroth has exactly the right system for the particular requirements of these machines. With
our product range, we are able to cover the full spectrum of applications. In the “Commercial Vehicle” application center,
where specialists from the different product divisions work together as a team, we provide comprehensive assistance, in
selecting the best suited components to the drafting of complete system solutions.

Components for Drive and Control Systems

Products:
• Implement hydraulics,
from the simple throttle
control to the technically
sophisticated LUDV control.
• Complete control systems Fixed displacement pump
for optimal handling.
Variable displacement pump Compact units
Everything From a Single
Source
Variable displacement pump LS control valve
At Rexroth you will find
the complete range of
commercial vehicle drive
and control systems from a
single source: the Mobile
Variable displacement pump Compact hydraulic system
Hydraulics technology
division of Bosch Rexroth is
able to join forces with other
product divisions, namely
Axial Piston Units, External Fixed displacement motor LUDV control valve
Gear Units, Radial Piston
Motors, Mobile Controls,
Gears and Mobile
Electronics, in order to
provide each system with all External gear LS control valve
the equipment required. pumps/motors

Electronic control system Control valve for throttle control

Fan drives
 3

Contents
• Dump trucks /
roll-off tippers
• Crane drives
• Energy balance
• Components
• Prospects

Basic Requirements for Optimum Operation Application Center: System Consulting, Project Planning
Our powerful drive and control systems are essential and Optimization
parts and therefore form the basic frame for optimum The Rexroth Application Centers have the function of
operation of truck mounted equipment. They are analysing current and future customer requirements in the
characterised by reliability, economy, high productivity and field of drive and control technology and working out
ease of use. For the implement hydraulics, qualities such as appropriate solutions – from individual components to
economy, handling capacity and ease of use are the main complete systems. The future belongs to vehicles and
criteria. In addition to conventional throttle control, machines that simultaneously can be made more powerful,
increasing use is now being made of user-friendly and more rapidly available and more competitively priced. Drive
energy-saving load-sensing or LUDV systems. systems that can be specifically optimized for individual
applications are therefore necessary. With our Commercial
On-site all Over the World Vehicle Application Center we provide the requisite
The Rexroth sales network spans 80 countries. This network application-oriented know-how, the latest modern
gives us a global presence of production sites, trading simulations and powerful test systems. In close co-operation
subsidiaries, distributors and service centers. So, wherever with our customers and partners, we devise complete turnkey
you may be in the world, you and your customers will enjoy systems with a minimum of interfaces and with perfectly
the support of expert partners in drive and control systems. matched components. In addition, in our Application
Centers, we make use of the effects of synergy between the
various Rexroth divisions specializing in different
technologies.
4 Throttle Control

Hydraulics for Drump Trucks,

Skid Handlers and and Roll-off Tippers
To load and unload commercial vehicles, the vehicles are often equipped with special devices and attachments, such as
tipper cylinders. The hydraulic pumps are generally mounted on the side of the vehicle’s gearbox integrated power
take-off units (PTOs). The PTOs are engaged and disengaged by means of the truck’s pneumatic system.

Dump Truck Drives Based on the

Throttle Control Principle
Hydrostatic Transmission
Rexroth KFA-type fixed displacement pumps
are axial piston pumps based on the proven
bent-axis principle. They are available in the
nominal sizes 23, 32, 45, 63, 80, 107 and 125
cc/rev., with working pressures up to 5000 psi
(350 bar), except the size 125 which is suitable
for peak pressure of 4350 psi (300 bar). KFA
pumps are of fixed displacement design and
used in open circuits. This range of pumps
features low noise levels, a heavy duty rotary
group and space saving dimensions.

One special feature compared to other pumps is

the patented system for easily changing the
direction of rotation from outside, without
having to dismantle the pump. The threaded
insert in the pressure port is screwed into the
opposite port. This insert also acts as an
adjustment tool to reduce the noise level and
pressure pulsations.

Patented system
for changing the
direction of rotation
 5

Implement Hydraulics for Dump Trucks, Skid Handlers or Roll-off

Tippers Based on the Load-sensing Open Center Principle
Sophisticated Hydraulic Systems
Loading and unloading systems are designed as
load-sensing systems with open-center inlet
unit. The Rexroth M4-12 valve block permits
highly sensitive proportional control of the
individual users. The actuating system can be
mechanical, hydraulic or electro-hydraulic. The
static support and three valve axis are actuated
electro-hydraulically by proportional or
on-off control. An emergency cut-off valve can
also be integrated in the inlet unit. In addition,
an internal pilot oil supply is provided. Finally,
for modern actuating systems, a built-in
electronic unit for analogue and digital signals
(CAN system) is available.
The M4-12 valve block can handle pump
pressure up to 5000 psi (350 bar) and work port
pressure up to 6100 psi (420 bar).
6 LUDV and Load-sensing Systems

Hydraulics for Loading Cranes,

Cargo Cranes and Timber Loading Cranes
Efficient variable displacement pumps based on the axial piston principle are used for the hydraulic systems of truck
loading cranes, cargo cranes and timber loading cranes. Wherever dynamic performance, economic operation and fast
working speeds are the main priorities, variable displacement pumps, with different control systems depending on the
specific requirements, provide the ideal solution. Rexroth systems are optimally tuned to the particular application and are
customised to meet individual user requirements. They are characterised by high reliability, safety and ease of use, even
under difficult operating conditions.

Construction and Loading Cranes for Loads up Loading Crane Control Based on the LUDV Principle
to 10 mt with LUDV Control (Load-independent Flow Distribution)
In this application range, the main requirements
are good mobility and high load capacity of the
crane. Rexroth systems are ideal for rapid and
powerful material handling. SX control blocks
are based on the LUDV system, which
distributes the oil flow independently of the
actual load. LUDV control systems enable a
number of operating movements to be
perfomed simultaneously and independently of
one another. In addition, the SX control block
provides two speed stages, for sensitive and
aggressive operation of the loads. An emergency
stop switch and power beyond line are already
built into the inlet unit. The SX control block
replaces the old dual-circuit systems.
Construction and Loading Cranes with Load-
sensing Control
In these systems, there is constant interaction
between the pump and control block in order to
supply each individual crane function with only
the quantity of oil actually required for the
current operating function. Several functions
can be operated at the same time, because the
(KVAA)
variable displacement pump always delivers
exactly the quantity of oil that the combined
loads require. When none of the loads are in
operation, the pump automatically switches to
“standby” mode. In this mode it delivers about 3
litres/min against a set pressure of lower than
360 psi (25 bar), corresponding to a power input
of less than 1 kilowatt.
 7

Load-sensing Control Block for Loading Cranes Load-sensing Control Block

The Rexroth M4 load-sensing control block
provides a reliable basis also for high-pressure
applications with maximum pressures of
5000/6100 psi (350/420 bar). The M4 is able to
control all the functions of a construction crane.
The central inlet unit can distribute high flows
to up to ten valve functions. Overall, the
pressure drop of the LS-valve is very low,
potentially reducing the cooler size.

Rexroth M4-12 (LS system)

• Inlet unit with change-over axis for
emergency stop, static support and crane
operating functions.
• Primary pressure relief system
• Integral pilot oil supply
• Cut-off for pilot oil supply (secondary cut-off
system)
• Simple conversion from open-center to
closed-center variants
• Electro-hydraulic actuation with manual
override lever
• Built-in CAN electronic system with
positional sensor for safety cut-off
• Stroke limit for maximum flow setting
• LS pressure limiting valves for supply pressure
(KVAA)
control
• Secondary pressure relief and anti-cavitation
valves for protection of dynamic loads
• Electronic flow management possible for
highest flexibility
8 Technology

Innovative and Competitive

Hydraulics for Commercial Vehicle Equipment

Rexroth KVAA variable displacement pump (left)

Rexroth KFA fixed displacement pump (right)

Rotary Group and Genaral Features - Tapered pistons sealed with piston rings
- Rotary group proven millions of times - Forced lubrication of all moving parts
- Low weight - Reduced pressure pulsations due to the noise-optimised
- Space saving design enables installation pump technology
in tight mounting space - No drain line required: internal drain to the pump inlet
- Bent-axis axial piston design side
- Self-priming for open circuit - Two shaft sealing rings, sealing to the inside and outside.
- Spherical, self-centring control area A relief hole between the two seals prevents any build up
- Cylinder transmission without universal joint of pressure

Operating Principle and Features - The drive shaft and mounting flange are suitable for
- The flow is proportional to the drive speed and direct mounting on the PTO of all common truck
the displacement, which, in the case of the variable transmissions conforming to the European DIN and US-
displacement pump, is infinitely variable between 0 SAE standards
and Vg max - The pumps have robust tapered roller bearings, making
- Suitable for simple throttle control (KFA) or energy them also suitable for mounting on drive shafts with
saving load-sensing systems (KVAA) universal joints
- The favourable dimensions and lightweight construction - High overall efficiency
(aluminium housing) provide advantages of easy - Patented simple system for changing the direction of
installation and reduced weight rotation
 9

Fields of Application

Comparison between drive systems with throttle control and Tipper Vehicles
load-sensing control clearly shows the energy-saving - Rear tippers,
possibilities of the LS control system. In addition to improved 3-sided tippers
ease of use and sensitivity of control, energy costs are reduced. - Roll-off dumpers, dump trucks
- Hook tippers
Truck Mounted Cranes
- Loading cranes, timber loading
cranes
- Lift platforms
- Service cranes (mobile cranes)
Local Authority Vehicles
- Refuse disposal trucks
- Road-sweeping vehicles
- Fire trucks
Tankers
- Tankers for liquids, granulates
and flour
- Drives for feed pumps and
compressors
Special Vehicles
- Refrigeration vehicles
- Glass transporters, brick
Pump flow qv (L/min) Pump flow qv (L/min) transporters
- Flushing and vacuuming vehicles
Throttle Control with Fixed Load-sensing Control with
- Drives for generators
Displacement Pump Variable Displacement Pump
- Additional traction drives
The fixed displacement The drive power of the
Fan Drives
pump is designed for the variable displacement pump
maximum required power is adjusted to the actual
and therefore delivers 100% requirements by the LS
of the drive power. When the controller. In this system, no
power requirement is less, excess oil flow is produced by
the excess oil flow is the variable displacement
throttled, converted to waste pump, so that no power is
heat and cooled down by lost in the form of waste
large heat exchangers. heat.
10 Components

Overview of Components
Axial piston units, external gear units, radial piston motors, mobile controls, gears and mobile electronics.
Rexroth offers you the complete range of equipment from a single source.

KFA Fixed Displacement Pump External Gear Pump/Motor

Open circuit operation Fixed displacement pumps in
Nominal pressure 300 bar standard and silence versions
Peak pressure 350 bar Nominal pressure 250 bar
Peak pressure 280 bar
Data sheet RE 91 501
Data sheet 1 987 760 100
and data sheet 1 987 760 101

KVAA Variable Displacement Pump LS Control Block M4-12

Open circuit operation Hydraulically or electro hydraulically
Nominal pressure 300 bar operated
Peak pressure 350 bar Nominal flow 100 l/min
Operating pressure up to 420 bar
Data sheet RA 92 250
Data sheet RA 64 278

Axial Piston Pump A10VO LS Control Block M4-15

Open circuit operation Hydraulically or electro hydraulically
Nominal pressure 250 bar operated
Peak pressure 315 bar Nominal flow 150 l/min
Operating pressure up to 420 bar
Data sheet RA 92 703
Data sheet RE 64 282

Axial Piston Pump A11VO LUDV Control Block SX14

Open circuit operation Mechanically, hydraulically or
Nominal pressure 350 bar electro hydraulically operated
Peak pressure 400 bar Nominal flow 120 l/min
Operating pressure up to 300 bar
Data sheet RA 92 500
Data sheet RE 64 125

Fixed Displacement Motor A2FM RC Control Unit

Open and closed circuit operation For closed-loop and open-loop
Nominal pressure 400 bar control of hydrostatic drives and
Peak pressure 450 bar implement hydraulic functions.

Data sheet RA 91 001 Data sheet RE 95 200

 Prospects 11

Prospects for Commercial Vehicle Technology

Technical systems for commercial vehicles are being constantly improved and advanced. In this process of development,
Rexroth lays particular emphasis on the possibility of operating equipment at higher pressures and speeds. At the same time,
Rexroth developers are constantly working to reduce the weight and installation space of the components. A trend towards
bus systems can also be discerned. The aim is to develop hydraulic systems that are more economical, ecological and
user-friendly. Rexroth meets this challenge through intensive collaboration and constant dialogue with its customers.
These steps form the foundations for success in the future.

Key Applications and Lines of Development

Grapple

Tipper valve
with relief valve

M4-12
Bosch Rexroth Corporation
Mobile Hydraulics
Axial & Radial Piston Units
8 Southchase Court
Fountain Inn, SC 29644-9018,
USA
Telephone (864) 967-2777
Facsimile (864) 962-5338
www.boschrexroth-us.com

Bosch Rexroth Corporation

Mobile Hydraulics
Mobile Controls, Electronics,
and External Gear Units
1700 Old Mansfield Road
Wooster, OH 44691-0394, USA
Telephone (330) 263-3300
Facsimile (330) 263-3330
www.boschrexroth-us.com

Printed in USA
RA 98 075/03.05