RE 92058/2022-08-02, BoschRexrothAG
Axial piston units
with DS2 secondary control
A4VSG series 10 and 3x
RE 92058/2022-08-02
Replaces: 11.2018
▶ For highly dynamic applications
▶ Sizes 40 to 1000
▶ Nominal pressure 315 bar
▶ Maximum pressure 400bar
▶ Closed circuit
Features
▶ Highly dynamic rotary drive
▶ Motor and generator operation for both directions
of rotation
▶ With energy recovery and energy storage
▶ With rotational speed, position, or torque control for
high control performance and dynamics
▶ Throttle-free coupling and energy transmission of any
number of independently operating axial piston units
(motor or generator operation) on acommon supply
line with constant working pressure.
▶ Compact digital control electronics.
Contents
Type code 2
Function 4
Circuit diagram DS.. Sizes 40 to 1000 5
Working pressure range 8
Technical data 9
Permissible radial and axial loading of the drive shaft 10
DS2R rotational speed control 11
Incremental encoder GEL 293 12
Connector for solenoids 12
Swivel angle sensor AWXF 13
Electrically releasable check valve RVE 14
Anti-cavitation valve S...A 14
Digital controller assembly group SYHNC100-SEK...3x 15
Dimensions, size 40 to 1000 16
A4VSG...DS2 for use in winch and crane applications 34
Holding the load in the event of ahydraulic system
failure and manual overload protection MOPS 35
Dimensions of all valve block attachments 36
Project planning notes 37
Safety instructions 38
BoschRexrothAG, RE 92058/2022-08-02
2 A4VSG Series 10 and 3x | Axial piston units with DS2 secondary control
Type code
Hydraulic fluid 40 71 125 180 250 355 500 750 1000
01 Mineral oil and HFD hydraulic fluids (no code)
● ● ● ● ● ● ● ● ●
HFA, HFB, and HFC hydraulic fluids
Only with sealing material NBR nitrile rubber and shaft seal PTFE.
Please order with code P in position 09.
● ● ● ● ● ● ● – – E
Axial piston unit
02 Swashplate design, variable, nominal pressure 315 bar, maximum pressure 400 bar
A4VS
Operating mode
03 Pump / motor, closed circuit
G
Size (NG)
04 Geometric displacement, see table of values on page 9
40 71 125 180 250 355 500 750 1000
Control device 40 71 125 180 250 355 500 750 1000
05
Secondary rotational speed
control
With mounted control valve
● ● ● ● ● ● ● ● ● DS2R
With mounted servo valve
○ ○ ○ ○ ○ ○ ○ ○ ○ DS2S
Without valve
○ ○ ○ ○ ○ ○ ○ ○ ○ DS2E
Additional valve (see table Flow direction on page5 to 7) 40 71 125 180 250 355 500 750 1000
06 Load-holding function
with LS 1363
Clock
wise swivel direction
● ● ● ● ● ● ● ● ● LR
Counter-clockwise swivel direction
● ● ● ● ● ● ● ● ● LL
Load-holding function with LS 1363
not piped up (see page34)
● ● ● ● ● ● ● ● ● LX
Without load-holding function
● ● ● ● ● ● ● ● ● 0
Series 40 71 125 180 250 355 500 750 1000
07 Series 1, index 0
● ● – – – – – – – 10
Series 3, index 0
– – ● ●
▲
●
▲
● ● 30
Series 3, index 3; efficiency-optimized rotary group
– – – – ● – ● ○ – 33
Direction of rotation 40 71 125 180 250 355 500 750 1000
08 Viewed on drive shaft
Variable
● ● ● ● ● ● ● ● ● W
Sealing material
1)
40 71 125 180 250 355 500 750 1000
09 FKM (fluorocarbon rubber) according to ISO 1629
● ● ● ● ● ● ● ● ● V
Drive shaft 40 71 125 180 250 355 500 750 1000
10 Parallel keyed shaft DIN6885
● ● ● ● ● ● ● ● ● P
Splined shaft DIN5480
● ● ● ● ● ● ● ● ● Z
Mounting flange 40 71 125 180 250 355 500 750 1000
11 In accordance with ISO 3019-2 metric 4-hole
● ● ● ● ● ● – – – B
8-hole
– – – – – – ● ● ● H
Working port 40 71 125 180 250 355 500 750 1000
12 SAE flange ports A and B, position lateral on same side,
metric fastening thread
● ● ● ● ● ● ● ● ● 10
●
= Available
○
= On request
‒
= Not available ▲ = Not for new projects
Type code
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15
A4VS G / W – V 10
1)
For more information about sealing material, see data sheet 92100
RE 92058/2022-08-02, BoschRexrothAG
3 Axial piston units with DS2 secondary control | A4VSG Series 10 and 3x
Type code
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15
A4VS G / W – V 10
Through drives (for mounting options and dimensions see data sheet 92100)
13
Flange ISO 3019-1
(metric)
Hub f
or s
plined shaft
1)
Diameter Attachment Diameter 40 71 125 180 250 355 500 750 1000
Without through drive
● ● ● ● ● ● ● ● ● N00
125, 4-hole
32x22x14x9g
● ● ● ● ● ○ ○ ○ ○ K31
140, 4-hole 40x2x18x9g
– ● ● ● ● ● ● ○ ● K33
160, 4-hole 50x2x24x9g
– – ● ● ● ● ● ○ ● K34
224, 4-hole 60x2x28x9g
– – – – ● ● ● ● ● K35
224, 4-hole 70x3x22x9g – – – – – ● ● ○ ○ K77
315, 8-hole
80x3x25x9g – – – – – – ● ○ ○ K43
400, 8-hole 90x3x28x9g – – – – – – – ● ● K76
400, 8-hole 100x3x32x9g – – – – – – – – ● K88
With mounted incremental encoder 1000 pulses/rev. ● ● ● ● ● ● ● ● ● T03
3)
Prepared for mounted incremental encoder,
through drive plugged with cover
● ● ● ● ● ● ● ● ● T10
3)
Special tachometer mounting ○ ○ ○ ○ ○ ○ ○ ○ ○ T99
Prepared for special tachometer mounting,
plugged with cover
○ ○ ○ ○ ○ ○ ○ ○ ○ T00
Pr
epar
ed for through drive, with pressure-proof
plugged cover
● ● ● ● ● ● ● ● ● K99
Valves
40 71 125 180 250 355 500 750 1000
14 Without valve block ● ● ● ● ● ● ● ● ● 0
Mounted electrically releasable check valve RVE ● ● ● ● ● ● ● ● ● 1
2)
Electrically releasable shut-off block for combination
with load-holding function LS 1363, type code L,
without overload protection for deactivated isolator valve.
● ● ● ● ● ● ● ● ● 2
4)
Electrically releasable shut-off block for combination
with load-holding function LS 1363, type code L,
and block for manual overload protection MOPS
● ● ● ● ● ● ● ● ● 3
Filtration
40 71 125 180 250 355 500 750 1000
15 Without filter ● ● ● ● ● ● ● ● ● N
Intermediate plate filter (see data sheet 92076) ● ● ● ● ● ● ● ● ● Z
●
= Available
○
= On request – = Not available Notice
▶ Note the project planning notes on page 37.
▶ In addition to the type code, please specify the
relevant technical data when placing your order.
(See also data sheet 92100)
1) Hub for splined shaft according to ANSI B92.1a
2) Combination with swivel direction (position 06) L or R not possible.
3) Preferred types
4) For more information see "A4VSG...DS2 for use in winch and
crane applications" on page34
BoschRexrothAG, RE 92058/2022-08-02
4 A4VSG Series 10 and 3x | Axial piston units with DS2 secondary control
Function
Function
Secondary control is an energy-saving drive concept with
high dynamics for the installation of rotational speed,
position, or torque controls with energy recovery.
The secondary controlled hydrostatic axialpiston units
operate on asupply network with constant high pressure
and low pressure.
The power takeoff or return to the supply network is
throttle-free and based on demand whereby the
displacement of the axial piston units adapts to the
respective load case.
Any number of units operating as amotor or pump can
thereby be arranged in parallel. Four-quadrant operation is
possible, whereby the units for reversing the rotational
speed or torque are swiveled over "zero". This also reverses
the direction of the flow.
ND
n
soll
n
ist
1
6
3
4 5
2
7
8
Flow direction
Swiveling range
1)
Direction of rotation
2)
High pressure in Operating mode
Clockwise Counter-clockwise
15° 0° 15°
CW
CCW
Clockwise B to A – B Motor
Clockwise – A to B B Pump
Counter-clockwise – B to A B Motor
Counter-clockwise A to B – B Pump
Clockwise B to A – A Pump
Clockwise – A to B A Motor
Counter-clockwise – B to A A Pump
Counter-clockwise A to B – A Motor
An energy accumulator can be installed in the high and low
pressure system between the primary and secondary units
if necessary.
The flow peaks are covered by the accumulator.
It is also used to store the energy recovered in the hydraulic
network from the secondary unit if no other consumers are
present.
Together with the pressure-controlled primary unit and the
operating conditions of the secondary unit, the charge state
of the accumulator and its pre-charge pressure determine
the constant high pressure of the system.
The specific properties of the secondary control, such as
the reduction in technical equipment in the primary area,
the possibilities of energy recovery and the storage of
braking energy, and the virtually load-independent
rotational speed and positioning accuracy open up awide
field of applications.
1 Drive 5 Secondary unit
2 Pressure controller 6 HP accumulator
3 Control electronics 7 LP accumulator
4 Primary unit 8 Output drive
Associated electronics (see also page 15)
▶ Digital controller assembly group SYHNC100-SEK...3x
▶ Amplifier card VT-VRRA 1-527-20/V0
(for sizes 40 and 71)
▶ Amplifier card VT-VRRA 1-537-20/V0
(for sizes 125 to 1000)
▶ Card holder VT3002-1-2x/32F
1) Cf. swivel angle indicator
2) Viewed on drive shaft
RE 92058/2022-08-02, BoschRexrothAG
5 Axial piston units with DS2 secondary control | A4VSG Series 10 and 3x
Circuit diagram DS.. Sizes 40 to 71
Circuit diagram DS.. Sizes 40 to 71
▼ Circuit diagram standard A4VSG...DS2R/...W-... 10 T03...1N
M
1
T
1
T
2
1
1.2
1.3
2
3
1.1
M
2
P
ST
R
KV
A
P
E
A
U
S
U
R(L)K TM
B
M
A
B
b
a
G
U
P
A
T
B
Sp
Secondary unit components
1 Axial piston unit A4VSG size 40 to 71
1.1 4-way control valve (see data sheet 29026)
NG (A4VS) Type
40, 71 4WRPH6 C3 B24L -2X/G24KO/M-750
1.2 Swivel angle sensor AWXF (see page 13)
1.3 Incremental encoder GEL 293 (see page 12)
2 Electrically releasable check valve RVE
Ordering code: Order item 14, type code 1 (see page14)
3 Anti-cavitation valve, order separately (see page 14)
Flow direction
Size
40 to 71
Swivel
direction
1)
Direction of rotation
2)
High pressure in
3)
Operating mode Control valve Sign
Clockwise Counter-clockwise 4WRPH Swivel angle
Control
part
Flow
direction
Actual value
15° 0° 15°
CW
CCW
Clockwise B to A A Pump P to A
B to T
Positive
Clockwise A to B A Motor
P to A
B to T
Positive
Counter-
clockwise
B to A A Pump
P to B
A to T
Negative
Counter-
clockwise
A to B A Motor
P to B
A to T
Negative
Ports
A Working pressure (high-pressure series)
B Low pressure (high-pressure series)
M
A
;
M
1
Measuring working pressure
M
B
Measuring low pressure
M
2
Measuring working pressure
M
3
;
M
4
Measuring control pressure (from NG125)
S
P
External control pressure
T Fluid drain
T
1
; T
2
Leakage/air bleeding
K Flushing
R(L) Control fluid return flow
U Bearing flushing
P
ST
Pilot pressure
E Boost pressure
R
KV
Control fluid return flow
P Control pressure
1) Vertical view of the optical swivel angle indicator
2) Viewed on drive shaft
3) Valid for high pressure at port A (standard) When using the
MPOS block, only high pressure at port A is possible.
BoschRexrothAG, RE 92058/2022-08-02
6 A4VSG Series 10 and 3x | Axial piston units with DS2 secondary control
Circuit diagram DS.. Sizes 125 to 355
Circuit diagram DS.. Sizes 125 to 355
▼ Circuit diagram standard A4VSG...DS2R/...W-... 10 T03...1N
M
1
T
1
T
2
1
1.2
1.3
2
3
1.1
M
2
P
ST
R
KV
A
P
E
A
U
S
U M
3
M
4
R(L)K TM
B
M
A
B
b
a
G
U
P
A
T
B
Sp
Secondary unit components
1 Axial piston unit A4VSG size 125 to 355
1.1 4-way control valve (see data sheet 29026)
NG (A4VS) Type
125 to 355 4WRPH10 C3 B50L -2X/G24KO/M-750
1.2 Swivel angle sensor AWXF (see page 13)
1.3 Incremental encoder GEL 293 (see page 12)
2 Electrically releasable check valve RVE
Ordering code: Order item 14, type code 1 (see page14)
3 Anti-cavitation valve, order separately (see page 14)
Flow direction
Size
125 to 355
Swivel
direction
1)
Direction of rotation
2)
High pressure in
3)
Operating mode Control valve Sign
Clockwise Counter-clockwise 4WRPH Swivel angle
Control
part
Flow
direction
Actual value
15° 0° 15°
CW
CCW
Clockwise B to A A Pump P to B
A to T
Positive
Clockwise A to B A Motor
P to B
A to T
Positive
Counter-
clockwise
B to A A Pump
P to A
B to T
Negative
Counter-
clockwise
A to B A Motor
P to A
B to T
Negative
Ports
A Working pressure (high-pressure series)
B Low pressure (high-pressure series)
M
A
;
M
1
Measuring working pressure
M
B
Measuring low pressure
M
2
Measuring working pressure
M
3
;
M
4
Measuring control pressure (from NG125)
S
P
External control pressure
T Fluid drain
T
1
; T
2
Leakage/air bleeding
K Flushing
R(L) Control fluid return flow
U Bearing flushing
P
ST
Pilot pressure
E Boost pressure
R
KV
Control fluid return flow
P Control pressure
1) Vertical view of the optical swivel angle indicator
2) Viewed on drive shaft
3) Valid for high pressure at port A (standard).
When using the MPOS block, only high pressure at port A is
possible
.
RE 92058/2022-08-02, BoschRexrothAG
7 Axial piston units with DS2 secondary control | A4VSG Series 10 and 3x
Circuit diagram DS.. Sizes 500 to 1000
Circuit diagram DS.. Sizes 500 to 1000
▼ Circuit diagram standard A4VSG...DS2R/...W-... 10 T03...1N
1
1.2
1.3
2
3
1.1
U
S
b
a
G
U
P
A
T
B
M
B1
U
R
2
R
3
R
4
R
5
R
6
R
7
M
A1
B
R(L)TK
M
1
T
1
T
2
M
2
A
M
P
M
B2
M
A2
P
ST
R
KV
P
E
A
Secondary unit components
1 Axial piston unit A4VSG size 500 to 1000
1.1 4-way control valve (see data sheet 29026)
NG (A4VS) Type
500 to 1000 4WRPH10 C3 B50L -2X/G24KO/M-750
1.2 Swivel angle sensor AWXF (see page 13)
1.3 Incremental encoder GEL 293 (see page 12)
2 Electrically releasable check valve RVE
Ordering code: Order item 14, type code 1 (see page14)
3 Anti-cavitation valve, order separately (see page 14)
Flow direction
Size
500 to 1000
Swivel
direction
1)
Direction of rotation
2)
High pressure in
3)
Operating mode Control valve Sign
Clockwise Counter-clockwise 4WRPH Swivel angle
Control
part
Flow
direction
Actual value
15° 0° 15°
CW
CCW
Clockwise B to A A Pump P to A
B to T
Positive
Clockwise A to B A Motor
P to A
B to T
Positive
Counter-
clockwise
B to A A Pump
P to B
A to T
Negative
Counter-
clockwise
A to B A Motor
P to B
A to T
Negative
Ports
A Working pressure (high-pressure series)
B Low pressure (high-pressure series)
M
A1
; M
1
; M
2
Measuring working pressure
M
B1
Measuring low pressure
M
A2
Measuring control pressure
M
B2
Measuring control pressure
M
P
External control pressure
T Fluid drain
T
1
; T
2
Leakage/air bleeding
K Flushing
R(L) Control fluid return flow
U Bearing flushing
P
ST
Pilot pressure
E Boost pressure
R
KV
Control fluid return flow
P Control pressure
R2 - R7 Air bleeding the control
1) Vertical view of the optical swivel angle indicator
2) Viewed on drive shaft
3) Valid for high pressure at port A (standard).
When using the MPOS block, only high pressure at port A is
possible
.
BoschRexrothAG, RE 92058/2022-08-02
8 A4VSG Series 10 and 3x | Axial piston units with DS2 secondary control
Working pressure range
Working pressure range
Pressure at working port A or B Definition
Nominal pressure p
nom
315bar
1)
The nominal pressure corresponds to the maximum design pressure.
Maximum pressure p
max
400bar
2)
The maximum pressure corresponds to the maximum working pressure within asingle
operating period. The sum of single operating periods must not exceed the total
operating period.
Single operating period 1 s
Total operating period 300 h
Minimum pressure
(high-pressure side)
15 bar Minimum pressure at the high-pressure side (A or B) which is required to prevent
damage to the axial piston unit.
Minimum pressure
(low-pressure side)
Minimum pressure on the low-pressure side (A or B) required to prevent damage to
the axial piston unit. The minimum pressure depends on the rotational speed and the
boost pressure (see diagram).
Rate of pressure change R
Amax
16000bar/s Maximum permissible speed of pressure build-up and reduction during apressure
change across the entire pressure range.
Recommended boost pressure p
SP
(input) (for boost pumps, see data sheet 92100)
16bar Size 40 to 500 series 1x and 30
10 bar Sizes 250 and 500 series 33
25bar Size 750 to 1000 series 30
Maximum boost pressure - attachment pump p
Smax
at control
3)
:
50bar For details on the pilot or control pressure, see diagram "Required pilot pressure
depending on the working pressure"
Case pressure at connection K
2
, K
3,
R(L)
Max. static pressure p
L max
4bar absolute
4)
Maximum 1.2bar higher than inlet pressure at port S, but not higher than p
L max.
The permissible case pressure depends on the rotational speed (see diagram).
Adrain line to the reservoir is required.
Pressure peaks p
L peak
6 bar absolute t< 0.1 s
▼ Minimum pressure, low-pressure side (boost pressure)
20
18
16
14
12
10
8
6
0.5 0.6 0.7 0.8 0.9 1.0
Inlet pressure p
e
[bar]
Rotational speed n [rpm]
NG 750 and
1000/30
NG 40 to 500/30
NG 250 and 500/33
Minimum recommended
setting (pressure gauge
indicator)
▼ Rate of pressure change R
Amax
p
nom
∆t
∆p
Time t
Pressure p
For details on the shaft seal ring, see data sheet 92100.
▼ Required pilot pressure depending on the working pressure
315
150
150 200 250 315
250
200
Working pressure p
nom
[bar]
Maximum
permissible
Pilot pressure p
St
[bar]
Notice
The table data are reference values (valid for mineral oil).
Specified pressures according to DIN24312.
Please contact us for special operating conditions
(sales.industry.horb@boschrexroth.de).
1) Due to the permissible data of the control valve and other system
components
2) For permissible inlet pressure of the respective attachment
pump, see the corresponding data sheet
3) For permissible inlet pressure of the respective attachment
pump, see the corresponding data sheet
4) Please contact us if the value cannot be observed
RE 92058/2022-08-02, BoschRexrothAG
9 Axial piston units with DS2 secondary control | A4VSG Series 10 and 3x
Technical data
Technical data
For ahighly dynamic accurate drive system, abacklash-free
minimum mass moment of inertia directly on the shaft of
the secondary unit is required. Information on this can be
found in the row "Required minimum total moment of iner-
tia". A higher moment of inertia improves the control behav-
ior.
Size NG 40 71 125 180 250 355 500 750 1000
Geometric displacement, per
revolution
V
g max
cm
3
40 71 125 180 250 355 500 750 1000
Maximum
rotational
speed
1)
at 1.0 V
gmax
;
p
E
≥ 15bar
n
nom
rpm 3700 3200 2600 2400 2000 2000 1800 1600 1600
at 0.8 V
gmax
;
p
E
≥ 15bar
n
max
rpm 4900 4100 3400 2900 2600 2200 2000 1800 1600
Power at n
nom
, V
g max
and Δp = 300 bar
P
kW 74 114 163 216 250 355 450 600 800
Torque at V
g max
and Δp = 300 bar
M
Nm 191 339 597 859 1194 1695 2387 3581 4775
Control
volume
from 0 to V
g max
V
S max
cm
3
5.9 10.5 26.0 26.0 50.9 50.9 63.8 105 129
Actuating
time
from 0 to V
g max
t
s
s 0.030 0.040 0.050 0.050 0.060 0.060 0.080 0.090 0.10
Moment of inertia
kgm
2
0.0049 0.0121 0.0300 0.055 0.0959 0.19 0.3325 0.66 1.20
Required minimum total
moment of inertia
kgm
2
0.025 0.06 0.15 0.27 0.48 0.95 1.66 3.33 6
Weight (with RVE and
incremental encoder) approx.
m
kg 67 83 126 140 225 248 381 523 630
Determining the characteristics for operation as apump
Flow q
v
=
V
g
× n × η
v
[l/min]
1000
Torque
M
=
V
g
× Δp
[Nm]
20 × π × η
hm
Power
P
=
2 π × M × n
=
q
v
× Δp
[kW]
60000 600 × η
t
Key
V
g
= Displacement per revolution [cm
3
]
Δp
= Differential pressure [bar]
n
= Rotational speed [rpm]
η
v
= Volumetric efficiency
η
hm
= Hydraulic-mechanical efficiency
η
t
= Total efficiency (η
t
= η
v
× η
hm
)
Notice
▶ Theoretical values, without efficiency and tolerances;
values rounded
▶ Operation above the maximum values or below the
minimum values may result in aloss of function,
areduced service life or in the destruction of the
axial piston unit. We recommend checking loads
through tests or calculation/simulation and
comparing them with the permissible values.
▶ Special requirements apply in the case of belt drives.
Please contact us.
Determining the characteristics for operation as amotor
Displacement q
v
=
V
g
× n
[l/min]
1000 × η
v
Torque
M
=
V
g
× Δp × η
hm
[Nm]
20 × π
Output power
P
=
2 π × M × n
=
q
v
× Δp × η
t
[kW]
60000 600
Key
V
g
= Displacement per revolution [cm
3
]
Δp
= Differential pressure [bar]
n
= Rotational speed [rpm]
η
v
= Volumetric efficiency
η
hm
= Hydraulic-mechanical efficiency
η
t
= Total efficiency (η
t
= η
v
× η
hm
)
1) The values are applicable:
– for the optimum viscosity range from ν
opt
= 36 to 16mm
2
/s
– with hydraulic fluid based on mineral oils
BoschRexrothAG, RE 92058/2022-08-02
10 A4VSG Series 10 and 3x | Axial piston units with DS2 secondary control
Permissible radial and axial loading of the drive shaft
Permissible radial and axial loading of the drive shaft
Size NG 41 71 125 180 250 355 500 750 1000
Maximum radial force at a/2
a
a/2
a/2
F
q
F
q max
N 1200 1700 2500 3100 4000 4400 5000 6000 10000
Maximum axial force
at case pressure
p
max
1 bar absolute
F
ax
+
–
± F
ax max
N 1000 1400 1900 2250 3000 3600 4000 5450 8000
at case pressure
p
max
4 bar absolute
+ F
ax max
N 620 810 1050 1400 1850 2100 2500 3150 4700
– F
ax max
N 1380 1950 2750 3050 4150 5050 5500 7800 11000
Notice
▶ The values given aremaximum values and do not
apply to continuous operation. The drive with radial
loading (pinion, V-belt) is not permissible!
1) Vertical view of the optical swivel angle indicator
2) Viewed on drive shaft
RE 92058/2022-08-02, BoschRexrothAG
11 Axial piston units with DS2 secondary control | A4VSG Series 10 and 3x
DS2R rotational speed control
DS2R rotational speed control
Rotational speed control is when the DS2 control device
changes the swivel angle and thus the displacement of the
axial piston unit at aconstant working pressure until the
torque required to maintain the specified rotational speed
is built up.
In asupply network with constant working pressure,
the torque is proportional to the swivel angleIn the
displacement of the axial piston unit. The displacement is
sensed by an inductive position transducer,
the rotational speed by an incremental encoder.
A control valve controls the displacement.
When higher requirements are placed on the dynamics of
the drive system, the control valve can be replaced with
aservo valve.
When the emergency shut-down is used, the electrically
releasable check valve RVE (hydraulic connector) at the
pressure port is brought to the locked position.
This then prevents energy from being supplied to the
secondary unit; only regenerative braking with energy
recovery to the hydraulic network is possible.
The following pages describe:
▶ The incremental encoder GEL 293 for sensing the
rotational speed
▶ The position transducer AWXF for sensing the
swivel angle
▶ The electrically releasable RVE A4VS check valve
▶ The digital controller assembly group SYHNC100-SEK
Information on pilot valve (DS2R) 4WRPH6/10..-750 can
be found in data sheet 29026.
BoschRexrothAG, RE 92058/2022-08-02
12 A4VSG Series 10 and 3x | Axial piston units with DS2 secondary control
Incremental encoder GEL 293
Dimensions [mm]
Incremental encoder GEL 293
Technical data (type code position 12 "T03")
Resolution
T03 1000 increments/revolution
Type of protection according to
EN60529
IP 66 with installed and
locked plug-in connector
Power consumption: R
L
= ∞; U
B
= 5 V ≤1.3 W
Ambient temperature –20°C to +85°C
Signal pattern T
Supply voltage U
S
= 5 V ±5%; signal voltage U
Si
= 5 V
Clockwise-rotating signal image viewed on drive shaft
A+
A-
B+
B-
Track 1
Track 2
Track 1
Track 2
Electrical connection
Maximum cable lengths
Between the incremental encoder and the downstream
electronics: Earth the cable shield on one side of the
receiver. The data specified are reference values and
refer to the cable type LiYCY 6 (10) x 0.25 mm
2
.
f
[kHz] 5 10 20 50 100 200
l
max
[m] 200 200 200 200 145 72
U
S
= 5V ±5%
Track 1
Track 2
Track 1
Track 2
Right (clockwise)
▼ Dimensions (inmm)
approx. 80
51.5
29.5
ø 115
The plug-in connector is included in the scope of delivery.
It is possible to use other rotational speed sensing
systems. In this case, please contact us
(sales.industry.horb@boschrexroth.de).
Connector for solenoids
DEUTSCH DT04-2P-EP04
Molded, 2-pin, without bidirectional suppressor diode.
The following type of protection ensues with the mounted
mating connector:
▶ IP67/IP66 (DIN/EN 60529)
▼ Switching symbol ▼ Circuit diagram pin image
▼ Plug-in connector
Directional valve with device connector K40
(DEUTSCH connector)
Code
2P DT06
K40..
Voltage
DC/AC
U
Current
I
max
Color Wire cross
section
[mm
2
]
Material
number
..AWG14 10...32 V 5 A gray AWG14-16
1.3..2.08
R900733451
..AWG16 10...32 V 5 A gray AWG16-18
0.83..1.3
R901017847
▼ Dimensions (inmm)
16
X
16
32
View X
The mating connector is not included in the scope of
delivery and must be ordered separately.
The following are required:
Load-holding function LS1363 1 connector
Electrically releasable check valve 1 connector
Electrically releasable shut-off block 1 connector
Manual overload protection MOPS 2 connectors
Accessories (not included in the scope of delivery)
Crimping tool Type HDT-4800, Deutsch
Notice
Further information in RE08006 "Plug-in connectors
and wiring harnesses for valves and sensors in
hydraulic systems".
RE 92058/2022-08-02, BoschRexrothAG
13 Axial piston units with DS2 secondary control | A4VSG Series 10 and 3x
Swivel angle sensor AWXF
Dimensions [mm]
Swivel angle sensor AWXF
Technical data
Measuring system Differential transformer
Control stroke mm ±4.5
Linearity tolerance % ≤1.0
Carrier frequency kHz 5
Coil resistance
(At 20°C)
Primary coil Ω 120
per secondary
coil
Ω 280
Electrical
connection
Plug-in connection
M12 × 1, 4-pin
Plug-in connection type of
protection according to EN 60529
IP66/IP67 with mounted
and locked plug-in
connector
Ambient temperature –20°C to +80°C
▼ Electrical connection
1
2
43
AWXF004D02
1
prim. sec.
2
3
4
▼ Dimensions (inmm)
87
1
63
A
Adapter ring,
size-dependent
1 Plug-in connector is included in the scope of delivery.
▼ Table of values dimension A
Size
40 71 125 180 250 355 500 750 1000
86 90 96 86 81 81 81 81 81
BoschRexrothAG, RE 92058/2022-08-02
14 A4VSG Series 10 and 3x | Axial piston units with DS2 secondary control
Electrically releasable check valve RVE
Electrically releasable check valve RVE
(Order item 14, type code 1)
Technical data
Electric (see also directional seat valve M–3SED6, data sheet 22049)
DC voltage V 24
Power consumption W 30
Duty cycle Continuous operation
Type of protection according to EN 60529 IP66/IP67 with mounted and locked plug-in connector
Hydraulic (see also cartridge valves type LC.., data sheet 21010)
Size Logic element Installed in the housing Maximum flow q
v max
in l/min
at apressure drop of 5 bar
40 LC16B40D
-7X/ AGEV4-05701-AB/46 200
71 LC25B40D-7X/ AGEV4-05702-AB/46 400
125 LC32B40D-7X/ AGEV4-05703-AB/46 700
180 LC32B40D-7X/ AGEV4-05703-AB/46 700
250 LC32B40D-7X/ AGEV4-05704-AB/46 700
355 LC32B40D-7X/ AGEV4-05704-AB/46 700
500 LC40B40D-7X/ AGEV4-05705-AB/46 1200
750 LC40B40D-7X/ AGEV4-05705-AB/46 1200
1000 LC40B40D-7X/ AGEV4-05705-AB/46 1200
Anti-cavitation valve S...A
(Without order item, selection according to the
following table)
Ordering code for A4VSG
Size Anti-cavitation valve
40 S10A1.0
71 S15A1.0
125 S20A1.0
180 S20A1.0
250 S25A1.0
355 S25A1.0
500 S30A1.0
750 S30A1.0
1000 S30A1.0
Notice
▶ For details on the anti-cavitation valves,
see data sheet20375.
RE 92058/2022-08-02, BoschRexrothAG
15 Axial piston units with DS2 secondary control | A4VSG Series 10 and 3x
Digital controller assembly group SYHNC100-SEK...3x
Digital controller assembly group SYHNC100-SEK...3x
(Without order item; selection according to data sheet 30162)
Features
The digital controller assembly group SYHNC100-SEK-...-3x
is suitable for the rotational speed control, closed loop
torque control and o
pen loop torque control of secondary
controlled axial piston units type A4VS..DS2.
It contains interfaces to measure the swivel angle position
of single or tandem units as well as for rotational speed
return with incremental encoders. The software contains
control and monitoring functions specifically designed for
the secondary control.
Additional features:
▶ Up to 2 modules for evaluating the signals from
up to 4 LVDT swivel angle sensors
▶ Up to 2 incremental encoder inputs with monitoring
function for rotational speed sensing
▶ Up to 8 analog inputs (voltage or current) for the
setpoint specification
▶ Up to 6 analog outputs for controlling downstream
valve amplifiers
▶ Digital inputs and outputs for communication with
ahigher-level control
▶ Profibus DP or CANopen for communication with
ahigher-level control
▶ Layout of the master/slave applications via internal
CAN interface
▶ Installation on a35 mm top hat rail
Software functionality
The software basically contains the control types: rotational
speed control, closed loop torque control, and open loop
torque control.
You can switch between the control types during operation
without any hitches.
The configuration, parameterization and diagnosis of the
SYHNC100-SEK-...-3x is done using the PC program WINPED.
Only the "WIN-PED 6.6" version is used.
This can be downloaded from
www.boschrexroth.com/hnc100 free of charge.
System-specific software extensions can be created
on request.
Monitoring functions
▶ Cable break monitoring for incremental and SSI encoders
▶ Cable break monitoring for swivel angle sensor
▶ Acceleration too high
▶ Overspeed (max. rotational speed)
▶ Rotational speed difference target / actual
▶ Swivel angle difference target / actual
Further information
Data sheet 30162 "Digital controller assembly group
HNC100-SEK for secondary control of axialpiston units,
type SYHNC100-SEK
Notice about the system structure
The secondary unit with ordering code 04 = "DS2R"
(with control valve) additionally requires the following,
which are not included in the scope of delivery:
▶ Digital controller assembly group SYHNC100-SEK-...-3x
according to data sheet 30162
▶ Amplifier VT-VRRA 1-527-20/V0 according to
data sheet 30041 (for A4VS size 40 and 71)
or
Amplifier VT-VRRA 1-537-20/V0 according to
data sheet 30041 (for A4VS size 125 to 1000)
▶ Card holder VT3002-1-2X/32F,
material number 1834486001, according to
data sheet 29928
BoschRexrothAG, RE 92058/2022-08-02
16 A4VSG Series 10 and 3x | Axial piston units with DS2 secondary control
Dimensions, size 40
Dimensions [mm]
Dimensions, size 40
DS2 – secondary controlled unit with RVE check valve
Bidirectional direction of rotation
U
L
R
R(L)
X
K
M
2
T
1
ø15
85
150
200
T
W
B
A
M
A
M
B
M
1
15°
15°
0
144
25
ø125
-0.063
79
150
45°
45°
ø160
90
18
52
8
30
30
260
205.5 276
135
227
330
S
p
79
50.8
A
B
50.8
ø18.5
23.8
23.8
33
102
69
ø20
48
5
395.5
148
E
P
ST
P
R
KV
Pumps
center
View W
View X
RE 92058/2022-08-02, BoschRexrothAG
17 Axial piston units with DS2 secondary control | A4VSG Series 10 and 3x
Dimensions, size 40
Dimensions [mm]
▼ Splined shaft DIN5480 ▼ Parallel keyed shaft DIN6885
Z ‒ W32x2x14x9g P ‒ Ø32 AS 10x8x56
M10
1) 2)
ø40
22
36
28
M10
1)2)
68
ø40
22
35
ø32
+0.018
58
+0.002
Ports Standard Size
1)
p
max abs
[bar]
2)
State
6)
A, B Working port (high-pressure series)
Fastening thread
SAE J518
3)
DIN 13
3/4 in
M10 × 1.5; 17 deep
400 O
M
A
; M
B
Measuring working pressure DIN 3852 M14 × 1.5; 12 deep 400 X
M
1
; M
2
Measuring working pressure DIN 3852 G 1/4 in; 12 deep 400 X
S
P
Control pressure DIN 3852 M22 × 1.5; 14 deep 315 O
T Fluid drain DIN 3852 M22 × 1.5; 14 deep 4 X
T
1
; T
2
Leakage/air bleeding DIN 3852 G 1/4 in; 12 deep 4 X
K Flushing DIN 3852
4)
M22 × 1.5; 14 deep 4 O
5)
R(L) Control fluid return flow DIN 3852
4)
M22 × 1.5; 14 deep 4 O
5)
U Bearing flushing DIN 3852 M14 × 1.5; 12 deep 7 X
P
ST
Pilot pressure ISO 228 G 1/2; 15 deep 315 piped up
E Boost pressure DIN 3852
4)
M22 × 1.5; 20 deep 50 O
R
KV
Control fluid return flow DIN 3852
4)
M22 × 1.5; 14 deep 100 piped up
P Control pressure DIN 3852
4)
M22 × 1.5; 14 deep 315 piped up
Shaft key
width 10
1) Observe the notes in the instruction manual concerning the
maximum tightening torques.
2) Depending on the application, momentary pressure peaks can occur.
Keep this in mind when selecting measuring devices and fittings.
3) Metric fastening thread is a deviation from standard.
4) The countersink may be deeper than specified in the standard.
5) Depending on the installation position, K or R(L) must be connected
(also see installation instructions in data sheet 92100).
6) O=Must be connected (plugged on delivery)
X=Plugged (in normal operation)
BoschRexrothAG, RE 92058/2022-08-02
18 A4VSG Series 10 and 3x | Axial piston units with DS2 secondary control
Dimensions, size71
Dimensions [mm]
Dimensions, size71
DS2 – secondary controlled unit with RVE check valve
Bidirectional direction of rotation
X
U
R(L)
M
2
L
R
B
A
0
15°15°
S
p
48
ø15
170
97
ø140
-0.063
170
9393
45°
45°
180
18
8
61
101
106
27
92
34
152
296
243 151
422.5
258.5
292
166 27
27.8
27.8
ø25
57.2
ø25
57.2
99.5
62
37.5
220
T
M
A
M
1
A
B
M
B
W
T1
K
E
P
ST
P
R
KV
View W
View X
RE 92058/2022-08-02, BoschRexrothAG
19 Axial piston units with DS2 secondary control | A4VSG Series 10 and 3x
Dimensions, size71
Dimensions [mm]
▼ Splined shaft DIN5480 ▼ Parallel keyed shaft DIN6885
Z ‒ W40x2x18x9g P ‒ Ø40 AS 12x8x58
M12
1) 2)
ø40
28
45
28
M12
1)2)
68
ø50
28
43
ø40
+0.018
70
+0.002
Ports Standard Size
1)
p
max abs
[bar]
2)
State
6)
A, B Working port (high-pressure series)
Fastening thread
SAE J518
3)
DIN 13
1 in
M12 × 1.75; 17 deep
400 O
M
A
; M
B
Measuring working pressure DIN 3852 M14 × 1.5; 12 deep 400 X
M
1
; M
2
Measuring working pressure DIN 3852 G 1/4 in; 12 deep 400 X
S
P
Control pressure DIN 3852 M22 × 1.5; 14 deep 315 O
T Fluid drain DIN 3852 M27 × 2; 12 deep 4 X
T
1
; T
2
Leakage/air bleeding DIN 3852 G 1/4 in; 12 deep 4 X
K Flushing DIN 3852
4)
M27 × 2; 14 deep 4 O
5)
R(L) Control fluid return flow DIN 3852
4)
M27 × 2; 16 deep 4 O
5)
U Bearing flushing DIN 3852 M14 × 1.5; 12 deep 7 X
P
ST
Pilot pressure ISO 228 G 1/2; 15 deep 315 piped up
E Boost pressure DIN 3852
4)
M22 × 1.5; 20 deep 50 O
R
KV
Control fluid return flow DIN 3852
4)
M22 × 1.5; 14 deep 100 piped up
P Control pressure DIN 3852
4)
M22 × 1.5; 14 deep 315 piped up
Shaft key
width 12
1) Observe the notes in the instruction manual concerning the
maximum tightening torques.
2) Depending on the application, momentary pressure peaks can occur.
Keep this in mind when selecting measuring devices and fittings.
3) Metric fastening thread is a deviation from standard.
4) The countersink may be deeper than specified in the standard.
5) Depending on the installation position, K or R(L) must be connected
(also see installation instructions in data sheet 92100).
6) O=Must be connected (plugged on delivery)
X=Plugged (in normal operation)
BoschRexrothAG, RE 92058/2022-08-02
20 A4VSG Series 10 and 3x | Axial piston units with DS2 secondary control
Dimensions, size125
Dimensions [mm]
Dimensions, size125
DS2 – secondary controlled unit with RVE check valve
Bidirectional direction of rotation
B
A
E
U
K
T
Z
M
B
M
A
B
A
W
15 150
U
R(L)
X
L
R
M
3
M
4
R
KV
P
S
P
39
284.4
203
14
ø160
-0.063
200
111.5
50
45°
45°
22
121
8
125
70
33
112
39
186
413.5
ø20
114.5
200
315
322.9
354
255 180.9
ø30
66.7
ø32
66.7
41.5
31.8
135.5
M
2
T
1
M
1
K
B
A
31.8
ø200
E
P
ST
View X
View W
View Z
RE 92058/2022-08-02, BoschRexrothAG
21 Axial piston units with DS2 secondary control | A4VSG Series 10 and 3x
Dimensions, size125
Dimensions [mm]
▼ Splined shaft DIN5480 ▼ Parallel keyed shaft DIN6885
Z ‒ W50x2x24x9g P ‒ Ø50 AS 14x9x80
M16
1) 2)
ø40
36
54
45
M16
1)2)
92
ø50
36
53.5
ø50
+0.018
82
+0.002
Ports Standard Size
1)
p
max abs
[bar]
2)
State
6)
A, B Working port (high-pressure series)
Fastening thread
SAE J518
3)
DIN 13
1 1/4 in
M14 × 2; 19 deep
400 O
M
A
; M
B
Measuring working pressure DIN 3852 M14 × 1.5; 12 deep 400 X
M
1
; M
2
Measuring working pressure DIN 3852 M14 × 1.5; 12 deep 400 X
M
3
; M
4
Measuring working pressure DIN 3852 M14 × 1.5; 12 deep 400 X
S
P
Control pressure DIN 3852 M22 × 1.5; 14 deep 315 O
T Fluid drain DIN 3852 M33 × 2; 18 deep 4 X
T
1
; T
2
Leakage/air bleeding DIN 3852 G 1/4 in; 12 deep 4 X
K Flushing DIN 3852
4)
M33 × 2; 18 deep 4 O
5)
R(L) Control fluid return flow DIN 3852
4)
M33 × 2; 18 deep 4 O
5)
U Bearing flushing DIN 3852 M14 × 1.5; 12 deep 7 X
P
ST
Pilot pressure ISO 228 G 1/2; 15 deep 315 piped up
E Boost pressure DIN 3852
4)
M22 × 1.5; 14 deep 50 O
R
KV
Control fluid return flow DIN 3852
4)
M22 × 1.5; 14 deep 100 piped up
P Control pressure DIN 3852
4)
M22 × 1.5; 14 deep 315 piped up
Shaft key
width 14
1) Observe the notes in the instruction manual concerning the
maximum tightening torques.
2) Depending on the application, momentary pressure peaks can occur.
Keep this in mind when selecting measuring devices and fittings.
3) Metric fastening thread is a deviation from standard.
4) The countersink may be deeper than specified in the standard.
5) Depending on the installation position, K or R(L) must be connected
(also see installation instructions in data sheet 92100).
6) O=Must be connected (plugged on delivery)
X=Plugged (in normal operation)
BoschRexrothAG, RE 92058/2022-08-02
22 A4VSG Series 10 and 3x | Axial piston units with DS2 secondary control
Dimensions, size 180
Dimensions [mm]
Dimensions, size 180
DS2 – secondary controlled unit with RVE check valve
Bidirectional direction of rotation
X
L
R
U
R(L)
M
3
M
4
K
A
B
U
K
15° 15°0
45°
354
ø20
200
114.5
33
50
200
111.5111.5
45°
112
203
14
437.5
265 201.4
ø200
T
M
B
M
A
W
R
KV
P
S
P
39
284.4
ø160
-0.063
22
121
8
125
70
39
186
315
322.9
ø30
66.7
ø32
66.7
41.5
31.8
135.5
B
A
31.8
M
2
T
1
M
1
E
P
ST
View X
View W
RE 92058/2022-08-02, BoschRexrothAG
23 Axial piston units with DS2 secondary control | A4VSG Series 10 and 3x
Dimensions, size 180
Dimensions [mm]
▼ Splined shaft DIN5480 ▼ Parallel keyed shaft DIN6885
Z ‒ W50x2x24x9g P ‒ Ø50 AS 14x9x80
M16
1) 2)
ø40
36
54
45
M16
1)2)
92
ø50
36
53.5
ø50
+0.018
82
+0.002
Ports Standard Size
1)
p
max abs
[bar]
2)
State
6)
A, B Working port (high-pressure series)
Fastening thread
SAE J518
3)
DIN 13
1 1/4 in
M14 × 2; 19 deep
400 O
M
A
; M
B
Measuring working pressure DIN 3852 M14 × 1.5; 12 deep 400 X
M
1
; M
2
Measuring working pressure DIN 3852 G 1/4 in; 12 deep 400 X
S
P
Control pressure DIN 3852 M22 × 1.5; 14 deep 315 O
T Fluid drain DIN 3852 M33 × 2; 18 deep 4 X
T
1
; T
2
Leakage/air bleeding DIN 3852 G 1/4 in; 12 deep 4 X
K Flushing DIN 3852
4)
M33 × 2; 18 deep 4 O
5)
R(L) Control fluid return flow DIN 3852
4)
M33 × 2; 18 deep 4 O
5)
U Bearing flushing DIN 3852 M14 × 1.5; 12 deep 7 X
P
ST
Pilot pressure ISO 228 G 1/2; 15 deep 315 piped up
E Boost pressure DIN 3852
4)
M22 × 1.5; 14 deep 50 O
R
KV
Control fluid return flow DIN 3852
4)
M22 × 1.5; 14 deep 100 piped up
P Control pressure DIN 3852
4)
M22 × 1.5; 14 deep 315 piped up
Shaft key
width 14
1) Observe the notes in the instruction manual concerning the
maximum tightening torques.
2) Depending on the application, momentary pressure peaks can occur.
Keep this in mind when selecting measuring devices and fittings.
3) Metric fastening thread is a deviation from standard.
4) The countersink may be deeper than specified in the standard.
5) Depending on the installation position, K or R(L) must be connected
(also see installation instructions in data sheet 92100).
6) O=Must be connected (plugged on delivery)
X=Plugged (in normal operation)
BoschRexrothAG, RE 92058/2022-08-02
24 A4VSG Series 10 and 3x | Axial piston units with DS2 secondary control
Dimensions, size250
Dimensions [mm]
Dimensions, size250
DS2 – secondary controlled unit with RVE check valve
Bidirectional direction of rotation
24
144.5
265
233
293.5 356.9
55
160
M
4
M
3
L
R
15°15° 0
R(L)
U
X
497.5
424
W
T
U
K
B
A
M
A
M
B
ø224
-0.072
265
143.5
ø280
45°
45°
30
152.5
150
8
90
43
144
248
17
B
A
36.5
R
KV
P
SP
184
123
K
M
1
T
1
M
2
39
39
ø38
36.5
79.4
144.5 50.5
ø38
79.4
8
E
P
ST
View X
View W
RE 92058/2022-08-02, BoschRexrothAG
25 Axial piston units with DS2 secondary control | A4VSG Series 10 and 3x
Dimensions, size250
Dimensions [mm]
▼ Splined shaft DIN5480 ▼ Parallel keyed shaft DIN6885
Z ‒ W60x2x28x9g P ‒ Ø60 AS 18x11x100
M20
1) 2)
ø62
42
70
59
M20
1)2)
115
ø62
42
64
ø60
+0.018
105
+0.002
Ports Standard Size
1)
p
max abs
[bar]
2)
State
6)
A, B Working port (high-pressure series)
Fastening thread
SAE J518
3)
DIN 13
1 1/2 in
M16 × 2; 21 deep
400 O
M
A
; M
B
Measuring working pressure DIN 3852 M14 × 1.5; 12 deep 400 X
M
1
; M
2
Measuring working pressure DIN 3852 G 1/4; 12 deep 400 X
S
P
Control pressure DIN 3852 M22 × 1.5; 14 deep 315 O
T Fluid drain DIN 3852 M42 × 2; 20 deep 4 X
T
1
; T
2
Leakage/air bleeding DIN 3852 G 1/4 in; 12 deep 4 X
K Flushing DIN 3852
4)
M42 × 2; 20 deep 4 O
5)
R(L) Control fluid return flow DIN 3852
4)
M42 × 2; 20 deep 4 O
5)
U Bearing flushing DIN 3852 M14 × 1.5; 12 deep 7 X
P
ST
Pilot pressure ISO 228 G 1/2; 15 deep 315 piped up
E Boost pressure DIN 3852
4)
M22 × 1.5; 14 deep 50 O
R
KV
Control fluid return flow DIN 3852
4)
M22 × 1.5; 14 deep 100 piped up
P Control pressure DIN 3852
4)
M22 × 1.5; 14 deep 315 piped up
Shaft key
width 18
1) Observe the notes in the instruction manual concerning the
maximum tightening torques.
2) Depending on the application, momentary pressure peaks can occur.
Keep this in mind when selecting measuring devices and fittings.
3) Metric fastening thread is a deviation from standard.
4) The countersink may be deeper than specified in the standard.
5) Depending on the installation position, K or R(L) must be connected
(also see installation instructions in data sheet 92100).
6) O=Must be connected (plugged on delivery)
X=Plugged (in normal operation)
BoschRexrothAG, RE 92058/2022-08-02
26 A4VSG Series 10 and 3x | Axial piston units with DS2 secondary control
Dimensions, size 355
Dimensions [mm]
Dimensions, size 355
DS2 – secondary controlled unit with RVE check valve
Bidirectional direction of rotation
15°15°
0
U
K
123
233
248
17
ø224
-0.072
265
143.5143.5
ø280
45°
45°
30
152.5
150
8
90
40
144
424
526.5
184293.5
ø24
144.5
265
55
305
356.9
393
W
B
A
M
B
M
A
T
K
M
1
T
1
M
2
X
M
3
M
4
U
R
L
R(L)
B
A
36.5
R
KV
P
SP
39
39
ø38
36.5
79.4
144.5 50.5
ø38
79.4
E
P
ST
View X
View W
RE 92058/2022-08-02, BoschRexrothAG
27 Axial piston units with DS2 secondary control | A4VSG Series 10 and 3x
Dimensions, size 355
Dimensions [mm]
▼ Splined shaft DIN5480 ▼ Parallel keyed shaft DIN6885
Z ‒ W70x3x22x9g P ‒ Ø76 AS 20x12x100
M20
1) 2)
ø72
42
82
69
M20
1)2)
115
ø62
42
64
ø60
+0.018
105
+0.002
Ports Standard Size
1)
p
max abs
[bar]
2)
State
6)
A, B Working port (high-pressure series)
Fastening thread
SAE J518
3)
DIN 13
1 1/2 in
M16 × 2; 21 deep
400 O
M
A
; M
B
Measuring working pressure DIN 3852 M14 × 1.5; 12 deep 400 X
M
1
; M
2
Measuring working pressure DIN 3852 G 1/4; 12 deep 400 X
M
3
; M
4
Measuring working pressure DIN 3852 M18 × 1.5; 12 deep 400 X
S
P
Control pressure DIN 3852 M22 × 1.5; 14 deep 315 O
T Fluid drain DIN 3852 M42 × 2; 20 deep 4 X
T
1
; T
2
Leakage/air bleeding DIN 3852 G 1/4 in; 12 deep 4 X
K Flushing DIN 3852
4)
M42 × 2; 20 deep 4 O
5)
R(L) Control fluid return flow DIN 3852
4)
M42 × 2; 20 deep 4 O
5)
U Bearing flushing DIN 3852 M18 × 1.5; 12 deep 7 X
P
ST
Pilot pressure ISO 228 G 1/2; 15 deep 315 piped up
E Boost pressure DIN 3852
4)
M22 × 1.5; 14 deep 50 O
R
KV
Control fluid return flow DIN 3852
4)
M22 × 1.5; 14 deep 100 piped up
P Control pressure DIN 3852
4)
M22 × 1.5; 14 deep 315 piped up
Shaft key
width 18
1) Observe the notes in the instruction manual concerning the
maximum tightening torques.
2) Depending on the application, momentary pressure peaks can occur.
Keep this in mind when selecting measuring devices and fittings.
3) Metric fastening thread is a deviation from standard.
4) The countersink may be deeper than specified in the standard.
5) Depending on the installation position, K or R(L) must be connected
(also see installation instructions in data sheet 92100).
6) O=Must be connected (plugged on delivery)
X=Plugged (in normal operation)
BoschRexrothAG, RE 92058/2022-08-02
28 A4VSG Series 10 and 3x | Axial piston units with DS2 secondary control
Dimensions, size500
Dimensions [mm]
Dimensions, size500
DS2 – secondary controlled unit with RVE check valve
Bidirectional direction of rotation
R(L)
T
M
B1
M
A1
B
A
M
P
W
R
2
R
7
R
4
R
6
R
3
R
5
K
T
1
M
2
L
R
M
B2
M
A2
X
U
15~15~0
50
45°
8x45°(=360°)
155
30
30°
ø225
13
ø315
-0.081
ø230
+5
10°
ø405
190
ø24
161
ø360
16
+5
47
80
155
280
189
16
48
279 50
281
190
190
22°30'
110
363
205
245
110
361
190
170
435
104
109
571.5
255255
ø50
96.8
154
44.5
ø50
96.8
60
44.5
B
A
E
P
ST
P
R
KV
View X
View W
Eye bolt M16; 27 deep
DIN 580
RE 92058/2022-08-02, BoschRexrothAG
29 Axial piston units with DS2 secondary control | A4VSG Series 10 and 3x
Dimensions, size500
Dimensions [mm]
▼ Splined shaft DIN5480 ▼ Parallel keyed shaft DIN6885
Z ‒ W80x3x25x9g P ‒ Ø80 AS 22x14x125
M20
1) 2)
ø83
42
90
76
M20
1)2)
180
ø83
42
85
ø80
+0.030
130
+0.011
Ports Standard Size
1)
p
max abs
[bar]
2)
State
6)
A, B Working port (high-pressure series)
Fastening thread
SAE J518
3)
DIN 13
2 in
M20 × 2.5; 24 deep
400 O
M
A1
; M
B1
Measuring working pressure DIN 3852 M18 × 1.5; 12 deep 400 X
M
A2
; M
B2
, M
P
Measuring control pressure DIN 3852 M14 × 1.5; 12 deep 315 X
M
1
; M
2
Measuring working pressure DIN 3852 G 1/4; 12 deep 400 X
T Fluid drain DIN 3852 M48 × 2; 20 deep 4 X
T
1
; T
2
Leakage/air bleeding DIN 3852 G 1/4 in; 12 deep 4 X
K Flushing DIN 3852
4)
M48 × 2; 20 deep 4 O
5)
R(L) Control fluid return flow DIN 3852
4)
M48 × 2; 20 deep 4 O
5)
R
2
to R
7
Air bleeding the control DIN 3852 M14 × 1.5; 12 deep 315 X
U Bearing flushing DIN 3852 M18 × 1.5; 12 deep 7 X
P
ST
Pilot pressure ISO 228 G 3/4; 17 deep 315 piped up
E Boost pressure DIN 3852
4)
M27 × 2; 20 deep 50 O
R
KV
Control fluid return flow DIN 3852
4)
M27 × 2; 16 deep 100 piped up
P Control pressure DIN 3852
4)
M27 × 2; 16 deep 315 piped up
Shaft key
width 22
1) Observe the notes in the instruction manual concerning the
maximum tightening torques.
2) Depending on the application, momentary pressure peaks can occur.
Keep this in mind when selecting measuring devices and fittings.
3) Metric fastening thread is a deviation from standard.
4) The countersink may be deeper than specified in the standard.
5) Depending on the installation position, K or R(L) must be connected
(also see installation instructions in data sheet 92100).
6) O=Must be connected (plugged on delivery)
X=Plugged (in normal operation)
BoschRexrothAG, RE 92058/2022-08-02
30 A4VSG Series 10 and 3x | Axial piston units with DS2 secondary control
Dimensions, size750
Dimensions [mm]
Dimensions, size750
DS2 – secondary controlled unit with RVE check valve
Bidirectional direction of rotation
X
M
A2
M
B2
L
R
15°
15°
0
U
R4
R2
R3
R6
R7
R5
K
T1
M2
M
P
B
M
B1
M
A1
R(L)
T
M
1
317
400
ø495
ø450
13
16
30°
10°
50
58
32
301 50
ø255
ø263
ø400
-0.089
232
114
119
235
275
304
110110
582
45°
161
47
16
+5
89
621.5
478
361.1
182
232 232
45°
8x45°(=360)
22°30'
355
232
232
ø22
178
ø50
96.8
44.5
154
ø50
96.8
44.5
60
B
A
E
P
ST
P
R
KV
View X
Eye bolt M16; 27 deep
DIN 580
RE 92058/2022-08-02, BoschRexrothAG
31 Axial piston units with DS2 secondary control | A4VSG Series 10 and 3x
Dimensions, size750
Dimensions [mm]
▼ Splined shaft DIN5480 ▼ Parallel keyed shaft DIN6885
Z ‒ W90x3x28x9g P ‒ Ø90 AS 25x14x125
M24
1) 2)
ø95
50
105
91
M24
1)2)
180
ø95
50
95
ø90
+0.035
130
+0.013
Ports Standard Size
1)
p
max abs
[bar]
2)
State
6)
A, B Working port (high-pressure series)
Fastening thread
SAE J518
3)
DIN 13
2 in
M20 × 2.5; 28 deep
400 O
M
A1
; M
B1
Measuring working pressure DIN 3852 M18 × 1.5; 12 deep 400 X
M
A2
; M
B2
:M
P
Measuring working pressure DIN 3852 M14 × 1.5; 12 deep 400 X
M
1
; M
2
Measuring working pressure DIN 3852 G 1/4; 12 deep 400 X
R
2
to R
7
Air bleeding the control DIN 3852 M14 × 1.5; 12 deep 315 X
T Fluid drain DIN 3852 M48 × 2; 20 deep 4 X
T
1
; T
2
Leakage/air bleeding DIN 3852 G 1/4 in; 12 deep 4 X
K Flushing DIN 3852
4)
M48 × 2; 20 deep 4 O
5)
R(L) Control fluid return flow DIN 3852
4)
M48 × 2; 20 deep 4 O
5)
U Bearing flushing DIN 3852 M18 × 1.5; 12 deep 7 X
P
ST
Pilot pressure ISO 228 G 3/4; 17 deep 315 piped up
E Boost pressure DIN 3852
4)
M27 × 2; 20 deep 50 O
R
KV
Control fluid return flow DIN 3852
4)
M27 × 2; 16 deep 100 piped up
P Control pressure DIN 3852
4)
M27 × 2; 16 deep 315 piped up
Shaft key
width 22
1) Observe the notes in the instruction manual concerning the
maximum tightening torques.
2) Depending on the application, momentary pressure peaks can occur.
Keep this in mind when selecting measuring devices and fittings.
3) Metric fastening thread is a deviation from standard.
4) The countersink may be deeper than specified in the standard.
5) Depending on the installation position, K or R(L) must be connected
(also see installation instructions in data sheet 92100).
6) O=Must be connected (plugged on delivery)
X=Plugged (in normal operation)
BoschRexrothAG, RE 92058/2022-08-02
32 A4VSG Series 10 and 3x | Axial piston units with DS2 secondary control
Dimensions, size1000
Dimensions [mm]
Dimensions, size1000
DS2 – secondary controlled unit with RVE check valve
Bidirectional direction of rotation
View X
Eye bolt M16; 27 deep
DIN 580
B
A
B
A
M
B1
M
A1
R(L)
T
MP
T
1
M
1
M
2
R
6
R
5
R
7
R
4
R
3
R
2
K
X
U
15°
15° 0
L
R
M
B2
M
A2
55
121
126
62.5
ø450
ø495
232
232
199
311 311
360
51
30°
13
16
45°
35
ø322
ø333
+5
-0.089
ø400
231
201
232 232
22°30'
343
140 140
16
+5
47 98
203
45°
431
344
96.8
ø50
44.4
44.5
96.8
ø50
75169
44.5
96.8
370
543
694.5
258
298
327
376
169
ø22
45°
8x45°(=360°)
E
P
ST
P
R
KV
RE 92058/2022-08-02, BoschRexrothAG
33 Axial piston units with DS2 secondary control | A4VSG Series 10 and 3x
Dimensions, size1000
Dimensions [mm]
▼ Splined shaft DIN5480 ▼ Parallel keyed shaft DIN6885
Z ‒ W100x3x32x9g P ‒ Ø100 AS 28x16x160
M24
1) 2)
ø104
50
105
91
M24
1)2)
215
ø104
50
106
ø100
+0.035
165
+0.013
Ports Standard Size
1)
p
max abs
[bar]
2)
State
6)
A, B Working port (high-pressure series)
Fastening thread
SAE J518
3)
DIN 13
2 in
M20 × 2.5; 24 deep
400 O
M
A1
; M
B1
Measuring working pressure DIN 3852 M18 × 1.5; 12 deep 400 X
M
A2
;
M
B2
:M
P
Measuring working pressure DIN 3852 M14 × 1.5; 12 deep 400 X
M
1
; M
2
Measuring working pressure DIN 3852 G 1/4; 12 deep 400 X
R
2
to R
7
Air bleeding the control DIN 3852 M14 × 1.5; 12 deep 315 X
T Fluid drain DIN 3852 M48 × 2; 20 deep 4 X
T
1
; T
2
Leakage/air bleeding DIN 3852 G 1/4 in; 12 deep 4 X
K Flushing DIN 3852
4)
M48 × 2; 20 deep 4 O
5)
R(L) Control fluid return flow DIN 3852
4)
M48 × 2; 20 deep 4 O
5)
U Bearing flushing DIN 3852 M18 × 1.5; 12 deep 7 X
P
ST
Pilot pressure ISO 228 G 3/4; 17 deep 315 piped up
E Boost pressure DIN 3852
4)
M27 × 2; 20 deep 50 O
R
KV
Control fluid return flow DIN 3852
4)
M27 × 2; 16 deep 100 piped up
P Control pressure DIN 3852
4)
M27 × 2; 16 deep 315 piped up
Shaft key
width 28
1) Observe the notes in the instruction manual concerning the
maximum tightening torques.
2) Depending on the application, momentary pressure peaks can occur.
Keep this in mind when selecting measuring devices and fittings.
3) Metric fastening thread is a deviation from standard.
4) The countersink may be deeper than specified in the standard.
5) Depending on the installation position, K or R(L) must be connected
(also see installation instructions in data sheet 92100).
6) O=Must be connected (plugged on delivery)
X=Plugged (in normal operation)
BoschRexrothAG, RE 92058/2022-08-02
34 A4VSG Series 10 and 3x | Axial piston units with DS2 secondary control
A4VSG...DS2 for use in winch and crane applications
A4VSG...DS2 for use in winch and crane applications
For use in cranes and winches, specifically in the marine
and offshore sectors, safety functions are required to
comply with the specifications of the classification
societies. For this purpose control blocks are available,
which guarantee the required emergency functions such
as holding the load in the event of ahydraulic system
failure, emergency lifting and lowering, or the emergency
jettisoning of aload in the event of asystem failure.
The following combinations are available:
▶ Holding the load in the event of ahydraulic system
failure
▶ Holding the load in the event of ahydraulic system
failure and manual overload protection
MOPS(Manual Overload Protection System)
▶ Emergency lifting and lowering in the event of
asystem failure
Holding the load in the event of ahydraulic system failure
Order item 14, code 2:
Electrically releasable shut-off block for combination with
load-holding function LS1363
Order item 6, code LL/LR
▼ Layout diagram
12
Control valve
Load-holding
function
Shut-off block
Axial piston unit
1 Load-holding function
▶ 0V = load-holding function on, winch drive off.
▶ 24V = load-holding function off, winch drive on.
2 Shut-off block
▶ 0V = enable axial piston unit inactive
▶ 24V = enable axial piston unit active.
The load-holding function with LS 1363 is mounted
between the control valve and the secondary unit and
allows the secondary unit to swivel into apredefined end
stop in an emergency. This function ensures that when the
shut-off block is closed, the load is held withmaximum
torque and no high pressure without the use of any external
control or PLC.
The clockwise (LR) / counter-clockwise (LL)
swivel parameter is necessary to determine the correct
effective direction of the holding torque.
For LX, the load-holding function LS 1363 is not piped up
when delivered and can thus be piped up to adapt to the
swivel direction. The end user is then responsible for
the piping.
In the secondary controlled winch drive, the LS1363 is
switched on with 24V and is inactive. The emergency
function is activated when the valve is switched off.
The winch drive can no longer be controlled.
Notice
This order item 14, code 2 does not have
integratedmaximum pressure limitation as standard.
This must be provided externally or as amounting block.
Please contact us for atechnical explanation
(sales.industry.horb@boschrexroth.de).
RE 92058/2022-08-02, BoschRexrothAG
35 Axial piston units with DS2 secondary control | A4VSG Series 10 and 3x
Holding the load in the event of ahydraulic system failure and manual overload protection MOPS
Holding the load in the event of ahydraulic system failure and manual overload protection MOPS
Order item 14, code 3:
Electrically releasable shut-off block for combination with
load-holding function LS1363, type code LL/LR,
and manual overload protection MOPS
▼ Layout diagram
1
2
3
Control valve
Load-holding function
MOPS block
Axial piston unit
1 Load-holding function
▶ 0V = load-holding function on, winch drive off.
▶ 24V = load-holding function off, winch drive on.
2 MOPS block shut-off function
▶ 0V = enable axial piston unit inactive
▶ 24V = enable axial piston unit active
3 MOPS block pressure limitation
▶ 0V = system pressure p
HD
on, MOPS function off
▶ 24V = system pressure p
HD
off, MOPS function on
In addition to holding the load withmaximum torque and
no high pressure, this block combination also enables the
"manual overload protection" function, which can be used
to drop the load in the event of an emergency in order to
secure the crane and the crew. The function of the
load-holding function with LS1363 is described
onpage34.
▼ Layout diagram for emergency lifting and lowering
In the event of asystem failure, this function and an
emergency unit can be used to lift the suspended load
on board again or to lower it to the bottom of the sea with
limited function.
1
2
3
Control valve
Load-holding function
MOPS block
Axial piston unit
Emergency
lifting / lowering
Emergency
unit
The load-holding function, MOPS block shut-off function
and MOPS block pressure limitation are controlled as
described under order item 14, code 3 on the left
Emergency lifting and lowering
Notice
The emergency lifting and lowering function
must be designed specifically for the project.
Please contact us for atechnical explanation
(sales.industry.horb@boschrexroth.de).
BoschRexrothAG, RE 92058/2022-08-02
36 A4VSG Series 10 and 3x | Axial piston units with DS2 secondary control
Dimensions of all valve block attachments
Dimensions [mm]
Dimensions of all valve block attachments
DS2 – Secondary controlled unit with all valve block attachments (order item 14, code 3)
Bidirectional direction of rotation
A
2
A
9
A
3
A
1
A
6
A
7
A
4
A
5
A
8
NG A1 A2 A3 A4 A5 A6 A7 A8 A9
40
401 260 365 130 342 225 83 332 227
71
433 265 360 158 357 240 88 364 232
125
519 340 441 177 426 305 115 450 307
180
519 340 441 177 436 315 115 450 307
250
595 343 459 212 478 350 191 526 310
355
602 344 447 212 498 370 190 533 311
500
674 469 447 254 545 410 165 605 436
750
717 469 447 292 585 450 165 648 436
1000
782 484 462 309 600 465 180 713 451
RE 92058/2022-08-02, BoschRexrothAG
37 Axial piston units with DS2 secondary control | A4VSG Series 10 and 3x
Project planning notes
Project planning notes
▶ The axial piston variable pump A4VSG is intended for
use in aclosed circuit.
▶ The project planning, installation and commissioning
of the axial piston unit requires the involvement of
skilled personnel.
▶ Before using the axial piston unit, please read the
corresponding instruction manual completely and
thoroughly. If necessary, this can be requested from
BoschRexroth.
▶ Before finalizing your design, please request abinding
installation drawing.
▶ The specified data and notes contained herein must be
observed.
▶ Depending on the operating conditions of the
axialpiston unit (working pressure, fluid temperature),
the characteristic curve may shift.
▶ The characteristic curvemay also shift due to the
dither frequency or control electronics.
▶ Preservation: Our axial piston units are supplied as
standard with preservation protection for amaximum
of 12months. If longer preservation protection is
required (maximum 24months), please specify this in
plain text when placing your order. The preservation
periods apply under optimal storage conditions,
details of which can be found in the datasheet90312
or the instruction manual.
▶ Not all versions of the product are approved for
use in safety functions according to ISO13849.
Please consult the proper contact at BoschRexroth
ifyou require reliability parameters (e.g.MTTF
d
)
for functional safety.
▶ Depending on the type of control used,
electromagnetic effects can be produced when using
solenoids. Applying adirect voltage signal (DC)
to solenoids does not create electromagnetic
interference (EMI) nor is the solenoid affected by EMI.
Electromagnetic interference (EMI) potential exists
when operating and controlling asolenoid with
amodulated direct voltage signal (e.g.PWM signal)
Appropriate testing and measures should be taken by
the machine manufacturer to ensure other components
or operators (e.g.with pacemaker) are not affected by
this potential.
▶ Pressure controllers are not safeguards against
pressure overload. Be sure to add apressure relief
valve to the hydraulic system.
▶ For controllers requiring external pilot pressure,
sufficient control fluid must be provided to the
associated ports to ensure the required pilot pressures
for the respective controller function. These controllers
are subject to leakage due to their design. An increase
in control fluid demand has to be anticipated over the
total operating time. The design of the control fluid
supply must thus be sufficiently large. If the control
fluid is too low, the respective controller function may
be impaired and undesired system behavior may result.
▶ For drives that are operated for along period of time
with constant rotational speed, the natural frequency
of the hydraulic system can be stimulated by the
excitation frequency of the pump (rotational speed
frequencyx9). This can be prevented with suitably
designed hydraulic lines.
▶ Please note the details regarding the tightening
torques of port threads and other threaded joints in
the instruction manual.
▶ The ports and fastening threads are designed for the
p
max
permissible pressures of the respective ports,
seethe connection tables. The machine or system
manufacturer must ensure that the connecting
elements and lines correspond to the specified
application conditions (pressure, flow, hydraulic fluid,
temperature) with the necessary safety factors.
▶ The service ports and function ports are only intended
to accommodate hydraulic lines.
BoschRexrothAG, RE 92058/2022-08-02
BoschRexrothAG
An den Kelterwiesen 14
72160 Horb a.N.
Germany
Phone +49 7451 92-0
sales.industry.horb@boschrexroth.de
www.boschrexroth.com
©BoschRexrothAG2017. All rights reserved, also regarding any disposal,
exploitation, reproduction, editing, distribution, aswellas intheevent
ofapplications forindustrial property rights. The data specified within only
serves todescribe the product. No statements concerning acertain
condition or suitability for acertain application can be 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 our
products are subject to anatural process of wear and aging.
38 A4VSG Series 10 and 3x | Axial piston units with DS2 secondary control
Safety instructions
BoschRexrothAG
Zum Eisengießer 1
97816 Lohr am Main
Germany
Phone +49 9352 18-0
info.ma@boschrexroth.de
www.boschrexroth.com
Safety instructions
▶ During and shortly after operation, there is arisk of
getting burnt on the axial piston unit and especially on
the solenoids. Take the appropriate safety measures
(e.g.by wearing protective clothing).
▶ Moving parts in control equipment (e.g.valve spools)
can, under certain circumstances, get stuck in position
as aresult of contamination (e.g.contaminated
hydraulic fluid, abrasion, or residual dirt from
components). As aresult, the hydraulic fluid flow and
the build-up of torque in the axial piston unit can no
longer respond correctly to the operator’s
specifications. Even the use of various filter elements
(external or internal flow filtration) will not rule out
afault but merely reduce the risk. The machine/system
manufacturer must test whether remedial measures are
needed on the machine for the application concerned
in order to bring the driven consumer into asafe
position (e.g.safe stop) and ensure any measures are
properly implemented.
▶ In certain conditions, moving parts in high pressure
relief valves might get stuck in an undefined position due
to contamination (e.g.contaminated hydraulic fluid).
This can result in restriction or loss of load-holding
functions in lifting winches.
The machine/system manufacturer must check whether
additional me
asures are required on the machine for the
relevant application in order to keep the load in asafe
position and ensure they are properly implemented.