Bosch Rexroth A4CSG 30 Series User manual

RE 92105-01-X-B2/2019.08.06, BoschRexrothAG
Axial piston variable pump
A4CSG Series 30
for explosive areas
II 2G Ex h IIC T4-T1 Gb X and
II 3G Ex h IIC T4-T1 Gc X
RE 92105-01-X-B2/2019.08.06
Replaces: 08.2017
Information onexplosion protection
▶ Application per Directive2014/34/EU (ATEX)
▶ Gas: II 2G Ex h IIC T4-T1 Gb X according
toDINENISO80079-36 :2016,
DINENISO80079-37:2016
▶ Gas: II 3G Ex h IIC T4-T1 Gc X according
toDINENISO80079-36 :2016,
DINENISO80079-37:2016
Features ofthe ATEX version
The ATEX version isan advanced development ofthe
A4CSG for compliance with Directive2014/34/EU (ATEX).
External features distinguishing it from the standard pump
asper data sheet 92105 are the ground terminal, the
Ex marking and the CE marking onthe name plate.
For ATEX category II 2G Ex h IIC T4-T1 Gb X, an additional
temperature sensor for monitoring the operation data
issupplied.
Temperature classes per DINENISO80079-36
Depending onthe two temperature classes, T3 and T4,
observe the maximum permissible temperatures
(see "Hydraulic fluid" and "Operating data monitoring –
X parameters").
▶ Sizes 250, 355, 500
▶ Nominal pressure 350 bar
▶ Maximum pressure 400 bar
▶ Closed circuit
Part II ofinstruction manual
inaccordance with ATEX
Directive(2014/34/EU)
data sheet
Contents
Type code 2
Hydraulic fluids 4
Operating data monitoring – X parameters 5
Leakage temperature monitoring
for ATEX category II 2G Ex h IIC T4-T1 Gb X 6
Filtration ofthe hydraulic fluid 7
Shaft seal 7
Working pressure range 8
Technical data 9
HD – hydraulic control, pilot-pressure related 11
EP – Electrohydraulic control with proportional sole-
noids 12
Solenoid technical data 13
Circuit diagrams 14
Dimensions, size250to 500
Combination pumps 36
Dimensions, through drive 38
Integrated boost pump and
valve technology (version F..) 44
Filtration types 46
Installation instructions 47
Project planning notes 50
Safety instructions 51

BoschRexrothAG, RE 92105-01-X-B2/2019.08.06
2A4CSG Series 30 | Axial piston variable pump
Type code
1) -S2145 only up to 3bar case pressure for temperature class T4
2) See DINENISO80079-36, 6.4.2.1
Axial piston unit
01 Swashplate design, variable, nominal pressure 350bar, maximum pressure 400bar A4CS
Operating mode
02 Pump, closed circuit G
Size
03 Geometric displacement, see "Technical data" page 9 250 355 5001)
Control device
04 Proportional control hydraulic control,
pilot-pressure related
(HD1T and HD1U not available)
see 92080
● ● ● HD...
electrohydraulic see 92084 ● ● ● EP
Series
05 Series 3, index 0 30
Directions ofrotation
06 Viewed ondrive shaft clockwise R
counter-clockwise L
Sealing material 250 355 500
07 FKM (fluoroelastomer) and ATEX version II 2G Ex h IIC T4-T1 Gb X ● ● ● R
FKM (fluoroelastomer) and ATEX version II 3G Ex h IIC T4-T1 Gc X ● ● ● A
Drive shaft 250 355 500
08 Parallel keyed shaft DIN 6885 ● ● ● P
Splined shaft DIN5480 ● ● ● Z
Mounting flange 250 355 500
09 Based onISO 3019-2 (metric) 4-hole ● ● –B
8-hole – – ● H
Working port
10 SAE flange ports Aand B, positioned laterally opposite each other, metric fastening thread 35
SAE flange port S, positioned laterally offset from Aand Bby 90°, metric fastening thread
Boost pump
11 With integrated boost pump ● ● ● F
●= Available ○= Onrequest –= Not available
Notices
▶ When ordering, please indicate the equipment group,
category, explosiongroup, temperature class and type
ofprotection required for your intended ATEX
application.
▶ Potential equalization: The pump must begrounded.
For: Grounding points, please refer tothe drawings
starting onpage 21. Compared tothe standard
pump, the technical data isrestricted interms
oftemperature, case pressure and bearing flushing/
installation position.
▶ To avoid mechanically generated sparks from aluminum
contaminants with iron oxide and/or rust particles
onthe surface2), the pump comes painted toprotect
against corrosion. Please contact your Rexroth partner
for available colors.
▶ The service life ofthe bearings must becalculated. The
load cycle forms the basis for this. Please contact us.
Type code
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15
A4CS G / 30 – 35 4

RE 92105-01-X-B2/2019.08.06, BoschRexrothAG
3Axial piston variable pump | A4CSG Series 30
Type code
Type code
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15
A4CS G / 30 – 35 4
Through drive3) (for mounting options, see page page 36) 250 355 500
12 With through-drive shaft, without hub, without intermediate flange, closed with cover ● ● ● 99
With through drive for mounting asecond unit
Flange ISO 3019-2 (metric) Hub for splined shaft DIN5480
125, 4-hole W32×2×14x9g ○● ● 314)
140, 4-hole W40×2×18x9g ○ ○ ● 334)
160, 4-hole W50×2×24x9g ● ● ● 344)
224, 4-hole W60×2×28x9g ●○● 35
224, 4-hole W70×3×22x9g –● ● 77
315, 8-hole W80×3×25x9g – – ● 43
400, 8-hole W90×3×28x9g – – – 764)
Flange ISO 3019-2 (metric) Hub for splined shaft SAEJ744
80, 2-hole 3/4in (19-4) ● ● ● B24)
100, 2-hole 7/8 in (22-4) ● ● ● B34)
100, 2-hole 1 in (25-4) ● ● ● B44)
125, 4-hole 1 in (25-4) ○ ○ ○ E14)
125, 2-hole 1 1/4 in (32-4) ● ● ● B54)
160, 4-hole 1 1/4 in (32-4) ○ ○ ○ B84)
125, 2-hole 1 1/2 in (38-4) ● ● ● B64)
180, 4-hole 1 1/2 in (38-4) ○ ○ ○ B94)
180, 4-hole 1 3/4 in (44-4) ○ ○ ○ B74)
Flange SAE J744 Hub for splined shaft SAEJ744
82-2 (A) 5/8 in (16-4) ● ● ● 014)
82-2 (A) 3/4in (19-4) ○● ● 524)
101-2 (B) 7/8 in (22-4) ● ● ● 684)
101-2 (B) 1 in (25-4) ○● ● 044)
127-2 (C) 1 1/4 in (32-4) ● ● ● 074)
127-4 (C) 1 1/4 in (32-4) ○ ○ ○ 154)
127-2 (C) 1 1/2 in (38-4) ● ● ● 244)
152-4 (D) 1 3/4 in (44-4) ● ● ● 174)
Valves
13 Boost, control pressure relief and flushing valve integrated;
pilot operated high-pressure relief valve integrated ● ● ● 4
Filtration (see page 46)
14 Without filter ● ● ● N
With threaded port for filter inthe boost circuit ● ● ● D
Special version (optional)
15 Without special version ● ● ●
With double shaft seal ● ● –-S1111
With double shaft seal and active flushing – – ●-S2145
●= Available ○= Onrequest –= Not available
Notices
Please observe the project planning notes on page 50!
For information onstoring and preserving axial piston units,
see Data Sheet 90312.
3) All attachment pumps must comply with the application-specific
ATEX classification.
4) For Equipment Category II 2G Ex h IIC T4-T1 Gb X not available

BoschRexrothAG, RE 92105-01-X-B2/2019.08.06
4A4CSG Series 30 | Axial piston variable pump
Hydraulic fluids
Hydraulic fluids
The A4CSG variable pump isdesigned for operation
with HLP mineral oil according toDIN 51524.
See thefollowing datasheets forapplication instructions and
requirements forhydraulic fluids before thestart ofproject
planning:
▶ 90220: Hydraulic fluids based onmineral oils and related
hydrocarbons
Explanation regarding the selection ofhydraulic fluid
Selection ofhydraulic fluid shall make surethat the operating
viscosity inthe operating temperature range iswithin the
optimum range (νopt; see selection diagram).
Please note
The leakage temperature which isinfluenced bypressure and
rotational speed isalways above the reservoir temperature.
Temperature class T4 and T3 asto ATEX:
For safety instructions, see “Operating data monitoring – X
parameters” onpage 5.
Ignition temperature ofhydraulic fluid
The pump isapproved for temperature classes T4 toT1
according toDINENISO80079-36 and -37.
Under DINENISO80079-37, only hydraulic fluids with
an ignition temperature atleast 50 K above the maximum
surface temperature ofthe approved temperature class should
beused. Example: For the temperature class T4, the ignition
temperature ofthe hydraulic fluid should be≥ 185°C.
Viscosity and temperature ofhydraulic fluids
Viscosity Temperature Comment
Cold start νmax≤1000 mm2/s θSt≥-25 °C t≤3 min, without load (p≤50 bar)
Maximum permissible temperature difference between axial
piston unit
and hydraulic fluid inthe system maximum 25 K
Warm-up phase ν=1000 to100 mm2/s θ≥ -25°C For pnom,0.5×nmax und t≤15min
Continuous operation ν=100 to16 mm2/s T3
θ=-25°C to+90°C
T4
θ=-25°C to+80°C
Measured atthe drain port
Observe the permissible temperature range ofthe shaft seal
νopt=36 to16 mm2/s optimal operating viscosity and efficiency range
Short-term operation νmin≤10 mm2/s T3
θ=-25°C to+90°C
T4
θ=-25°C to+80°C
t<3 min, p<0.3×pnom
▼Selection diagram
-25 -10 10 30 50 80 9070
0
10
40
60
20
100
200
400
600
1000
16
36
VG 22
VG 32
VG 46
VG 68
VG 100
Optimum operating viscosity range vopt
Optimum efficiency
Maximum permissible viscosity oncold start
Minimum permissible viscosity for short-term operation
Temperature θ[°C]
Viscosity v[mm2/s]
Minimum permissible temperature oncold start

RE 92105-01-X-B2/2019.08.06, BoschRexrothAG
5Axial piston variable pump | A4CSG Series 30
Operating data monitoring – X parameters
Operating data monitoring – X parameters
Safety instructions
Temperature class T3–T1
ATEX category II 3G Ex h IIC T3–T1 Gc X
To observe the maximum leakage temperature of 90 °C,
at least one of the following measures must be taken and
checked regularly:
▶ Check the leakage temperature atport TorR(L)
(maximum distance 30cm)
▶ Check the maximum inlet temperature of60°C atthe
suction port
▶ Check a maximum inlet temperature that must
bedetermined for the following operating points when
commissioning:
– Maximum working pressure and maximum
possible flow
– Maximum working pressure and minimum flow
Also monitor the reservoir level. Take appropriate action
ifthe temperature exceeds limits.
When the minimum boost pressure of8bar isnot
reached, switch off the system immediately.
ATEX category II 2G Ex h IIC T3–T1 Gb X
To observe the maximum leakage temperature of90°C,
the following measures must betaken:
▶ Install the supplied temperature sensor onthe unit
according tothe specifications inchapter 7.4.9 ofthe
instruction manual.
▶ Continuously monitor the leakage temperature ofeach
pump with atemperature sensor onports TorR(L)
(maximum distance toport 30cm).
▶ Connect both temperature sensors with a switching-off
for the system atthe limit temperature of90°C.
▶ This shut-off function should betested during
commissioning; see Chapter 8.1.1 ofthe instruction
manual.
▶ Reservoir level monitoring isalso required.
When the minimum boost pressure of8bar isnot
reached, switch off the system immediately.
Operating conditions for T3 and T4
Size T3 T4
250 ● ●
355 ● ●
500 ● ●
500...-S2145 ●●1)
Safety instructions
Temperature class T4
The size500...–S2145 isapproved just up to 3bar case
pressure for temperature classT4.
ATEX category II 3G Ex h IIC T4 Gc X
To observe the maximum leakage temperature of 80 °C,
at least one of the following measures must be taken and
checked regularly:
▶ Check the leakage temperature atport TorR(L)
(maximum distance 30cm)
▶ Check the maximum inlet temperature of50°C atthe
suction port
▶ Check a maximum inlet temperature that must
bedetermined for the following operating points
when commissioning:
– Maximum working pressure and maximum
possible flow
– Maximum working pressure and minimum flow
Also monitor the reservoir level. Take appropriate action
ifthe temperature exceeds limits.
When the minimum boost pressure of8bar isnot
reached, switch off the system immediately.
ATEX category II 2G Ex h IIC T4 Gb X
To observe the maximum leakage temperature of80°C,
the following measures must betaken:
▶ Install the supplied temperature sensor onthe unit
according tothe specifications inchapter 7.4.9 ofthe
instruction manual.
▶ Continuously monitor the leakage temperature ofeach
pump with atemperature sensor onports TorR(L)
(maximum distance toport 30cm).
▶ Connect both temperature sensors with a switching-off
for the system atthe limit temperature of80°C.
▶ This shut-off function should betested during
commissioning; see Chapter 8.1.1 ofthe instruction
manual.
▶ Reservoir level monitoring isalso required.
When the minimum boost pressure of8bar isnot
reached, switch off the system immediately.
1) Just up to maximum 3bar case pressure

BoschRexrothAG, RE 92105-01-X-B2/2019.08.06
6A4CSG Series 30 | Axial piston variable pump
Leakage temperature monitoring for ATEX category II 2G Ex h IIC T4-T1 Gb X
Leakage temperature monitoring for ATEX
category II 2G Ex h IIC T4-T1 Gb X
The temperature ofthe leakage ismonitored by asensor
with measuring resistance PT100 EN 60751 ofaccuracy
classB, which issupplied asloose part. The sensor must
beinstalled inport U1(cf. schematic and installation
drawings onthe following pages).
Electrical data
Port oncertified explosion-proof current circuits with the
following peak values:
▶Ui= 30V
▶Pi= 750mW
The inner inductivity and capacity are small enough
tobeneglected.
Electric port, sensor
Cable Sensor
Number Color Port
1
2
white
yellow
left
3
4
Brown
green
right
5 Black shielding
Notice – evaluation electronics for temperature
monitoring
The necessary evaluation electronics are not included
inthe scope ofdelivery. The sensor must beoperated
via an explosion-proof current circuit. The protection class
must beat least that ofthe sensor (see “Information
onexplosion protection” onpage 1).
12 34
PT100
2314 55

RE 92105-01-X-B2/2019.08.06, BoschRexrothAG
7Axial piston variable pump | A4CSG Series 30
Filtration ofthe hydraulic fluid
Filtration ofthe hydraulic fluid
Finer filtration improves thecleanliness level
ofthehydraulic fluid, which increases theservice life
oftheaxial piston unit.
A cleanliness level ofatleast 20/18/15 under ISO4406
should bemaintained.
Atahydraulic fluid viscosity ofless than 10mm²/s
(e.g. due tohigh temperatures during short-term operation)
atthedrain port, acleanliness level ofatleast 19/17/14
under ISO4406 isrequired.
For example, viscosity is10mm²/s at:
– HLP32atemperature of73°C
– HLP46atemperature of85°C
A "threaded port for filter inthe boost circuit" isoptionally
available with order designation D .
The filter elements must comply with the application-
related ATEX classification. They are not part ofthe
delivery.
Bearing flushing
Bearing flushing isrequired for asafe, continuous operation
under the following operating conditions:
▶ When installed vertically (drive shaft up) for lubricating
the front bearing and shaft seal
▶ When operated attemperature and viscosity limits when
using mineral oil
▶ For above-reservoir installation
Port "U" atthe front flange ofthe variable displacement
pump isused forbearing flushing. The flushing fluid flows
through the front bearing and discharges with the pump
drain atthe drain port.
The following flushing flows are recommended depending
onsize:
Size 250 355 500
recommended flushing flow qsp l/min 10 15 20
For the flushing flows stated, there isa pressure differential
ofapproximately 3bar between the port "U" (including
fitting) and the drain chamber.
Notice about bearing flushing for series 30
When using bearing flushing onport U, the throttle screw
inport Umust beturned in to the end stop.
Shaft seal
Permissible pressure load
The service life ofthe shaft seal ring isaffected by the
rotational speed ofthe axial piston unit and the leakage
pressure (case pressure). Momentary (t < 0.1s) pressure
peaks ofup to6bar are permitted. The service life ofthe
shaft seal decreases with increasing frequency ofpressure
peaks and increasing mean differential pressure.
The pressure inthe housing must beequal toorgreater
than the ambient pressure.
3
2
1
02500
2000
1000
01500
500
Differential pressure ∆p [bar]
Rotational speed n[rpm]
NG500
NG355
NG250
Case pressure atport K2, K3, R(L), T
Maximum pressure
static pLmax
3 bar1)
Maximum pressure
dynamic pLmax
5 bar2)
Pressure peaks
pLpeak
6 bar t<0.1s
Notice
At case pressure 0 to3bar without special version.
At case pressure 1 to5bar with special version S1111
and S2145
▶ For size 500 and temperature class T4 just up to
maximum 3bar case pressure.
1) Permissible differential pressure onshaft seal (housing pressure
toambient pressure), not toexceed pLmax. A drain line tothe
reservoir isrequired.
2) Only with double shaft seal, see type code position 15

BoschRexrothAG, RE 92105-01-X-B2/2019.08.06
8A4CSG Series 30 | Axial piston variable pump
Working pressure range
Working pressure range
Pressure atworking port A orB Definition
Nominal pressure pnom 350 bar The nominal pressure corresponds tothe maximum design pressure.
Maximum pressure pmax 400 bar 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 onthe high-pressure side (AorB) required toprevent
damage tothe axial piston unit.
Minimum pressure (low-pressure side) Speed-related
(see diagram)
Minimum pressure onthe low-pressure side (AorB) required toprevent
damage tothe axial piston unit. The low pressure isapplied atport MK4
when the flushing slide isdeflected.
Rate ofpressure change RAmax 16000bar/s Maximum permissible pressure build-up and reduction speed during
apressure change across the entire pressure range.
Boost pressure
Minimum boost pressure pSp (at nnom)16 bar NG250 to500 series 30
Measuring port: MK4
(Please contact us for multiple coupled
pumps.)
Maximum static boost pressure pSp max 30 bar
Permissible pressure peaks in
boost pressure
minimum 4 bar
maximum 40 bar
Pressure atsuction port S (version with integrated boost pump)
Minimum pressure pSmin ≥0.8 bar absolute Minimum pressure atsuction port S(inlet) that isrequired inorder toavoid
damage tothe axial piston unit.
Maximum pressure pS max 30bar abs.
Control pressure for EP and HD control
Minimum required control
pressure pSt min
Double boost
pressure
at NG 355 +5 bar
Measuring port M1(small stroking chamber)
▼Required low pressure depending onthe
Speed ratios
20
18
16
14
12
10
8
6
0.5 0.6 0.7 0.8 0.9 1.0
Minimum recommended
setting (pressure
gauge reading)
NG250 to500
Low pressure pabs [bar]
Speed ratio n/nnom
shut-off limit1)
▼Rate ofpressure change
pnom
∆t
∆p
Time t
Pressure p
Pressure p
t1
t2tn
Single operating period
Minimum pressure (high-pressure side)
Maximum pressure pmax
Nominal pressure pnom
Time t
Total operating period = t1+ t2+ ... + tn
Notice
Working pressure range applies when using hydraulic
fluids based onmineral oils.
All assembled parts must meet the ATEX classification
for the application inquestion.
1) See also "Monitoring the operational data" onpage5

RE 92105-01-X-B2/2019.08.06, BoschRexrothAG
9Axial piston variable pump | A4CSG Series 30
Technical data
Technical data
Size NG 250 355 500
Geometric displacement,
per revolution
Variable pump Vg max cm3250 355 500
Integrated boost pump Vg Sp cm363 80 98
Rotational speed1) maximum atVg max nnom rpm 1800 1800 1800
minimum2) nmin rpm 800 800 800
Flow (variable pump)
with Vg max and
nmax qvL/min 450 638 900
nE= 1500 rpm qVE L/min 375 532 750
Power3)
at Vg max , ∆p = 350 bar and
nmax PkW 262 373 525
nE= 1500 rpm PEkW 219 311 438
Torque3) atVg max and ∆p = 350bar TNm 1391 1976 2783
∆p = 100bar TNm 398 564 795
Rotary stiffness ofdrive shaft P ckNm/rad 527 800 1145
ZckNm/rad 543 770 1209
Moment ofinertia oftherotary group JTW kgm20.0959 0.19 0.3325
Maximum angular acceleration4) αrad/s2775 600 540
Case volume VL 10 8 14
Weight (pump with EP control and integrated boost pump without filter) approx. mkg 260 275 390
Determining theoperating characteristics
Flow qv=Vg×n×ηv[l/min]
1000
Torque T=Vg×Δp [Nm]
20×π×ηhm
Power P=2π×T×n=qv×Δp [kW]
60000 600×ηt
Key
VgDisplacement per revolution [cm3]
Δp Differential pressure [bar]
nRotational speed [rpm]
ηvVolumetric efficiency
ηhm Hydraulic-mechanical efficiency
ηtTotal efficiency (ηt=ηv×ηhm)
Notices
▶ Theoretical values, without efficiency and tolerances;
values rounded
▶ Exceeding the maximum/dropping below the minimum
values can lead toaloss offunction, reduction
inservice life ordestruction ofthe axial piston unit,
thereby nullifying explosion protection. We recommend
checking loads through tests orcalculation/simulation
and comparing them with the permissible values.
Flow direction
Direction
ofrotation
Swiveling range*
right left
BtoA A toBclockwise
AtoB B toAcounter-clockwise
* cf. swivel angle indicator
15° 0° 15°
cw
ccw
1) The values are applicable:
‒ for the optimum viscosity range from νopt = 36 to16mm2/s
‒ with hydraulic fluid onthe basis ofmineral oils
2) Lower values onrequest
3) Without boost pump
4) The data are valid forvalues between the minimum required and
maximum permissible rotational speed.
Valid forexternal excitation (e.g. diesel engine 2 to8 times rotary
frequency; cardan shaft twice the rotary frequency).
The limit value isonly valid forasingle pump.
The load capacity ofthe connection parts must beconsidered.

BoschRexrothAG, RE 92105-01-X-B2/2019.08.06
10 A4CSG Series 30 | Axial piston variable pump
Working pressure range
Permissible radial and axial loading ofthe drive shaft
Size NG 250 355 500
Permissible axial force + Fax max N 1800 2000 2000
− Fax max N 1800 2000 2000
Permissible radial force Fq max N 2000 2200 2500
Permissible input and through drive torques
Size NG 250 355 500
Torque
at Vg max and Δp= 350 bar1)
Tmax Nm 1391 1976 2783
Input torque for drive shaft, maximum2)
P
DIN 6885
TE max Nm 2300 3557 5200
∅mm 60 70 80
Z
DIN 5480
TE max Nm 2782 3952 5566
∅in 60 70 80
Maximum through drive torque (Tmax =TD max)
TD max Nm 1391 1976 2783
▼ Distribution oftorques
TE
TD
T
1
T
2
Pump 1 Pump 2
Torque at1st Pump T1
Torque at2nd Pump T2
Torque at3rd Pump T3
Input torque TE=T1+ T2+ T3
TE<TE max
Through-drive torque TD=T2+ T3
TD<TD max
F
ax +
–
F
q
a
a/2a/2
1) Efficiency not considered
2) For drive shafts free ofradial force

RE 92105-01-X-B2/2019.08.06, BoschRexrothAG
11Axial piston variable pump | A4CSG Series 30
HD – hydraulic control, pilot-pressure related
HD – hydraulic control, pilot-pressure related
HD–Proportional control,hydraulic,pilot-pressurerelated
(see data sheet 92080)
(HD1T and HD1U isnot available)
Stepless adjustment ofthe pump displacement according
tothe pilot pressure. The control isproportional tothe
specified pilot pressure setpoint value (difference between
X1, X2).
For version Fwith integrated boost pump, the control
issupplied internally with the control pressure from the
boost circuit. This saves using aseparate control pressure
pump.
Optional:
▶ Control characteristics (HD1, HD2, HD3)
▶ Pressure control (HD.A, HD.B, HD.D)
▶ Remote pressure control (HD.GA, HD.GB, HD.G)
▶ Power control (HD1P)
▼Characteristic curve
pSt
Vg
Vg max
Vg
Vg max
pSt
Notice
The spring feedback inthe controller and pump control
spring centering are nosafety devices.
The controller can stick inan undefined position due
tointernal contamination (contaminated hydraulic fluid,
abrasion orresidual contamination from system
components). Asaresult, the flow inthe axial piston
unit will nolonger respond correctly tothe operator's
specifications.
Check whether the application onyour machine requires
additional safety measures tobring the driven consumer
toasafe position (immediate stop). Ifnecessary, make
sure these are appropriately implemented.
▼Circuit diagram
Example: Standard A4CSG 500 HD1...F..4M
MAB
R(L)
K2T
US MS
A
M
A
K
1
M
B
B
MK4
K4
ME3
E3M1
M2
X2XA
X1
K3

BoschRexrothAG, RE 92105-01-X-B2/2019.08.06
12 A4CSG Series 30 | Axial piston variable pump
EP – Electrohydraulic control with proportional solenoids
EP – Electrohydraulic control with proportional solenoids
EP – Proportional control, electrohydraulic
(see data sheet 92084)
The EP control adjusts the pump displacement
proportionally tothe current atthe solenoid. Current-
regulated control units with pulse width modulation
are recommended for controlling the solenoids.
For version Fwith integrated boost pump, the control
issupplied internally with the control pressure from the
boost circuit. This saves using aseparate control pressure
pump.
The proportional solenoids should not beoperated with
acurrent higher than the rated current. Inaddition, each
proportional solenoid must beprotected by afuse
corresponding toits rated current (maximum 3 Irated
inaccordance with IEC/EN 60127-2) ora motor protection
switch with short circuit and thermal fast-triggering
mechanism (set torated current).
▼Characteristic curve
I
Vg
Vg max
Vg
Vg max
I
Notice
The spring feedback inthe controller and pump control
spring centering are nosafety devices.
The controller can stick inan undefined position due
tointernal contamination (contaminated hydraulic fluid,
abrasion orresidual contamination from system
components). Asaresult, the flow inthe axial piston
unit will nolonger respond correctly tothe operator's
specifications.
Check whether the application onyour machine requires
additional safety measures tobring the driven consumer
toasafe position (immediate stop). Ifnecessary, make
sure these are appropriately implemented.
▼Circuit diagram
Example: Standard A4CSG 500 EPD...F..4D
1
2
M1
M2
MAB 2K3R(L) S
K T
US M
A
MA
K1 MB
B
MK4
K4
ME3
E3
EE
The breaking capacity ofthis fuse should beequal
toorgreater than the possible short circuit current
ofthe supply voltage source.
Optional:
▶ Pressure control (EPA, EPB, EPD)
▶ Remote pressure control (EPGA, EPGB, EPG)
Ground connection
All solenoids and pumps should have aground connection.
For ground connection points, refer tothe relevant
installation drawing inthe chapter "Dimensions".
Current-regulated control units with PWM signal (pulse
width modulation) are recommended for controlling the
solenoids. These must comply with the application-related
ATEX classification.

RE 92105-01-X-B2/2019.08.06, BoschRexrothAG
13Axial piston variable pump | A4CSG Series 30
Solenoid technical data
Solenoid technical data
Axial piston units come with the following solenoids.
Size 250 355 500
Proportional solenoid type GRCE 063 AGD G01 GRCE 063 AGD G01 GRCE 063 AGD G02
Version 001 001 001
Characterization R913030728 – 24 VDC R913030728 – 24 VDC R913030730 – 24 VDC
Tube FHTP 062 924251 or
MSM 924251-P
FHTP 062 924251 or
MSM 924251-P
FHTP 062 924299 or
MSM 924299-P
Mounting nut MSM 472794
O-ring 31 x 2.5 – 70Sh A NBR
Solenoid body – variant FHMPE 063 926635 – 001
Resistance R20 Ω20.2
Rated current Inom A DC 0.800
Maximum current
control range
IG= 1.1 x Inom A0 to0.880
Rated voltage URV24.2
Limit power PLW24.9
Waviness W %48
Duty cycle ED S1 (100%)
Ambient temperature TA°C -30 to+65
Temperature class T4
Supply Current source must besuitable for aprotection class III
appliance (extra-low protective voltage).
Connection line FL4G11Y 2 X 1.5mm2
Diode for limiting disconnect overvoltage Internally molded 1.5 KE68CA maximum 90V
Disconnect overvoltage Maximum 90V
Maximum switching frequency 4 switches/s
Explosion protection according toRL
94/9/EC and IECEx
CE 0637 Ex II 2G Ex mb IIC T4 Gb
II 2D Ex mb IIIC T130 °C Db
Incompliance with standards EN60079-0: 2012 EN 60079-18: 2009
IEC 60079-0: 2011 IEC 60079-18: 2009
EC type examination certificate IBExU 13 ATEX 1040 X
IECEx certificate ofconformity IECEx IBE 13.0017 X
IP rating per IEC/EN 60529 Minimum IP67
Appliance protection class according
toDIN VDE 0580
III
EC declaration ofconformity DC013315-001 DC013315-001 DC013316-001

BoschRexrothAG, RE 92105-01-X-B2/2019.08.06
14 A4CSG Series 30 | Axial piston variable pump
Circuit diagrams
Circuit diagrams
▼ Circuit diagram A4CSG 250, 355...EP....ATEX category II 2G Ex h IIC T4-T1 Gb X
Ports
A, B Working port (high-pressure series)
SSuction port
MS Suction pressure measuring
K1Flushing port
K2, K3Flushing port
MA, MB, MABP Working pressure measurement
M1, M2 Control pressure measuring
E1 Filter, supply
E2 Filter, return
E3 Boost port (external)
ME3 Measuring boost pressure
K4Accumulator port
MK4 Measuring flushing pressure
R(L) Fluid filling, air bleeding
TFluid drain
T1Pressure relief valve relief port
UFlushing port (bearing flushing)
U1Measured value transducer, temperature
XA2, XB2, XAB Pilot pressure port for pressure controller
XA2 XAB XB2
b
a
E2E1MS
S
U1
UT
U
BA
T1
MBMA K1
E3
ME3
MABP
K4
MK4
M1M2 R(L)TK2K3

RE 92105-01-X-B2/2019.08.06, BoschRexrothAG
15Axial piston variable pump | A4CSG Series 30
Circuit diagrams
▼ A4CSG 500...EP circuit diagram.... ATEX category II 2G Ex h IIC T4-T1 Gb X
Ports
A, B Working port (high-pressure series)
SSuction port
MS Suction pressure measuring
K1Flushing port
K2, K3Flushing port
MA, MB, MAB Working pressure measurement
M1, M2 Control pressure measuring
E1 Filter, supply
E2 Filter, return
E3 Boost port (external)
ME3 Measuring boost pressure
K4Accumulator port
MK4 Measuring flushing pressure
R(L) Fluid filling, air bleeding
TFluid drain
T1Pressure relief valve relief port
UFlushing port (bearing flushing)
U1Measured value transducer, temperature
XA2, XB2, XAB Pilot pressure port for pressure controller
U1
UT
T1
K4
MK4
E3
ME3
MAB E2E1
B AMBMA K1
R(L)
TK3
K2SMS
MS
XB2
XAB
XA2
M1
M2
ab
U

BoschRexrothAG, RE 92105-01-X-B2/2019.08.06
16 A4CSG Series 30 | Axial piston variable pump
Circuit diagrams
▼ Circuit diagram A4CSG 250, 355 EP....ATEX category II 3G Ex h IIC T4-T1 Gc X
Ports
A, B Working port (high-pressure series)
SSuction port
MS Suction pressure measuring
K1Flushing port
K2, K3Flushing port
MA, MB, MAB Working pressure measurement
M1, M2 Control pressure measuring
E1 Filter, supply
E2 Filter, return
E3 Boost port (external)
ME3 Measuring boost pressure
K4Accumulator port
MK4 Measuring flushing pressure
R(L) Fluid filling, air bleeding
TFluid drain
T1Pressure relief valve relief port
UFlushing port (bearing flushing)
XA2, XB2, XAB Pilot pressure port for pressure controller
XA2XABXB2
b
a
E2 E1 MS
S
U
BA
T1
MB MAK1
E3
ME3
MAB
K4
MK4
M1 M2R(L)TK2 K3

RE 92105-01-X-B2/2019.08.06, BoschRexrothAG
17Axial piston variable pump | A4CSG Series 30
Circuit diagrams
▼ A4CSG 500...EP circuit diagram.... ATEX category II 3G Ex h IIC T4-T1 Gc X
Ports
A, B Working port (high-pressure series)
SSuction port
MS Suction pressure measuring
K1Flushing port
K2, K3Flushing port
MA, MB, MAB Working pressure measurement
M1, M2 Control pressure measuring
E1 Filter, supply
E2 Filter, return
E3 Boost port (external)
ME3 Measuring boost pressure
K4Accumulator port
MK4 Measuring flushing pressure
R(L) Fluid filling, air bleeding
TFluid drain
T1Pressure relief valve relief port
UFlushing port (bearing flushing)
XA2, XB2, XAB Pilot pressure port for pressure controller
U
T1
K4
MK4
E3
ME3
MAB E2 E1
BAMB MAK1
R(L)
TK3K2 S MSMS
XB2
XAB
XA2
M1
M2
ab

BoschRexrothAG, RE 92105-01-X-B2/2019.08.06
18 A4CSG Series 30 | Axial piston variable pump
Dimensions, size250...-S1111 ATEX category II 2G Ex h IIC T4-T1 Gb X
Dimensions [mm]
Dimensions, size250...-S1111 ATEX category II 2G Ex h IIC T4-T1 Gb X
Remote-controlled electrohydraulic control with proportional solenoid and pressure control
Connection table, seepage 20
▼ ViewX
280.2 253.2
XA2
260
225
180 XAB
XB2
50
10000
40 ME3
30
MABP
E3
36
252
233
E2
280
K3
K2
U
78
U
55
KZ
U1
265
55
78
151
150
45°
45°
144.5
E1
24
M12x16
7
201)
TMBS265
90 143.5 143.5
150 Y18
374 51
477
509 23
60
M1
36.5
38
79.4
B
13
R
51.5
-0.072
15°0
Ø224
L
15°
U1
55
R(L)
192
17
248
M2
Ground connection
Ground connection
Flange 224, 4-hole,
based onISO 3019-2
(metric)
Pressure control
Side A
Pressure control
Side B
Ground connection
deep
Solenoid A
Solenoid B
End-splice according to
DIN 46228-A1.5-7
Connection line
GRCE063AGD01: FL4G11Y; 2x1.5mm2sw/br
1) 10mm shorter for version with single shaft seal

RE 92105-01-X-B2/2019.08.06, BoschRexrothAG
19Axial piston variable pump | A4CSG Series 30
Dimensions, size250...-S1111 ATEX category II 2G Ex h IIC T4-T1 Gb X
Dimensions [mm]
Remote-controlled electrohydraulic control with proportional solenoid and pressure control
M95.7
U1A
BE3
XBE2 K4 AUU1
+0.07 +0.02
Ø56
Ø78
Ø115
Ø171
55
E1 K1
88.5
ST13
N147 10.3
192.5 46
200 200 95
137
509
50.8
MK4
MA
HAGGLUNDS
K4
www.hagglunds.com
Ø38
79.4
55
88.9
Ø63
36.5
A
K1
MS
S
374
477
T1
382
394
▼ ViewY ▼ ViewU
▼ Sectional view M-N▼ ViewZ
Pressure relief valve,
initial control pressure Pressure relief valve A
Pressure relief valve B
Flushing pressure
relief valve
to flange surface
to flange surface
to flange surface
to flange surface
to flange surface

BoschRexrothAG, RE 92105-01-X-B2/2019.08.06
20 A4CSG Series 30 | Axial piston variable pump
Dimensions, size250...-S1111 ATEX category II 2G Ex h IIC T4-T1 Gb X
Dimensions [mm]
Ports Standard Size pmax abs [bar]1) State5)
A, B Working line (high-pressure series) SAE J5182) 1 1/2 in 400 O
Fastening thread A/B DIN 13 M16 × 2; 21 deep
SSuction port (standard pressure series) SAE J5182) 2 1/2 in 30 O
Fastening thread S DIN 13 M12 × 1.75; 17deep
MA,MB,MABP Measuring working pressure A/B DIN 3852 M14 × 1.5; 12deep 400 X
MSMeasuring suction DIN 3852 M14 × 1.5; 12deep 30 X
TFluid drain DIN 38523) M42×2; 20deep 4 X4)
E1Filter, supply DIN 3852 M33 × 2; 18 deep 40 X
E2Filter, return DIN 3852 M33 × 2; 18 deep 40 X
K1Flushing port DIN 3852 M33 × 2; 18 deep 5 O
K2, K3Fluid filling + air bleeding
Return flow (drain port)
DIN 38523) M42×2; 20deep 4 X4)
R(L) 4 O4)
UBearing flushing DIN 38523) M14 × 1.5; 12deep 7 X
E3Boost pressure supply DIN 3852 M33 × 2; 18 deep 40 X
ME3 Measuring boost pressure DIN 3852 M14 × 1.5; 12deep 40 X
K4Accumulator port DIN 3852 M33 × 2; 18 deep 40 X
MK4 Measuring boost pressure DIN 3852 M14 × 1.5; 12deep 40 X
M1, M2Control pressure measuring DIN 3852 M18 × 1.5; 12 deep 400 X
XA2, XB2, XAB Pilot pressure, remote control pressure controller DIN 3852 M14 × 1.5; 12deep 350 O
U1Measure value transducer, temperature6)
Drive shaft, see page 23
1) Depending onthe application, momentary pressure peaks can
occur. Keep this inmind when selecting measuring devices and
fittings.
2) Only dimensions according toSAE J518, metric fastening thread
isa deviation from the standard.
3) The countersink may bedeeper than specified inthe standard.
4) Depending onthe installation position, T, K2, K3orR(L) must
beconnected (see also from page 47)
5) O=Must beconnected (comes plugged)
X=Plugged (in normal operation)
6) Temperature sensor must beinstalled.