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Electric Drives Linear Motion and

and Controls Hydraulics Assembly Technologies Pneumatics Service

Axial Piston Variable Pump RE 92250/02.07


Replaces: 04.06
/16

KVA

Technical data sheet

Series 6
Sizes 55 ... 107
Nominal pressure 300 bar
Peak pressure 350 bar
for commercial vehicles, open circuit

Contents Features
Ordering Code / Standard Program 2 – Variable pump with axial tapered piston rotary group of bent
axis design. Designed especially to meet the requirements of
Technical Data 3
commercial vehicles.
DRS - Pressure Control with Load Sensing 6
– The output flow is proportional to the drive speed and pump
EP - Electric Control with Proportional Solenoid 7 displacement and is steplessly variable between maximum
and zero (qv max to qv min = 0).
Unit Dimensions, Size 55 8
– Favourable power/weight ratio, small overall dimensions,
Unit Dimensions, Size 80 10
optimum efficiency and economic design
Unit Dimensions, Size 107 12
– Self aspirating, for open circuit operation
Installation Notes 14
– Flange and shaft designed for direct mounting on truck gear-
General Notes 15 box PTO‘s

– Further Informations:
Fixed pump KFA__________________________ RE 91501
designed especially to meet the requirements of commercial
vehicles.
/16 Bosch Rexroth AG KVA RE 92250/02.07

Ordering Code / Standard Program


KVA7V O / 6 3 – M E K 64
01 02 03 04 05 06 07 08 09 10 11

Axial piston unit


Bent axis design, variable, nominal pressure 300 bar, peak pressure 350 bar,
01 KVA7V
for commercial vehicles (truck)

Operation mode
02 Pump in open circuits O

Size
03 ≈ Displacement Vg max in cm3 55 80 107

Control devices 55 80 107


Pressure control with load sensing    DRS
04 Electric control with proportional solenoid U = 24 V positive characteristics  – – EP2
negative characteristics – –  EP4

Series
05 6

Index
06 3

Direction of rotation
Viewed on shaft end clockwise R
07
counter-clockwise L

Seals
08 FKM (2 back to back shaft seals) M

Shaft end
09 Splined shaft similar DIN ISO 14 (for truck use) E

Mounting flange
10 Special flange ISO 7653-1985 (for truck use) K

Service line ports


11 Threaded port A(B), rear 64
l = available – = not available
RE 92250/02.07 KVA Bosch Rexroth AG /16

Technical Data
Hydraulic fluid Selection diagram

Before starting project planning, please refer to our data -40° -20° 0° 20° 40° 60° 80° 100°
sheets RE 90220 (mineral oil) and RE 90221 (environmentally 1600 1600
1000
acceptable hydraulic fluids) for detailed information regarding 600
the choice of hydraulic fluids and conditions of use. 400
200

VG 68
VG

VG 32
VG 46
VG 2
If environmentally acceptable hydraulic fluids are being used,

10
2
the limitations regarding technical data and seals mentioned in

0
100
RE 90221 must be observed. 60
When ordering please indicate the used hydraulic fluid. 40 36

viscosity ν in mm2/s
nopt.
Attention: 20
For the operation with water-containing HF-fluids the variable 16
pump KVA is not suitable.
10
Viscosity range
We recommend that a viscosity (at operating temperature) for 5 5
optimum efficiency and service life purposes of -40° -25° -10° 0° 10° 30° 50° 70° 90° 115°
temperature t in °C
νopt = opt. operating viscosity 16...36 mm2/s
tmin = -25°C hydraulic fluid temperature range tmax = +115°C
be chosen, taken the tank temperature (open circuits) into
account. Details regarding the choice of hydraulic fluid
The correct selection of hydraulic fluid requires knowledge of
Limits of viscosity range the operating temperature in relation to the ambient tempera-
ture, in an open circuit the tank temperature.
The following values apply in extreme cases:
The hydraulic fluid should be selected so that within the
νmin = 5 mm2/s operating temperature range, the operating viscosity lies within
short term (t < 3 min.) at max. permitted temperature the optimum range (νopt) (see shaded section of the selection
tmax = 115°C. diagram). We recommend that the highest possible viscosity
νmax = 1600 mm2/s range should be chosen in each case.
short term (t < 3 min.) with cold start (p < 30 bar, Example: At an ambient temperature of X° C an operating tem-
n ≤ 1000 rpm, tmin = -25°C). perature of 60° C is set in the circuit. In the optimum viscosity
Note that the maximum hydraulic fluid temperature of 115°C range (νopt; shaded area) this corresponds to the viscosity
must not be exceeded locally either (e.g. bearing area). The classes VG 46 or VG 68; to be selected: VG 68.
temperature in the bearing area is - depending on pressure and Please note: The case drain temperature, which is affected by
speed - up to 12 K higher than the average case drain tempe- pressure and rotational speed, is always higher than the tank
rature. temperature. At no point in the system may the temperature be
This axial piston unit can not be operated in a temperature higher than 115°C.
range of less than -25°C. If this cannot be achieved due to unusual operating parameters
or high ambient temperatures, please contact us.

Filtration
The finer the filtration, the cleaner the fluid and the longer the
service life of the axial piston unit.
To ensure proper function of the axial piston unit, the hydraulic
fluid must have a cleanliness level of at least
20/18/15 according to ISO 4406.
At very high hydraulic fluid temperatures (90°C to max. 115°C),
a cleanliness level of at least
19/17/14 according to ISO 4406 is required.
Please contact us, if these cleanliness levels cannot be achie-
ved.
/16 Bosch Rexroth AG KVA RE 92250/02.07

Technical Data
Operating pressure range Temperature range
Inlet The FKM shaft seal ring is admissible for a case temperature
range from -25°C bis +115°C.
Pressure at port S
Note:
The minimum inlet pressure depends on the speed.
This axial piston unit can not be operated in a temperature
The following limits may not be exceeded.
range of less than -25°C.
pabs min_______________________________________ 0,8 bar
The maximum pressure pabs max also depends on speed (see Direction of flow
succeeding diagram).
Direction of rotation, viewed on shaft end
clockwise counter-clockwise
Minimum inlet pressure at S to B S to A
suction port S with increased speed
In order to avoid damage of the pump a minimum inlet pressure
at the suction port must be assured. The minimum inlet pres-
sure is related to the rotational speed and the displacement of
the variable pump.
1,5

1,4 2,0
1,9
1,8
1,3 1,7
Inlet pressure pabs in bar
n max 1

1,6
1,2 1,5
1,4
n

1,3
1,1 1,2
1,1
Speed

1,0 1,0
0,9
0,9
0,8
0,8
0,6 0,7 0,8 0,9 1,0
Vg
Displacement
Vg max

Note:
– max. permissible speed nmax perm. (speed limit, see page 5)
– min. and max. permissible inlet pressure at port S
Outlet
Maximum pressure at port A or B
(pressure specifications in according to DIN 24312)
Nominal pressure pN__________________________ 300 bar
Peak pressure pmax_ __________________________ 350 bar

Case drain
The case of the pump is connected to the inlet port. A separate
case drain is therefore not required (purge port R is plugged)
Exception:
When using the DRS control a separate drain line from port T
to the tank is mandatory (not required for EP control).
RE 92250/02.07 KVA Bosch Rexroth AG /16

Technical Data
Table of values (theoretical values, without efficiencies and tolerances; values rounded)
Size 55 80 107
Displacement Vg max cm3 54,8 80 107
Speed max. 1)
at Vg max nmax1 rpm 2500 2240 2150
at Vg < 0,74 • Vg max (see diagram, page 4) nmax2 rpm 3400 3000 2900
Speed max. 2) nmax perm. rpm 3750 3350 3200
Flow at nmax 1 and Vg max qv max 1 L/min 137 179 230
Power at qv max 1 and Δp = 300 bar Pmax 1 kW 68 90 115
Torque at Vg max and Δp = 300 bar T Nm 261 382 510
Mass moment TG Nm 21 28,5 41
Moment of inertia (of the rotating parts) J kgm2 0,0034 0,0064 0,0102
Filling capacity V L 0,6 0,8 1,2
Mass (approx.) m kg 16 20 24
1) The values shown are valid for an absolute pressure pabs = 1 bar at the suction port »S« and when operated on mineral fluid
with a specific mass of 0,88 kg/L.
2) Maximum speed (speed limit) for an increase in the inlet pressure p
abs at the suction port S and Vg < Vg max

Determining the size

Vg • n • ηv Vg = Displacement per revolution in cm3


Flow qv = L/min
1000 Δp = Differential pressure in bar
n = speed in rpm
Vg • Δp
Torque T = Nm
20 • π • ηmh ηv = Volumetric efficiency
ηmh = Mechanical-hydraulic efficiency
2π•T•n qv • Δp
Power P = = kW ηt = Overall efficiency
60000 600 • ηt

Permissible axial loading on the drive shaft


The values given are maximum values and do not apply to continous operation. For drives with radial loading (pinion, V-belt drives),
please contact us!

Size 55 80 107
when stopped or when axial piston unit
± Fax max N 0 0 0
working in pressureless conditions

Axial force / – + Fax zul. N/bar 8,7 10,6 12,9


Fax
operating pressure + − Fax zul. N/bar -66 -86 -103
When considering the permissible axial force, the force-transfer direction must be taken into account:
− Fax max = increase in service life of bearings
+ Fax max = reduction in service life of bearings (avoid if at all possible)

Accessories for KVA


For the KVA-pump the following accessories are available from Rexroth:
– Coupling flange, used in pump operation via a joint shaft (see RE 95001)
– Suction pipe, in all variations (see RE 95004)
– Adaption flange, for KVA-mounting in unfavourable mounting conditions (on enquiry)
/16 Bosch Rexroth AG KVA RE 92250/02.07

DRS - Pressure Control with Load Sensing


Function of the pressure control Characteristic DRS

max. 10 bar
The pressure control keeps the pressure in a hydraulic system
constant within its control range even under varying flow condi- max
350
tions. The variable pump only moves as much hydraulic fluid as
is required by the actuators. If the operating pressure exceeds

Operating pressure pB in bar


the setpoint set at the integral pressure control valve, the pump
displacement is automatically swivelled back until the pressure
deviation is corrected.
In zero pressure non-running condition, the pump is swivelled
to its starting position Vg max by means of the control spring.
Setting range for pressure control__________ 80 to 320 bar
Standard setting:_____________________________ 300 bar
50
Note: min
Any pressure relief vlave included in the circuit to limit the max.
pressure must be set to a cracking pressure at least 20 bar Vg min Displacement Vg max
above the pressure control setting.
Circuit diagram DRS

The pressure control is superimposed on the load sensing X T


valve, i.e. the load sensing function operates below the set
pressure.

Load sense function


The load sensing control is a flow control option that operates R
as a function of the load pressure to regulate the pump dis- A (B)
placement to match the actuator flow requirement. Vg min Vg max
A1 (1)
The flow depends here on the cross section of the external
sensing orifice (1) fitted between the pump outlet and the
actuator. The flow is independent of the load pressure below R1
the pressure cut-off setting and within the control range of the
S
pump.
The sensing orifice is usually a separately arranged load
sensing directional valve (control block). The position of the
directional valve piston determines the opening cross section Zero stroke operation
of the sensing orifice and thus the flow of the pump.
The standard pump unit is designed for intermittent constant
The load sensing control compares pressure before and after pressure operation. Short-term operation at zero stroke
the sensing orifice and maintains the pressure drop across the (< 10 min.) is permissible up to a operating pressure
orifice - and therefore the pump flow - constant as a function of pmax = 300 bar at a tank temperature of ≤ 50°C.
the orifice size.
Note:
If the differential pressure Dp increases, the pump is swivel- When using the DRS control a drain line is mandatory from the
led back towards Vg min and, if the Dp decreases the pump is T port to tank to maintain thermal stability.
swivelling out towards Vg max until the pressure drop across the
sensing orifice in the valve is restored.
Δporifice = ppump – pactuator When ordering, state in clear text:
Setting range for Δp:_______________________19 ... 40 bar - Setting of the pressure control
- Δp - setting of the load sensing function
Standard setting:______________________________ 30 bar
(If there is no clear specification, pump will be delivered with
The stand-by pressure in zero stroke operation (sensing orifice standard setting, see above.)
plugged) is slightly above the ∆p setting.
(1) The sensing orifice (control block) is not included in the
pump supply.
RE 92250/02.07 KVA Bosch Rexroth AG /16

EP - Electric Control with Proportional Solenoid


With the Electric control with proportional solenoid, the pump Circuit diagram
displacement is adjusted proportionally to the solenoid current,
EP2 (Size 55)
resulting in a magnetic control force, acting directly onto the
control spool that pilots the pump control piston.
EP2 - Starting position in unpressurised state at Vg min.
EP4 - Starting position in unpressurised state at Vg max.
R
Charactreristic EP A (B)
Vg max Vg min
800 A1
700 EP2
600 R1
Control current I in mA

500 S
400
300
200
EP4 (Size 107)
100 EP4

0 0,2 0,4 0,6 0,8 1,0


Vg min Displacement Vg max R
A (B)
Note: Vg min Vg max
For submerged in-tank installation when using the EP control, A1
only the mineral hydraulic fluids can be used with the fluid
temperature limited to 80°C. R1
To control the proportional solenoids the following electronic
S
amplifier and controller are available (also as to the Internet
under www.boschrexroth.com/mobile-electronic):
– BODAS controller RC (RE 95200)
and application software
– Analog amplifier RA (RE 95230) Note
By using an proportional amplifier control of swivel time is also The spring centering in the pilot control unit is not a
possible. safety device
Through contamination in the control unit – e.g. in hydraulic
Technical data of solenoids fluid, wear particles, or particles out of a system – the valve
spool can get stuck in an undefined position. In this case, the
EP2 EP4
pump flow does not follow the command inputs of the machi-
Sizes 55 107 ne operator anymore.
Voltage 24VDC +20% 24VDC +20% – Make sure that a proper emergency shut down function
Control current can bring the driven machine movements to a safe position
Start of control Vg min 200 mA Vg max 200 mA immediately (e.g. stop).
End of control Vg max 600 mA Vg min 600 mA – Maintain the specified cleanliness level 20/18/15 (<90°C)
Limiting current 0,77 A 0,68 A or 19/17/14 (>90°C) to ISO 4406.

Nominal resistance
22,7 Ω 24,2 Ω
(at 20°C)
Dither frequency 100 Hz 100 Hz
Duty cycle 100 % 100 %
Type of protection IP 65 IP 54
Hirschmann to
AMP-
DIN EN
Connector Junior Timer
175 301 - 803-A /
2 pin
ISO 4400
/16 Bosch Rexroth AG KVA RE 92250/02.07

Unit Dimensions, Size 55 Before finalizing your design, please request


approved installation drawing. Dimensions in mm.

DRS Pressure control, with load sensing

267
214
156
X T
130*)

80
15 R

122
120
110
-0.05
ø80 -0.03

R120

105
113
80
32
0'

10*)
3

76
12°

91
Y

ø13
9 180 110 ± 0.4

39
A1
R1
229
232
242

View Y View Y
conter-clockwise rotation clockwise rotation 105
40
12 T
T
X X

S A B S

17
G3/4

G1

14

R1 A1
A1 R1

27.5 27.5
118

*) center of gravity
RE 92250/02.07 KVA Bosch Rexroth AG /16

Unit Dimensions, Size 55 Before finalizing your design, please request


approved installation drawing. Dimensions in mm.

EP2 Electric control, with proportional solenoid


Note:
The position of the plug can be changed by turning the
276
solenoid body.
Note the following procedure:
R 1. Loosen the fastening nut (1)

131
2. Turn the magnet body (2) to the desired position
3. Tighten the fastening nut
Tightening torque of fastening nut: 5+1 Nm
R1 Y (width across flat 26, double hexagon DIN 3124)
A1
(2)
(1)

View Y View Y
conter-clockwise rotation clockwise rotation

R1 A1 A1 R1
S A B S

Shaft end
E Splined shaft similar DIN ISO 14
8x32x35
26.1
ø34.9 -0.1

28
9.5
M12x1.751)2)
ø8.1

12
36.8
groove for retaining ring 55
35x1.5 DIN 471

Ports
A, B Service line ports (high pressure series) DIN ISO 228 G 3/4, 16 deep 330 Nm2)
S Suction port DIN ISO 228 G 1; 18 deep 480 Nm2)
T Case drain (only DRS) ISO 6149 M12x1,5; 12 deep 50 Nm2)
A1 Gauge port - high pressure ) 3 ISO 6149 M10x1; 8 deep 30 Nm2)
R1 Gauge port - suction pressure ) 3 ISO 6149 M10x1; 8 deep 30 Nm2)
R 3
Air bleed ) ISO 6149 M18x1,5 60 Nm2)
X Port for Dp control (load sensing) ISO 11926 7/16-20UNF-2B; 11,5 deep 40 Nm2)
1) centering bore according to DIN 332 (thread according to DIN13)
2) please observe the general notes for the max. tightening torques on page 15.
3) plugged
10/16 Bosch Rexroth AG KVA RE 92250/02.07

Unit Dimensions, Size 80 Before finalizing your design, please request


approved installation drawing. Dimensions in mm.

DRS Pressure control, with load sensing

289
236
178
X T
142*)
80
R
15

128
126
116
R120
-0.05
ø80 -0.03

105
128
80
36
0'

12*)

86
3

103
12°

ø13
9 117 ± 0.4

37
A1 195

R1

248
252
263

View Y View Y 105


conter-clockwise rotation clockwise rotation
40
T 12 T
X X

S A B S

14 18
G1

G1 1/4

R1 A1 A1 R1

30 30
128

*) center of gravity
RE 92250/02.07 KVA Bosch Rexroth AG 11/16

Unit Dimensions, Size 80 Before finalizing your design, please request


approved installation drawing. Dimensions in mm.

Shaft end
E Splined shaft similar DIN ISO 14
8x32x35
26.1

ø34.9 -0.1
28
9.5
M12x1.751)2)
ø8.1

12
36.8
groove for retaining ring 55
35x1.5 DIN 471

Ports
A, B Service line ports (high pressure series) DIN ISO 228 G 1, 18 deep 480 Nm2)
S Suction port DIN ISO 228 G 1 1/4; 20 deep 720 Nm2)
T Case drain (only DRS) ISO 6149 M12x1,5; 12 deep 50 Nm2)
A1 Gauge port - high pressure 3) ISO 6149 M10x1; 8 deep 30 Nm2)
R1 Gauge port - suction pressure 3) ISO 6149 M10x1; 8 deep 30 Nm2)
R 3
Air bleed ) ISO 6149 M18x1,5; 60 Nm2)
X Port for Dp control (load sensing) ISO 11926 7/16-20UNF-2B; 11,5 deep 40 Nm2)
1) centering bore according to DIN 332 (thread according to DIN13)
2) please observe the general notes for the max. tightening torques on page 15.
3) plugged
12/16 Bosch Rexroth AG KVA RE 92250/02.07

Unit Dimensions, Size 107 Before finalizing your design, please request
approved installation drawing. Dimensions in mm.

DRS Pressure control, with load sensing

307
250
191
172*) X T
15
R 80

134
132
124
R120
ø80 -0.06
-0.03

105
138
80
40
14*)
0'

91
3

110
12°

ø13
9
124 ± 0.4

206
43 Y
A1
R1

259
264
282

View Y View Y 105


conter-clockwise rotation clockwise rotation 40
T 13 T
X X

S A B S

14
G1 1/4
G1

A1 19.5
A1
R1 R1

31.5 31.5
139

*) center of gravity
RE 92250/02.07 KVA Bosch Rexroth AG 13/16

Unit Dimensions, Size 107 Before finalizing your design, please request
approved installation drawing. Dimensions in mm.

EP4 Electric control, with proportional solenoid

306

178
Y
A1
R1

View Y View Y
conter-clockwise rotation clockwise rotation

S A B S

R1 A1 A1 R1

Shaft end
E Splined shaft similar DIN ISO 14
8x32x35
26.1
ø34.9 -0.1

28
9.5
M12x1.751)2)
ø8.1

12
36.8
groove for retaining ring 55
35x1.5 DIN 471

Ports
A, B Service line ports (high pressure series) DIN ISO 228 G 1, 18 deep 480 Nm2)
S Suction port DIN ISO 228 G 1 1/4; 20 deep 720 Nm2)
T Case drain (only DRS) ISO 6149 M12x1,5; 12 deep 50 Nm2)
A1 Gauge port - high pressure ) 3 ISO 6149 M10x1; 8 deep 30 Nm2)
R1 Gauge port - suction pressure ) 3 ISO 6149 M10x1; 8 deep 30 Nm2)
R 3
Air bleed ) ISO 6149 M18x1,5; 60 Nm2)
X Port for Dp control (load sensing) ISO 11926 7/16-20UNF-2B; 11,5 deep 40 Nm2)
1) centering bore according to DIN 332 (thread according to DIN13)
2) please observe the general notes for the max. tightening torques on page 15.
3) plugged
14/16 Bosch Rexroth AG KVA RE 92250/02.07

Installation Notes
General
During commissioning and operation, the axial piston unit must be filled with hydraulic fluid and air bled. This is also to be obser-
ved following a relatively long standstill as the system can be drained through the hydraulic lines.
The case is connected to the inlet port S. A seperate case drain to tank is not required.
Exception: version with DRS control. When using the DRS control a drain line from port T to tank is mandatory to maintain thermal
stability.
In all operating conditions, the suction and drain line must flow into the tank below the minimum fluid level.
The minimum suction pressure at port S must not fall below 0,8 bar absolute.
Installation position
As to the examples mentioned below.

Installation below the tank (standard) Installation above the tank


Pump above minimum fluid level in tank.
Pump below minimum fluid level in tank.
- Note: - max. perm. suction height
Recommendation installation position: 1 and 2.
hmax = 800 mm
- min. perm. suction pressure at port S

1 2 3 4

T T L2 L2
R1 R1
R A1 R A1
S S

S S
R R
T
T

Installation Air bleed Filling Installation Air bleed Filling


position position
1 R S 3 R (L2) S (L2)

2 R1 S 4 R1 (L2) S (L2)
RE 92250/02.07 KVA Bosch Rexroth AG 15/16

General Notes
– The KVA pump is designed to be used in open circuits.
– Project planning, assembly and commissioning of the pump require the involvement of trained personnel.
– The working and functional ports are only designed to accommodate hydraulic piping.
– There is a danger of burns from the pump and especially the solenoids during and shortly after operation. Suitable safety
precautions, e.g. protective clothing plan.
– The characteristic curve may shift depending on the operating status (operating pressure, fluid temperature) of the pump.
– Tightening torques:
- The tightening torques specified in this data sheet are maximum values and may not be exceeded (maximum value for screw
thread). Manufacturer specifications for the max. permissible tightening torques of the used fittings must be observed!
- For DIN 13 fastening screws we recommend checking the tightening torque individually according to VDI 2230
Edition 2003.
– The data and information contained herein must be adhered to.
16/16 Bosch Rexroth AG KVA RE 92250/02.07

Bosch Rexroth AG © This document, as well as the data, specifications and other information
Hydraulics set forth in it, are the exclusive property of Bosch Rexroth AG. It may not be
Product Segment Axial Piston Units reproduced or given to third parties without its consent.
Elchingen Plant The data specified above only serve to describe the product. No statements
Glockeraustraße 2 concerning a certain condition or suitability for a certain application can be
89275 Elchingen, Germany derived from our information. The information given does not release the user
from the obligation of own judgment and verification. It must be remembered that
Phone +49 (0) 73 08 82-0
our products are subject to a natural process of wear and aging.
Facsimile +49 (0) 73 08 72 74
Subject to change.
info.brm-ak@boschrexroth.de
www.boschrexroth.com/axial-piston-pumps