Re92105 01 X b2 - 2017 08

Axial piston variable pump A4CSG
for explosive areas Part II of instruction manual

according to ATEX directive
II 2G bck IIC Tx and II 3G ck IIC Tx 2014/34/EU data sheet
RE 92105-01-X-B2
Edition: 08.2017
Replaces: 12.2016
▶▶ Sizes 250, 355, 500

▶▶ Nominal pressure 350 bar
▶▶ Maximum pressure 400 bar
▶▶ Closed circuit
Details on explosion protection Contents

▶▶ Field of application according to ATEX 2014/34/EU Ordering code for standard program 2
▶▶ Gas: II 2G bck IIC Tx according to DIN EN 13463-1:2009, Ordering code for standard program 3
DIN EN 13463-5:2011, DIN EN 13463-6:2005, Hydraulic fluids 4
DIN EN 13463-8:2003 Monitoring the operational data – specification for Tx 5
▶▶ Gas: II 3G ck IIC Tx according to DIN EN 13463-1: 2009, Shaft seal 7
DIN EN 13463-5:2011, DIN EN 13463-8:2003 Operating pressure range 8
Technical data 9
Features of the ATEX version HD – hydraulic control pilot-pressure releated 11
The ATEX version is an advanced development of the EP – electrohydraulic control
A4CSG for compliance with Directive 2014/34/EU (ATEX). with proportional solenoid 12
External features distinguishing it from the standard pump Technical data – solenoid 13
as per data sheet 92105 are the ground connection termi- Size dimensions 250 to 500 18
nal, the Ex marking and the CE marking on the name plate. Combination pumps A4CSA4CSG + 39 39
For ATEX category II 2G bck IIC Tx, one additional tempera- Dimensions through drive 41
ture sensor is supplied, which monitor the operational Integrated boost pump and valve technology 47
data. Filtration types 49
Temperature classes according to EN 13463-1 Installation instructions 50
Depending on the temperature classes T3 and T4 the maxi- Project planning notes 53
mum temperatures should be noted (please refer “hydraulic Safety instructions 54
fluid” and “monitoring the operational data for Tx”).
RE 92105-01-X-B2/08.2017, Bosch Rexroth AG

2/56 A4CSG for explosive areas | Axial piston variable pump
Ordering code for standard program
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15
A4CS G / 30 – 35 4
Axial piston unit
01 Variable swashplate design, nominal pressure 350 bar, maximum pressure 400 bar A4CS
Operating mode
02 Pump in closed circuit G
Size
03 Geometric displacement, see “Technical data” Page 9 250 355 5001)
Control device
04 Proportional control hydraulic control, pilot-pressure see 92080
related ● ● ● HD..
(HD1T and HD1U not available)
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 (fluor-caoutchouc) seals and ATEX version II 3G bck IIB T4 ● ● ● R
FKM (fluor-caoutchouc) seals and ATEX version II 3G ck IIB T4 ● ● ● 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
Port for working lines

10 SAE flange ports A and B, located on same side, metric fastening thread 35
SAE flange port S, position offset laterally from A and B by 90°, metric fastening thread
Boost pump
11 With integrated boost pump ● ● ● F
● = Available ○ = On request – = Not available
Note ▶▶ In order to avoid mechanically generated sparks from

▶▶ When ordering, please state which equipment group, contaminants made of aluminum with iron oxide and/
category, explosion group, temperature class and or particles of rust of the surface2), the pump is
ignition protection type are required for your planned painted as standard with corrosion protecting. Please
ATEX application. contact your partner from Rexroth about the available
▶▶ Potential equalization: The pump must be grounded. colors for the painted units.
For: grounding points, please refer to the drawings ▶▶ The service life of the bearings must be calculated.
starting on Page 21. Compared to the standard The load cycle forms the basis for this. Please contact
pump, there are restrictions in the technical data us.
relating to temperature, case pressure and bearing
flushing/installation position. 1) Not permissible for the temperature class T4
2) See DIN EN 13463-1, 6.4.2.1
Bosch Rexroth RE 92105-01-X-B2/08.2017

Axial piston variable pump | A4CSG for explosive areas 3/56
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15
A4CS G / 30 – 35 4
Through drive1) (for attachment options, see page Page 39) 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 Flushing, control pressure and feed valve integrated; pilot-controlled high-pressure relief valve integrated ● ● ● 4
Filtration (see Page 49)

14 Without filter ● ● ● N
With threaded port for filter in the boost circuit ● ● ● D
Special version
15 Without special version
With double shaft seal ● ● – -S1111
With double shaft seal and active flushing – – ● -S2145
● = Available ○ = On request – = Not available
Note
Note the project planning notes Page 53.
Please find notes for storage and preservation of axial 3) All attachment pumps must correspond to the ATEX classification
for the application concerned.
piston units in the data sheet 90312.
4) Not available for device category II 2G bck IIC Tx

Hydraulic fluids
Hydraulic fluids
The A4CSG variable pump is designed for operation with Temperaturklasse T4 according to ATEX:
HLP mineral oil according to DIN 51524. At no point of the component may the temperature be
Application instructions and requirements for hydraulic higher than 80 °C, howerver.
fluids should be taken from the following data sheets The temperature difference specified in the table is to be
before the start of project planning: taken into account when determining the viscosity in the
▶▶ 90220: Hydraulic fluids based on mineral oils and bearing. If the above conditions cannot be maintained due
related hydrocarbons to extreme operating parameters, please contact the
responsible member of staff at Bosch Rexroth.
Details regarding the selection of hydraulic fluid
The hydraulic fluid should be selected so that the operating Ignition temperature of hydraulic fluid
viscosity in the operating temperature range is within the The pump is approved for temperature class T3 and T4
optimum range (νopt, see selection diagram). according to DIN EN 13463-1, -5, -6 and -8.
According to DIN EN 13463-5 only use hydraulic fluids
Note whose ignition temperature is at least 50k higher than the
Temperature class T3 according to ATEX: maximum surface temperature of the approved tempera-
At no point of the component may the temperature be ture class. E.g.: the requiered temperature class for the
higher than 90 °C, however. application is T4. Therefor the ignition temperature of the
hydraulic fluid has to 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
Permissible temperature difference ΔT ≤ 25 K between axial piston unit and hydraulic fluid in the system
Warm-up phase ν = 1000 to 100 mm2/s θ ≥ -25 °C for pnom, 0.5 × nmax and t ≤ 15 min
Continuous operation ν = 100 to 16 mm /s2
T3 Note the permissible temperature range of the shaft seal
θ = -25 °C to +90 °C measured at the drain port
T4
θ = -25 °C to +80 °C
νopt = 36 to 16 mm2/s range of optimum operating viscosity and efficiency
Short-term operation νmin ≤ 10 mm /s
2
T3 t < 3 min, p < 0.3 × pnom
θ = -25 °C to +90 °C
T4
θ = -25 °C to +80 °C
▼▼ Selection diagram
maximum permissible viscosity for cold start

1000
600
400
200
VG 68
VG 46
VG
VG 32
VG 2
10
2
100
Viscosity v [mm2/s]
optimum operating viscosity range vopt

optimum efficiency 60
40
36
20
16
minimum permissible viscosity for short-term operation
10
-25 -10 0 10 30 50 70 80 90
minimum permissible temperature for cold start Temperature θ [°C]

Monitoring the operational data – specification for Tx
Safety instructions Safety instructions

Temperature class T3: Temperature class T4:
ATEX category II 3G ck IIC T3 The size 500 is not permissible for the temperature class
To observe the maximum leakage temperature of 90 °C, T4.
at least one of the following measures must be checked ATEX category II 3G ck IIC T4
regularly: To observe the maximum leakage temperature of 80 °C,
▶▶ Check the leakage temperature at port T or R(L) at least one of the following measures must be checked
(maximum distance 30 cm) regularly:
▶▶ Check the maximum inlet temperature of 60 °C at the ▶▶ Check the leakage temperature at port T or R(L)
suction port (maximum distance 30 cm)
▶▶ Check a maximum inlet temperature, which must be ▶▶ Check the maximum inlet temperature of 50 °C at the
ascertained when commissioning for the following suction port
operating points: ▶▶ Check a maximum inlet temperature, which must be
–– maximum working pressure and maximum possible ascertained when commissioning for the following
flow operating points:
–– maximum working pressure and minimum flow –– maximum working pressure and maximum possible
Reservoir level monitoring must also be provided. flow
Appropriate action must be taken if the temperature –– maximum working pressure and minimum flow
exceeds the temperature limits. Reservoir level monitoring must also be provided.
Switching off is required if the boost pressure falls below Appropriate action must be taken if the temperature
the minimum value allowed of 8 bar. exceeds the temperature limits.
Switching off is required if the boost pressure falls below
ATEX category II 2G bck IIC T3 the minimum value allowed of 8 bar.
To observe the maximum leakage temperature of 90 °C,
the following measures must be taken: ATEX category II 2G bck IIC T4
▶▶ Install the supplied temperature sensor on the unit To observe the maximum leakage temperature of 80 °C,
according to the specifications in chapter 7.4.9 of the the following measures must be taken:
instruction manual. ▶▶ Install the supplied temperature sensor on the unit
▶▶ Monitor the case drain temperature on each pump according to the specifications in chapter 7.4.9 of the
permanently with a temperature sensor at port T or instruction manual.
R(L) (maximum distance 30 cm to the port). ▶▶ Monitor the case drain temperature on each pump
▶▶ Connect the temperature sensors with a switching-off permanently with a temperature sensor at port T or
for the system at the limit temperature of 90°C. R(L) (maximum distance 30 cm to the port).
▶▶ Switching off must be tested during commissioning ▶▶ Connect the temperature sensors with a switching-off
– see chapter 8.1.1 of the instruction manual. for the system at the limit temperature of 80°C.
Reservoir level monitoring is also required. ▶▶ Switching off must be tested during commissioning
Switching off is required if the boost pressure falls below – see chapter 8.1.1 of the instruction manual.
the minimum value allowed of 8 bar. Reservoir level monitoring is also required.
Operating conditions for T3 and T4 Switching off is required if the boost pressure falls below
the minimum value allowed of 8 bar.
Size T3 T4
250 ● ●
355 ● ●
500 ● –
● = allowed – = not allowed
See also installation positions on page 41

Case drain temperature monitoring for ATEX category

II 2G bck IIC Tx
The temperature of the case drain fluid is monitored by one
sensor with measuring resistance PT100 EN 60751 of
precision class B, which are supplied as loose parts. The
sensor must be installed in port U1 (cf. schematic and
installation drawings on the following pages).
Electrical data
Port on certified explosion-protected 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
1 2 3 4 5 12 3 45
PT100
Cable Sensor
Number Color Connection

1 white counter-clockwise
2 yellow
3 Brown clockwise
4 green
5 black Screen
Note – evaluation electronics for temperature monitoring

The necessary evaluation electronics are not included in
the scope of supply. The sensor must be operated via an
explosion-protected current circuit. The protection class
must be at least the same as the sensor (see “Details on
explosion protection” on page 1).

Shaft seal
Filtration of the hydraulic fluid Bearing flushing

Finer filtration improves the cleanliness level of the hydrau- For the following operating conditions bearing flushing is
lic fluid, which increases the service life of the axial piston required for a safe, continuous operation:
unit. ▶▶ With vertical installation (drive shaft facing upwards) for
A cleanliness level of at least 20/18/15 is to be maintained lubricating the front bearing and the shaft seal.
according to ISO 4406. ▶▶ Operation with borderline conditions for temperature
Our advice here, depending on the system and application, and viscosity for operation with mineral oil.
for the A4CSG filter cartridges β20 ≥ 100. ▶▶ With above-reservoir installation.
Bearing flushing is realized at port “U” in the area of the
A “threaded port for filter in the boost circuit” is optionally front flange of the variable pump. The flushing fluid flows
available with order designation D . through the front bearing and discharges with the pump
The filter cartridges must comply with the application- drain at the drain port.
related ATEX classification. They are not part of the Depending on pump size, the following flushing flows are
delivery. recommended:
Size 250 355 500
recommended flushing qsp l/min 10 15 20
flow
For the flushing flows stated, there is a pressure differential

of approximately 3 bar between the port “U” (including
fitting) and the drain chamber.
Note on bearing flushing for series 30
When using bearing flushing on port U, the throttle screw
in port U must be turned in to the end stop.
Shaft seal
Permissible pressure loading

The service life of the shaft seal ring is affected by the
speed of the axial piston unit and the drain pressure (case
pressure). Short-term (t < 0.1 s) pressure spikes of up to
10 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 case must be equal to or greater than
the ambient pressure.
3
Differential pressure ∆p [bar]
NG355
2
NG500
NG250
0
0 500 1000 1500 2000 2500
Rotational speed n [rpm]

Working pressure range
Working pressure range
Pressure at working ports 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
Single operating period 1 s within the single operating period. The sum of the single operating
Total operating period 300 h periods must not exceed the total operating period.
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) Speed related Minimum pressure at the low-pressure side (A or B) which is required
(see diagram) in order to prevent damage to the axial piston unit. The low pressure is
present at port MK4 with the flushing slide deflected.
Rate of pressure change RA max 16000 bar/s Maximum permissible speed of pressure build-up and reduction during
a pressure change across the entire pressure range.
Boost pressure
Minimum boost pressure pSp (at nnom) 16 bar NG250 to 500 series 30
30 bar Measuring port MK4
Maximum static boost pressure pSp max
(Please contact us for coupled
Permissible pressure peaks in minimum 4 bar multiple pumps)
boost pressure 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 absolute
Control pressure for EP and HD control.
Minimum required control pressure pSr min double boost pressure Measuring port M1 (small stroking chamber)
at NG 355 +5 bar
▼▼ Required low pressure in dependence on

t2
speed ratio t1 tn
Single operating period
20
Maximum pressure pmax
Low pressure pabs [bar]
18
Nominal pressure pnom
16 NG 250 to 500
Pressure p
14 Min. recommended
12 setting (manometer
10 indicator)
8 Switch off limit1)
6
0.5 0.6 0.7 0.8 0.9 1.0
Minimum pressure (high-pressure side)
Speed ratio n/nnom
▼▼ Rate of pressure change Time t
pnom Total operating period = t1 + t2 + ... + tn

∆t Note
Pressure p
Working pressure range valid when using hydraulic fluids

∆p
based on mineral oils.
All ancillary parts must comply with the application-
related ATEX classification.
Time t
1) See also “Monitoring the operating data” on page 5

Technical data
Technical data
Size Size 250 355 500

Displacement geometrical, Variable pump Vg max cm 3
250 355 500
Per revolution Integrated boost pump Vg Sp cm3 63 80 98
Rotational speed1) maximum at Vg max nnom min–1 1800 1500 1800
minimal 2)
nmin min –1
800 800 800
Flow (variable pump) nmax qv L/min 450 532 900
at Vg max and nE = 1500 min–1 qVE L/min 375 532 750
Power3) nmax P kW 262 311 525
at Vg max , ∆p = 350 bar and nE = 1500 min–1 PE kW 219 311 438
Torque at Vg max and
3)
∆p = 350 bar T Nm 1391 1976 2783
∆p = 100 bar T Nm 398 564 795
Rotary stiffness of drive shaft P c kNm/rad 527 800 1145
Z c kNm/rad 543 770 1209
Moment of inertia for rotary group JTW kgm 2
0.0959 0.19 0.3325
Maximum angular acceleration4) α rad/s2 775 600 540
Case volume V L 10 8 14
Mass (pump with EP control and integrated boost pump with filter) approx. m kg 260 275 390
Determining operating characteristics Note

Vg × n × ηv ▶▶ Theoretical values, excluding efficiencies and toler-
Flow qv = [l/min]
1000 ances; values rounded
Vg × Δp ▶▶ Exceeding the maximum or falling below the minimum
Torque T = [Nm]
20 × π × ηhm permissible values can lead to a loss of function, a
2 π × T × n qv × Δp reduction in operational service life or total destruc-
Power P = = [kW]
60000 600 × ηt tion of the axial piston unit and thereby to a loss of
explosion protection. Bosch Rexroth recommend
Key testing the loads by means of experiment or calcula-
Vg Displacement per revolution [cm ] 3
tion / simulation and comparison with the permissible
Δp Differential pressure [bar] values.
n Rotational speed [rpm]
ηv Volumetric efficiency
Flow direction
ηhm Hydraulic mechanical efficiency
ηt Total efficiency (ηt = ηv × ηhm) Direction of rotation Swiveling range*
clockwise counter-
clockwise
B to A A to B clockwise
A to B B to A counter-clockwise
* cf. swivel angle indicator
1) The values apply:

‒ to the optimum viscosity range from νopt = 36 to 16 mm2/s
‒ to hydraulic fluid based on 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.
Apply to external excitation (e.g. diesel engine 2- to 8-fold rotary
frequency, cardan shaft 2-fold rotary frequency).
The limit value only applies to a single pump.
The load capacity of the connecting parts must be considered.

Technical data
Permissible radial and axial forces of the drive shafts

Size Size 250 355 500
Permissible axial force + Fax max N 1800 2000 2000
Fax +
– − Fax max N 1800 2000 2000
Permissible radial force Fq Fq max N 2000 2200 2500
a/2a/2
a
Permissible input and through-drive torques

Size Size 250 355 500
Torque Tmax Nm 1391 1976 2783
at Vg max and Δp = 350 bar1)
Input torque at drive shaft, maximum2)
P TE max Nm 2300 3557 5200
DIN 6885 ∅ mm 60 70 80
Z TE max Nm 2782 3952 5566
DIN 5480 ∅ in 60 70 80
Maximum through-drive torque (Tmax = TD max)
TD max Nm 1391 1976 2783
▼▼ Torque distribution
T1 T2
TE
Pump 1 Pump 2
TD
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
1) Efficiency not considered

2) For drive shafts without radial force

HD – hydraulic control pilot-pressure releated
HD – hydraulic control pilot-pressure releated
HD – Proportional control, hydraulic, pilot-pressure ▼▼ Circuit diagram
related (see data sheet 92080) Example: Standard A4CSG 500 HD1...F..4M
(HD1T and HD1U is not available)

Stepless adjustment of the pump displacement according to BMB K1 MA A
the pilot pressure. The control is proportional to the specified
pilot pressure (difference between X1, X2). K4
For version F with integrated boost pump, the control is X2 X1 XA
MK4
supplied internally with the control pressure from the boost
circuit. This saves using a separate control pressure pump.
Optional:
ME3 M2
▶▶ Pilot pressure curves (HD1, HD2, HD3) E3 M1
▶▶ Pressure control (HD.A, HD.B, HD.D)
▶▶ Remote pressure control (HD.GA, HD.GB, HD.G)
▶▶ Power control (HD1P)
▼▼ Characteristic curve
pSt
MAB U K2 K3T R(L) S MS
Vg Vg
Vg max Vg max
pSt

EP – electrohydraulic control with proportional solenoid
EP – electrohydraulic control with proportional solenoid
EP – proportional control electrohydraulic The ability of this fuse to switch off must be equal to or
(see data sheet 92084) greater than the possible short circuit current of the supply
EP control adjusts the pump displacement proportionally to voltage source.
the current at the solenoid. Current-regulated controllers
with pulse-width modulation are recommended for control- Optional:
ling the solenoids. ▶▶ Pressure control (EPA, EPB, EPD)
For version F with integrated boost pump, the control is ▶▶ Remote pressure control (EPGA, EPGB, EPG)
supplied internally with the control pressure from the boost
circuit. This saves using a separate control pressure pump. Ground connection
The proportional solenoids must not be operated with a All solenoids and pump must have a ground connection.
current higher than the rated current. In addition, each For ground connection points, please refer to the relevant
proportional solenoid must be protected by a fuse corre- installation drawing in chapter “Dimensions”.
sponding to its rated current (maximum 3 Irated in accor- Current-regulated controllers with PWM signal (pulse-width
dance with IEC/EN 60127-2) or a motor protection switch modulation) are recommended for contr olling the sole-
with short circuit and thermal fast-triggering mechanism noids. These must comply with the application-related ATEX
(set to rated current). classification.
▼▼ Characteristic curve
Vg Vg
Vg max Vg max
▼▼ Circuit diagram
Example: Standard A4CSG 500/700 EPD...F..4D
B MB K1 MA A
K4
MK4
ME3 M2
E3 M1
M ABU K 2 K3T R(L) E2 E1 S MS

Technical data – solenoid
The axial piston units are equipped 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
Identification marking R913030728 – 24 VDC R913030728 – 24 VDC R913030730 – 24 VDC
Tubus FHTP 062 924251 or FHTP 062 924251 or FHTP 062 924299 or
MSM 924251-P MSM 924251-P MSM 924299-P
Mounting nut MSM 472794
O seal 31 x 2.5 – 70Sh A NBR
Solenoid body – variant FHMPE 063 926635 – 001
Resistor R20 Ω 20.2
Nominal current Inom A DC 0,800
Maximum flow control range IG = 1.1 x Inom A 0 to 0,880
Rated voltage UB V 24.2
Borderline power PG W 24.9
Waviness W % 48
Duty cycle ED S1 (100%)
Ambient temperature Ta °C -30 to +65
Temperature class T4
Power supply Current source must be suitable for protection class III (extra-low protective
voltage)
Connection line FL4G11Y 2 X 1.5 mm2
Diode for limiting switch-off Internally molded 1.5 KE68CA maximum 90 V
overvoltage
Switch-off overvoltage Maximum 90 V
Maximum switching frequency 4 switches/second
Explosion protection according to CE 0637 Ex II 2G Ex mb IIC T4 Gb
RL 94/9/EC and IECEx II 2D Ex mb IIIC T130 °C Db
In agreement with standards EN 60079-0 2012 EN 60079-18: 2009
IEC 60079-0: 2011 IEC 60079-18: 2009
EC type approval certificate IBExU 13 ATEX 1040 X
IECEx Certificate of Conformity IECEx IBE 13.0017 X
Type of protection according to Min. IP67
IEC/EN 60529
Protection class according to III
DIN VDE 0580
EC – Declaration of Conformity DC013315-001 DC013315-001 DC013316-001

▼▼ Circuit diagram A4CSG 250, 355...EP....ATEX category II 2G bck IIC Tx
B MB K1 MA A
T1
K4
XA2 XAB XB2

MK4
a b
ME3
E3
UT
MABP U M1 K2 K3 T R(L) E2 E1 U1 MS M2
S
Ports
A, B Working port (high-pressure series)
S Suction port
MS Suction pressure measurement
K1 Housing flushing
K2, K3 Housing flushing
MA, MB, MABP Measuring operating pressure
M1, M2 Measuring, control pressure
E1 Filter, supply
E2 Filter, return
E3 Boost port (external)
ME3 Boost pressure measurement
K4 Accumulator port
MK4 Flushing pressure measurement
R(L) Fluid filling, air bleeding
T Fluid drain
T1 DB valve relief port
U1 Measured value transducer, temperature
U Flushing port (bearing flushing)
XA2, XB2, XAB Pilot pressure port for pressure controller

▼▼ Schematic A4CSG 500...EP.... ATEX category II 2G bck IIC Tx
B MB K1 MA A
XA2 XB2
T1
K4
MK4
a b
XAB
M2
ME3
M1
E3
UT
MAB U K2 K3 T R(L) E2 E1 U1 MS S MS
Ports
S Suction port
K1 Housing flushing
MA, MB, MAB Measuring operating pressure
E1 Filter, supply
E2 Filter, return
K4 Accumulator port
T Fluid drain
U1 Measured value transducer, temperature

▼▼ Circuit diagram A4CSG 250, 355 EP....ATEX category II 3G ck IIC Tx
B MB K1 MA A
T1
K4
MK4 XA2 XAB XB2
a b
ME3
E3
MAB U M1 K2 K3 T R(L) E2 E1 MS M2
S
Ports
S Suction port
K1 Housing flushing
E1 Filter, supply
E2 Filter, return
K4 Accumulator port
T Fluid drain

▼▼ A4CSG 500...EP circuit diagram.... ATEX category II 3G ck IIC Tx
B MB K1 MA A
XA2 XB2
T1
K4
MK4
a b
XAB
M2
ME3
M1
E3
MAB U K2 K3 T R(L) E2 E1 MS S MS
Ports
S Suction port
K1 Housing flushing
E1 Filter, supply
E2 Filter, return
K4 Accumulator port
T Fluid drain

18/56 A4CSG for explosive areas | Axial piston variable pump Dimensions [mm]
Size dimensions 250 ATEX category II 2G bck IIC Tx
Electrohydraulic control with proportional solenoid and pressure control, remote controlled
Connection line
GRCE063AGD01: FL4G11Y; 2x1.5 mm2 sw/br
Pressure control
side A Ground
280.2 253.2
connection
260
Ground XA2 Ferrule according to DIN 46228-A1.5-7
225
connection 180 Pressure control
50
XAB
XB2 side B
40 MABP ME3
10000
30 E3
36
252
233
E2
K2
K3
28
U
78
U
0
55 55
265
K
U1
78
144.5
24
150
45°
45°
151
E1
7 T MB M12x16 deep 265

90 S
150 Y 18 143.5 143.5
374 51
477
509 23
▼▼ View X
60
36.5
38
79.4
M1 Solenoid A
Flange 224, 4-hole,
based on ISO 3019-2
B
(metric)
51.5
13
-0.072
15° 0 15°
R
Ø224
U1
55
L
192
R(L)
Ground connection
Solenoid B
17 M2
248
Connection table, see Page 20.
Bosch Rexroth AG, RE 92105-01-X-B2/08.2017

Dimensions [mm] Axial piston variable pump | A4CSG for explosive areas 19/56
▼▼ View Z ▼▼ Section M-N
Pressure-relief
Pressure-relief valve, initial M 95.7
valve A
control pressure
U1
B E3 A
Ø171+0.07
+0.02
Ø115
U1
Ø78
Ø56
X B E2 K4 A U
55
88.5
E1 K1
S
Pressure-relief T1 3
N 147
valve B 10.3
Pressure-relief
192.5 46
valve, flushing
95
200 200 pressure 137
to flange surface 509
▼▼ View Y ▼▼ View U
50.8
36.5
MK4
S
K4
Ø38
HAGGLUNDS
www.hagglunds.com
88.9
79.4
Ø63
55 MA
MS K1
A
T1
374 to flange surface

Ports Standard Size1) pmax abs [bar]2) Status6)

A, B Service line (high-pressure series) SAE J5183) 1 1/2 in 400 O
Fastening thread A/B DIN 13 M16 × 2; 21 deep
S Suction port (standard pressure series) SAE J5183) 2 1/2 in 30 O
Fixing thread S DIN 13 M12 × 1.75; 17 deep
MA, MB, MABP Measuring operating pressure A/B DIN 3852 M14 × 1.5; 12 deep 400 X
MS Suction measurement DIN 3852 M14 × 1.5; 12 deep 30 X
T Fluid drain DIN 3852 4)
M42 × 2; 20 deep 4 X5)
E1 Filter, supply DIN 3852 M33 × 2; 18 deep 40 X
E2 Filter, return DIN 3852 M33 × 2; 18 deep 40 X
K1 Housing flushing DIN 3852 M33 × 2; 18 deep 5 O
K2, K3 Fill + air bleed DIN 3852 4)
M42 × 2; 20 deep 4 X5)
R(L) Drain port for fluid (drain port) 4 O5)
U Bearing flushing DIN 38524) M14 × 1.5; 12 deep 7 X
E3 Infeed DIN 3852 M33 × 2; 18 deep 40 X
ME3 Boost pressure measurement DIN 3852 M14 × 1.5; 12 deep 40 X
K4 Accumulator port DIN 3852 M33 × 2; 18 deep 40 X
MK4 Boost pressure measurement DIN 3852 M14 × 1.5; 12 deep 40 X
M1, M2 Measuring, control pressure DIN 3852 M18 × 1.5; 12 deep 400 X
XA2, XB2, XAB Pilot pressure remote control pressure DIN 3852 M14 × 1.5; 12 deep 350 O
controller
U1 Measure value transducer, temperature7)
1) For notes on tightening torques, see operating instructions 4) The spot face can be deeper than as specified in the standard
2) Momentary pressure spikes may occur depending on the applica- 5) Depending on the installation position, T, K2, K3 or R(L) must be
tion. Keep this in mind when selecting measuring devices and fit- connected (see also from Page 50)
tings. 6) O = Must be connected (plugged when delivered)
3) Only dimensions according to SAE J518, metric fastening thread is a X = Plugged (in normal operation)
deviation from standard. 7) Temperature sensor must be connected.

Size dimensions 250 ATEX category II 3G ck IIC Tx
Connection line
Pressure control
side A Ground 280.2 253.2
260
Ferrule
Ground 225 XAB connection DIN 46228-A1.5-7
180
connection
XA2 XB2 Pressure control
50
side B
10000
40 MABP ME3
30 E3
36 E2
233
252
K2
B K3
28
0
U
78
55 55
K Z
265
Ø 24
78
151
144.5
150
45°
45°
MB E1
7 T 265
90
S M12x16
143.5 143.5
18
150 Y 195
374 51 ▼▼ View X
477
509
532
36.5
Ø 38
79.4
Flange 224, 4-hole, M1

based on ISO 3019-2
Solenoid A
(metric) B
51.5
Ø 224 -0.072
13
L R
~15 0 ~15
55
144
192
R(L)
Ground connection
Solenoid B
17
248 M2

Pressure-relief
▼▼ View Z
valve A ▼▼ Section M-N
Pressure-relief valve, initial M
control pressure
E3
A
+0.07
Ø171 +0.02
Ø115
Ø78
Ø56
X B E2 K4 A U
55
88.5
E1 K1
B
Pressure-relief
S T1
3
N 147 Pressure-relief 10.3
valve B
192.5 valve, flushing 46
200 200 pressure 95
137
50.8
36.5
MK4 MA
K4
79.4
88.9
38
63
55
MS S K1 A
T1
to flange surface 382 477 to flange surface


A, B Service line (high-pressure series) SAE J518 3)
1 1/2 in 400 O
T Fluid drain DIN 38524) M42 × 2; 20 deep 4 X5)
M42 × 2; 20 deep 4 X5)
U Bearing flushing DIN 3852 4)
M14 × 1.5; 12 deep 7 X
controller
2) Momentary pressure spikes may occur depending on the application. 5) Depending on the installation position, T, K2, K3 or R(L) must be
Keep this in mind when selecting measuring devices and fittings. connected (see also from Page 50)
3) Only dimensions according to SAE J518, metric fastening thread is a 6) O = Must be connected (plugged when delivered)
deviation from standard. X = Plugged (in normal operation)

▼▼ Parallel keyed shaft DIN 6885 ▼▼ Splined shaft DIN 5480

P ‒ AS18x11x100 Z – W60x2x28x9g
42 42
M20 x 2.5 1) 2)
M20 x 2.5 1) 2)
15 Key width 18 15
3
ø60+0.030
+0.011
64 -0.2
59
105 70
1) Center bore according to DIN 332 (thread according to DIN 13)

2) For notes on tightening torques, see operating instructions

Connection line
Pressure control
side A 280.2 253.2
260
Ground
225 XAB Ferrule DIN 46228-A1.5-7
180 connection
Ground
50
connection
side B
10000
40 MABP ME3
30 E3
44 E2
233
252
243
U1 K2
B K3
28
U U
0
78
K2 55 55 Z
265
Ø 24
78
151
144.5
150 45°
45°
MB E1
7 T 265
S M12x16 deep
90 18 143.5 143.5
150 Y
381 51
484
516 60 ▼▼ View X
539
36.5
Ø 38
79.4
Flange 224, 4-hole

M1
based on
Solenoid A
ISO 3019-2 (metric) B
U1
51.5
Ø 224 -0.072
13
L R
~15 0 ~15
55
144
192
R(L)
Ground
Solenoid B
17 connection
248 M2

▼▼ View Z Pressure-relief
▼▼ Section M-N
valve A
control pressure U1
E3
A
+0.07
Ø171 +0.02
Ø115
Ø78
Ø56
X B E2 K4 A U
55
88.5
E1 K1
B
S T1
Pressure-relief 3
N 147 Pressure-relief 10.3
valve B
192.5 valve, flushing 46
200 200 pressure 95
137
50.8
36.5
MK4 MA
K4
79.4
88.9
38
63
55
MS S K1 A
T1 381 to flange surface


M42 × 2; 20 deep 4 X6)
M42 × 2; 20 deep 4 X6)
controller
1) Center bore according to DIN 332 (thread according to DIN 13) 5) The spot face can be deeper than as specified in the standard
2) For notes on tightening torques, see operating instructions 6) Depending on the installation position, T, K2, K3 or R(L) must be
3) Momentary pressure spikes may occur depending on the application. connected (see also from Page 50)
Keep this in mind when selecting measuring devices and fittings. 7) O = Must be connected (plugged when delivered)

Connection line
Pressure control
side A 280.2 253.2
260
Ground Ferrule DIN 46228-A1.5-7
225 XAB
180 connection
Ground
50
connection
side B
10000
40 MABP ME3
30 E3
44 E2
233
252
243
K2
B K3
28
0
U K 78
55 55
Z
265
Ø 24
78
151
144.5
150
45°
45°
MB E1
7 T 265
90
S M12x16
143.5 143.5
18
150 Y 195
381 51
484
516
▼▼ View X
539
36.5
Ø 38
79.4
Flange 224, 4-hole, M1

based on ISO 3019-2 Solenoid A
(metric) B
51.5
Ø 224 -0.072
13
L R
~15 0 ~15
55
144
192
R(L)
Ground
Solenoid B
17 connection
248 M2

▼▼ View Z ▼▼ Section M-N

Pressure-relief
valve A
control pressure
E3
A
+0.07
Ø171 +0.02
Ø115
Ø78
Ø56
X B E2 K4 A U
55
88.5
E1 K1
B
S T1
3
Pressure-relief N 147 10.3
46
valve B 192.5 Pressure-
95
200 200 relief valve, 137
flushing to flange surface 516
pressure
50.8
36.5
MK4 MA
K4
79.4
88.9
38
63
55
MS S K1 A
T1


M42 × 2; 20 deep 4 X5)
M42 × 2; 20 deep 4 X5)
controller
2) Momentary pressure spikes may occur depending on the application. 5) Depending on the installation position, T, K2, K3 or R(L) must be
Keep this in mind when selecting measuring devices and fittings. connected (see also from Page 50)
3) Only dimensions according to SAE J518, metric fastening thread is 6) O = Must be connected (plugged when delivered)
a deviation from standard. X = Plugged (in normal operation)

Drive shaft
P ‒ AS20x12x100 S – W70x3x22x9g
42 42
M20 x 2.5 1) 2)
M20 x 2.5 1) 2)
15 Key width 20
15
4.5
ø70+0.030
+0.011
74 -0.2
69
105 82

2) For notes on tightening torques, see operating instructions

Connection line
Ground
connection M2 X
A2
332 306
XB2 Ferrule
MAB MB DIN 46228-A1,5-7
R(L)
ME3 110 110

396
E3
315
304
E2 U1
280
Ø24
281
190
Ø
U
55
36
0
Z
K3 K2
170
161
5
190
E1
55
40
Ø
16+5 T MS 155 155
8x
80 190 190
45
°(
45
=3
°
155 60
415 23 °) 22°30
`
425 10000
520
552 59 ▼▼ View X
44.5
Ø50
Y
96.8
Solenoid A B
Ground connection
48 211
M1 Pressure control
Flange 315, 4-hole, U side A
based on ISO 3019-2
(metric) XA2
136
U1
Ø315 -0.081
230+5
225
15° 0° 15°
L R
136
50
XB2
Pressure control
30 XAB side B
279 50
Ground connection
Solenoid B
50
10000

▼▼ View Z Pressure-relief ▼▼ Section M-N

valve A
41 50 15
MB MA °
Pressure-relief valve, initial U1
control pressure
ME3
E3
M K4
A
+0.07
Ø171+0.02
Ø113
Ø78
X B E2 K4 A
U
E1 K1
B
Pressure-relief valve,
3.4
Pressure-relief
MS S MS
flushing pressure
M-N 10.3
valve B
46
191 192.5 95
205 205
Y ▼▼ View U
▼▼ View Y
44.5 MA
MK4
MS
K4
Ø63
96.8
88.9
Ø50
55
147
MS 50.8 S K1 A
T1 MS



Service line (high-pressure series) SAE J5184) 2 in 400 O
A, B
Fastening thread A/B DIN 13 M20 x 2.5; 24 deep
Suction port (standard pressure series) SAE J5184) 2 1/2 in 30 O
S
M48 × 2; 22 deep 4 X6)
M48 × 2; 22 deep 4 X6)
M1 Measuring stroking chamber pressure DIN 3852 M22 × 1.5; 14 deep 400 X
Pilot pressure remote control pressure
XA2, XB2, XAB DIN 3852 M14 × 1.5; 12 deep 350 O
controller

Connection line
Ground
connection M2 X
A2
332 306
XB2 Ferrule
MAB MB DIN 46228-A1,5-7
R(L)
110 110
ME3
396
315
304
E3
280
Ø24
281
E2
190
Ø
55
36
U
0
Z
170
K3 K2
161
5
190
E1
55
40
Ø
16+5 T MS 155 155
8x
80 190 190
45
°(
45
=3
°
155 60
415 23 °) 22°30
`
425
520
552 ▼▼ View X
44.5
Ø50
Y
96.8
Solenoid A B
Ground connection
48 211
M1 Pressure control
Flange 224, 4-hole,
U side A
based on ISO 3019-2
(metric) XA2
136
Ø315 -0.081
230+5
225
15° 0° 15°
L R
136
50
XB2
Pressure control
30 XAB side B
279 50
Ground connection
Solenoid B
50
10000

▼▼ View Z Pressure-relief ▼▼ Section M-N
valve A
control pressure
E3
A
+0.07
Ø171 +0.02
Ø113
Ø78
Ø56
X B E2 K4 A U
55
88.5
E1 K1
B
S T1
Pressure relief 3
valve B N 147 Pressure-relief 10.3
valve, flushing 46
191 192.5 95
pressure
205 205 137
50.8
44.5
MA
MK4
K4
88.9
96.8
63
50
55
MS S K1
A
T1
MS 415 to flange surface


Service line (high-pressure series) SAE J518 4)
2 in 400 O
A, B
Fastening thread A/B DIN 13 M20 x 2.5; 24 deep
Suction port (standard pressure series) SAE J5184) 2 1/2 in 30 O
S
T Fluid drain DIN 38525) M48 × 2; 22 deep 4 X6)
M48 × 2; 22 deep 4 X6)
U Bearing flushing DIN 3852 5)
M18 × 1.5; 12 deep 7 X
Pilot pressure remote control pressure
XA2, XB2, XAB DIN 3852 M14 × 1.5; 12 deep 350 O
controller
deviation from standard.

Drive shaft
P ‒ AS25x14x125 Z – W90x3x28x9g
42 42
M20 x 2.5 1) 2)
M20 x 2.5 1) 2)
15 Key width 22 15
3
ø80+0.030
+0.011
85 -0.2
76
130 90

2) For maximum tightening torques, please refer to the “Project plan-
ning notes” on page 53 .

Combination pumps A4CSG + A4CSG
The variable pump A4CSG can be supplied with through

drive despite the integrated boost pump, corresponding to U1 U1
the ordering code on page 3.
If no further pumps are factory-mounted the simple type U
m1 U
m2
code is sufficient.
K K
The delivery contents then include:

for all through drives except F/99: L1
L2
hub, mounting bolt, seal and, if applicable, an intermediate
flange for F/99: A
with through-drive shaft, without coupling, without interme-
diate flange; unit closed fluid-tight with pressure-tight cover
By using combination pumps, it is possible to have inde-

pendent circuits without the need for splitter gearboxes. m1, m2 [kg]
When ordering combination pumps, the type designations L1, L2 [mm]
of the 1st and 2nd pump must be linked by a “+”. 1
▶▶ Order example: Tm = (m1 • L1 + m2 • L2 ) [Nm]
102
A4CSG 500 EPG / 30 R – APH35F434M +
A4CSG 500 EPG / 30 R – AZH35F994M
For through drives F/01, 04, 07, 24, 52, 68 and B6, various Total length A
possible attachment angle positions are available. As stan- A4CSG A4CSG (2. Pump with through drive F/99, with filter)
dard, the second pump is attached at the same angle as the (1. pump) NG250 NG355 NG500
supplied screws are shown in the drawing “Dimensions NG250 1079 – –
through drive” on page 41. NG355 1086 1114 –
If this angle varies, please contact us. NG500 1143 1150 1235
If a gear pump is to be factory mounted as attachment
pump, please contact us.
Note
▶▶ All attachment pumps have to conform to the applied
ATEX classification.
Maximum permissible drive and through-drive torques,
see page Page 9.
Permissible mass moment of inertia

Size 250 355 500
Permissible mass moment of inertia Tm Nm 9300 9300 15600
Permissible mass torque for dynamic mass Tm Nm 930 930 1560
acceleration 10g ≙ 98.1 m/sec2
Mass m1 kg 260 275 390
Distance, center of gravity l1 mm 270 280 300
1) To air bleed the stroking chamber, use the highest port on the control
(see control data sheet)

Summary of mounting options on A4CSG
Through drive - A4CSG Mounting option 2. Pump

Flange Hub for splined shaft 1)
Code A4CSG A4VSO/G A10V(S)O/31/324)
NG (shaft) NG (shaft) NG (shaft)
Flange ISO 3019-2 (metric)
80, 2-hole 3/4 in (19-4) F/B2 – – 18 (S)/31
100, 2-hole 7/8 in (22-4) F/B3 – – 28 (S)/31
1 in (25-4) F/B4 – – 45 (S)/31
125, 2-hole 1 1/4 in (32-4) F/B5 – – 71 (S)/31
1 1/2 in (38-4) F/B6 – – 100 (S)/31
125, 4-hole W32 F/K1 – 40 (Z) –
140, 4-hole W40 F/33 – 71 (Z) –
160, 4-hole W50 F/34 – 125, 180 (Z) –
224, 4-hole W60 F/35 250 (Z) 250 (Z) –
W70 F/77 355 (Z) –
315, 8-hole W80 F/43 500 (Z) –
Flange SAE J744 (ISO 3019-1)2)
82-2 (A) 5/8 in (16-4) F/01 – – –
3/4 in (19-4) F/52 – – 18 (S)/31
101-2 (B) 7/8 in (22-4) F/68 – – 28 (S)/31
1 in (25-4) F/04 – – 45 (S)/31
127-2 (C) 1 1/4 in (32-4) F/07 – – 71 (S)/31
1 1/2 in (38-4) F/24 – – 100 (S)/31
152-4 (D) 1 3/4 in (44-4) F/17 – – 140 (S)/313)
1) according to DIN 5480 (e.g. W32) or according to SAE J744

(e.g. 3/4 in)
2) 2 = 2-hole, 4 = 4-hole
3) On request
4) If a through drive for an A10V(S)O with R-shaft is desired, please
contact us.

A4CSG
Dimensions for explosive areas | Axial piston variable pumpAxial piston variable pump | A4CSG for explosive areas 41/56
[mm]
Dimensions through drive
with through-drive shaft Splined shaft DIN 5480 Availability over sizes Code
without hub or intermediate flange, Diameter 250 355 500 F/
plugged with pressure-tight cover and O-ring for W42x1.25x32x9g ● ● − 99
later mounting W55x1.25x42x9g − − ● 99
● = Available − = Not available
▼▼ F/99 ▼▼ F/99
M16 x 2; 24 deep1) M16 x 2; 24 deep1)

75 75 75 75
M20 x 2.5; 24 deep1) O-ring M20 x 2.5; 24 deep1)
42 42 95.7 63 63 O-ring
42 42
89
70
+0.02
ø171+0.07
102
89
ø56
M2
ø78
ø171 +0.02
+0.07
70 70
ø78
M2
70
89
89
102
shown without cover M3

shown without cover M3
10.3 10.3
Splined shaft 46
46
M4 Splined shaft
M4 50
M5
M5
M1 (to mounting flange face)
M1 (to mounting flange face)
99 Size M1 M2 M3 M4 M5 99 Size M1 M2 M3 M4 M5
250 509 500 552 ø115 3.4 41 95
ø115 3 95 137
355 516
1) Thread according to DIN 13, see operating instructions for details

on tightening torques

Flange ISO 3019-2 Availability over sizes Code

Diameter Hub for splined shaft DIN 5480 250 355 500 F/
125, 4-hole W32x2x14x9g ○ ● ● 31
140, 4-hole W40x2x18x9g ○ ○ ● 33
160, 4-hole W50x2x24x9g ● ● ● 34
224, 4-hole W60x2x28x9g ● ○ ○ 35
● = Available ○ = On request
▼▼ F/31 ▼▼ F/33
M4 M4
M3 M3
M61) M61)
2)
2)
+0.07
+0.07
ø140 +0.02
ø125 +0.02
60 80
ø1 ø1
45º 45
º
M5 M5
M1 (to mounting M1 (to mounting
flange face) flange face)
355 539 11.5 46 M12; 355 541 12.5 60 M12;
10 10
500 575 12.5 51 18 deep 500 577 14.5 50 14.5 deep
▼▼ F/34 ▼▼ F/35
M61) M61) 2)
2)
ø2
ø2 80
00
+0.10
ø224 +0.03
+0.07
ø160 +0.02
M3
M3
45º M5 45º M5
M4 M4
250 531 250 547
66 M16; M20;
355 538 12.5 10 355 554 12.5 81 8
22 deep 30 deep
500 574 67 500 611
1) Thread according to DIN 13, see operating instructions for details 2) 4 fixing screws and O-ring seal are included in the delivery
on tightening torques. contents.


Diameter Hub for splined shaft DIN 5480 250 355 500 F/
224, 4-hole W70x3x22x9g ○ ● ● 77
315, 8-hole W80x3x25x9g ○ ○ ● 43
▼▼ F/77 ▼▼ F/43
M61) 3)
M61) 2)
ø1 ø3
80 60
+0.10
ø315 +0.03
+0.10
ø224 +0.03
M3
M3
45
8x °
45 45 22° 30”
° M5 ° M5
M4 M4
355 575 12.4 92 500 660 53.5 143 20 M20;
M20; 26 deep
8
30 deep
500 611 12.5 94.5
1) Thread according to DIN 13, see operating instructions for details 3) 8 fixing screws and O-ring seal are included in the delivery con-
on tightening torques. tents.
2) 4 fixing screws and O-ring seal are included in the delivery con-
tents.


Diameter Hub for splined shaft SAE J744 250 355 500 F/
100, 2-hole 7/8 in 13T 16/32DP ● ● ○ B3

125, 2-hole 1 1/4 in 14T 12/24DP ● ○ ○ B5
125, 2-hole 1 1/2 in 17T 12/24DP ○ ● ○ B6
▼▼ F/B3 ▼▼ F/B5
M4 M4
M61) M3 M3
M6 1)
2)
2)
+0.02
ø125 +0.07
+0.02
ø100 +0.05
M2
M2
80
ø1
ø140 45º
M5
45 M5
º M1 (to mounting
M1 (to mounting
flange face)
flange face)
B3 Size M1 M2 M3 M4 M5 M6 B5 Size M1 M2 M3 M4 M5 M6
250 531 200 18.5 43.5 10 250 545 224 19.9 58 10
M12; 18 deep M16; 24 deep
355 538 200 18.5 43.5 10 355 552 224 19.9 58 10
▼▼ F/B6
M4
M3
M61)
2)
+0.02
ø125 +0.07
M2
80
ø1
45º
M5
M1 (to mounting
flange face)
B6 Size M1 M2 M3 M4 M5 M6
355 552 224 10 66 10.4 M16; 24 deep

Flange SAE J744 (ISO 3019-1) Availability over sizes Code

82-2 (A) 5/8 in 9T 16/32DP ● ● ● 01

82-2 (A) 3/4 in 11T 16/32DP ○ ● ● 52
101-2 (B) 7/8 in 13T 16/32DP ● ● ● 68
101-2 (B) 1 in 15T 16/32DP ○ ● ● 04
▼▼ F/01; F/52 ▼▼ F/68; F/04
M61)(F/K01)
+0.05
ø82.55 +0.02
ø101.6 +0.02
+0.05
M61) 2)
45 45
° °
M3
ø106.5
ø146
M3
B 2) B
M5 M5
M61)(F/K52)
M4 M4
250 531 250 531
10.5 M10; M12;
355 538 33 10 355 538 18.5 43.5 10
15 deep 15 deep
500 574 9.3 500 574
355 531 M10; 355 538 18.9 M12;
19.5 40.5 10 48.4 10
500 574 15 deep 500 574 19.4 15 deep
1) Thread according to DIN 13, see operating instructions for details 2) 2 fixing screws and O-ring seal are included in the delivery con-
on tightening torques. tents.

Flange SAE J744 (ISO 3019-1) Availability over sizes Code

127-2 (C) 1 1/4 in 14T 12/24DP ● ● ● 07

127-2 (C) 1 1/2 in17T 12/24DP ○ ● ● 24
152-4 (D) 1 3/4 in 13T 8/16DP ● ● ● 17
▼▼ F/K07; F/24 ▼▼ F/17
2)
M61) 2) M61)
161.6
ø152.4 +0.02
+0.07
ø127 +0.02
+0.07
ø181
161.6
M3 M3
45
° M5 M5
M4 M4
flange face)
flange face)
250 545 250 531
19.9 M16; M16; 22 deep
355 552 58 13 355 538 10.4 73 13
24 deep
500 588 18.3 500 600 M16; 32 deep
24 Size M1 M3 M4 M5 M6
250 545
10.4 75 M16;
355 552 13
24 deep
500 588 10.3 67
2) 2 fixing screws and O-ring seal are included in the delivery
contents.

Integrated boost pump and valve technology (version F..)
High-pressure relief valves Control pressure limiting valve (for EP and HD)
(Pos. 5) (Pos. 8)
Two pilot-controlled pressure relief valves use pressure limi- Direct controlled, high-pressure-related relief
tation to prevent damage to the hydraulic pump resulting At low working pressure, the auxiliary pump pressure is
from overpressure. Each pressure side is assigned to a regulated to the set the value (e.g. 32 bar). This pressure is
pressure-relief valve. needed by the HD and EP controls to swivel out reliably.
Protection is provided by reducing the high pressure to the Using this valve saves a separate control pressure pump.
low pressure side. If the operating pressure exceeds the pressure of the boost
Pressure safeguarding is set by default to 350 bar. If pump, control is provided by the check valve via the high
another setting is required, please state this in the plain pressure. At the same time, increasing operating pressure
text. leads to the control pressure-relief valve being relieved.
▶▶ Maximum set value for pressure controller: 350 bar. This reduces the boost pump pressure to the set boost
▶▶ Cracking pressure of high-pressure relief valve: at least pressure (e.g. 16 bar).
30 bar above the set value of the pressure controller. This function leads to energy savings, improved efficiency
▶▶ Maximum cracking pressure of high-pressure relief valve: and a longer service life of the auxiliary pump.
400 bar. For settings, see Page 8.
▶▶ In all operating conditions, the high-pressure relief
valves may be subjected to current for maximum Control fluid filter (Pos. 10)
5 seconds (as a rule < 1 second). The HD and EP controls of size 500 with internal control
pressure supply from the high pressure are equipped with
Boost-pressure relief valve (Pos. 3) 0.2 mm coarse dirt filters as standard (independently of the
Directly controlled filtration order designation)
The boost pressure can be set on the boost-pressure relief Dimensions as shown from Page 32. For the circuit dia-
valve. gram, see Page 11 in this data sheet (part II).
Boost pressure Flushing valve (Pos.04)

To prevent damage to the system, a low pressure safeguard- For a safe opening of the flushing valve a pressure differ-
ing is recommended in which the static pressure compo- ence between A and B is required. The necessary pressure
nent is monitored. Ports ME3 or MK4, for example, are suit- difference is dependind at a particular speed of the respec-
able for low pressure monitoring. To prevent any tive nominal size. It is shown in the diagram.
impermissible drop in pressures, ports E2, E3 or K4 can be To prevent damage to the system the circuit temperature
used to connect a low pressure accumulator. The design of has to be monitored.
the accumulator and the choice of the optimum connection
Opening pressure difference [bar]
35
location must be decided in dependence on the hydraulic
transmission behavior of the system and the operating 30
NG500 NG355
conditions taking the available boost volume into account. 25
Depending on the quantity of system case drain fluid, it
20
may be necessary to increase the boost quantity with a NG250
larger or an additional boost pump. 15
10
Integrated boost pump (Pos. 9)
5
Standard size
0
Size 250 355 500 1000 1500 2000
800 2200
cm3 63 1) 80 1) 98
Speed [min-1]
1) Larger boost pumps available on request

▼▼ Circuit diagram
Example A4CSG...EPG...F..4N II3G... Component

Sizes 500. Additional sizes available on request. 1 EPG control
2 Pressure relief valves (not included in the delivery contents)
B MB K1 MA A 3 Boost pressure-relief valve
4 3 4 Flushing valve
K4 5 High-pressure relief valves
1 2
MK4 XA XB 6 Bypass valve
7 Boost check valves
5
8 Control pressure-relief valve
6 9 Integrated boost pump
ME3 10 Control fluid filter for HD and EP (NG 500)

M2 M1
E3
7 10
8
9
MAB U K2 K3T R(L) E 2 E1 S MS
Circuit diagram NG 500
Ports pmax abs [bar] Status

A, B Service line (pressure port) 400 O
S Suction port 30 O
MA, MB,
Measuring operating pressure A/B 400 X
MAB
MS Suction measurement 30 X
T Fluid drain 4 X
E1 Filter, supply 40 X
E2 Filter, return 40 X
K1 Flushing port 5 O
K2, K3 Fill + air bleed 4 X

R(L) Drain port for fluid (drain port) 4 O
U Bearing flushing 7 X
E3 Infeed 40 X
ME3 Boost pressure measurement 40 X
K4 Accumulator port 40 X
MK4 Boost pressure measurement 40 X
M1 Measuring stroking chamber pressure 400 X
M2 Measuring stroking chamber pressure 400 X
Pilot pressure remote control
XA, XB 350 O
pressure controller

Filtration types
Filtration types 1)2)
Independently of the selected boost circuit filtration, the Circuit diagram1)

size 500 HD and EP controls are equipped with 0.2 mm Example: A4CSG...EPD...F..4D
control fluid coarse dirt filters. (see circuit diagram) Size 500. Additional sizes available on request.
Without filter in the boost circuit (version N) B MB K1 MA A
Ports E1 and E2 are delivered plugged and pressure-proof

and internally connected. K4
Boost circuit filters can be connected subsequently to these MK4
ports.
The internal continuity between E1 and E2 must be plugged
for this purpose (please contact us).
For device dimensions, see pages 12 to 19.
ME3 M2
See circuit diagram on page 29. E3 M1
Ports for external boost circuit filtration (version D)

Ports E1 and E2 are provided for a filter port.
These ports are open and are plugged with plastic screws
for transportation only.
The internal continuity between E1 and E2 is plugged
closed. M ABU K 2 K3T R(L) E2 E1 S MS
Control fluid filter for HD and EP

(sizes 500 and 750)
Ansicht Z
M2
E2
E1
M1 M3
Size M1 M2 M3 Port E1/E2 Standard

250 477 55 193 M33 × 2; 18 deep DIN 3852
355 484 55 193 M33 × 2; 18 deep DIN 3852
500 520 55 193 M33 × 2; 18 deep DIN 3852
Ports pmax abs [bar] Status

E1 Filter, supply 50 O
E2 Filter, return 50 O
1) Componentsand ports, see page 30

2) All attachment pumps must correspond to the ATEX classification
for the application concerned.

Installation instructions
General Installation position

The axial piston unit must be filled with hydraulic fluid and See the following examples 1 to 10.
air bled during commissioning and operation. This must Additional installation positions are possible upon request.
also be observed following a longer standstill as the axial Recommended installation position: 1.
piston unit may empty via the hydraulic lines.
Especially with the “drive shaft upwards” and with avove– Note
reservoir installation position, bearing flushing is necessary ▶▶ You can expect installation positions 3, 4, 8 and 9 to affect the
for lubrication of the front bearing and of the shaft seal at control device. Because of gravity, dead weight and case pres-
port U. See Page 6. sure, minor characteristic displacements and actuating time
changes may occur.
The drain in the case interior must be directed to the reser-
voir via the highest reservoir port (T, R(L), K2, K3).
If a shared drain line is used for several units, make sure Key
that the respective case pressure is not exceeded. The S Suction port
shared drain line must be dimensioned to ensure that the T, K2, K3, R(L) Fluid filling + air bleeding (drain port)
maximum permissible case pressure of all connected units A, B Pressure port
is not exceeded in any operational circumstances, particu-
U Bearing flushing port
larly at cold start. If this is not possible, separate reservoir
SB Baffle (baffle plate)
lines must be laid as required.
ht min Minimum required immersion depth (200 mm)
To achieve favorable noise values, decouple all connecting
lines using elastic elements and avoid above-reservoir hmin Minimum required spacing to reservoir bottom
(100 mm)
installation.
hs max Maximum permissible suction height 800 mm for
In all operating conditions, the suction lines and the drain
version F. For version K, not the external boost
lines must flow into the reservoir below the minimum fluid pump specification.
level. The permissible suction height hS results from the
overall loss of pressure, it must not, however, be higher
than hS max = 800 mm. The minimum suction pressure at port
S must not fall below 0.8 bar absolute during operation
either.
For external feed in supply (version K..) please refer to the
attachment pump data sheet for details on the minimum
suction pressure.
When designing the reservoir, ensure that there is adequate
spacing between the suction line and the drain line. This
minimizes oil turbulence and carries out degassing, which
prevents the heated hydraulic fluid from being sucked
directly back in again.

Below-reservoir installation (recommended) Note

Below-reservoir installation is when the axial piston unit is
▶▶ For installation position 5 the axial piston unit must be
installed outside of the reservoir and below the minimum
operated with bearing flushing.
fluid level.
Installation position Air bleed Filling Installation position Air bleed Filling
1 R(L) R(L) 3 K2; R(L) plug K2
SB
SB
ht min
ht min
hmin
R(L) hmin
K2
S
S
2 T; R(L) plug T 4 K3; R(L) plug K3

SB
SB
ht min
ht min
hmin
hmin
S T
K3
S
5 T; R(L) plug T
Key see Page 41
SB
ht min
hmin
U

Above-reservoir installation Note

Above-reservoir installation means that the axial piston unit
▶▶ For above-reservoir installation the axial piston unit
is installed above the minimum fluid level of the reservoir.
must be operated with bearing flushing.
A check valve in the drain line is to be avoided. Exceptions
The port F is part of the external piping and must be
maybe permissible, please consult us first.
provided by the customer for simplified fluid filling and air
bleeding.
Installation position Air bleed Filling
6 R(L) R(L) Installation position Air bleed Filling
8 K2; R(L) K2; R(L)
F1
R(L) F1
K2
S F2
F2
hS max S
SB
hS max SB
ht min
ht min
hmin hmin
7 T; R(L) T; R(L)
F2 9 K3; R(L) K3; R(L)
F1
S T F1
K3
F2
SB hS max
S
ht min SB hS max
hmin ht min
hmin
10 T; R(L) T; R(L)
Key
S Suction port F1
T, K2, K3, R(L) Fluid filling + air bleeding (drain port) T
A, B Pressure port
F
U Bearing flushing port SB 2 S
SB Baffle (baffle plate)
hS max
ht min Minimum required immersion depth (200 mm)

ht min
hmin
hmin Minimum required distance to the reservoir bottom
(100 mm)
hs max Maximum permissible suction high 800mm for ver-
sion F. For version K observe the external boost
pump specification.

Project planning notes
Project planning notes ▶▶ Pressure controllers are not protection against overpres-
sure. A pressure relief valve is to be provided for the
▶▶ The Axial piston variable pump A4CSG ATEX is designed hydraulic system.
for use in a closed circuit. ▶▶ Service line ports:
▶▶ The project planning, installation and commissioning of –– The ports and fixing threads are designed for the
the axial piston unit require the involvement of qualified specified peak pressure. The machine or system
skilled personnel. manufacturer must ensure that the connecting ele-
▶▶ Before using the axial piston unit, please read the cor- ments and lines correspond to the specified operat-
responding instruction manual completely and thor- ing conditions (pressure, flow, hydraulic fluid, tem-
oughly. If necessary, request it from Bosch Rexroth. perature) with the necessary safety factors.
▶▶ Before finalizing your design, please request a binding –– The working ports and function ports can only be
installation drawing. used to accommodate hydraulic lines.
▶▶ The specified data and notes must be observed. ▶▶ The A4CSG axial piston variable pump is, except for
▶▶ Depending on the operating state of the axial piston unit momentary pressure reduction, not approved for motor/
(working pressure, fluid temperature), the characteristic reversing operation as this can cause impermissible
may shift. heating of the case drain fluid.
▶▶ Preservation: Our axial piston units are supplied as
standard with protection to preserve them for a maxi-
mum of 12 months. If longer preservative 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 variants of the product are approved for use in
safety functions according to ISO 13849. Please consult
the responsible contact person at Bosch Rexroth if you
require reliability parameters (e.g. MTTFd) for functional
safety.
▶▶ Depending on the type of control used, electromagnetic
effects can be produced when using solenoids. When a
direct current is applied, solenoids do not cause electro-
magnetic interference nor is their operation impaired by
electromagnetic interference.
Other behavior can result when a modulated direct
current (e.g. PWM signal) is applied. Potential electro-
magnetic interference for persons (e.g. persons with a
pacemaker) and other components must be tested by
the machine manufacturer.

Safety instructions
Safety instructions
▶▶ During and shortly after operation, there is a risk of

burns on the axial piston unit and especially on the
solenoids. Take appropriate safety measures (e.g. by
wearing protective clothing).
▶▶ Moving parts in control and regulation systems
(e.g. valve spools) may in certain circumstances become
stuck in an undefined position due to contamination
(e.g. contaminated hydraulic fluid, abrasion or residual
dirt from components). As a result, the flow of hydraulic
fluid and the build-up of momentum in the axial piston
unit can no longer meet the operator's specifications.
Even the use of different filter cartridges (external or
internal inlet filter) will not rule out a fault but merely
reduce the risk. The machine/system manufacturer must
check whether additional measures on the machine are
required for the relevant application in order to bring
the powered load into a safe position (e.g. safe stop)
and ensure all appropriate measures are taken.

Safety instructions

56 A4CSG for explosive areas | Axial piston variable pump
Safety instructions
Bosch Rexroth AG © This document, as well as the data, specifications and other information set
Mobile Applications forth in it, are the exclusive property of Bosch Rexroth AG. It may not be
An den Kelterwiesen 14 reproduced or given to third parties without our consent. The information is
72160 Horb a.N., Germany provided solely for the purpose of product description. No statement concern-
Phone +49 7451 92-0 ing a specific characteristic or suitability for a specific application may be
info.ma@boschrexroth.de inferred from the information provided by us. The information given does not
www.boschrexroth.com/brm release the user from the obligation of own judgment and verification. It must
be remembered that our products are subject to a natural wear and aging
process.

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Axial piston variable pump A4CSG

for explosive areas Part II of instruction manual

▶▶ Sizes 250, 355, 500

Details on explosion protection Contents

 RE 92105-01-X-B2/08.2017, Bosch Rexroth AG

Ordering code for standard program

Sealing material 250 355 500

Drive shaft 250 355 500

Mounting flange 250 355 500

Port for working lines

● = Available ○ = On request – = Not available

Note ▶▶ In order to avoid mechanically generated sparks from

Bosch Rexroth RE 92105-01-X-B2/08.2017

Ordering code for standard program

Filtration (see Page 49)

● = Available ○ = On request – = Not available

 RE 92105-01-X-B2/08.2017, Bosch Rexroth AG

maximum permissible viscosity for cold start

optimum operating viscosity range vopt

Bosch Rexroth RE 92105-01-X-B2/08.2017

Monitoring the operational data – specification for Tx

Safety instructions Safety instructions

● = allowed – = not allowed

See also installation positions on page 41

 RE 92105-01-X-B2/08.2017, Bosch Rexroth AG

Case drain temperature monitoring for ATEX category

Electric port, sensor

Number Color Connection

Note – evaluation electronics for temperature monitoring

Bosch Rexroth RE 92105-01-X-B2/08.2017

Filtration of the hydraulic fluid Bearing flushing

For the flushing flows stated, there is a pressure differential

Permissible pressure loading

 RE 92105-01-X-B2/08.2017, Bosch Rexroth AG

Working pressure range

Pressure at working ports A or B Definition

▼▼ Required low pressure in dependence on

▼▼ Rate of pressure change Time t

pnom Total operating period = t1 + t2 + ... + tn

Working pressure range valid when using hydraulic fluids

1) See also “Monitoring the operating data” on page 5

Bosch Rexroth RE 92105-01-X-B2/08.2017

Size Size 250 355 500

Determining operating characteristics Note

1) The values apply:

 RE 92105-01-X-B2/08.2017, Bosch Rexroth AG

Permissible radial and axial forces of the drive shafts

Permissible radial force Fq Fq max N 2000 2200 2500

Permissible input and through-drive torques

1) Efficiency not considered

Bosch Rexroth RE 92105-01-X-B2/08.2017

HD – hydraulic control pilot-pressure releated

HD – Proportional control, hydraulic, pilot-pressure ▼▼ Circuit diagram

(HD1T and HD1U is not available)

 RE 92105-01-X-B2/08.2017, Bosch Rexroth AG

EP – electrohydraulic control with proportional solenoid

M ABU K 2 K3T R(L) E2 E1 S MS

Bosch Rexroth RE 92105-01-X-B2/08.2017

Technical data – solenoid

The axial piston units are equipped with the following

 RE 92105-01-X-B2/08.2017, Bosch Rexroth AG

▼▼ Circuit diagram A4CSG 250, 355...EP....ATEX category II 2G bck IIC Tx

XA2 XAB XB2

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