A10VO Variable Displacement Piston Pump PDF

Electric Drives Linear Motion and
and Controls Hydraulics Assembly Technologies Pneumatics Service
A10VO Variable
Displacement Piston Pump
Technical Information Manual
The Drive & Control Company

A10VO PISTON PUMP MANUAL-MODULE 3A
Reproduction or use of editorial or pictorial content in any manner is

prohibited without the express permission of:
BOSCH REXROTH CANADA CORP.
While every precaution has been taken in the preparation of this manual,
the publisher assumes no responsibility for errors or omissions. Neither is
any liability assumed for damages resulting in the misuse of the printed
material contained herein.
First Edition 1996

Revised Edition 2006
Printed in Canada for:
Bosch Rexroth Canada Corp.

3426 Mainway Drive
Burlington, Ontario
Canada L7M 1A6
Phone: (905) 335-5511

Fax: (905) 335-9859
Toll Free: 1-877-266-7811

1-877-COMPU-11
Bosch Rexroth Canada Corp. 3426 Mainway Dr. Burlington, ON L7M 1A8 www.boschrexroth.ca
16/06/2006 Page 2 of 23
TABLE OF CONTENTS
FEATURES...................................................................................................................................... 4
FUNCTIONAL PURPOSE ............................................................................................................... 4
DESCRIPTION ................................................................................................................................ 6
SPECIFICATIONS........................................................................................................................... 7
Pressure ...................................................................................................................................... 7
R.P.M .......................................................................................................................................... 7
Case Drain................................................................................................................................... 7
OPERATING CONDITIONS............................................................................................................ 7
Operating Viscosity...................................................................................................................... 7
Recommended Filtration ............................................................................................................. 7
Inlet Conditions ............................................................................................................................ 7
Leakage Line ............................................................................................................................... 8
Direction of Rotation .................................................................................................................... 8
DFR CONTROL............................................................................................................................... 9
CONTROL VALVE ASSEMBLY .................................................................................................... 10
Identification Drawing ................................................................................................................ 10
Pressure Regulation .................................................................................................................. 10
Flow Regulation ......................................................................................................................... 11
PUMP PERFORMANCE TEST ..................................................................................................... 11
TEST EQUIPMENT ....................................................................................................................... 12
Gauge Test Port Kit ................................................................................................................... 12
PORT SIZES ................................................................................................................................. 12
OPTIONAL ACCESSORIES ......................................................................................................... 13
Low Oil Shut–Off Block.............................................................................................................. 13
UNIT DIMENSIONS ...................................................................................................................... 14
STANDARD MODELS USED........................................................................................................ 22
STANDARD SPARE PARTS......................................................................................................... 23
Replacement Pump Control Valve ............................................................................................ 23
Replacement Seal Kits .............................................................................................................. 23
Split Flanges .............................................................................................................................. 23
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FEATURES
• High Efficiency through load sensing (= fuel savings)

• Maximum Pressure Control Built In
• Long Service Life
• Large Range of Flow Rates Available
• Low Noise Level
• Cast Iron Construction
• Standard Mounting Flange Dimensions
• Standard Drive Shaft Dimensions
• Direct Engine Mount or PTO Drive Capability
FUNCTIONAL PURPOSE
This pump is preferred over a fixed displacement (gear) pump. A fixed displacement pump
delivers a set volume of oil for each revolution of its drive shaft. Any of this fluid flow that is not
required, by the hydraulic system to do work, is sent back to the oil reservoir over a restriction.
This oil flow times the pressure difference (between the system and the reservoir) is power that
has been drawn from the engine and is now being turned into heat. The heat generated is a direct
indication of fuel wasted and of unnecessary wear and tear on the hydraulic fluid, thus on the
hydraulic system's mechanical components.
On the other hand, this variable displacement pump monitors (senses) by way of a small
hydraulic line connecting it to the control valves – the power requirement (load) on your hydraulic
system and provides just enough fluid flow and pressure to meet your system's immediate need.
This means that the pump can be left running constantly and as your system's requirement
changes the pump will simply adjust itself accordingly. By doing this, energy is not wasted away
in the form of heat; translating into fuel savings for you and less wear and tear in your hydraulic
system.
An adjustable pressure limit (up to 4100 PSI) is also built onto the pump. It operates by reducing
the output flow – all the way to zero if necessary – keeping the pressure supply to your hydraulic
system from ever going too high.
Different maximum displacements (sizes) with standard mounting flanges, are available to match
the needs of your system. Also, various combinations of drive shafts (splined or keyed), rotation
directions (left hand or right hand) and port locations (rear or side) can be chosen to facilitate your
particular installation requirements (ie. direct engine mounting as well as transmission power take
off mounting can be accommodated).
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FUNCTIONAL PURPOSE CONTINUED
Variable displacement swash plate design piston pump.
1. Housing
2. Control Piston
3. Drive Shaft
4. Swash Plate
5. Control Valve Assembly
6. Pistons (x7)
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DESCRIPTION
Axial piston pumps model A10V0 are swash plate design variable displacement pumps. As
illustrated by the picture under functional purpose they basically consist of a housing (1), control
pistons (2) located inside cylinder barrel, drive shaft (3), swash plate (4), a control valve assembly
(5), and pistons (6)
This piston pump smoothly and continuously varies its displacement (volumetric output – size), by
altering the angle of its swash plate. As your system operates, valves monitor the loads
(pressures) on the actuators (cylinders and motors) and control the swash plate accordingly. The
greater the angle of the swash plate, relative to the drive shaft, the further the pistons stroke in
and out, therefore the greater the fluid flow.
There are two control valves, located in a removable housing, bolted to the pump. The standard
type of control used is referred as flow and pressure compensation, type DFR. A simple
explanation of how this works is described in the next paragraph. We have limited the explanation
to one short paragraph as a detailed explanation goes beyond the technical requirements of this
Generic Manual.
The flow and pressure compensator control, also known as a load– sensing control, matches
pump output flow and pressure to system demand. This control will automatically regulate the
pump displacement to deliver the flow required to maintain a constant pressure drop across a
valve spool or other flow limiting device. When there is no system demand, the pump stands by at
zero flow and low pressure. When the system demands flow, the pump delivers only the flow
required by the system, at a pressure required to move the load.
To protect the system from infinite load pressures, the pressure compensator section of the
control will cause the pump to automatically de-stroke when the pre–adjusted maximum system
pressure is reached.
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SPECIFICATIONS
Pressure
The pressure range for the standard models used as outlined under standard models is 4,100
PSI maximum.
R.P.M .
NOTE: This figure is dependant on inlet conditions ensure you follow recommended installation
guidelines as per commissioning instructions.
Maximum speed (flooded suction)

P/N 130985 (A10V028) = 3000 rpm
P/N 130272, 124691 and 117556 (A10V045) = 2600 rpm
P/N 103616 and 149312 (A10V071) = 2200 rpm
Case Drain
Ensure pump mounted with case drain at highest to location to ensure pump prime is not lost and
remains adequately lubricated. Maximum permissible pressure of the case drain can be 7 PSI
(0.5 bar) maximum, higher than inlet pressure or suction pressure. Yet case pressure no higher
than 30 PSI (2 bar) absolute.
OPERATING CONDITIONS
Operating Viscosity
Operating viscosity range: For optimum efficiency and pump life, we recommend that the
operating viscosity (at operating temperature) be selected in the range of √opt = optimum
operating viscosity 81...167 SUS (16...36 mm2/s) taking into consideration the reservoir
temperature range.
Viscosity limits: The following values are valid for extreme operating conditions of short duration.
√min = 60 SUS (10 mm2/s) for short periods at max. permissible drainage oil temperature of
94º F (90ºC) √max = 4635 SUS (1000 mm2/s) for short periods upon cold start.
Recommended Filtration
In order to guarantee reliable function, both return and pressure filters should have 10 micron min
Inlet Conditions
(Suction Line)
The suction line, pipe or hose, should be as short and straight as possible. The pipe section
should be such that the negative pressure at the suction port never falls below 11.6PSI (abs.) (0,8
bar) and never rises above 29PSI (abs.) (2 bar). Make sure connection points are airtight and that
hoses are sufficiently pressure resistant against external air pressure. Use plastic hoses with
supporting mesh. Make sure there are no kinks in the hose when installing.
16/06/2006 Page 7 of 23
Leakage Line
(Case Drain)
Leakage lines should be laid out so that the housing always remains filled with oil and the ingress
of air at the radial seal is prevented even during long periods of in-operation. The leakage line just
always enter the tank (Reservoir) below the minimum oil level.
Direction of Rotation
Is always defined as viewed on the drive shaft and indicated by a directional arrow. It is not
possible to change the direction of rotation of the drive without conversion of the pump.
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DFR CONTROL
16/06/2006 Page 9 of 23
CONTROL VALVE ASSEMBLY
Identification Drawing
1. Flow regulation
2. Control valve spools
3. Gauge test port From the pump's output port
4. To the pump's control piston
5. To the pump's low pressure case then back to the reservoir
6. Connection to the load sensing shuttle valve system in the main control valves
7. Adjustable command springs
8. Pressure Regulation
9. Control valves and their adjustment screws
Pressure Regulation
Maximum system pressure setting. See module 2A Hydraulic Installation and Commissioning
manual for instructions for testing maximum pressure setting. These detailed instructions will
assist you when changing pressure setting. The pressure is set with the pressure setting screw.
1. Remove the cap nut with 17 mm external hexagon.
2. Undo the lock nut with 17 mm external hexagon.
3. Set the pressure range by turning the setting screw with hexagon socket head 4 mm.
4. Lock the setting screw with lock nut, external hexagon 17 mm. Turning the setting screw
clockwise increases the pressure. Turning the setting screw counter–clockwise reduces
the pressure. One turn of the setting screw corresponds to 50 bar pressure range 20 to
250 bar.
5. Screw on the cap nut with external hexagon 17 mm and tighten to a torque of Ma =
8.5Nm. (186 Inch/Lbs.)
16/06/2006 Page 10 of 23
CONTROL VALVE
ASSEMBLY CONTINUED
Flow Regulation (Standby Pressure)
As mentioned in Module 2A Hydraulic Installation and Commissioning. Manual this setting should
not require adjustment. Although if the factory setting is incorrect (usually 200 PSI) or you wish to
increase please review detailed instructions as below.
The flow is set at the flow setting screw.
1. Remove the cap nut with 13 mm external hexagon.
2. Undo the lock nut with 13 mm external hexagon.
3. Set the flow range by turning the setting screw with 3 mm hexagon socket.
4. Lock the setting screw with the lock nut, 13 mm external hexagon. Turning the setting
screw clockwise increases the flow. Turning the setting screw counter–clockwise
decreases the flow.
5. Screw on the cap nut with 13 mm external hexagon and tighten to a torque of Ma =
8.5Nm. (186 Inch/Lbs.)
PUMP PERFORMANCE TEST
A simple test can be performed to investigate condition of the variable displacement pump. Only
initiate this test if system operation becomes sluggish or complaints of excessive noise with
respect to pump operation.
Ensure vehicle or prime mover is turned off. Remove the case drain from the reservoir or simply
disconnect line at pump housing. Select the easiest option then ensure adequate hose is
available to insert into measuring bucket. Because of the many pump sizes available we suggest
you contact your nearest Bosch Rexroth office for standard leakage rates for your specific pump.
Upon receiving this information deadhead a valve function as outlined under Module 2A
commissioning instructions. Allow unit to run for the desired time limit as specified by Bosch
Rexroth. Measure the quantity of oil to confirm pump operation is okay. At this time a quick
inspection of hydraulic oil is also recommended which may identify early signs of pump wear. If
within desired rates reinstall case drain. If not please contact Bosch Rexroth for further
assistance.
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TEST EQUIPMENT
Gauge Test Port Kit
To assist in commissioning the A10V0 pump you may purchase a test kit that can be installed on
the control valve as shown under Identification Drawing. Simply remove the plug and install the
following parts before commencing pressure adjustments.
198400 - Test Kit Includes:
• 1 only P/N 101077 Adaptor Fitting

• 1 only P/N 002036 Threaded Connector
• 1 only P/N 001020 Capillary Hose
• 1 only P/N 003450 Direct Connector
• 1 only P/N 014386 Pressure Gauge (0–3000 PSI)
PORT SIZES
Model code 103616 and 149312

Reference: A10V071 Series 31
Suction Port = 2"SAE Flange
Pressure Port = 1" SAE Flange
Case Drain Port = SAE–10 (7/8–14)
Load Sense Port = SAE–4 (7/16–20)
Model Code 131006

Suction Port = 1 1/2" SAE
Flange Pressure Port = 1" SAE
Flange Case Drain Port = SAE–10 (7/8–14)
Model code 130272

Suction Port = Threaded 1 7/8–12
Pressure Port = Threaded 1 5/16–12
Model code 130985

Suction Port = 1 1/4 SAE Flange
Pressure Port = 3/4 SAE Flange
16/06/2006 Page 12 of 23
OPTIONAL ACCESSORIES
Low Oil Shut–Off Block
This block available for inline or direct mounting to pump will rescue
The hydraulic pump from catastrophic failure should the reservoir oil level become too low.
Intended for use on variable displacement piston pumps only.
Please refer to Module #9 for more information on this unit.
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UNIT DIMENSIONS A10V071
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UNIT DIMENSIONS A10V071,45,28
16/06/2006 Page 20 of 23
UNIT DIMENSIONS A10V045 SERIES50
16/06/2006 Page 21 of 23
STANDARD MODELS USED
Part Number Model Code and Description Common Usage

103616 A10V071DFR/31L-PKC92N00 Large Trucks
4.3 IN3/REV = 36 GPM @ 2000 RPM left hand rotation side Front Mounted
ports / 1 1/4" keyed shaft
149312 A10V071DFR/31R-PKC91N00 Large Trucks

4.3 IN3/REV = 36 GPM @ 2000 RPM right hand rotation P.T.O. Mounted
rear ports / 1 1/4" keyed shaft
131006 A10V045DFR/31L-PKC62N00 Medium Trucks
2.74 IN3/REV = 23 GPM @ 2000 RPM left hand rotation Front Mounted
side ports / 1" keyed shaft
131019 A10V045DFR/31R-PKC62N00 Medium Trucks

2.74 IN3/REV = 23 GPM @ 2000 RPM right hand rotation (1 ton)
side ports / 1" keyed shaft
130272 A10V045DFR/51R-PUC64N00 Medium Trucks

2.74 IN3/REV = 23 GPM @ 2000 RPM right hand rotation P.T.O. Mounted
rear ports / 7/8" x 13 tooth splined shaft
130985 A10V028DFR/31R-PKC61N00 Small Trucks

1.71 IN3/REV = 15 GPM @ 2000 RPM right hand rotation (1 ton)
rear ports / 7/8" keyed shaft
NOTE: These pumps are also available in many other configurations and sizes. If your needs
cannot be met by a pump on this list, please contact your nearest Bosch Rexroth location for
assistance.
16/06/2006 Page 22 of 23
STANDARD SPARE PARTS
Replacement Pump Control Valve
For all models as listed in this section P/N 024356
Replacement Seal Kits
Model Code Repair Kit P/N
Ref: P/N 103616 and 1149312 P/N 110178

Model # A10V071 Series 31
Ref: P/N 131006 and 131019 P/N 110183

Ref: P/N 130272 P/N 024052

Ref: P/N 130985 P/N 110182

NOTE: For additional spare parts and repair information please contact your nearest Bosch
Rexroth location for assistance.
Split Flanges
Model Code Pressure Suction
Ref: P/N 103616 and 149312 SF-20-30 SF-32-30

Model # A10V071 Series 31 P/N 004070 P/N 003885
Ref: P/N 131006 and 131019 SF-16-30 SF-24-30

Ref: P/N 130985 SF-12-30 SF-20-30

16/06/2006 Page 23 of 23

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Electric Drives Linear Motion and

and Controls Hydraulics Assembly Technologies Pneumatics Service

The Drive & Control Company

Reproduction or use of editorial or pictorial content in any manner is

BOSCH REXROTH CANADA CORP.

First Edition 1996

Printed in Canada for:

Bosch Rexroth Canada Corp.

Phone: (905) 335-5511

Toll Free: 1-877-266-7811

• High Efficiency through load sensing (= fuel savings)

FUNCTIONAL PURPOSE CONTINUED

Variable displacement swash plate design piston pump.

5. Control Valve Assembly

Maximum speed (flooded suction)

CONTROL VALVE ASSEMBLY

1. Remove the cap nut with 17 mm external hexagon.

2. Undo the lock nut with 17 mm external hexagon.

Flow Regulation (Standby Pressure)

The flow is set at the flow setting screw.

1. Remove the cap nut with 13 mm external hexagon.

2. Undo the lock nut with 13 mm external hexagon.

PUMP PERFORMANCE TEST

Gauge Test Port Kit

198400 - Test Kit Includes:

• 1 only P/N 101077 Adaptor Fitting

Model code 103616 and 149312

Model Code 131006

Model code 130272

Model code 130985

Low Oil Shut–Off Block

Intended for use on variable displacement piston pumps only.

Please refer to Module #9 for more information on this unit.

UNIT DIMENSIONS A10V071

UNIT DIMENSIONS A10V071

UNIT DIMENSIONS A10V045

UNIT DIMENSIONS A10V045

UNIT DIMENSIONS A10V028

UNIT DIMENSIONS A10V028

UNIT DIMENSIONS A10V071,45,28

UNIT DIMENSIONS A10V045 SERIES50

STANDARD MODELS USED

Part Number Model Code and Description Common Usage

149312 A10V071DFR/31R-PKC91N00 Large Trucks

131019 A10V045DFR/31R-PKC62N00 Medium Trucks

130272 A10V045DFR/51R-PUC64N00 Medium Trucks

130985 A10V028DFR/31R-PKC61N00 Small Trucks

STANDARD SPARE PARTS

Replacement Pump Control Valve

For all models as listed in this section P/N 024356

Replacement Seal Kits

Model Code Repair Kit P/N

Ref: P/N 103616 and 1149312 P/N 110178

Ref: P/N 131006 and 131019 P/N 110183

Ref: P/N 130272 P/N 024052

Ref: P/N 130985 P/N 110182

Model Code Pressure Suction

Ref: P/N 103616 and 149312 SF-20-30 SF-32-30

Ref: P/N 131006 and 131019 SF-16-30 SF-24-30