GLOBAL HYDRAULICS PROGRAM BOOK · GLOBAL HYDRAULICS PROGRAM BOOK . This is a common document valid within . Fiat Chrysler Automobiles Powertrain . Version 1.14 . Release Date: October

Project_Book_-_Bosch Rexroth Hydraulic Version 1.14 Original Date: 1st October, 2010 Revised Date 1st July 2017 Page 1 of 43

GLOBAL HYDRAULICS PROGRAM BOOK

This is a common document valid within Fiat Chrysler Automobiles Powertrain

Version 1.14

Release Date: October 1, 2010

Revised Date: 1st July 2017

Project_Book_-_Bosch Rexroth Hydraulic Version 1.14 Original Date: 1st October, 2010 Revised Date 1st July 2017 Page No. 2 of 43

DOCUMENT MANAGEMENT

Any questions or comments with respect to this specification should be directed to the project engineer for the specific project in question. This document contains product information to be used for the selection of components for Fiat Chrysler Automobiles Powertrain [from now FCA (NAFTA) & FCA (EMEA, LATAM, APAC)] programs. This document provides a basic guide to selecting the correct type of hydraulic system for the correct application. It also provides the necessary contact information to assist in application engineering, program management review, and stocking locations for ease of purchasing. All information contained in this document is superseded by the requirements of the FCA (NAFTA) & FCA (EMEA, LATAM, APAC) Specification.

A current, and accurate, copy of the specification can be obtained from the following web addresses:

http://supplierinfo.fiatpowertrain.com/index.php

https://www.esupplierconnect.com/




Revision

Date Version

No. Document Name Revision Paragraph Affected

Revised by

10th January 2010 1.0 FGA E&T-CPT Bosch Rexroth Hydraulic Program Book

First Released Version Greg Brayan

6th August 2011 1.1 FGA E&T-CPT Bosch Rexroth Hydraulic Program Book

Revised Fiat Logo , FGA E&T, updated accumulator part numbers

Greg Brayan


Updated size 10 directional valves to 4WEH series 4.3 Greg Brayan


Updated directional valve part numbers K72 pin-out. Added diaphragm Accumulator Added ABM Manifolds .Added S Check valves

5.1, 5.2, 5.3, 5.4

10.1 12.0 7.0

Greg Brayan

12th January 2012 1.4 FGA E&T-CPT Bosch Rexroth Hydraulic Program Book Program Book

Corrected Model Code for Directional Detent Valve 5.1 Greg Brayan


Changed Fiat Logo Add Pressure Gauge 18.0 Greg Brayan

1st January 2014 1.6 FGA E&T-CPT Bosch Rexroth Hydraulic Program Book

Update Cylinder Data Sheet Update Pressure Gauge

13.0 18.0 Greg Brayan


Update contact information 2.1 Greg Brayan

9th January 2014

1.8 FGA E&T-CPT Bosch Rexroth Hydraulic Program Book

Udpate Fiat Group Name, Contact Info, and Hydraulic Valves 5.1 - 5.2 - 5.3 - 5.4 Greg Brayan

1st January 2015 1.9 FCA-PT (Fiat Chrysler Automobiles Powertrain) Bosch Rexroth Hydraulic Program Book

Updated of FGA and CPT Logos, No ANSI Valves + Accumulator size + Small Power Units + Sytronix Solution

5.1.1 - 5.2.1 - 5.3.1 -

5.4.1 - 10.2 - 19.0.1 -

31

Biagio Scalone Massimo Cavalloni

1st July 2015 1.10 FCA-PT (Fiat Chrysler Automobiles Powertrain) Bosch Rexroth Hydraulic Program Book

Include CPT to FCA (NAFTA) changes & FGA E&T to FCA (EMEA, LATAM, AOAC) + Updated contacts of Mr.Falletti and Mr. Heider, Global Acceptance of NG6 + NG10 + of Manifolds Plates + power unit + FcP Solution + Pressure & Return Filters limitation + Line connection type for cylinders

4.1 + 4.2 + 5.1.1 +

5.2.1 + 5.3.1 + 12.2 +

13.0 + 19.0 + 31.0

Greg Brayan Biagio Scalone

1st January 2016 1.11 FCA-PT Bosch Rexroth Hydraulic Program Book

Extended the list of Bosch Rexroth Global Support Engineers 3 Biagio Scalone

1st July 2016 1.12 FCA-PT Bosch Rexroth Hydraulic Program Book

Update of Index Update of the links of documentations

??? Biagio Scalone Greg Brayan Massimo Cavalloni

1st January 2017 1.13 FCA-PT Bosch Rexroth Hydraulic Program Book

Created Section 3 for COMPONENTS Created Section 4 for SYSTEMS & SOLUTIONS Updated and Added PGF, PGH e PVV Pumps Just Cleaned selection chart pics Added Four-Way Poppet Directional Control ANSI Added Four-Way Poppet Directional Control Updated series 3X to 5X DO5 Directional Valves Updated version Viton Seal to Buna Seals Updated In Line Check Valves Series 1X Updated Series 4X to 6X for EMEA (New EU Pressure Equipment regulation 2014/68/EU replacing old one 97/23/EC) + Added table for NAFTA with Series 7X More Detailed Hydraulics Power Units and Components More Detailed Hydraulics Compact Power Units More Detailed Sytronix FcF5020 solution

3 4 3.1 3.2.1, 3.2.2 3.3.5 3.3.6 3.3.7, 3.3.8 3.4.1, 3.4.2, 3.4.5, 3.4.6, 3.4.9, 3.4.11 3.4.10 3.5.2 4.1.1, 4.1.2 4.1.3 4.2.1

Biagio Scalone Massimo Cavalloni Greg Brayan

1st July 2017 1.14 Project_Book_-_ Bosch Rexroth Hydraulic

FCA Logo Updated FCA contact updates Bosch Rexroth Hyperlink updated Accumulator Safety Block CDT3 Cylinder 2x to 3x family

All Pages 2.1 – 2.2 1.1 3.5.3 3.14

Biagio Scalone Brayan Greg


1. CONTACTS Information - SERVICE and SUPPORT

1.1. Projects and Sales Contacts Information - Bosch Rexroth & FCA

Bosch Rexroth FCA (EMEA, LATAM, APAC) (NAFTA) (EMEA, LATAM, APAC) (NAFTA)

Contact Biagio SCALONE

Greg BRAYAN

Roberto OLIVA

Brian MAYNARD

Company Bosch Rexroth AG

Branch in Italy Industrial Applications

Bosch Rexroth USA Account Manager

FCA SpA - EMEA FCA US LLC

Address SS Padana Sup.re 11, n.41

20063 Cernusco sul Naviglio (MI) Italy

2730 Research Drive Rochester Hills, MI 48309 (USA)

C.so Settembrini 167 Gate 19 Loft B

10135 Turin (Italy)

Phone +39 02 92365.835 248-672-5254 +39 011 003.6481

Mobile +39 348 4530 344 Fax +1 248 853 2035 +39 334 6543687 +1 313 423 7006

Email address

[email protected] [email protected] [email protected]

[email protected]

Website

www.boschrexroth.com http://supplierinfo.fiatpowertrain.com/

http://www.boschrexroth-us.com https://gsp.extra.chrysler.com/mfg/amedd/control/index.htm

mailto:[email protected]




http://www.boschrexroth.com/

http://supplierinfo.fiatpowertrain.com/

http://www.boschrexroth-us.com/

https://gsp.extra.chrysler.com/mfg/amedd/control/index.htm


1.2. Technical Requirements Contact List – Bosch Rexroth in the World

EMEA Germany HQ Italy Spain FranceLocal Hydraulic & Fluidic Support Technical Engineer Johannes GEBAUER Massimo CAVALLONI

@mail address [email protected] [email protected] No. (Office) +49 (9352) 18 1071 +39 (02) 92365 202Phone No. (Mobile or Beeper) +49 (173) 6912758 +39 (342) 0811184

Bosch Rexroth AG Bosch Rexroth S.p.A.Bgm.-Dr.-Nebel-Str. 2 SS Padana Superiore 11, no.41

Lohr am Main Cernusco s/Naviglio97816 20063Bayern Milano

Germany Italy

NAFTA USA MexicoLocal Hydraulic & Fluidic Support Technical Engineer Greg BRAYAN Jose CRUZ VAZQUEZ

@mail address [email protected] [email protected] No. (Office) +1 (248) 267 4058 +52 (55) 5747 7422Phone No. (Mobile or Beeper) +1 (248) 672 5254 +49 (711) 8113656808

Bosch Rexroth Corporation Bosch Rexroth S.A. de C.V.2730 Research Drive Neptuno 72 Col Unidad Industrial Vallejo

Rochester Hills Mexico City48309 7700

MI MexicoUSA Mexico

LATAM Brazil ArgentinaLocal Hydraulic & Fluidic Support Technical Engineer Alessandro GAIOTTO Francisco HANSING

@mail address [email protected] [email protected] No. (Office) +55 (11) 4075-9007 +54 (351) 4681-822Phone No. (Mobile or Beeper) +55 (11) 98533-4680 +54 (9351) 519-0536

Bosch Rexroth Ltda Bosch Rexroth SAICAv Tegula 888 Rosario 2302

Atibaia Carapachay12952-820 B1606DLDSao Paulo Buenos Aires

Brazil Argentina

APAC Japan Korea India ChinaLocal Hydraulic & Fluidic Support Technical Engineer Nobuo SAKASHITA Changho KIM Chetan PATIL Colin ZHENG

@mail address [email protected] [email protected] [email protected] [email protected] Phone No. (Office) +81 (29) 832 0151 +82 (51) 260 0771 +91 (20) 6608 2022 +86 (21) 22186040Phone No. (Mobile or Beeper) +81 000 83 73614 +82 (10) 3250 6209 +91 (855) 10 73555 +86 (180) 19026671

Bosch Rexroth Bosch Rexroth Korea Ltd. Bosch Rexroth (India) LimitedShanghai Bosch Rexroth Hydraulics &

Automation Ltd.5-1 Higashi-Nakanuki-machi 29 Mieum Sandan 1Ro Gangseo-gu 18/4 -19/4 - Hadapsar Industrial Estate 333 Fuquan (N.) Road

Tsuchiura Busan-si Pune Shanghai300-8588 618-260 411 013 200335Ibaraki - Maharashtra ShanghaiJapan Korea India China

Company(Name & Address)




+39 (02) 92365 835

Biagio SCALONE (GKAM)

[email protected]

+39 (348) 4530344Bosch Rexroth AG - Branch in Italy

SS Padana Superiore 11, no.41Cernusco s/Naviglio

20063MilanoItaly


Table of Contents

1. CONTACTS INFORMATION - SERVICE AND SUPPORT ...................................................................................... 4

1.1. PROJECTS AND SALES CONTACTS INFORMATION - BOSCH REXROTH & FCA .................................................................... 4 1.2. TECHNICAL REQUIREMENTS CONTACT LIST – BOSCH REXROTH IN THE WORLD ................................................................ 5

2. INTRODUCTION .............................................................................................................................................. 8

2.1. SCOPE OF DOCUMENT .......................................................................................................................................... 8

3. COMPONENTS - PRODUCTS OVERVIEW .......................................................................................................... 9

3.1. PUMPS ............................................................................................................................................................ 9 3.2. FILTERS ......................................................................................................................................................... 10

3.2.1. Pressure filters, INLINE DIN 24550 ....................................................................................................... 10 3.2.2. Return Filters TANK MOUNTED, DIN 24550 ......................................................................................... 11

3.3. DIRECTIONAL CONTROL VALVES .................................................................................................................. 13 3.3.1. NG6 (D03) Four-Way Directional Control Valves 8 Watt (ANSI version) .............................................. 13 3.3.2. NG6 (D03) Four-Way Directional Control Valves 8 Watt ...................................................................... 14 3.3.3. NG6 (D03) Four-Way Directional Control Valves 30Watt (ANSI version) ............................................. 15 3.3.4. NG6 (D03) Four-Way Directional Control Valves 30 Watt .................................................................... 16 3.3.5. Four-Way Poppet Directional Control Valves (Pre-Opening) (ANSI Version) ........................................ 17 3.3.6. Three-Way Poppet Directional Control Valves ..................................................................................... 17 3.3.7. NG10 (D05) Four-Way Directional Control Valves 35 Watt (ANSI version) .......................................... 18 3.3.8. NG10 (D05) Four-Way Directional Control Valves 35 Watt .................................................................. 18 3.3.9. NG16 (D07) Four-Way Directional Control Valves 30 Watt (ANSI Version) .......................................... 19 3.3.10. NG16 (D07) Four-Way Directional Control Valves 30 Watt .................................................................. 19

3.4. FLOW CONTROL MODULE ............................................................................................................................ 20 3.4.1. NG6 (D03) Double Throttle Sandwich Module ..................................................................................... 20 3.4.2. NG6 (DO3) Check Valve Sandwich Module Data Sheet RE21534 ..................................... 20 3.4.3. NG6 (DO3) Pressure Reducing Direct Operating: Sandwich Module .................................................... 21 3.4.4. NG10 (DO5) Pressure Reducing Direct Operating: Sandwich Module .................................................. 21 3.4.5. NG10 (D05) Flow Control Sandwich Modules ....................................................................................... 22 3.4.6. NG10 (DO5) Check Valve Pilot Operated Sandwich Module ................................................................ 22 3.4.7. NG6 (DO3) Pressure Relief Valve Pilot Operated Sandwich Module .................................................... 23 3.4.8. NG10 (DO5) Pressure Relief Valve Pilot Operated Sandwich Module .................................................. 23 3.4.9. NG16 (D07) Flow Control Sandwich Modules ....................................................................................... 24 3.4.10. INLINE CHECK VALVES 1179-1 G thread ports ...................................................................................... 24 3.4.11. THROTTLE CHECK VALVE - MK .............................................................................................................. 24 3.4.12. Flow Control Valve Sub Plate Mounted ................................................................................................ 25

3.5. ACCUMULATORS .......................................................................................................................................... 26 3.5.1. Diaphragm Accumulators ..................................................................................................................... 26 3.5.2. Bottom Repairable Bladder Accumulators ........................................................................................... 26 3.5.3. Accumulator Safety Isolation Blocks .................................................................................................... 27 3.5.4. Accumulator Accessories ...................................................................................................................... 27

3.6. SUBPLATES ................................................................................................................................................... 28 3.7. MANIFOLDS .................................................................................................................................................. 28

3.7.1. Manifolds - NG6 (DO3) ......................................................................................................................... 28 3.7.2. Manifolds - NG10 (DO5) ....................................................................................................................... 28 3.7.3. Manifolds - Cover Plates ....................................................................................................................... 29

3.8. PRESSURE RELIEF VALVES ............................................................................................................................. 30 3.9. PRESSURE SEQUENCE VALVE MODULAR ...................................................................................................... 30 3.10. ON / OFF WATER VALVES .......................................................................................................................... 30 3.11. PRESSURE RELIEF & REDUCING VALVES .................................................................................................... 31 3.12. PROPORTIONAL DIRECTIONAL VALVES & CLOSED LOOP CONTROLLERS .................................................. 32 3.13. COMPONENTS - MISCELLANEOUS ................................................................................................................. 33 3.14. HYDRAULIC CYLINDERS, ISO 6020/2 ......................................................................................................... 34

4. SYSTEMS & SOLUTIONS ................................................................................................................................ 35


4.1. HYDRAULIC POWER UNIT ................................................................................................................................ 35 4.1.1. Horizontal Power Units with STEEL Tank for FCA-PT Plants as DIN Specification ................................ 36 4.1.2. Components for HORIZONTAL POWER UNIT MATRIX Steel Tank ......................................................... 37 4.1.2.B. Variable Vane - Pump Motor Group sizing using 1800 RPM ............................................................ 37 4.1.2.D. Axial Piston – Pump Motor Group sizing using 1800 RPM ............................................................... 38 4.1.3. COMPACT Power Units with ALUMINUM tank for FCA-PT Plants ........................................................ 39

4.2. ENERGY SAVING WITH BOSCH REXROTH TECHNOLOGIES ....................................................................................... 40 4.2.1. SYTRONIX FcP-5020 Variable Speed Pump Drive Systems .................................................................... 41

5. NOTE … HOW TO LOOK FOR OFFICIAL DOCUMENTATION FROM BOSCH REXROTH. .................................... 42


2. INTRODUCTION

2.1. Scope of Document The Program Book provides a list of Bosch Rexroth Hydraulic Products to be used for the FCA-PT Programs. The use of components not listed in the Program Book requires a deviation from FCA-PT Engineering (“FCA (NAFTA)” for Chrysler Powertrain and “FCA (EMEA, LATAM, APAC)” for Fiat Group Automobiles Engine and Transmission). The controlled version of this document is stored on the Bosch Rexroth website: http://www.boschrexroth.com/ftpctpspec Web address reference is available on the following Fiat Chrysler Automobiles Powertrain web sites: http://supplierinfo.fiatpowertrain.com/index.php https://www.esupplierconnect.com/

http://www.boschrexroth.com/ftpctpspec




3. COMPONENTS - Products Overview

3.1. PUMPS

Photo Symbol Ordering code Data Sheet

Vane Pump; Variable Displacement RE10515

PV7-1X/10-14RE01MC0-16 R900 580 381 PV7-1X/16-20RE01MC0-16 R900 580 382 PV7-1X/25-30RE01MC0-16 R900 580 383 PV7-1X/40-45RE37MC0-16 R900 580 384 PV7-1X/63-71RE07MC0-14 R900 506 808 PV7-1X/100-118RE07MC0-16 R900 506 809 PV7-1X/100-150RE07MC0-08 R900 561 846

Axial Piston Pump; Variable Displacement RE92711

A10VSO18,,, A10VSO28,,, A10VSO45… A10VSO71… A10VSO100… A10VSO140… E-A10VSO28… E-A10VSO45… E-A10VSO71… E-A10VSO100… E-A10VSO140…

Internal Gear Pump; Fixed Displacement

PGF Data Sheet RE10213 PGF1-2X/004RE01VU2 R900 086 163 PGF1-2X/005RE01VU2 R900 086 164 PGF2-2X/006RE01VE4 R900 932 265 PGF2-2X/008RE01VE4 R900 932 266 PGF2-2X/011RE01VE4 R900 932 271 PGF2-2X/022RE20VE4 R900 932 126 PGF3-3X/025RE07VE4 R900 932 088 PGF3-3X/032RE07VE4 R900 932 112 PGF3-3X/040RE07VE4 R900 932 111

PGH Data Sheet RE10223 PGH4-3X/050RE11VE4 R901 147 109 PGH5-3X/063RE11VE4 R901 147 122

Vane Pump; Fixed Displacement

PVV Data Sheet RE10335 PVV1-1X/018RA15UMB R900 940 633 PVV1-1X/027RA15UMB R900 936 954 PVV2-1X/040RA15DMB R900 942 115 PVV2-1X/055RA15DMB R900 936 290

https://brmv2.kittelberger.net/borexmvz2-internet/Detailview.jsp;jsessionid=4E98CCCA7329AE00385FDB476A4BEFAE.borex-tc?language=en-GB&publication=NET&&edition_id=1085118&document_id=1077637

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https://brmv2.kittelberger.net/borexmvz2-internet/Detailview.jsp;jsessionid=67FDDDE8844FE7386DF8973E780DC399.borex-tc?language=en-GB&publication=NET&ccat_id=20160&edition_id=1136714&document_id=1074454

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3.2. FILTERS 3.2.1. Pressure filters, INLINE DIN 24550 Data Sheet RE51421

Filter Rating m

Max. Filter Flow Capacity L/min. Filter Model Code Part Number

3 20 245LEN0063H3XLB00-V5.0-M-R4 R928030033

10 30 245LEN0063H10XLB00-V5.0-M-R4 R928030545

3 30 245LEN0100H3XLB00-V5.0-M-R4 R928030034

10 70 245LEN0100H10XLB00-V5.0-M-R4 R928030546

3 130 245LEN0160H3XLB00-V5.0-M-R6 R928030037

10 190 245LEN0160H10XLB00-V5.0-M-R6 R928030549 Electrical Indicator: In addition to a visual indicator, a dual electrical indictor is required. Switching points for 75% and 100% clog indication. Model code WE-2SP-M12X1, Part number R928028410.

https://dc-us.resource.bosch.com/media/us/products_13/product_groups_1/industrial_hydraulics_5/pdfs_4/re51421.pdf


3.2.2. Return Filters TANK MOUNTED, DIN 24550 Data Sheet RE51424

Return Filters DIN24550

Filter Rating µm


3 25 10TEN0063-H3XLA00V2.2-M-R4 R928019856

10 60 10TEN0063-H10XLA00V2.2-M-R4 R928019845

3 30 10TEN0100-H3XLA00V2.2-M-R4 R928019857

10 70 10TEN0100-H10XLA00V2.2-M-R4 * R928019846

Electrical Indicator: In addition to a visual indicator, a dual electrical indictor is required. Switching points for 75% and 100% clog indication. Model code WE-2SP-M12X1, Part number R928028410.

* This filter model to be used for the compact power units shown in Section 4.

https://brmv2.kittelberger.net/borexmvz2-internet/Detailview.jsp;jsessionid=37753E7A30539B0A19F7B91DFF13675A.borex-tc?language=en-GB&publication=NET&ccat_id=20270&edition_id=1134832&document_id=1114604



Return Filters

Filter Rating µm


3 70 10TEN0160-H3XLA00-V2,2-M-R5 R928041298

10 135 10TEN0160-H10XLA00-V2,2-M-R5 R928047167

3 130 10TEN0250-H3XLA00-V2,2-M-R6 R928019861

10 200 10TEN0250-H10XLA00-V2,2-M-R6 R928019850

Electrical Indicator: In addition to a visual indicator, a dual electrical indictor is required. Switching points for 75% and 100% clog indication. Model code WE-2SP-M12X1, Part number R928028410.

* This filter model to be used for the compact power units shown in Section 4.


3.3. DIRECTIONAL CONTROL VALVES 3.3.1. NG6 (D03) Four-Way Directional Control Valves 8 Watt (ANSI version) [Approved only at FCA (NAFTA) Plants]

Sub plate mounted, 24 V DC, P= 8 Watts, NBR seals, M12 connector on each solenoid. Pin Configuration: pin 4 24V, pin 3 0V, pins 2 & 1 bridged. Note : 8Watt is allowed for application usage under 200Bar and 30Watt for applications from 200Bar and higher

Data Sheet RE23178-00

Data Sheet RE08010 M12X1 K72L

Symbol Model Number & Description Part Number

P

b

T

A B

a

4WE6J6X/EG24N9K72L=AN SO407

Double Solenoid, 3-Position, A&B to Tank, Pressure Blocked

R901261658

P

b

T

A B

a

4WE6W6X/EG24N9K72L=AN SO407 Double Solenoid, 3-Position,

A&B Bleed to Tank, Pressure Blocked R901320275

b

P T

A B

4WE6D6X/EG24N9K72L=AN SO407

Single Solenoid, Spring Return R901275215

b a

P T

A B

4WE6D6X/OFEG24N9K72L=AN SO407 Double Solenoid, 2-Position, Detented R901275214

https://brmv2.kittelberger.net/borexmvz2-internet/Detailview.jsp;jsessionid=F6272DFF2F3CEB6871D190A5606BAF44.borex-tc?language=en-GB&publication=NET&&edition_id=1115172&document_id=1077026



3.3.2. NG6 (D03) Four-Way Directional Control Valves 8 Watt [Approved only at FCA (EMEA/LATAM/APAC) Plants]

Sub plate mounted, 24 V DC, P= 8 Watts, NBR seals, M12 connector on each solenoid. Pin Configuration: pin 4 24V, pin 3 0V, pins 2 & 1 bridged.

8Watt is allowed for application usage under 200Bar and 30Watt for applications from 200Bar and higher

Data Sheet RE23178-00



P

a

T

A B

b

4WE6J6X/EG24N9K72L SO407


R901235379

P

a

T

A B

b

Only ANSI Version = AN

a

P T

A B

4WE6D6X/EG24N9K72L SO407


a b

P T

A B

4WE6D6X/OFEG24N9K72L SO407 Double Solenoid, 2-Position, Detented R901379543




3.3.3. NG6 (D03) Four-Way Directional Control Valves 30Watt (ANSI version) [Approved only at FCA (NAFTA) Plants]

Sub plate mounted, 24 V DC, P= 30 Watts, NBR seals, M12 connector on each solenoid, pin configuration: pin 4 24V, pin 3 0V, pins 2 & 1 bridged. Note : 8Watt is allowed for application usage under 200Bar and 30Watt for applications from 200Bar and higher

Data Sheet RE23178



P

b

T

A B

a

4WE6J6X/EG24N9K72L=AN


R901235359

P

b

T

A B

a

4WE6W6X/EG24N9K72L=AN

Double Solenoid, 3-Position, A&B Bleed to Tank, Pressure Blocked

R901257360

b

P T

A B

4WE6D6X/EG24N9K72L=AN


b a

P T

A B

4WE6D6X/OFEG24N9K72L=AN

Double Solenoid, 2-Position, Detented

R901235363

http://dc-america.resource.bosch.com/media/us/products_13/product_groups_1/industrial_hydraulics_5/pdfs_4/re23178.pdf



3.3.4. NG6 (D03) Four-Way Directional Control Valves 30 Watt [Approved only at FCA (EMEA/LATAM/APAC) Plants]

Subplate mounted, 24 V DC, P= 30 Watts, NBR seals, M12 connector on each solenoid, pin configuration: pin 4 24V, pin 3 0V, pins 2 & 1 bridged.

Note : 8Watt is allowed for application usage under 200Bar and 30Watt for applications from 200Bar and higher

Data Sheet RE23178



P

a

T

A B

b

4WE6J6X/EG24N9K72L


R901235012

P

a

T

A B

b

4WE6W6X/EG24N9K72L Double Solenoid, 3-Position,


a

P T

A B

4WE6D6X/EG24N9K72L

Single Solenoid, Spring Return

R901235368

a b

P T

A B

4WE6D6X/OFEG24N9K72L Double Solenoid, 2-Position, Detented R901235353

http://dc-america.resource.bosch.com/media/us/products_13/product_groups_1/industrial_hydraulics_5/pdfs_4/re23178.pdf



3.3.5. Four-Way Poppet Directional Control Valves (Pre-Opening) (ANSI Version) [Approved only at FCA (NAFTA) Plants]

Sub plate Mounted, 24 V DC, 30 Watts, NBR Seals, M12 Connector on Each Solenoid M12 Pin Configuration: Pin 4 = 24V, Pin 3 = 0V, Pin 2 Bridged to Pin 1 Leak Free – Operating Pressure up to 420 bar, Maximum Flow: 25 L/min

Symbol Model Code & Description Part Number

4SEC6E1X/CG24N9K72L./P XXX=AN

Further details for check valves or requested cartridge throttle, see Data Sheet

RE22035

4SEC6EA1X/CG24N9K72L./P XXX=AN

4SEC6EB1X/CG24N9K72L./P XXX=AN

4SEC6E1X/CG24N9K72L=AN R901373042

4SEC6EA1X/CG24N9K72L=AN On demand

4SEC6EB1X/CG24N9K72L=AN On demand

3.3.6. Three-Way Poppet Directional Control Valves [Approved only at FCA (NAFTA) Plants] Sub plate Mounted, 24 V DC, 30 Watts, NBR Seals, M12 Connector on Each Solenoid M12 Pin Configuration: Pin 4 = 24V, Pin 3 = 0V, Pin 2 Bridged to Pin 1 Leak Free – Operating Pressure up to 350 bar, Maximum Flow: 25 L/min

Symbol Model Code & Description Part Number

M-3SED6CK1X/350CG24N9K72L=AN R901260862

M-3SED6UK1X/350CG24N9K72L=AN On demand

b a

b

b

b

b

b

a

a

a

a

a

a

a

b

b



3.3.7. NG10 (D05) Four-Way Directional Control Valves 35 Watt (ANSI version) [Approved only at FCA (NAFTA) Plants] Sub plate mounted, 24 V DC, P= 35 Watts, NBR seals, M12 connector on each solenoid, pin configuration: pin 4 24V, pin 3 0V, pins 2 & 1 bridged

Data Sheet RE23340



P

b

T

A B

a

4WE10J5X/CG24N9K72L /M =AN Double Solenoid, 3-Position,

A&B to Tank, Pressure Blocked R901349723

P

b

T

A B

a

4WE10W5X/CG24N9K72L /M =AN Double Solenoid, 3-Position,


b

P T

A B

4WE10D5X/CG24N9K72L /M =AN Single Solenoid, Spring Return R901350504

b a

P T

A B

4WE10D5X/OFCG24N9K72L /M =AN Double Solenoid, 2-Position, Detented R901401279

3.3.8. NG10 (D05) Four-Way Directional Control Valves 35 Watt [Approved only at FCA (EMEA/LATAM/APAC) Plants] Sub plate mounted, 24 V DC, P= 35 Watts, NBR seals, M12 connector on each solenoid, pin configuration: pin 4 24V, pin 3 0V, pins 2 & 1 bridged

Data Sheet RE23340



P

a

T

A B

b

4WE10J5X/CG24N9K72L Double Solenoid, 3-Position,

A&B to Tank, Pressure Blocked R901349475

P

a

T

A B

b

4WE10W5X/CG24N9K72L Double Solenoid, 3-Position,


a

P T

A B

4WE10D5X/CG24N9K72L Single Solenoid, Spring Return R901349576

a b

P T

A B

4WE10D5X/OFCG24N9K72L Double Solenoid, 2-Position, Detented R901349726






3.3.9. NG16 (D07) Four-Way Directional Control Valves 30 Watt (ANSI Version) [Approved only at FCA (NAFTA) Plants] Sub plate mounted, 24 V DC, P= 30 Watts, NBR seals, M12 connector on each solenoid, pin configuration: pin 4 24V, pin 3 0V, pins 2 & 1 bridged, internally piloted and internally drained.

Data Sheet RE24751


Symbol Model Number & Description Part Number 4WEH16J7X/6EG24N9ETK72L/B10=AN

Double Solenoid, 3-Position,

A&B to Tank, Pressure Blocked

R901257378

4WEH16W7X/6EG24N9ETK72L/B10=AN

Double Solenoid, 3-Position, A&B Bleed to Tank, Pressure Blocked

R901257388

4WEH16D7X/6EG24N9ETK72L/B10=AN

Single Solenoid, Spring Return

R901257392

3.3.10. NG16 (D07) Four-Way Directional Control Valves 30 Watt [Approved only at FCA (EMEA, LATAM, APAC) Plants] Subplate mounted, 24 V DC, P= 30 Watts, NBR seals, M12 connector on each solenoid, pin configuration: pin 4 24V, pin 3 0V, pins 2 & 1 bridged, internally piloted and internally drained.

Data Sheet RE24751


Symbol Model Number & Description Part Number 4WEH16J7X/6EG24N9ETK72L/B10


A&B to Tank, Pressure Blocked

R901241389

4WEH16W7X/6EG24N9ETK72L/B10


A&B Bleed to Tank, Pressure Blocked

R901251893

4WEH16D7X/6EG24N9ETK72L/B10







3.4. FLOW CONTROL MODULE 3.4.1. NG6 (D03) Double Throttle Sandwich Module Data Sheet RE27506


Dual Flow Control Module Meter in or

meter out throttling Z2FS6-2-4X/2Q

R900481622

A Port Flow Control Module Meter in or

meter out throttling Z2FS6A2-4X/2Q

R900427254

B Port Flow Control Module Meter in or

meter out throttling Z2FS6B2-4X/2Q

R900423224

Pilot Operated Check Valve Sandwich Module Data Sheet RE21548

Dual P.O. Check Module Z2S6-1-6X/ R900347495

A Port P.O. Check Module Z2S6A1-6X/ R900347498

B Port P.O. Check Module Z2S6B1-6X/ R900347501

3.4.2. NG6 (DO3) Check Valve Sandwich Module Data Sheet RE21534

P Port Check Module Z1S6P05-4X/N R901152381





3.4.3. NG6 (DO3) Pressure Reducing Direct Operating: Sandwich Module Data Sheet RE26570


P Port Pressure Reducing Module

ZDR6DP2-4X/25YM Adjustable to 25 Bar R900483785



A Port Pressure Reducing Module

ZDR6DA2-4X/25Y Adjustable to 25 Bar R900410808



B Port Pressure Reducing Module

ZDR6DB2-4X/25YM Adjustable to 25 Bar R900449839



3.4.4. NG10 (DO5) Pressure Reducing Direct Operating: Sandwich Module Data Sheet RE26585


P Port Pressure Reducing Module




A Port Pressure Reducing Module


ZDR10DA2-5X75Y Adjustable to 75 Bar R900438008


B Port Pressure Reducing Module







3.4.5. NG10 (D05) Flow Control Sandwich Modules Data Sheet RE27518


Dual Flow Control Module Meter in or

meter out throttling Z2FS10-5-3X/

R900989095

A Port Flow Control Module meter out throttling Z2FS10A5-3X/S2

R900571890

B Port Flow Control Module meter out throttling Z2FS10B5-3X/S2

R900989106

3.4.6. NG10 (DO5) Check Valve Pilot Operated Sandwich Module Data Sheet RE21553





P Port Check Module Z1S10P05-1-4X/N R901285818

T Port Check Module Z1S10TA05-2TB9-4X/N R901274777




3.4.7. NG6 (DO3) Pressure Relief Valve Pilot Operated Sandwich Module Data Sheet RE25751


P To T Pressure Relief Module

ZDB6VP2-4X/50 Adjustable to 50 Bar R900432804



A To T Pressure Relief Module

ZDB6VA2-4X/50 Adjustable to 50 Bar R900431678



B To T Pressure Relief Module

ZDB6VB2-4X/50 Adjustable to 50 Bar R900430645



3.4.8. NG10 (DO5) Pressure Relief Valve Pilot Operated Sandwich Module Data Sheet RE25761


P To T Pressure Relief Module




A To T Pressure Relief Module




B To T Pressure Relief Module







3.4.9. NG16 (D07) Flow Control Sandwich Modules

Data Sheet RE27526 Symbol Model Number & Description Part Number

Dual Flow Control Module Meter in throttling Z2FS16-8-3X/S

R900470529

Dual Flow Control Module Meter out throttling Z2FS16-8-3X/S2

R900473688




3.4.10. INLINE CHECK VALVES 1179-1 G thread ports Data Sheet RE20378

3.4.11. THROTTLE CHECK VALVE - MK Data Sheet RE27219

Inline Throttle check valve Part No.

MK 6 G1X R901353428 MK 8 G1X R901226940 MK 10 G1X R900420289 MK 15 G1X R901410695 MK 20 G1X R901224660

Port Size Cracking Pressure (Bar)

Model Code (Series 1X)

Part Number (Series 1X)

G ¼ 0.5 S 6 A05-1X/450J3 R901454046 G 3/8 0.5 S 8 A05-1X/450J3 R901454052 G ½ 0.5 S 10 A05-1X/450J3 R901424189 G ¾ 0.5 S 15 A05-1X/450J3 R901454065 G 1 0.5 S 20 A05-1X/450J3 R901424190

G 1 ¼ 0.5 S 25 A05-1X/420J3 R901454079 G 1 ½ 0.5 S 30 A05-1X/420J3 R901454090


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3.4.12. Flow Control Valve Sub Plate Mounted Data Sheet RE28163

Photo Symbol Ordering code

Part Number Flow control valve

2FRM6B76-3X/1,5QMV R900 210 900

2FRM6B76-3X/3QMV R900 209 088

2FRM6B76-3X/6QMV R900 205 527

2FRM6B76-3X/1,5QRV R900 211 379

2FRM6B76-3X/3QRV R900 211 776

2FRM6B76-3X/6QRV R900 205 528

2FRM10-3X/25LB R900 423 256

2FRM10-3X/50LB R900 423 261



3.5. ACCUMULATORS 3.5.1. Diaphragm Accumulators Data Sheet RE50150

Volume (Liters)

Pressure Rating (Bar)

Ports ISO 1179-1 G thread

Model Code Part Number

1.0 200 G ½ HAD1.0-200-1X/2G04E-1N111-BA R901164367

3.5.2. Bottom Repairable Bladder Accumulators FCA (EMEA/LATAM/APAC) Plants Data Sheet RE50171 (CE)

FCA (NAFTA) Plants Data Sheet RA50175 (ASME)

** Note: The accumulator model codes will require a suffix code dependent upon the country where the accumulator is being shipped. Replacing ** in the model code for Europe will be a CE Suffix. For the U.S. and Mexico a 7X series accumulator with G ports and the ASME suffix should be selected. For Brazil, an NR-13 certification is required. For China SELO certification must be selected. Please check with Bosch Rexroth for the requirements of other countries.

Volume (Liters)




1 350 G 1 ¼ HAB1-350-6X/0G05G-2N111-BA R901435300

2,5 350 G 1 ¼ HAB2,5-350-6X/0G07G-2N111-CE R901435301

4 350 G 1 ¼ HAB4-350-6X/0G07G-2N111-CE R901435302

6 350 G 1 ¼ HAB6-350-6X/0G07G-2N111-CE R901435303

10 330 G 2 HAB10-330-6X/0G09G-2N111-CE R901435304

20 330 G 2 HAB20-330-6X/0G09G-2N111-CE R901435305

24 330 G 2 HAB24-330-6X/0G09G-2N111-CE R901435306

32 330 G 2 HAB32-330-6X/0G09G-2N111-CE R901435307

50 330 G 2 HAB50-330-6X/0G09G-2N111-CE R901435308

Volume (Liters)




4 207 G 1 ¼ (BSPP) HAB4-207-7X/0G07G-2N111-ASME On Demand

10 207 G 2 (BSPP) HAB10-207-7X/0G09G-2N111-ASME R978059650

345 G 2 (BSPP) HAB10-345-7X/0G09G-2N111-ASME R978059646


345 G 2 (BSPP) HAB20-345-7X/0G09G-2N111-ASME R978059660


345 G 2 (BSPP) HAB35-345-7X/0U09G-2N111-ASME R978059611


http://www.boschrexroth.com/various/utilities/mediadirectory/download/index.jsp?object_nr=RE50171-B

https://dc-us.resource.bosch.com/media/us/products_13/product_groups_1/industrial_hydraulics_5/pdfs_4/ra50175.pdf


3.5.3. Accumulator Safety Isolation Blocks The Accumulator Safety Blocks are used for safety, isolation and unloading of hydraulic accumulators. Chrysler and Fiat specifications require a safety block to be provided for each accumulator application. Each safety block is equipped with a manual isolation valve with locking handle, manual unloading valve, safety relief valve and a 24 V solenoid unloading valve.

Note: Per FCA specification, a pressure gauge is required between the Accumulator Safety Block and the Accumulator. Data Sheet RE50131

Unloading Valve (4) Plug Adapter Description Part Number

DIN Connector Adapter Equipped with Z-Diode and Indicator Light (DIN to M12 Adapter to be Added to the Solenoid Valve)

R901 034 223

3.5.4. Accumulator Accessories

Description Volume QTY Part Number

Clamp 1.0 Liter 1 1 531 316 019 Clamp 4...6 Liter 2 1 531 316 022 Clamp 10 Liter 1 1 531 316 026 Clamp 20…35 Liter 2 1 531 316 026 Support Bracket 10…35 Liter 1 1 531 334 008 Rubber Support Ring 10…35 Liter 1 1 530 221 042 Charging Kit 0 538 103 014 Charging Kit – 5X R978046091

Accumulator Size


Size Model Code Part Number

1. L G ½ DN 10 ABZSS 10 E 3X / 200E / S30 G24 K4 V 104 R901300615

4 - 6 L G 1 ¼ DN 10 ABZSS 10 E 3X / 210E / S12 G24 K4 V 104 R901105602

4 - 6 L G 1 ¼ DN 10 ABZSS 10 E 3X / 330E / S12 G24 K4 V ---- R900709609

4 - 6 L G 1 ¼ DN 10 ABZSS 10 E 3X / 350E / S12 G24 K4 V 104 R901384008

10 - 20 L G 2 DN 20 ABZSS 20 E 3X / 210E / S13 G24 K4 V 104 R901103634

35 L G 2 DN 30 ABZSS 30 E 3X / 210E / S309 G24 K4 V 104 R901212503

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3.6. SUBPLATES Steel or Ductile Iron Sub plates with Metris threads for valve bolt down Data Sheet RE45100

Size


Description

Model Code

Part Number

NG6 (D03)

G ¼ Bottom Ported G341/01 R900424447

G 3/8 Bottom Ported G342/01 R900424448

G ½ Bottom Ported G502/01 R900455110

NG10 (D05)

G ½ Bottom Ported G67/01 R900424460

G ¾ Bottom Ported G534/01 R900467259

NG16 (D07)

G ¾ Bottom Ported with X & Y Ports G172/01 R900424410

G 1 Bottom Ported with X & Y Ports G174/01 R900424413

3.7. MANIFOLDS 3.7.1. Manifolds - NG6 (DO3) Ductile Iron Manifolds with Bottom Cylinder Ports and Side Gauge Ports Data Sheet RE48107

Size


Number of Stations


NG6 (D03)

P & T: G ¾ A & B: G 1/2 A B Test Points G1/4 P & T: Both ends A & B: Bottom Face Test Points: one on each side.

2 2HSR06-3X/01DS08FE/ZN8& R900188031

3 3HSR06-3X/01DS08FE/ZN8& R900188032

4 4HSR06-3X/01DS08FE/ZN8& R900188033

5 5HSR06-3X/01DS08FE/ZN8& R900188034

6 6HSR06-3X/01DS08FE/ZN8& R900188035

7 7HSR06-3X/01DS08FE/ZN8& R900188036

Alternate Manifolds (for North America or as requested by other regions) Data Sheet RA09907

P & T: G 1 A & B: G 1/2 A B Test Points G1/4 P & T: Both ends A & B: Bottom Face Test Points: one on each side.

2 ABM6PN-1X/02D2-01GM R978908745

3 ABM6PN-1X/03D2-01GM R978908746

4 ABM6PN-1X/04D2-01GM R978908747

5 ABM6PN-1X/05D2-01GM R978908748

6 ABM6PN-1X/06D2-01GM R978908749

7 ABM6PN-1X/07D2-01GM R978908750

3.7.2. Manifolds - NG10 (DO5) Ductile Iron Manifolds with Bottom Cylinder Ports and Side Gauge Ports Data Sheet RE48110

Size


Number of Stations


NG10 (D05)

P & T: G 1 A & B: G 3/4 A B Test Points G1/4 P & T: Both ends A & B: Bottom Face

2 2HSR10-3X/01DS08FE/ZN8& R900196376

3 3HSR10-3X/01DS08FE/ZN8& R900196377

4 4HSR10-3X/01DS08FE/ZN8& R900196378






Test Points: one on each side.

5 5HSR10-3X/01DS08FE/ZN8& R900196379

6 6HSR10-3X/01DS08FE/ZN8& R900196380

Alternate Manifolds (for North America or as requested by other regions) Data Sheet RA09907

P & T: G 1 A & B: G 3/4 A B Test Points G1/4 P & T: Both ends A & B: Bottom Face Test Points: one on each side.

2 ABM10PN-1X/02D3-01GM R978908753

3 ABM10PN-1X/03D3-01GM R978908754

4 ABM10PN-1X/04D3-01GM R978908755

5 ABM10PN-1X/05D3-01GM R978908756

6 ABM10PN-1X/06D3-01GM R978908757

3.7.3. Manifolds - Cover Plates HAS series CP6 series Data Sheet RE48042 Data Sheet RA09907

Size Description Model Code Part Number

NG6 (D03)

Cover Plate (Blanking Plate) with Metric Bolts

HSA06A001-3X/M00 R900316232

Alternate for North America or as requested by other regions

CP6NN-1X/D01 R978839953

NG10 (D05)


HSA10B001-3X/M00 R900302150


CP10NN-1X/D01P R978839951

NG16 (D07)


HSA16B001-3X/M00 R900381272


CP16NN-1X/D01 R978907735

Photo Symbol Ordering code Rexroth Part Data Sheet

Adaptor plates -

NG 10 / 6 R900527515 RE48045

(Example) Sandwich plate with different configurations

Ordering FCA (EMEA, LATAM, APAC) Only

HZS 06 …

RE48050

Cover plates -

HSA 06 A 001 3X/M00 R900316232 RE48042

HSA 10 B 001 3X/M00 R900302150 RE48042



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http://www.boschrexroth.com/RDSearch/rd/r_48045/re48045_2006-06.pdf

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3.8. PRESSURE RELIEF VALVES

Data Sheet RE25402

Photo Symbol Ordering code Rexroth Part Data Sheet

Pressure relief valve

DBDS 6 K1X/210E R900 768 637 RE 25402 DBDS 10 K1X/210E R900 768 636 RE 25402 DBDS 20 K1X/210E R900 769 368 RE 25402 DBDS 6 K1X/330VE R900 768 635 RE 25402

Pressure relief valve; Direct operated

DBDA 6 K1X/100 R900 425 080 RE 25402 DBDA 6 K1X/200 R900 425 081 RE 25402 DBDS6K1X/25 R900 420 245 RE 25402 DBDS6K1X/50 R900 423 727 RE 25402 DBDS6K1X/100 R900 423 723 RE 25402 DBDS6K1X/200 R900 423 724 RE 25402 DBDS10K1X/25 R900 420 276 RE 25402 DBDS10K1X/50 R900 424 153 RE 25402

3.9. PRESSURE SEQUENCE VALVE MODULAR Data Sheet RE26088

Photo Symbol Ordering code Rexroth Part

Pressure sequence Valve - Z ; Sandwich plate

ZDZ6DP2-4X/210-180YM R901074698

3.10. ON / OFF WATER VALVES

Data Sheet RE50235

Photo Symbol Ordering FCA (EMEA,LATAM, APAC) Only

On Off Water Valve / Water Cooler

ABZ AW Series





3.11. PRESSURE RELIEF & REDUCING VALVES

Photo Symbol Ordering code Data Sheet

Pressure reducing valve, direct operated

DR 10 DP … RE26580

Pressure reducing valve, pilot operated

DR …5X… RE26892 Size 10, 16, 25 and 32

Pressure reducing valve, pilot operated

DR …4X…Size 10 & 25 Only RE26893

Pressure cut-off valve, pilot operated-pump connection in P or A

DA6V… RE26405






3.12. PROPORTIONAL DIRECTIONAL VALVES & CLOSED LOOP CONTROLLERS

Photo Symbol Ordering code Rexroth Part

Proportional directional valves with integrated electronics

WRKE … RE29075

WRAE … RE29055

WREE … RE29061

WRZE … RE29115

High Response Servo Valve with Integrated Digital Axis Controller

IACR...SERIES RE29391

[at FCA (NAFTA) Profi-Net Only]

4/3 Proportional Directional Valve, Direct Operated, with pQ Functionality

IACP…SERIES RE29050

Proportional pressure control valves

(Z)DER … RE29179

Proportional pressure relief valves

(Z)DBEE … RE29158

DBETE … RE29162

DBETRE … RE29166

Hydraulic Closed Loop Controller

HNC Series 3X RE30139

VT-HACD Series RE30543-10-Z














3.13. COMPONENTS - Miscellaneous

Photo Symbol Ordering code Rexroth Part / Data Sheet

Pressure cut-off valve, pilot operated

DA10…30..

RE26411 and

DAW10…30…

Pressure gauge - Isolator valve

AB21-14 R900 012 965

AF6EP4X/XV R900 978 704 RE50031

Multi-circuit gauge isolator

MS 6 A2X/V R900 346 295 -

Pressure Gauge

Pressure Gauge PSI/MPA FCA [Global] plants

ABZM Series RE50205

Ordering No. Includes Operating Pressure in Green

2,300 PSI/MPA Center Back Mount R978056598

2,300 PSI/MPA Lower Back Mount R978056597

1,500 PSI/MPA Center Back Mount R978056599

1,500 PSI/MPA Lower Back Mount R978056600

Air Breather

TLF111 RE51415

Float Switch / Breather With filter, level and temperature monitor

ABZ MS-37 series RE50216


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3.14. HYDRAULIC CYLINDERS, ISO 6020/2

Data Sheet RE17049

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4. SYSTEMs & SOLUTIONs

4.1. Hydraulic POWER UNIT Reference "FCA (NAFTA) chemical management chart" for proper fill port fitting size per fluid type used.

Preferred Hydraulic power unit design requires Pump Motor group to be mounted horizontal under or on top of reservoir.

All Power Units will comply with FCA (NAFTA) Sound & Vibration Specifications as listed in Specification.

Power Units can employ a PV7 variable volume vane pump or A10 Axial piston for the main system.

A 2nd gear or vane pump may be used for the re-circulation / filtration loop. Should a heat exchanger be required for an application, a heat exchanger will be added in the re-circulation line.

For maintenance purposes, the pump case drain line will be tubed to the return side of the reservoir.

Should accumulators be required for an application, they can be added to the power unit along with lockable accumulator safety isolation block. Please contact Bosch Rexroth for application assistance.


Tank ( Volume in Liter )

L L1 B B1 H H1 H2

100 635 1005 460 660 660 1100 1420

160 810 1255 590 850 660 1160 1425

250 1010 1460 690 890 680 1180 1445

400 1515 1955 735 1050 680 1365 1445

630 1515 1960 945 1250 770 1560 1515

800 2012 2900 900 1100 770 1312 2070

1000 2012 2900 1065 1255 800 1444 2100

4.1.1. Horizontal Power Units with STEEL Tank for FCA-PT Plants as DIN Specification Horizontal power units may be used for a FCA Powertrain application provided that three design considerations have been met. The three design considerations listed in FCA’s Global Hydraulic Specification are: A) Altitude: Horizontal power units may not be used when the plant elevation exceeds 1000 meters. B) Sound Level: The complete power unit sound level must be below 75 dB(A). C) Fluid Viscosity: The hydraulic fluid viscosity required for the application must not cause pump cavitation. Horizontal power units can be provided in a number of different reservoir sizes, 100, 160 & 250 Liters. A 400L power unit is also available when the pump drive speed is 1500 RPM (for EMEA/LATAM, APAC) and 1800 RPM (for NAFTA). Each power unit is equipped with an independent offline filtration circuit. Should a heat exchanger be required for an application a plate style heat exchanger would then be added in the offline circuit. The power unit is equipped with both dual level and dual temperature switches. If required for the application an accumulator with a lockable safety isolation block must be installed on the power unit. Please consult with Bosch Rexroth for design assistance. The specified dimensions are approximate, exact dimensions will be provided after receipt of order. Please take into consideration a removal space for the components assembled on the unit.


4.1.2. Components for HORIZONTAL POWER UNIT MATRIX Steel Tank 4.1.2.A. Variable Vane – Pump Motor Group sizing using 1500 RPM Electric Motor

[FCA (EMEA,LATAM,APAC)] Main Pump Nominal

Q@1500 RPM

Recirc. Pump Nominal

Q2 @ 1500 RPM

HP @ 1500 PSI (103.5 Bar)

Tank Size Liter

(Gallon) Main Vane Pump (Variable Volume)

Recirculating Pump GPM LPM GPM LPM

Main Pump HP (KW)

Total HP (KW) Both Pumps

100 (30)

PV7-1X/16-20 (20cc)

1.22 cubic in

AZPF 1X – 11 (11 cc)

GEAR PUMP 7.9 30 4.6 16.5 7.7 (5.7)

8.3 (6.2)

230 (60)

PV7-1X/25-30 (30cc)

1.83 cubic in

AZPF 1X – 19 (19 cc)

GEAR PUMP 11.9 45 7.9 28.5 11.6 (8.6)

12.6 (9.4)

230 (60)

PV7-1X/40-45 (45cc)

2.75 cubic in

AZPF 1X – 19 (19 cc)

GEAR PUMP 17.9 67.5 7.9 28.5 67.5 (17.4)

18.4 (13.7)

400 (100)

PV7-1X/63-71 (71cc)

4.33 cubic in

PVV1-1X/027 VANE PUMP 28.1 106.5 10.6 40.5 27.3 (20.4)

28.7 (21.4)

4.1.2.B. Variable Vane - Pump Motor Group sizing using 1800 RPM Electric Motor

[FCA (NAFTA) USE ONLY] Main Pump Nominal

Q @1800 RPM Recirc. Pump Nominal

Q2 @1800 RPM HP@1500 PSI

(103.5 Bar)

Tank Size Liter


Recirculating

Pump GPM LPM GPM LPM

Main pump HP (KW)

Total HP (KW) Both pumps

100 (30)

PV7-1X/16-20 (20cc)

1.22 cubic in

AZPF 1X - 11 (11 cc)

GEAR PUMP 9.5 36 5.5 19.8 9.2 (6.9)

10.0 (7.4)

230 (60)

PV7-1X/25-30 (30cc)

1.83 cubic in

AZPF 1X - 19 (19 cc)

GEAR PUMP 14.3 54 9.5 34.2 13.9 10.3)

15.1 (11.3)

230 (60)

PV7-1X/40-45 (45cc)

2.75 cubic in

AZPF 1X – 19 (19 cc)

GEAR PUMP 21.4 81 9.5 34.2 20.8 (15.5)

22.1 (16.5)

400 (100)

PV7-1X/63-71 (71cc)

4.33 cubic in

PVV1-1X/027 VANE PUMP 33.7 127.8 12.8 48.6 32.8 (24.5)

34.5 (25.7)

Reservoir Capacity L1 B1 H1 100 Liter 1005 660 1100 160 Liter 1255 850 1160 250 Liter 1460 890 1180

400 L (1000 RPM) 1955 1050 1345

Sound Level: Less than 75 dB(A) Fill Point: Quick Disconnect Coupling Installed before

return filter for filling HPU. See FCA Chemical Management Chart for coupler size based on plant location and oil type used.

Ports: ISO 1179-1 (G thread) Labels: Per FCA Spec. Options: Accumulator circuit, heat exchanger circuit Tubing/Fittings: Trivalent Chrome metric tubing & metric E02

fittings per FCA Spec.


4.1.2.C. Axial Piston – Pump Motor Group sizing using 1500 RPM Electric Motor

[FCA (EMEA,LATAM,APAC)] Main Pump Nominal

Q @1500 RPM Recirc. Pump Nominal

Q2 @1500 RPM Power

@1500 PSI (103.5 Bar)

Tank Size Liter


Recirculating

Pump GPM LPM GPM LPM

Main pump HP (KW)


100 (30)

A10VSO 18 (18cc)

AZPF 1X – 005 (8 cc)

GEAR PUMP 7.1 27 3.3 12 6.9 (5.2)

7.4 (5.5)

230 (60)

AA10VSO 28 (28cc)

AZPF 1X – 011 (11 cc)

GEAR PUMP 11.1 42 4.6 16.5 10.8 (8.0)

11.4 (8.5)

230 (60)

AA10VSO 45 (45cc)

AZPF 1X – 16 (16 cc)

GEAR PUMP 17.9 67.5 6.7 24 17.4 (12.9)

18.2 (13.6)

400 (100)

AA10VSO 71 (71cc)

PVV1-1X/027 VANE PUMP 28.1 106.5 10.6 40.5 27.3 (20.4)

28.7 (21.4)

4.1.2.D. Axial Piston – Pump Motor Group sizing using 1800 RPM Electric Motor [FCA (NAFTA) USE ONLY]

Main Pump Nominal Q @1800 RPM

Recirc. Pump Nominal Q2 @1800 RPM

Power @1500 PSI (103.5 Bar)

Tank Size Liter

(Gallon) Main Piston Pump (Variable Volume)

Recirculating Pump GPM LPM GPM LPM

Main pump HP (KW)


100 (30)

A10VSO 18 (18cc)

AZPF 1X – 005 (8 cc)

GEAR PUMP 8.6 32.4 4.0 14.4 8.3 (6.2)

8.8 (6.6)

230 (60)

AA10VSO 28 (28cc)

AZPF 1X – 011 (11 cc)

GEAR PUMP 13.3 50.4 5.5 19.8 13.0 (9.7)

13.7 (10.2)

230 (60)

AA10VSO 45 (45cc)

AZPF 1X – 16 (16 cc)

GEAR PUMP 21.4 81 8.0 28.8 20.8 (15.5)

21.9 (16.3)

400 (100)

AA10VSO 71 (71cc)

PVV1-1X/027 VANE PUMP 33.7 127.8 12.8 48.6 32.8 (24.5)

34.5 (25.7)


4.1.3. COMPACT Power Units with ALUMINUM tank for FCA-PT Plants ABSKG Series Vertical Power Units

For special applications such as clamping, a 40L or 60L vertical power unit is available. The use of the these compact power unit requires the approval of the responsible FCA Controls Engineer. The ABSKG series vertical power unit is provided with a fixed displacement gear pump to charge a small accumulator, the pump is then unloaded or tuned off. The power unit is equipped with both dual level and dual temperature switches. Please consult with Bosch Rexroth for design assistance.

The compact power units are designed to a modular concept. Refer to Data Sheet RE51013 Refer to NAFTA Compact Power Unit Conditions:

• Maximum Operating Pressure: p < 120 Bar (Higher pressure for clamping applications only if approved by the controls engineer)

• Rotational Speed: n = 1200 RPM (nominal) • Operating Mode: S3 – Intermittent (ED 20% 10minutes)

Basic Power Unit: • Internal Gear Pump Type PGF according to our chapter 3.1 • Aluminum Reservoir with Usable Content 40 Liters or 60 Liters • Required Sensor Technology

Control Varients: • Pressure Relief Circuit • Pump Unloading Circuit or E-Motor On/Off • Accumulator Charging Circuit • Accumulator Isolating Block • Diaphragm Accumulator up to 1.0 Liters • Bladder Accumulator up to 4.0 Liters • Compact power unit in vertical design (V1), horizontal design (B5) is also approved

The specified dimensions are approximate, exact dimensions will be provided after receipt of order. Please take into consideration a removal space for the components assembled on the unit.

If accumulator is installed: Accumulator isolation block label to be installed nearby: R900 740 807 (manual unloading) or R900 740 805 (electrical unloading)

Dimensions [mm]

Nominal Reservoir size 40 Liter 60 Liter

L 560 620 B 415 480 H 684 833

https://md.boschrexroth.com/modules/BRMV2PDFDownload-internet.dll/RE51013_2016-12.pdf?db=brmv2&lvid=1199553&mvid=12793&clid=20&sid=2460954D0827ACABE94C46546EC4D849.borex-tc&sch=M&id=12793,20,1199553

https://www.boschrexroth.com/en/us/products/product-groups/industrial-hydraulics/power-units/ppppv-power-units/index


4.2. ENERGY SAVING with Bosch Rexroth Technologies Bosch Rexroth since some years ago is thinking and realizing its Technologies in Energy Saving philosophy; which means not only thinking of products and solutions to reduce the pure costs of energy bill on the usage of machinery, but also a greater reduction in indirect consumption, such as temperature, noise and waste from the plant.

All our technologies where you will see our logo are products born, sized and produced by Bosch Rexroth already in Energy Efficiency mind.

As is our logo that you could see on all our solution for safety movements, electrical one and Hydraulic too; and all our products born and realized in to Safety functionality will have the logo of Safety on Board by Bosch Rexroth. For the specific use of Energy Efficiency solution by Bosch Rexroth on FCA-PT (Fiat Chrysler Automobiles Powertrain) plants in the world for hydraulics application we suggest our system named Sytronix :

In order to assess the possible size and dimensional standards for the FCA Global Powertrain, please contact us from time to time to assess the benefits and preview for correct sizing.

For more details on the proposals for Bosch Rexroth in the field of Energy Efficiency, please refer to the link https://www.boschrexroth.com/en/xc/trends-and-topics/energy-efficiency/index in English or link to https://www.boschrexroth.com/it/it/scenari-e-tendenze/efficienza-energetica/index in the Italian language.

FCA (NAFTA, EMEA, LATAM, APAC) prefers FcP solution Approval / Deviation of the Sytronix FcP 5020 shall be agreed with by FCA Electrical Engineer

https://www.boschrexroth.com/en/xc/trends-and-topics/energy-efficiency/index

https://www.boschrexroth.com/it/it/scenari-e-tendenze/efficienza-energetica/index


4.2.1. SYTRONIX FcP-5020 Variable Speed Pump Drive Systems FcP systems are designed for constant pressure applications and distinguish themselves by a very low noise level. Application examples include machine tools and small power units up to 18.5 kW. FcP-5020 is based on the robust frequency converter EFC-5610 and has been optimized for small power units. Using the quiet internal gear pump PGF or PGH, lower operating noises can be achieved without encapsulation. Sensors like level switches, oil temperature and filter monitoring of the power unit can be directly connected at the frequency converter and evaluated. This reduces the necessary cabling and accelerates the installation of the power unit in the machine. The FcP-5020 has been designed into pre-configured motor-pump assemblies consisting of:

• Hydraulic Internal Gear Pump, Model PGF and PGH • Electric Motor, Asychronous, IEC, IE3 Premium Efficiency • Vriable Frequency Converter, Model EFC-5610 • Pressure Transducer, Model HM20-2X • Motor Pump Standard Coupling Package

The Sytronix FcP-5020 can be applied under the following conditions: • Electric Motor 230 / 460 VAC, 60 Hz, IEC, IE3 • Maximum Working Pressure P < 120 Bar (Higher pressure P < 200 Bar only if approved by the controls engineer) • Rotational Speed : up to 3200 RPM • Operating Mode : Continuous • Sound Level Not to Exceed Specified Values as per “SP-F-Hydraulics”

Selected system must be approved by FCA Controls Engineer Please consult with Bosch Rexroth for design assistance Refer to the Following Documentation:

• Sytronix Catalog R999000332 (2016-09) • Frequency Converter Catalog R999000430 (2015-11) • FcP-5020 Quick Start Guide R912006684 (Edition 2)

https://brmv2.kittelberger.net/borexmvz2-internet/Detailview.jsp;jsessionid=D59598DD861E33B45DD4A30A0021A495.borex-tc?language=en-GB&publication=NET&ccat_id=23910&edition_id=1141273&document_id=1130757

https://md.boschrexroth.com/modules/BRMV2PDFDownload-internet.dll/R999000430_FU_EFC_3610_5610_2016_11_media.pdf?db=brmv2&lvid=1201365&mvid=12793&clid=20&sid=C884CE0710CB4E0A8E6BFD8587B4A3E3.borex-tc&sch=M&id=12793,20,1201365

https://brmv2.kittelberger.net/borexmvz2-internet/Detailview.jsp;jsessionid=D59598DD861E33B45DD4A30A0021A495.borex-tc?language=en-GB&publication=NET&ccat_id=23910&edition_id=1141046&document_id=1138907


5. NOTE … How to look for Official documentation from BOSCH REXROTH.

At the following link you can find every data sheet, catalogue and Multilanguage version of official documents released by Bosch Rexroth.

1st Write in DATASHEET No.

2nd Press SEARCH

http://www.boschrexroth.com/various/utilities/mediadirectory/index.jsp?language=en-GB&ccat_id=79960&remindCcat=on&publication=NET


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Documents

GLOBAL HYDRAULICS PROGRAM BOOK · GLOBAL HYDRAULICS PROGRAM BOOK . This is a common document valid within . Fiat Chrysler Automobiles Powertrain . Version 1.14 . Release Date: October