Electric Drives Linear Motion and
and Controls Hydraulics Assembly Technologies
LLC Load Limiting Control
Application Software
Data sheet
Version 10 (LLCB) and Version 30 (LLCA)
Electronic load limiting control for
power management in hydraulic systems
Inhalt
Type code 2
Variant LLCA 2
Parameterization and diagnostics 6
Required components 6
LLCA connection diagram (without CAN bus) 7
LLCA connection diagram (with CAN bus) 8
Variant LLCB 9
Functional description 9
Parameterization and diagnostics 10
LLCB connection diagram 11
Required components 12
Safety instructions 12
Pneumatics Service
RE 95 310/01.09
replaces: 03.06
Features
– The electronic load limiting control LLC is an easy-to-custom-
ize software system for managing power in hydraulic systems.
– The load limiting control LLC always matches the power input
of an adjustable axial piston pump with the available power
from the internal combustion engine.
– It prevents overloading of the internal combustion engine.
– The axial piston pump converts the maximum available power
at all times.
– Two variants of the load limiting control LLC are available: Vari-
ant A "Universal software" and variant B "Slew drive mode" for
controlling a slew drive irrespective of the diesel engine speed.
– The load limiting control LLC is designed for axial piston pump
from Rexroth.
– Adjustable parameters enable the user to easily customize the
software for different configurations of pumps, internal com-
bustion engines, sensors and machines.
– The load limiting control LLC is suitable for diesel engines with
or without a CAN-bus interface, protocol SAE J1939.
– Diagnostics and parameterization are performed with the
BODAS service PC software.
2/12 Bosch Rexroth AG LLC Load Limiting Control RE 95310/01.09

Type code
AS/ LLC 10
01 02 03 04

Type
01 Application software AS/

Software
02 Load Limiting Control LLC

Variante A
Load limiting control for two pumps
03
Option: CAN bus, Option: Constant speed control A

Variante B
Load limiting control for one pump, Option: Slew drive
03
Option: Power mode (switchable diesel power and speed drop) B

Version
LLCB 10
04
LLCA 30
Ordering information
The AS/LLC application software must only be used with the RC2-2/20 controller (variant B) or RC2-2/21 controller (variant A)
and other add-on components (see page 11). When placing an order, the hardware and software type codes should be linked with
a "+".
Example: RC2-2/21+AS/LLCA30

• With positive ID, the hydraulic system includes one or two

Variant LLCA
With the LLCA electronic load limiting control, it is possible to
design the size of the diesel engine in the hydraulic system for
the average power requirement and to reduce the power input
of the individual consumers (pumps) in the event of an over-
load. Thus, the load limiting control ensures optimum use of
power from the diesel engine with varying loads.
A10VO variable displacement pumps with an FHD pump
controller.
The total installed pump powers exceeds the diesel engine
power.
The controller controls the pressure reduction valves (DRE)
which in turn override the pilot pressures of the pumps,
thereby reducing the flow rate.

The electronic load limiting control supports different hydraulic
concepts and different diesel engine configurations. These
concepts can be used in any combination.
The electronic load limiting control is designed for controlling
variable displacement pumps in an open hydraulic circuit.
A third, uncontrolled pump can be used with both hydraulic
concepts. This pump has priority in the system. As a result, it
receives the power it requires with no reduction. Whatever pow-
er remains available is then divided between pumps 1 and 2.
Two different diesel engine configurations can be used:

A distinction is made between the following hydraulic concepts
for the purpose of control:
• With negative ID, the hydraulic system includes one or two
A11VO variable displacement pumps or variable double
pumps A8VO or A20VO, each with hydraulic power and load
limiting controllers (LG1, LE, LA1).
Each pump is set to 100 % of the available diesel power.
The controller controls the pump controller (LE) and/or the
pressure reduction valves (DRE) directly; the latter turn
down the setting on the pump power controller (LG1, LA1)
by means of an increased pilot pressure.
• In the case of diesel engines without a CAN-bus inter-
face, the controller receives the diesel engine's specified
speed from an angle sensor (accelerator pedal position as
specified speed) or from a fixed speed value set in the con-
troller. The actual speed is measured using a speed sensor
on the starter gear rim.
• In the case of diesel engines with a CAN-bus interface,
the controller receives the necessary data for the load limit-
ing control (specified and actual speed and/or torque and
engine temperature) directly via the CAN bus.
It is also possible to use a combination of analog sensors
and CAN-bus data.
RE 95310/01.09 LLC Load Limiting Control Bosch Rexroth AG 3/12

Variant LLCA
RC2-2/21 controller
with LLCA software
Error
lamp

BODAS service
PC software

Speed sensor

Angle
sensor

Pumps Optional
Diesel engine without
A8VO…LA1 or third pump
CAN interface
A11VO…LG1 / LE or
A20VO…LG1 / LE or
A10VO…FHD

Figure 1: Typical configuration for LLCA without CAN-bus interface

CAN-bus interface

RC2-2/21 controller
with LLCA software
BODAS service
PC software

Error
lamp

Optional
third pump on
power take-off

Diesel engine with Pumps

CAN interface A8VO…LA1 or
A11VO…LG1 / LE or
A20VO…LG1 / LE or
A10VO…FHD

Figure 2: Typical configuration for LLCA with CAN-bus interface

4/12 Bosch Rexroth AG LLC Load Limiting Control RE 95310/01.09

Variant LLCA
Safety switch

Actual speed

Specified Calculation Evaluation Load limiting Pump Pump 1

speed Speed drop Speed drop controller power
Pump 2
sharing

Power
mode 2/3
Temperature
Ext. power
limiting
Power
sharing 1
Power
sharing 2
Limp home mode
activated

Figure 3: How the LLCA load limiting control works

Functional description
Figure 3 illustrates how the load limiting control works: • As long as the total of the hydraulic powers does not exceed
the installed diesel power, the speed drop will not exceed
• The load limiting control calculates the current speed drop
the parameterized limit values. The load limiting control will
of the diesel engine from the speed setting and the diesel
not intervene.
characteristic depending on the set power mode.
• If, however, the diesel engine speed drop exceeds the limit
The power modes are used to switch between three different
value, the load limiting control will intervene and reduce the
permissible hydraulic powers. The switch is performed using
pump power.
switches which are connected to the controller.
The controller will calculate the available pump power as a
In the case of diesel engines with a CAN interface, torque
control value.
can alternatively be used for control purposes.
• The pump power distributor shares the pump power deter-
• The load limiting control compares the current speed drop
mined by the controller among the connected pumps.
with the parameterizable limit values. Different limit values
can be parameterized for different specified speeds. The percentages used for sharing the available power
between the connected pumps can be parameterized.
In case of diesel engines with a CAN interface, the
temperature of the diesel engine can also be taken into A switch on the controller also allows the operator to switch
account in this evaluation. As soon as the temperature value between two different distribution patterns.
passes out of a parameterizable range, the limit value for the
Instead of pump 2, a valve can also be connected and
drop in engine speed is further reduced.
parameterized for limp home mode or for precision mode.
By externally specifying the reduction in power, the maximum
power can be further limited. This is specified by means of a
limit potentiometer connected to the controller.
RE 95310/01.09 LLC Load Limiting Control Bosch Rexroth AG 5/12

Variant LLCA
Important features Important parameters
• The ratio in which the power reduction is distributed be- For a diesel engine with a CAN-bus interface:
tween pump 1 and pump 2 in the event of a limit load can be
• Diesel engine data (specified speed and actual speed via
set as a parameter. Depending on the parameter setting, the
CAN bus, specified torque and actual torque via CAN bus,
power reduction may be distributed evenly between the two
dynamic behavior, permissible speed drop)
pumps, or the division may be asymmetrical.
• CAN bus (baud rate, controller addresses, signal priorities)
A second distribution value of the power reduction can be
set as an optional additional parameter. An external switch • Configuration (number of pumps and limp home mode,
can then be used to switch between the two methods power sharing, hydraulic concept, specified-speed source)
(power sharing mode switch).
• Minimum and maximum magnetic current for pumps 1 and 2
• The total maximum permitted pump power can be reduced
• Load limiting control (dynamic controller data)
using an external potentiometer.
• Function (minimum/maximum temperatures, power reduc-
• An additional temperature mode is possible if a diesel engine
tion)
with a CAN-bus interface is used. If the temperature passes
above or below the limits set as parameters, power is re- For a diesel engine without a CAN-bus interface:
duced to a user-definable level.
• Diesel engine data (actual speed from sensor, number of
• Power modes: Switches between three different permissible teeth on flywheel, dynamic behavior, permissible speed drop)
hydraulic powers. These arise from the permissible speed
• Potentiometer for specified speed and power sharing
drops that are specified differently for each power mode.
• Configuration (number of pumps and limp home mode,
• Precision mode: A valve is controlled depending on the posi-
power sharing, hydraulic concept, specified speed source)
tion of a dial potentiometer. The drop in LS pressure caused
by the valve can be used to slow operating functions, e. g. for • Minimum and maximum magnetic current for pumps 1 and 2
precision work.
• Load limiting control (dynamic controller data)
• Automatic speed reduction: If no operating function is
requested for a longer period of time, the diesel engine
switches to idle mode to reduce fuel consumption. For this
purpose, a pressure switch (normally closed contact) must
be installed in an appropriate location. At low LS pressure,
the pressure switch closes, signaling to the controller that
automatic speed reduction is requested.
• If a diesel engine with a CAN-bus interface is used, the pres-
ent output currents from pump 1 and pump 2 are sent via the
CAN bus every 100 ms. This includes the power sharing set
externally with a potentiometer and, if relevant, error mes-
sages.
• The second proportional solenoid output can be used for
limp home mode or for controlling a valve for the fine mode
(parameterizable). Under normal circumstances this output
produces a constant 100 %; this value falls to 0 % in the
event of an error. Thus, the pumps can be switched by an
external valve to an operating mode that enables the device
to be run with no electronics.
• The inputs and outputs of the controller are monitored (for
cable break, short-circuit). In the event of an error or if the
safety switch is actuated, the drive is stopped immediately.
All of the above errors as well as errors in the CAN commu-
nication with the diesel engine and excessively high or low
engine temperature can be indicated by a flashing code on a
connected error lamp.
• All errors that occur are stored in the controller and can also
be read later in plain text form using BODAS service.
6/12 Bosch Rexroth AG LLC Load Limiting Control RE 95310/01.09

Variant LLCA
LLCA connection diagram (without CAN bus)

1 A 3)

13
Ignition lock7)
3A 41 Voltage supply for
30 15 42 the electronics
6)
10 A 27
Power supply for the
+12 V/+24 V 30 1
+ power outputs
- 31

Proportional outputs
31
2
Main pump 1
28 2)

Frequency inputs
33
Speed sensor 32
(optional) 30 Main pump 2,
44
LS pressure 43 valve control for
2)
(optional) 18 limp home mode
17
or valve control for
22 precision mode
7
(optional)
External specification Sensor supply5)

Switched outputs
of power reduction or 2 x 5 V/30 mA 29
specification for Error
36
precision mode 35
2) lamp
(optional)
Voltage

38
inputs

47 15 Signal lamp for

Angle position 46 automatic speed
2)
sensor on 49
reduction
accelerator pedal
or injection linkage
measurement

34
(optional)
Low-side
Current

input

3
inputs

45

5V Diagnostics connector
constant voltage 51
for BODAS service
TxD C
50
RS-232 D
RxD 24
8 B
E
Reserved 52 A
Temperature inputs

H
20

21
Ground
connection,
case
Teaching set speeds (optional) 37 1)
Switch inputs

Power sharing mode (optional) 48

Power mode 2 (optional) 10

Power mode 2 (optional) 11

1)Short,
low-resistance connection from a case screw to the device ground or vehicle ground
2)Separate ground connection from solenoid return line to battery (chassis possible)
3)Separate fuses recommended for switches, sensors and electronics
5)Sensor supply voltage for potentiometers and active sensors
6)Observe maximum current consumption where proportional solenoids and switched outputs are controlled simultaneously
7)Can be used as switch inputs if connected externally to GND

Figure 4: Inputs and outputs on the controller (variant LLCA, configuration without CAN-bus interface)
RE 95310/01.09 LLC Load Limiting Control Bosch Rexroth AG 7/12

Variant LLCA
LLCA connection diagram (with CAN bus)

1 A 3)

13
Ignition lock7)
3A 41 Voltage supply for
30 15 42 the electronics
6)
10 A 27 Power supply for the
+12 V/+24 V 30 1
+ power outputs
- 31

Proportional outputs
31 Main pump 1
2
2)
28

Frequency inputs
Speed sensor 33
32
(optional) 30 Main pump 2,
44
LS pressure 43 valve control for
2)
(optional) 18 limp home mode
17 or valve control for
22 precision mode
7
(optional)
External specification Sensor supply5)

Switched outputs
of power reduction or 2 x 5 V/30 mA 29
specification for Error
36
precision mode 2) lamp
35
(optional)
Voltage
38
47
inputs 15 Signal lamp for
Angle position 46 automatic speed
sensor on 49 2)
reduction
accelerator pedal
or injection linkage
34 measurement
(optional)
Low-side
Current

input
inputs

45

5V Diagnostics connector
constant voltage for BODAS service
51
TxD C
50
RS-232 D
RxD 24
8 B
E
Reserved 52
Temperature inputs

A
H
20 G
CAN H F

40
9 26
120 Ohm 25 4 )
39
21
Ground
CAN L
connection,
case
Teaching set speeds (optional)
Switch inputs

37 1)

Power sharing mode (optional) 48

Power mode 2 (optional) 10

Power mode 2 (optional) 11

1)Short,
low-resistance connection from a case screw to the device ground or vehicle ground
2)Separate ground connection from solenoid return line to battery (chassis possible)
3)Separate fuses recommended for switches, sensors and electronics
4)CAN bus: 120 Ω termination resistor recommended
5)Sensor supply voltage for potentiometers and active sensors
6)Observe maximum current consumption where proportional solenoids and switched outputs are controlled simultaneously
7)Can be used as switch inputs if connected externally to GND

Figure 5: Inputs and outputs on the controller (variant LLCA, configuration with CAN-bus interface)
8/12 Bosch Rexroth AG LLC Load Limiting Control RE 95310/01.09

Variant LLCB
The LLCB electronic load limiting control functions in basically
the same way as the LLCA variant, but is designed to control
only one pump instead of two.
In addition, the valve for the slew drive is controlled in such a
way that the flow rate for the slew drive motor is maintained
irrespective of the diesel engine speed. As a result, the slew
drive always turns at the same speed regardless of the speed
at which the diesel engine is running.
The electronic load limiting control is designed for controlling
variable displacement pumps in an open hydraulic circuit.
The following hydraulic concept can be used for control pur-
poses:
• The hydraulic system consists of the axial piston pumps
A8VO or A11VO with a hydraulic or electrohydraulic power
controller and load limiting controller (LA1, LG1, LE) together
with a control block (e.g. M7) with a pressure reduction valve
(DRE) on the slew drive spool.
The RC2-2/20 controller controls the pump controller and
the pressure reduction valve in the control block.
The following diesel engine configuration can be used:
Functional description
The diagram below illustrates how the load limiting control
works:
• From the specified speed value and the diesel characteristic,
the load limiting control calculates the current speed drop of
the diesel engine.
• The load limiting control compares the current speed drop
with the parameterizable limit values. Different limit values
can be parameterized for different specified speeds.
• As long as the total of the hydraulic powers does not exceed
the installed diesel power, the speed drop will not exceed
the parameterized limit values. The load limiting control will
not intervene.
• If, however, the diesel engine speed drop exceeds the limit
value, the load limiting controller will intervene and reduce
the pump power.
• The maximum permissible speed drop of the diesel engine
can be adjusted in three steps using the "power mode"
switches.

• Diesel engine with or without CAN-bus interface

The controller receives the specified speed for the diesel
engine from an angle sensor (accelerator pedal position as
specified speed). The actual speed is measured using a
speed sensor on the starter gear rim.
The LLCB variant does not evaluate the CAN bus.

RC2-20 controller
with LLCA software
Error
lamp

BODAS service
PC software

Speed sensor Slew drive

shaft in
control block
M7

Angle Slew drive

sensor GFB

Diesel engine with Pumps

or without CAN-bus A8VO... LA1..F.4 or
interface A11VO...LE / LG1

Figure 6: Configuration for LLCB

RE 95310/01.09 LLC Load Limiting Control Bosch Rexroth AG 9/12

Variant LLCB

Safety switch

Characteristic Slew drive

Teach shaft in
Slew drive
control block

Specified Diesel Calculation Load limiting Working

speed characteristic Speed drop control pump

Power mode 2/3

Actual speed

Maximum
power

Figure 7: How the LLCB load limiting control works

Important features
• The maximum flow rate of the slew drive motor can be
set using a characteristic irrespective of the diesel engine
speed.
• Power modes: Switches between three different permissible
hydraulic powers. These arise from the permissible speed
drops that are specified differently for each power mode.
• Maximum power mode: A switched input, "Maximum Power",
can be used to switch between reduced hydraulic handling
power and maximum working power.
• The definition of the ratio of specified speed to actual speed
can be executed in "Teach Mode" without BODAS service.
• All errors that occur are stored in the controller and can also
be read later in plain text form using BODAS service.
Important parameters
• Diesel engine data (number of teeth on the starter gear rim,
dynamic behavior, permissible speed drop)
• Potentiometer for specified speed
• Minimum and maximum magnetic current for working hydrau-
lic pump and slew drive valve
• Load limiting control (dynamic controller data)
10/12 Bosch Rexroth AG LLC Load Limiting Control RE 95310/01.09

Variant LLCB
LLCB connection diagram

Ignition lock
with starter 1 A 3) 41 Power supply
non-repeat
42
unit
8A 1 Supply of the power
27 outputs
12V/
24 V 2
28
0V
33
Speed sensor 32
31
A Working pump
2)
30
B Control block -
2) slew drive shaft

Angle position 47 +5 V / 15 mA
potentiometers 1K-5K
Error detection for

sensor on 46
+L
29
accelerator pedal or Error lamp
49
injection linkage
2)

Diagnostics connector
for BODAS serivce
TxD 51 C
RS232 RxD 50
17
D
B
E
A
G
Teach 37 52
F
H
Maximum power 48

Power mode 2 10
Power mode 3 11

1)

1) Short, low-resistance connection from the plug connector and one housing screw to the device ground
2) Separate ground connection from the solenoid return line to the battery (chassis also possible)
3) Separate fuses for switches and sensors

Figure 8: Inputs and outputs on the controller (variant LLCB)

11/12 Bosch Rexroth AG LLC Load Limiting Control RE 95310/01.09

Required components Parameterization and

The following electronic components are required: diagnostics
• BODAS RC2-2/21 controller with 52-pin mating connector
The parameters that need to be assigned for commissioning
(RE 95201) and AS/LLCA software, Version 30
the LLC load limiting control can be set easily using the
• BODAS RC2-2/20 controller with 52-pin mating connector BODAS service PC software.
(RE 95200) and AS/LLCB software, Version 10
• Speed sensor IDR (RE 95130) with mating connector for
diesel engine without a CAN bus
• Angle sensor WS1 (RE 95140) with mating connector for
diesel engine without a CAN bus
The following hydraulic components are required:
• Variable displacement pump with appropriate controller
A8VO…LA1 (RE 93010) or
A11VO…LG1 or LE (RE 92500) or
A20VO…LG1 or LE (RE 93100) or
A10VO…FHD (RE 92701)
• Possibly a mating connector, depending on the connector
variant selected for the pump
• For A11VO…LG1, A20VO…LG1 and A10VO…FHD sepa-
rate DRE4K pressure control valves (RE 29181) with mating You can configure BODAS serivce to display the most impor-
connector and control oil pump tant process data and the error messages for diagnostics and
• Possibly an additional valve and mating connector for limp troubleshooting purposes.
home mode (e.g. DRE4K...)
The following items are required for commissioning and service:
• BODAS service PC software (RE 95086)
• BODAS service connecting cable (RE 95086)
• Diagnostics socket (RE 95086)
12/12 Bosch Rexroth AG LLC Load Limiting Control RE 95 310/03.06

Safety instructions
• The suggested circuits do not imply any technical liability for
the system on the part of Rexroth.
• Lines to speed sensors must be shielded. The shielding is
to be connected to the electronics on one side or to the
machine or vehicle ground via a low-resistance connection.
• Lines to the electronics must not be routed close to other
power conducting lines in the machine or vehicle.
• Sufficient distance from radio systems must be maintained.
• All connectors must be unplugged from the electronics dur-
ing electrical welding operations.
• The electronics may only be tested with the proportional
solenoids connected.
• The proportional solenoids must not be connected to spark
suppression diodes.
• On/off solenoids at the outputs of the controller RC do not
need to be connected to spark suppression diodes.
• Other inductive loads that are in the system but not con-
nected to the controller RC must be connected to spark
suppression diodes.
• In order to preserve the warranty, any installation or replace-
ment of the RC software (flash EPROM) must be performed
by Rexroth staff.
• Observe operating instructions RE 95310-01-B for the LLCA
variant and RE 95311-B for the LLCB variant.

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Mobile Electronics it may not be reproduced or given to third parties.
The data specified above only serve to describe the product. No statements
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89275 Elchingen, Germany
derived from our information. The given information does not release the user
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Fax +49 (0) 73 08 72 74 that our products are subject to a natural process of wear and aging.
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