Beruflich Dokumente
Kultur Dokumente
Operating Instructions
The data specified above only serve to describe the product. No statements concerning a certain condition or suitability for a certain application can be derived from our information. The information given does not release the user from the obligation of own judgment and verification. It must be remembered that our products are subject to a natural process of wear and aging. This document, as well as the data, specifications and other information set forth in it, are the exclusive property of Bosch Rexroth AG. It may not be reproduced or given to third parties without its consent.. The cover shows a sample configuration . Thus the supplied product might deviate from the illustration. Original operating instructions
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Inhalt
1 About this document.......................................................................................5 1.1 Validity of the documentation. ....................................................................5 1.2 Additional documentation..........................................................................5 1.3 Illustration of information. ...........................................................................7 2 Safety instructions..........................................................................................9 2.1 General information on this chapter. ..........................................................9 2.2 Intended use..............................................................................................9 2.3 Improper use. .............................................................................................9 2.4 Qualification of personnel........................................................................10 2.5 General safety notes. ...............................................................................10 2.6 Product- and technology-related safety instructions................................ 10 2.7 Obligations of the operator/machine manufacturer. ................................. 11 3 Scope of delivery...........................................................................................13 4 Product description.......................................................................................14 4.1 Performance description..........................................................................14 4.2 Device description...................................................................................14 4.3 Product identification...............................................................................14 5 Transport and storage. ..................................................................................16 5.1 Transporting the control block.................................................................16 5.2 Storing the control block..........................................................................16 6 Assembly........................................................................................................18 6.1 Unpacking................................................................................................20 6.2 Coating the control block.........................................................................20 6.3 Installation conditions..............................................................................20 6.4 Required tools. .........................................................................................20 6.5 Assembling the control block...................................................................20 6.6 Mechanically connecting the control block..............................................21 6.7 Hydraulically connecting the control block...............................................22 6.8 Installing the electrical supply..................................................................22 6.9 Before first commissioning. ......................................................................23 7 Commissioning..............................................................................................24 7.1 First commissioning.................................................................................24 7.2 Re-commissioning...................................................................................25 8 Operation........................................................................................................26 9 Maintenance and repair. ................................................................................27 9.1 Definition..................................................................................................28 9.2 Inspection and maintenance....................................................................29 9.3 Repair......................................................................................................31 9.4 Spare parts..............................................................................................31 10 Disassembly and replacement.....................................................................33 10.1 Required tools. .........................................................................................33 10.2 Preparing for disassembly.......................................................................33 10.3 Disassemble the control block from the machine....................................33 10.4 Replacing components of the control block.............................................34 11 Disposal.......................................................................................................... 36 11.1 Environmental protection.........................................................................36 11.2 Recycling.................................................................................................36 12 Extension and conversion............................................................................37 12.1 Retrofit and conversion............................................................................37 12.2 Optional accessories...............................................................................37 13 Troubleshooting............................................................................................38 13.1 How to proceed for troubleshooting.........................................................38 14 Technical data . .............................................................................................41
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15 Appendix........................................................................................................ 42 15.1 Project/installation drawings....................................................................42 15.2 Hydraulic circuit diagrams. .......................................................................42 15.3 Electrical schematics...............................................................................42 15.4 Lubricant recommendations....................................................................42 15.5 Spare parts list.........................................................................................42 15.6 Address directory.....................................................................................42 16 Alphabetical index.........................................................................................43
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RDE64263-01-E (size 16) Spare parts lists RDE64263-02-E (size 32) RE 64294 Technical data sheet
RDE64294-01-E (size 16) Spare parts lists RDE64294-02-E (size 18) RDE64294-03-E (size 22) RDE64294-04-E (size 25) RDE64294-05-E (size 32) RE 64122 RDEF64122-E RE 64276 RE64276-E RE 64283 Technical data sheet Spare parts list Technical data sheet Spare parts list Technical data sheet
Open center control block SM Open center control block SM Load sensing control block M4-12 Load sensing control block M4-12 Load sensing control block M4-15
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Title Load sensing control block M4-15 Load sensing control block M4-22 Load sensing control block M4-22 Load sensing control block SP-08 Load sensing control block SP-08 LUDV control block M6-15 LUDV control block M6-15 LUDV control block M6-22 LUDV control block M7-22 LUDV control block SX 10 LUDV control block SX 10 LUDV control block SX 12 LUDV control block SX 12 LUDV control block SX 14 LUDV control block SX 14 LUDV control block SX14 NGE System documentation from the machine manufacturer Order confirmation Overall circuit diagram of the machine Supplied installation drawing/ hydraulic plan Pressure fluid on mineral oil basis Pressure fluid on mineral oil basis for axial piston machines
Document number RE64283-E RE 64279 RJE 64279-E RE 64139 RDEF64139-E RE 64284 RDE64284-E RE 64286 RE 64295 RE 64132 RDEF64132-E RE 64128 RDEF64128-E RE 64125 RDEF64125-E RE 64130
Document type Spare parts list Technical data sheet Spare parts list Technical data sheet Spare parts list Technical data sheet Spare parts list Technical data sheet Spare parts list Technical data sheet Spare parts list Technical data sheet Spare parts list Technical data sheet Spare parts list Spare parts list Operating Instructions
RE 90220 RE90220-1
Further documentation is available from Bosch Rexroth on request. Documents on the overall circuit diagram of the machine is available from the machine manufacturer. Also observe the generally applicable, legal or otherwise binding regulations of the European or national legislation and the rules for the prevention of accidents and for environmental protection applicable in your country.
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Type of risk
Signal word
Consequences in case of non-observance ff Risk prevention Warning signs: Draws attention to the danger Signal word: Identifies the degree of danger Type of risk: Identifies the type or source of the danger Consequences: Describes what occurs when the safety instructions are not complied with Precautions: States how the danger can be avoided
Table 2: Risk classes according to ANSI Z535.6-2006 Warning signs, signal word Meaning Indicates a dangerous situation which may cause death or severe injuries if not avoided Indicates a dangerous situation which may cause death or severe injuries if not avoided Indicates a dangerous situation which may cause minor or moderate injuries if not avoided Damage to property: The product or the environment could be damaged.
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1.3.2 Symbol
The following symbols indicate notes which are not safety-relevant but increase the understanding of the documentation.
Table 3: Meaning of the symbols Symbol Meaning If this information is not observed, the product cannot be used and/ or operated optimally.
Individual, self-dependent step Numbered instruction: The ciphers indicate that the steps are listed one after the other.
1.3.3 Denominations
The following denominations are used in this documentation:
Table 4: Denominations Denomination Mono block Meaning Control block which is moulded in one piece. As an option, further directional valve elements can be mounted to extend thefunctions. Control block element with 1 spool axis, in the following also referred to as section. Control spool Type of control of the main spool
1.3.4 Abbreviations
The following abbreviations are used in this documentation:
Table 5: Abbreviations Abbreviation DB DIN ISO RD RE RDE RDEF Meaning Pressure limitation valve Deutsche Industrie Norm (German Industry Standard) International Organization for Standardization Rexroth document in German Rexroth document in English Rexroth document in German/English Rexroth document in German/English/French
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Safety instructions
Safety instructions
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Safety instructions
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Safety instructions
Provide the appropriate emergency stop function to make sure that the actuated consumer can be set to a safe position (e.g. by stopping it immediately). Please comply with the specified cleanliness class for pressure fluids according to the Technical data sheet. If it should be necessary to disable any safety equipment temporarily, for example for commissioning or maintenance work, always take the appropriate measures to ensure that no hazard to a person's life or health or to property may occur. Also observe the superordinate operating instructions for the machine. Never remove or damage lead seals that have been fitted by Bosch Rexroth. Do not expose the control block to any mechanical loads under any circumstances. Never use the control block as a handle or step. Do not place any objects on top of the power unit. The warranty only applies to the delivered configuration. The warranty will not apply if the product is incorrectly assembled, not used as intended and/or handled improperly.
Risk of crushing limbs Risk of injuries caused by parts expelled by spring force when removing the plug screws from the valve during disassembly.
Keep your limbs away from gaps between switching element and valve housing. Carefully remove plug screws. Hold up strongly when loosening plug screws! Wear protective goggles! Do not screw plug screws and plug nuts more than five times after maintenance work. Handle valves only with protective gloves. Shut down the valve and let it cool down before you start working on the valve. Remove leaking oil immediately, use a drain tray, use protective gloves Work on electric components only after you have deenergized them. Deenergize the electrical connection before assembly and disassembly. Use appropriate lifting gear. Use the lifting devices at the control block.
Valve housing, valve magnet, connector Adjustment options and maintenance work Energized conductors, metallic construction components
Risk of burns with hot surfaces during operation Leaking oil Risk of injuries or danger of life caused by electricity flowing through the human body
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Safety instructions
Observation of the instructions from the factory security offices and of the work instructions from the operator What to do in an emergency. Bosch Rexroth offers training support in specific fields. An overview of the training contents is available on the Internet via the following link http://www.boschrexroth.de/didactic.
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Scope of delivery
Scope of delivery
The scope of delivery includes: Product-specific documentation Control block according to order confirmation ff Check the delivery contents for completeness. ff Check the delivery contents for possible transport damage.
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Product description
Product description
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Product description
Made in Germany
Made in Germany
Fig. 3: Name plate on control blocks manufactured from April 2005 indicating the year and the week of production, if necessary with bar code for internal BoschRexroth purposes
Made in Germany
7920
MNR: R917XXXXX
05wXX
1 Production line 2 Part number 3 Customer part number 4 Date of production 5 Serial number 6 Datamatrix Depending on the order, there might be deviations from the above name plates. E.g. on customer-specific name plates it is possible to replace the Rexroth logo with the the customer logo.
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Please absolutely observe the ambient conditions for storage and transport, seetable 7.
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Before commissioning, you must in any case check the control blocks for leakage towards the outside, see chapter 7 Commissioning on page 24. In case of leakage, the seals must be replaced.
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Assembly
Pressurized lines!
WARNING
Danger of life, risk of injury, severe injury or damage to property caused by ejection of oil or components! ff Make sure the relevant system component is not under pressure before assembling the product or when connecting and disconnecting plugs. ff Protect the system component against unintended switching on. High electrical voltage! Danger of life, risk of injury, severe injury or damage to property caused by electric shock! ff Switch off power supply to the relevant system component before assembling the product or when connecting and disconnecting plug-in connectors. ff Connect control block solenoids only if no voltage is applied. ff Protect the system component against unintended switching on.
Tripping hazard caused by cables and lines Risk of injury ff Lay the cables and lines so that they cannot be damaged and no one can trip over them. Risk of personal injuries caused by defective power supply Risk of injury caused by uncontrolled valve positions! This might result in malfunctions or failure of the control block. ff Always connect the earthing connections of the control block with the appropriate earthing system in your installation. ff Exclusively use a power pack with safe electrical isolation. ff Always comply with the country-specific regulations. Dangerous motions of the hydraulic consumer! Risk of injury caused by incorrect pin assignment or mixed up cable plugs due to unintended consumer motions! ff Make sure that all pipes and/or hoses are applied at the correct control block connection and do not mix them up in any case. ff After the completion of the connection work you must check the correct assignment of the cable plugs to each control block solenoid.
CAUTION
NOTE
Non-compliance with protection class IP67 and risk of short-circuit due to missing seals and caps Fluids and foreign matters may penetrate into the control block and destroy it. ff Prior to assembling make sure that all seals and plugs of the plug-in connections are tight.
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NOTE
Damage caused by incorrect assembly! When assembling hydraulic lines and hoses under mechanical stress, they are exposed to additional mechanical forces during operation, which reduces the service life of the control block and the complete machine. ff Assemble hydraulic lines and hoses without mechanical stress. Wear and malfunctions caused by contaminated pressure fluid The cleanliness of the hydraulic fluid has a considerable impact on the cleanliness and service life of the hydraulic system as a whole. Any pollution/ contamination of the hydraulic fluid will result in wear and malfunctions. In particular, foreign bodies like e.g. welding beats or metal cuttings in the hydraulic lines may damage the control block. ff Always ensure absolute cleanliness ff Assemble the control block free from any pollution. ff Make sure that all connections, hydraulic lines and add-on units (e.g. measuring instruments) are clean. ff Ensure that no pollutants are able to penetrate when sealing theconnections. ff Ensure that no detergents are able to penetrate the hydraulic system. ff Do not use cleaning rags/cotton waste or linty cloth for cleaning. ff Only use suitable and permitted sealing material for the seals. ff Possible oil residues from the factory check must be completely removed. ff Remove possible resinifications caused be incorrect storage. Functional impairment caused by wrong plug connections! Only use the plug connections listed in the Technical data sheet for electrical connection. ff Observe the assembly instructions of the manufacturer of the plug connections! ff Before commissioning, you must check the power supply whether the voltage complies with the details on the Installation drawing and whether the total of the solenoid currents to be expected is lower than or equals the capacity of the power supply. ff The plug connections may only be contacted in when deenergized. The assembly process must not be repeated more than 10 times. Incorrect connection wiring! The control block must only be connected by a specialized electrician or under supervision of the same. The lines used have to be suitable for operating temperatures of 20 C...+100 C. ff De-energize the connection line before installation. ff Avoid sharp bends in the connection line and the litz wires, in order to avoid short-circuits and interruptions. ff Route the connection line(s) using strain relief. The first attachment point must be located at a distance to the cable entry of 15 cm at most. ff Use fine-wired conductors with pressed-on wire end sleeves only.
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6.1 Unpacking
ff Dispose of the packaging in accordance with the currently applicable national regulations in your country.
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ff Observe the requirements for the contact surface specified in the Installation drawing. ff Check the smoothness of the flange surface in the machine (tolerance: 0.5 mm) ff Tighten mounting screws applying the tightening torque specified in the standard. ff Always mount the control block at the provided mounting points and only use screws having the property class according to EN ISO 4762 or EN ISO 4014 as specified in table 8. Bosch Rexroth recommends screwing with the following parameters:
Table 8: Fastening screws Series Dimensions Property class Tightening torque [Nm] Screw-in depth [mm]
1 M1-16 M8 8.8 / 10.9 27 / 40 M1-25 M10 8.8 / 10.9 54 / 79 10 1 M1-32 M12 8.8 / 10.9 93 / 37 M4-12 M10 8.8 / 10.9 41 / 60 12 15 M4-15 M10 8.8 / 10.9 54 / 79 10 1 M4-22 M16 8.8 / 10.9 230 / 338 M6-15 M10 8.8 / 10.9 54 / 79 10 M6-22 M12 8.8 / 10.9 93 / 137 12 M7-20 M12 8.8 / 10.9 93 / 137 12 M7-22 M16 8.8 / 10.9 230 / 338 16 M8-16 M16 8.8 / 10.9 230 / 338 16 M8-18 M16 8.8 / 10.9 230 / 338 16 M8-22 M16 8.8 / 10.9 230 / 338 16 M8-25 M16 8.8 / 10.9 230 / 338 16 M8-32 M20 8.8 / 10.9 464 / 661 20 1 M8-35 M16 8.8 / 10.9 230 / 338 M9-20 M16 8.8 / 10.9 230 / 338 16 M9-25 M16 8.8 / 10.9 230 / 338 16 1 MO-10 M10 8.8 / 10.9 54 / 79 1 MO-16 M8 8.8 / 10.9 27 / 40 1 MO-22 M10 8.8 / 10.9 54 / 79 1 MO-32 M12 8.8 / 10.9 93 / 137 1 MO-40 M16 8.8 / 10.9 230 / 338 MO-52 M20 8.8 / 10.9 464 / 661 20 SP-08 M8 8.8 / 10.9 25 / 30 10 14; 1 SM12 M8 SX10 M8 SX12 M8 SX14 M10 SX14NGE M10 1 Through-holes in the housing; the screw-in depth depends on the material of the nut thread.
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Commissioning
Commissioning
Risk of injury caused by enclosed air Air enclosed in hydraulic systems might cause components to vibrate during operation so that they strike against the limit stops and be damaged. Unexpected movements of the actuators might cause injuries. ff Depressurize the hydraulics before starting commissioning and relieve pressure accumulator, if necessary. ff Before commissioning you must make sure that enclosed air is completely removed from the system. This can be done by a small amount of pressure fluid q20 %qpump flowing through the pump in all switching positions. ff You must, in any case, observe the details for bleeding written down in the operating instructions of the machine.
CAUTION
NOTE
Product damages resulting from a lack of pressure fluid If you commission the control block without or with too little pressure fluid, the control block will be immediately damaged or even destroyed. ff When commissioning or re-commissioning a machine or system, you should ensure that the housing space, as well as the suction and work lines of the control block are filled with pressure fluid and that they remain filled with oil during operation.
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Commissioning
Observe the operating instructions of the machine where the control block isinstalled. ff Bleeding the hydraulic system Before the actual operation, you must switch the control block several times under operating pressure in each actuating direction and with reduced velocity. Thus, the remaining air in the control block is pressed out. Mechanical damage due to inadmissibly high acceleration of the pressure fluid and the control block spool is thus avoided and the control block's service life is increased. ff Leakage test Check whether during operation, hydraulic medium leaks at the control block and at the connections. ff Performing the functional test The functional test must be made according to the specifications of the machine manufacturer, see operating instructions of the machine. In any case: Slowly increase pressure; stop functional test immediately in case of leakage! ff Commission control block. Details for fine adjustment are available in the operating instructions of eachmachine.
ff Check the operating temperature of the machine after several hours of continuous operation. Too high operating temperatures indicate errors which must be analyzed and removed. ff Have a pressure fluid sample analytically tested for the required cleanliness class after first commissioning. Replace the pressure fluid if the required cleanliness class is not achieved. If the pressure fluid is not tested in the laboratory after first commissioning, the following applies: Replace the pressure fluid
7.2 Re-commissioning
Proceed as follows to re-commission the control block: ff Follow the instructions in chapter 7.1 First commissioning on page 24.
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Operation
The product is a component which does not require any settings or modifications during operation. ff Only use the product within the performance range provided in the technical data according to the Technical data sheet. The machine manufacturer is responsible for the correct projecting of the hydraulic system and its control. See operating instructions of the machine where the control block is installed.
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Risks caused by reduced safety during commissioning Experience has shown that the number of accidents during maintenance works is higher than during normal operation. Therefore we would ask you to observe any of the following safety instructions in the interest of safety. ff Regularly check the safety devices - if any - for correct functionality. ff Accomplish any maintenance work at due date, correctly and completely and document it. ff Adequately secure the maintenance area before starting maintenance works. ff Pay attention to cleanliness in order to avoid malfunctions caused by dirt. Paint residues on sealing surfaces must be removed before assembly. Make sure that paint residues do not enter block openings. Otherwise you riskmalfunctions. ff Operate the hydraulic product in maintenance mode possibly requiring the disassembly of certain protective covers with high alertness. Switch off the hydraulic product and secure it against unintended switching on. ff The user is not allowed to change the set values of safety valves. New adjustments may only be accomplished by authorized testing authorities. ff Put on your protective goggles, protective gloves and safety boots. Depressurize the hydraulic product and professionally relieve available pressure accumulators, if any. ff Let system sections and pressure lines which can be opened cool down before starting commissioning works. ff Slowly open segments which must still be pressurized. ff Please observe that, if there are check valves in the pressure lines above the pumps, the hydraulic system might still be pressurized after it has been disconnected from the actual pressure supply. Move all cylinders to the safe end position. ff Lower any load. Provide external safeguard if the load cannot be lowered. It is inadmissible to carry out maintenance work at lifted units without external safeguard. ff Switch off all pumps. ff Support vertical cylinders mechanically against sinking. ff Only new, structurally identical and tested components, spare parts and lubricants in original equipment quality are admitted for replacement/use. ff Make sure that all protective devices and especially all protective functions which could impair the safety-shutdown strategy are correctly installed and checked for functionality before each re-commissioning. ff After the completion of all works, please remove all tools and devices used for maintenance from the hydraulic product. Personal injuries caused by not functioning spare parts Spare parts that do not meet the technical requirements specified by BoschRexroth may cause personal injuries. ff Only use genuine spare parts from Bosch Rexroth.
CAUTION
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NOTE
Penetrating dirt and liquids will cause faults! Safe function of the control block is no longer ensured. ff Always ensure absolute cleanliness when working on the control block. ff Cover all openings with the appropriate protective equipment in order to prevent detergents from penetrating the system. ff Check that all seals and plugs of the plug-in connection are firmly fitted so that no humidity can penetrate the control block during cleaning. ff Dust accumulations on the control block have to be removed at regular intervals. Damage to the surface from solvents and aggressive cleaning agents! Aggressive detergents may damage the seals on the control block and let them age faster. ff Never use solvents or aggressive detergents. ff Only clean the control block using a damp, lint-free cloth. Only use water to do this and, if necessary, a mild detergent. Damage to the hydraulic system and seals! The water pressure of a high-pressure cleaner can damage the control block and seals of the hydraulic power unit. The water displaces the oil from the hydraulic system and seals. ff Do not use a high-pressure cleaner.
9.1 Definition
In accordance with DIN 31051:2003-6 the term maintenance means the combination of all technical and administrative measures and measures taken by the management during the life cycle of an item in order to maintain the functional condition or to return to the same, so that the item is able to meet the required function. These measures can be classified into: Maintenance (measures to delay the decrease of the existing wear reserve) Inspection (measures to determine and assess the actual condition of an item, including the determination of the cause of wear and the derivation of the required consequences for a future use) Repair (measures to return an item to a functional state, except improvements) Improvement (combination of all technical and administrative measures and
measures taken by the management to increase the functional safety of an item, without modifying the function required).
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Basically we recommend to keep an inspection and maintenance record where any system and site-specific works as well as inspection and maintenance intervals are defined and documented. If the specified operating and ambient conditions are observed, the control blocks are maintenance-free. Regular inspection and maintenance work is therefore not required. However, the following must be checked at least every three years (from the manufacturer date of the control block): ff The control block for leakage at the outside. ff All screws and connections for firm seat. ff All connection lines for damages. If damage is visible, replace the connectionline. Order information for seal kits is available in chapter 9.4 Spare parts onpage31.
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9.2.3 Replenishing/refilling
When replenishing/refilling your hydraulic system you must make sure that you use admissible hydraulic fluid (see Technical data sheet) of the same type and the same manufacturer. In case of major contamination and/or premature aging of the hydraulic fluid, the system including the tank must be cleaned and rinsed before refilling. Before refilling, you must always filter new hydraulic fluid according to the required cleanliness class because it usually does not comply with the required cleanliness class in its as-delivered state. Lines and hoses must be rinsed before installation. Use a filter aggregate when filling the hydraulic fluid tank. The filter element must be clean. Do not remove filter screens from the filler neck or the filter insert of filters when filling the hydraulic fluid tank. The filter mesh must at least meet the required cleanliness class of the entire system. If possible, it must even be finer. The applied filter unit must meet the requirements with regard to functional safety and service life. The maximum admissible degree of contamination of the hydraulic fluid is specified in the Technical data sheet in the chapter Technical data. If possible, replenish the hydraulic fluid tank using a filling coupling, if possible at the return filter.
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9.3 Repair
Repair works may only be performed by workshops authorized by Bosch Rexroth Machine manufacturers. Bosch Rexroth offers a wide range of repair services for the control block. ff Only use genuine spare parts from Bosch Rexroth for repairing the Rexroth product. Tested and pre-assembled original Rexroth assembly groups allow for successful repair requiring only little time. ff The spare parts lists of the control blocks are product-specific. Please indicate material and series number of the control block as well as the material number of the spare parts when ordering spare parts.
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WARNING
4. Disassemble control block from the machine observing the details of the machine manufacturer. 5. Place disassembled control block on a clean, solid and safe surface. 6. Protect open bores and connections of the block elements from contamination e.g. by applying plastic plugs.
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Do not clean the disassembled control block with a high-pressure cleaner. 7. Remove dirt and foreign matter from the control block. Do not use any detergents which could affect plastic or change the characteristics of plastic, which affect metals or react with metals or generate residues.
The following elements may bereplaced: 1. Seal between actuation andhousing 2. Seal between mono block and control block sections (optionally) 3. Pressure valves
3. Loosen tension rod nuts and/or cylinder screw nuts, if any, and disassemblesections. Adhesion forces may act between the individual block segments.
4. Remove all sealing elements. 5. Remove contamination, dirt, paint residues and corrosion from the flange surfaces of all connecting plates, end plates and control block sections. Avoid the deposition of dirt in the bores when cleaning the flange surfaces. 6. Check the sealing surfaces for the O-rings at the flange surface and at the undercut of the flange surface for defects. If damaged, each block element must be replaced by a new one! 7. Install O-rings according to the Spare parts list.
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8. Assembly of the individual block elements according to the numbering applied in advance. 9. Tighten the tie rod nuts/cylinder screws in clockwise direction. Tightening torque according to the Spare parts list. 10. If the control block is to be returned to the manufacturer for servicing purposes, close the control block connection surface with the provided protective plate or protect by means of equivalent packaging, in order to avoid contamination and damage.
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11 Disposal
11.1 Environmental protection
Careless disposal of the control block and the hydraulic fluid could lead to pollution of the environment. ff Empty residues from the control block and dispose of as metal scrap. Emptying residues means that the control block must be correctly empties so that no hydraulic fluid will drop out. The control block must be cleaned after emptying residues. ff Thus, dispose of the control block and the hydraulic fluid in accordance with the currently applicable national regulations in your country. ff Dispose of hydraulic fluid residues according to the respective safety data sheets valid for these hydraulic fluids. ff Dispose of the electronic products according to the valid regulations.
11.2 Recycling
Due to the high share of metals the products can mostly be recycled. In order to achieve an ideal metal recovery, disassembly into individual assemblies is required. The metals contained in electric and electronic assemblies can be recovered by means of special separation procedures as well. If the products contain batteries or accumulators, these have to be removed before recycling and furnished to the battery recycling, if possible.
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Troubleshooting
13 Troubleshooting
13.1 How to proceed for troubleshooting
ff Always work systematically and focused, even when under time pressure. Random and imprudent disassembly and readjustment of settings might result in the inability to restore the original error cause. ff You should first get a general idea of how the control block works in conjunction with the entire system. ff Try to find out whether the product has worked properly in conjunction with the entire system before the error occurred first. ff Try to determine any changes within the entire system into which the control block is integrated: Were there any changes to the control block's operating conditions or operating range? Were there any changes or repair works on the entire system (machine, electrics, control) or on the control block? If so: What were they? Was the control block or machine used as intended? How did the malfunction become apparent? ff Try to get a clear idea of the cause of the fault. Directly ask the (machine)operator.
Control block housing and/or control block section is leaking Connections leading to the actuator (screw sockets, screwing) are leaking Valve housing at the secondary valve/plug screw is leaking
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Troubleshooting
Possible causes Piping and hose assemblies are damaged Piping or hose assemblies are loose
Remedy Replace piping and hose assemblies. Tighten screwing and fittings according to the assembly instructions applicable for fittings. All assembly instructions are available from the machine manufacturer. Replace seals, see Installation drawing. Disassemble control block, clean flange surface. Replace control block section. Check tightening torque, see Technical data sheet. Remove oil and dirt from the control block. Do not use any detergents which could affect plastic or change the characteristics of plastic, which affect metals or react with metals or generate residues. Bleed hydraulic system, see Bleeding hydraulic system on page 25. Loosen tie rod nuts and tighten with specified tightening torque. Check cooler function, oil supply and pump pressure in neutral position. Avoid temperature shocks; for more information please see the Technical data sheet. Try several times to switch the valve by actuating the hand lever and/or the pilot control. Visually check the connections to the actuator, remove foreign matter using a magnet or forceps. Replace valve housing in case of jammed foreign matter. See malfunction above Control spool cannot be controlled mechanically. Reduce oil flow from the actuator to the tank. Check voltage supply and operating point Q/I, see Technical data sheet. Check plug-in connections. Replace pilot valve and/or magnetic valve. Undersupply (pump pressure too low). Provide minimum pump pressure, see Technical data sheet. Disassemble control oil supply and replace by a new one. Replace pilot valve. Provide minimum pump pressure, see Technical data sheet. Check control oil supply
Seals in the flange surface are damaged Deposition of dirt when mounting the control block Control block housing leaking at the flange surface Tightening torque of the tie rod to low Remaining oil from assembly/testing of the control block
Operating motion not constant Performance: mechanical actuation Control spool cannot be controlled mechanically
Air in the hydraulic fluid Tie rod screwed with too much/different tightening torque Oil temperature too high and/or temperature difference between hydraulic fluid and control block too high, thus blocking of control spool and control block as a result of different thermal expansion Dirt or foreign matter deposited during the assembly of the connector leading to the actuator jam the control spool
Control spool jams Control spool is retained due to the flow force which is caused by too much oil flow
Performance: Electrohydraulic actuation: Control spool shows no reaction or delayed reaction to electronic control
No solenoid current or solenoid current too low, wrong operating point (solenoid current not correctly adjusted to oil stream) Pilot valve and/or magnetic valve does not work Undersupply (pump pressure too low). Provide minimum pump pressure, see Technical data sheet. Control oil supply jams Pilot valves are contaminated
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Troubleshooting
Fault For valves in parallel operation: No pressure and/or no oil flow at the actuator if main spool is deflected, pressure builds up with much delay Neutral circulation pressure too high
Possible causes Oil flows to the actuator with minimum pressure due to undersupply
Remedy Increase pump oil flow by applying higher speed or larger pump, and/or reduce consumed volume using a volume throttle.
No load-sensing unloading (only for M4, M6, M7, SP, SX) Control spool not in neutral position For tongue: Check projecting size, see Technical data sheet. Pressure in the control caps too high (check control). Separate return flow from mutual return flow line, use separate return flow line or increase line cross-section. Replace input element. Pressure in the control caps too high (check control). Check set pressure at the secondary DB. Leakage values, see Technical data sheet. Mount leakage-free lowering-brake valve. Disassemble and clean latching. Replace latching unit. See Control spool cannot be deflected at the top of the Control spool jams table. Replace latching unit. Clean and grease latching unit Replace latching unit if malfunction cannot be removed.
Return flow pressure too high Input pressure compensator jams Motion at the actuator despite neutral position Control spool not in neutral position Secondary DB leaking and/or set too low Leakage at control spool too large No rest function Return force in the actuating device too high compared to the latching force (spring) Latching unit worn out Delatching force too high Control spool jams Latching unit damaged Latching force too high
In case of faults due to contamination, the oil quality has to be checked and improved, if applicable, by suitable measures, such as flushing or installing additional filters, in addition to the servicing works. If you could not remedy the occurred fault, please contact one of the addresses you find on the internet at http://www.boschrexroth.com or in the 15.6 Address directory on page 42.
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Technical data
14 Technical data
For details about the technical data of your control block, please refer to the Technical data sheet, see Table 1 on page 5. The data sheets are available on the Internet under www.boschrexroth.com. The preset technical data of your control block are available in the orderconfirmation.
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15 Appendix
15.1 Project/installation drawings
Installation drawings (quotation drawings) are available from Bosch Rexroth onrequest.
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Alphabetical index
16 Alphabetical index
A N
Nameplates 14
Q R
Qualification of personnel 10
E F
Electrical supply 22
Spare parts Contact person for 32 Order 31 Ordering address for 32 Storage conditions 16
Mobile control block assembling 20 coating 20 connecting hydraulically 22 disassembling 33 fastening 20 replacing components 34 storing 16 transporting 16
Unpacking 20
Bosch Rexroth AG Hydraulics Zum Eisengieer 1 97816 Lohr a. Main Germany Phone +49 9352 18-0 Fax +49 9352 18-3972 info.brm-mc@boschrexroth.de www.boschrexroth.com/brm