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Control blocks for mobile applications

MO, M1, M4, M6, M7, M8, M9, SM, SP, SX

RE 60425-B/06.2010 Replaces: 02.2008 English

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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About this document

About this document

1.1 Validity of the documentation


These instructions contain important information on the safe and appropriate transport, assembly, disassembly, commissioning, operation, maintenance, disassembly and simple troubleshooting of the series MO, M1, M4, M6, M7, M8, M9, SM, SP and SX control blocks. This documentation is intended for assembly fitters, operators and service technicians. ff Read these instructions completely, especially chapter 2 Safety instructions on page 9 before working with the control blocks. The operating instructions supplied by Bosch Rexroth - every part and any possibly relating documents - include safety-relevant information which must be incorporated in the operating instructions to be established by the machine manufacturer for his end product. These operating instructions apply for all control blocks of the listed series irrespective of their manufacturing date until a new version of this document isissued.

1.2 Additional documentation


The type MO, M1, M4, M6, M7, M8, M9, SM, SP and SX control blocks are system components. ff The product may not be commissioned until you are provided with the documentation marked with the book symbol and have understood and observed it.
Table 1: Additional documentation Title Open center control block MO Open center control block MO Open center control block M1 Open center control block M1 Open center control block MB Open center control block MB Document number RE 64354 RDE64354-E RE 64263 Document type Technical data sheet Spare parts list Technical data sheet

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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About this document

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

Technical data sheet Technical data sheet

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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About this document

1.3 Illustration of information


Consistent safety notes, symbols, terms and abbreviations are used so that you can quickly and safely work with your product using this documentation. For a better understanding, they are explained in the following sections.

1.3.1 Safety instructions


In this documentation, safety instructions are indicated whenever sequences of operations are explained which bear the risk of injury or damage to property. The measures described for preventing these hazards must be observed. Safety instructions are set out as follows:

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.

DANGER WARNING CAUTION NOTE

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About this document

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.

ff abc 1. abc 2. abc 3. abc

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

Directional valve element Main spool Actuation

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

2.1 General information on this chapter


The product was designed and manufactured considering the provisions of directives, standards and specifications relating to this technology. However, there is still the risk of injury and damage to property if you do not observe this chapter and the safety instructions in this documentation. ff Read these instructions completely and thoroughly before working with theproduct. ff Keep this documentation in a location where it is accessible to all users at alltimes. ff Always include the required documentation when you pass the product on tothird parties.

2.2 Intended use


The control block is exclusively intended to be installed in a machine or to be assembled together with other components to form a machine. The control block may be commissioned only if it is integrated in the machine for which it isdesigned. This product can be used as safety-related part of a control system. It does, however, not include any safety functions because they cannot be implemented self-dependently by the product. If the product is used for the implementation of safety functions, additional measures with regard to control and/or the safetyrelated part of the control must be specified by the system manufacturer or system designer. Further information is available in the standards for functional safety such as ISO 13849, IEC 62061 or specific technical guidelines. You should observe the operating conditions and performance limits specified in the technical data. The control block is a technical work appliance and not designed for private use. Intended use includes having read and understood these instructions, especially the chapter 2 Safety instructions on page 9. The control blocks are exclusively intended for the use indicated in the Technical data sheet. If you want to use the control block for purposes other than indicated in the Technical data sheet, please contact Bosch Rexroth inadvance.

2.3 Improper use


Any use other than described in the intended use is not the intended use and thusinadmissible. No rebuilding works must be implemented exceeding the extent described in this operating instructions. The valve is not suitable for being operated in explosive environments. Bosch Rexroth does not assume any liability for damages resulting from unintended use. The user bears all the risks resulting from unintended use.

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Safety instructions

2.4 Qualification of personnel


The activities described in this documentation require basic knowledge of mechanics, electrics and hydraulics as well as the knowledge of the appropriate technical terms. In order to ensure safe use, these activities may only be carried out by qualified technical personnel or an instructed person under the direction and supervision of a qualified person. Qualified personnel are those who can recognize potential hazards and apply the appropriate safety measures due to their professional training, knowledge and experience, as well as their understanding of the relevant conditions pertaining to the work to be undertaken. Qualified personnel must observe the rules/laws relevant to the specific subject area.

2.5 General safety notes


Observe the applied provisions for the prevention of accidents and for environmental protection. Observe the safety regulations and provisions of the country where the product is implemented/used. Exclusively use Rexroth control blocks in good technical order and condition. Check the control block for visible defects, for example cracks in the housing or missing lead seals, screws, covers or seals. Observe all notes on the product. Persons who assemble, operate, disassemble or maintain Rexroth products must not consume any alcohol, drugs or pharmaceuticals that may affect their ability to respond. Only use accessories and spare parts authorized by the manufacturer. Comply with the technical data and ambient conditions indicated in the product documentation. The installation or use of inappropriate products in safety-relevant applications could result in uncontrolled operating conditions when being used which in turn could cause injuries and/or damages to property. Therefore please only use a product for safety-relevant applications if this use is expressly specified and permitted in the documentation of the product. Do not commission the product until you can be sure that the end product (for example a machine or system) where the Rexroth product is installed complies with the country-specific provisions, safety regulations and application standards.

2.6 Product- and technology-related safety instructions


Control blocks should be used only within the performance range specified in the technical data. Make sure that all safety equipment belonging to the control block is present, has been installed properly and is fully functional. Do not displace, bypass or disable the safety equipment. The control block is no safety device. The control block could block in an undefined position due to internal pollution e.g. through polluted hydraulic fluid, abrasion dust or residual dirt. As a result, the actuated consumer may no longer be under the operators control.

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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.

2.6.1 Specific remaining risks and precautions


Table 6: Specific remaining risks and precautions Danger zone Sharp edges at the valve housing, at valve threads, at the valve controlspool Gap between switching elements and valve housing Valve housing Remaining risks Risk of cutting limbs Precautions, safety instructions Handle valves only with protective gloves.

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

Weight of the control block

Risk of injuries caused by falling down

2.7 Obligations of the operator/machine manufacturer


The operator/machine manufacturer of the control block from Bosch Rexroth is bound to provide for personnel training on a regular basis regarding the followingsubjects: Observation and use of the operating instructions as well as the legalstipulations Intended use and operation of the Bosch Rexroth product

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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

4.1 Performance description


See Technical data sheet The assignment of the valves to the technical data sheets is available in chapter 1.2 Additional documentation on page 5.

4.2 Device description


See Technical data sheet The assignment of the valves to the technical data sheets is available in chapter 1.2 Additional documentation on page 5.

4.3 Product identification


4.3.1 Details on the name plates
The details on the name plate apply for the control block at the time of delivery. In case of rebuilding works on the control block compared to the state as delivered, it could be possible that the details on the name plate do not apply for the control block you see. Changes to the control block result in the expiration of the warranty and liability of Bosch Rexroth. Any changes, additions, rebuilding works must be documented and noted permanently on the name plate using a marking punch, for example. Compare the material number on the name plate of each control block with the details on the installation drawing to make sure that the operating instructions apply for the product before you. In case of doubt, please contact Bosch Rexroth. Besides the manufacturer's brand (Bosch or Rexroth), the 10-digit material number (R9 ... ...) and the country of origin, the name plate of control blocks manufactured by Bosch or Rexroth before April 2005 only include details which are intended for internal Bosch Rexroth purposes. The name plates of control blocks manufactured from April 2005 include the year and week of production according to the following pattern: YY w XX YY = Year of production, XX = Calendar week Example: 05 w 15 = Year of production 2005, calendar week 15

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Product description

Fig. 1: Name plate on control blocks manufactured before January 2004


MANNESMANN REXROTH

Made in Germany

Fig. 2: Name plate on control blocks manufactured from January 2004


7920

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

Fig. 4: Name plate for SM, SX control blocks

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.

4.3.2 Further name plates on the control block


Further labels on the product are intended for internal Bosch Rexroth purposesonly.

00005158

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Transport and storage

Transport and storage

Please absolutely observe the ambient conditions for storage and transport, seetable 7.

5.1 Transporting the control block


Dimensions and weight (mass) of control blocks are available in the Technical data sheet. ff Make sure that the lifting capacity of the lifting gear is sufficient.

5.2 Storing the control block


5.2.1 Storage conditions
Store the Rexroth control blocks only in a dry and dust-free environment which is free from corrosives and fumes and which is subject to a low degree of humidity and only minor temperature changes. The following storage conditions must be complied with, monitored and documented:
Table 7: Ideal storage temperature Relative humidity (no condensation) UV protection Condensation Additional ozone formation close to the storage +5 C to +20 C max. 65 % 100 % None None

ff Check the correct storage of the control block on a monthly basis.

5.2.2 Corrosion protection


Rexroth control blocks are checked in the factory with mineral oil providing internal corrosion protection for closed control blocks. Unvarnished or galvanized control blocks are not protected against corrosion. Delayed commissioning, long transport and storage periods or decommissioning for a longer period of time may cause corrosion on Rexroth control blocks. In order to prevent this, additional corrosion precautions must be made.

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Transport and storage

5.2.3 Aging during storage and longer periods of standstill


Longer storage periods or longer periods of decommissioning may damage the seals and plastic components of Rexroth control blocks. ff Outside seals on control blocks which have been stored for more than 12 months must be checked for defects before assembly and must be replaced, ifnecessary. ff Seals acting towards the outside must be replaced after a storage or standstill period of three years. Seal kits are available at Bosch Rexroth.

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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Operating instructions for control blocks | RE 64025-B/06.2010

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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Operating instructions for control blocks | RE 64025-B/06.2010

6.1 Unpacking
ff Dispose of the packaging in accordance with the currently applicable national regulations in your country.

6.2 Coating the control block


If the control block is to be painted before being assembled, please observe thefollowing: ff Protect the hydraulic ports against paint application by screwing-in plastic threaded plugs completely beforehand. ff Protect fastening threads against paint by screwing in bolts. ff Mask the flange surfaces of the control blocks as well as the connection and end plates carefully before coating so that no dirt or paint may enter. ff Avoid paint being applied to the contacts of the electrical connections and make sure not to cause any damage to the connector. ff If you remove the plastic screw-in plugs after coating you must make sure that no paint chips enter the control block. Name plates are protected ex works against the application of paint using a foil which can be removed after coating.

6.3 Installation conditions


ff For installing the product always observe the ambient conditions specified in the technical data. (See Technical data sheet.)

6.3.1 Installation position


If not indicated otherwise in the technical documents, the control blocks can be installed in any position.

6.4 Required tools


For mounting the control block, you only need commercial tools suitable for the fastenings specified on the installation drawing.

6.5 Assembling the control block


6.5.1 Fastening the control block
For fastening, the control block is provided with fastening bores which can be seen on the Installation drawing. Please see the Installation drawing for the position tolerances of the fastening bores at the machine. Select the tightening torque according to the usual standard values for each bore size and screw tensioning class. Too much tightening torque might cause the jamming of the valve spool. If this is the case, you must reduce the tightening torque accordingly. Observe the adequate residual clamping force of the screws.

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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.

6.6 Mechanically connecting the control block


Please see the Installation drawing for the connection of the actuating elements incl. tolerances. Select the tightening torque according to the actuating elements. The actuation must be free of transverse forces! ff Make sure before commissioning that the switch is at zero position (spool in center position).

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6.7 Hydraulically connecting the control block


The connecting system and the tightening torque required for the hydraulic connection are specified on the Installation drawing and the Technical data sheet. The connection must be designed according to the appropriate standard. The standards are available at the distribution organizations which are commissioned with the distribution of the standards by the standard committee. ff Use the provided seal for each hydraulic connection.

6.8 Installing the electrical supply


De-energize the relevant part of the system. Information on the correct pin assignment are available in the Quotation/ installation drawing. Please see the Technical data sheet for the required connector type and its specifications.

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6.9 Before first commissioning


ff Make sure that the interfaces of the machine as well as the installation conditions allow for the safe operation of the Rexroth control block. In case of doubt, please contact Bosch Rexroth. ff Check the operating instructions for the machine to find out in which machine the Rexroth control block must be installed, and make a visual inspection to check whether the commissioning of the hydraulics might result in uncontrolled and dangerous motions. If necessary, observe the risk analysis/ risk evaluation of the machine. ff Take according precautions if risks are to be expected, e.g. make sure that the cylinder piston rod can be extended without any risks. ff Secure the load to be lifted additionally with lifting gear/load bearing equipment. ff Check whether the electrical control of the machine allows for the manual switching of the control block solenoids during commissioning. If manual switching is not possible or only under difficult conditions, you must prepare an external control for the internal functional test of the hydraulic system. ff Develop a program for the commissioning process and file it in the technical documents as annex to the operating instructions. ff Divide the functional circuit diagram in sub-circuits which can be commissioned one after the other. ff Read the functional circuit diagram and clarify ambiguous facts and specifications. ff Determine in which spool position the control blocks must be switched and how they must be adjusted. ff Apply important mandatory signs, prohibition signs, information signs and check whether the meaning of these signs is explained in the operating instructions. ff Observe the following order for commissioning: Pump circuit Parts of the control: e.g. depressurization and switch-over, free circulation, pressure reduction, etc. ff Ensure that pipes and/or hoses are connected to all ports and/or that the ports are closed by means of plug screws. ff Ensure that the cap nuts and flanges are tightened properly on pipe fittings and flanges. ff Switch pressure and flow valves, pump controllers, and sensors such as pressure switches, limit switches and temperature controllers to the switching positions and set values specified in the process program.

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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.

7.1 First commissioning


ff Let the control block acclimate itself for several hours before commissioning, otherwise water may condense in the housing. ff Make sure that all electrical and hydraulic connections are either used or covered. Commission the control block only if it is installed completely. ff Avoid temperature shocks. Do not exceed temperature differences of more than 20 C between control block and pressure fluid. Otherwise you risk jammed spools. If temperatures are below 20 C, the control block must be warmed up. Proceed as follows for the first commissioning of the control block: ff Completely fill the control block with permissible pressure fluid (see Technical data sheet). ff Before commissioning, the housing of the control block and, if available, the pre-control circuit must be completely filled with pressure fluid and must be bled (see below). ff Switch on hydraulic supply ff Activating the electrical supply ff Checking electrical connections Before first or re-commissioning, have the electrical connections checked for proper condition by a trained electrician or under the direction and supervision of a trained electrician.

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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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Maintenance and repair

Maintenance and repair

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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Maintenance and repair

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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Maintenance and repair

9.2 Inspection and maintenance


The goal of inspection and maintenance is to maintain the functionality of the system with its initial parameters. to ensure the permanent availability of the system. to determine weak points. to achieve the required service life of the system.

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.

9.2.1 Pressure fluids


The performance characteristics of pressure fluids deteriorate with increased aging (chemical deterioration). Acids and resin residues are formed which cause the bonding of mobile parts inside the control block. The following factors accelerate the aging process: High temperatures Air in the pressure fluid Humidity Water Metallic catalysts High operating pressure Contamination Observe the following general rule: From a hydraulic fluid temperature of > 70 C, aging speed doubles with every 10 C. Further information on hydraulic fluids based on mineral oil also applying for Rexroth control blocks are available in our technical data sheets RE 90220 hydraulic fluids on mineral oil basis RE 90220-1 hydraulic fluids on mineral oil basis

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Maintenance and repair

9.2.2 Malfunction caused by contaminated hydraulic fluid


Contaminations of the hydraulic fluid not only result in increased wear and reduced service life of the control block but also in malfunctions. This could impair the safety and reliability of the control block. Therefore you should regularly carry out the maintenance measures specified in the operating instructions of the machine and check cleanliness when working on the control block. The following aspects might cause the contamination of the hydraulic fluid: Wear during the operation of the machine (metallic and non-metallic abrasion) Leakages on the control block Contamination during maintenance/repair Use of contaminated (unfiltered) hydraulic fluid for replacement.

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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Maintenance and repair

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.

9.3.1 Contact person for repairs


Your contact person for repair is The machine manufacturer, see operating instructions of the machine where the Rexroth control block is installed Your authorized Bosch Rexroth service center.

9.3.2 Instructions for repair


For repair works, the control block may only be disassembled to the extent described in the operating instructions.

9.4 Spare parts


ff Order spare parts in writing. In urgent cases you can also order by phone, but you are kindly requested to confirm your order in writing e.g. by fax. ff Please send any enquiry to your nearest Bosch Rexroth service center or contact headquarters direct. (See chapter 2 Safety instructions on page 9.) ff When ordering spare parts, please indicate the following information from the product's name plate: The material number of the control block. ff Please indicate the following details from the spare parts list: Material number. ff Additionally indicate: The desired number of spare parts. The desired type of dispatch (e.g. as parcel, freight, air freight, by courier service, etc.). Spare parts and the corresponding material numbers are available in the Spare parts list, see Table 1 on page 5. Make sure that the sealing material for the used hydraulic fluid is suitable! See Technical data sheet.

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Maintenance and repair

9.4.1 Contact person for spare parts


Spare parts can be obtained from the machine manufacturer (specialty retailer), see operating instructions of the machine where the Rexroth control block is installed at your Bosch Rexroth specialty retailer.

9.4.2 Order address for spare parts


Please refer to www.boschrexroth.com and to chapter 15.6 Address directory on page 42 for addresses offoreign subsidiaries.

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Disassembly and replacement

10 Disassembly and replacement


Risk of injuries when disassembling under pressure If you do not switch off the pressure before disassembling the product, you may get injured or the control block or system components may be damaged. 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. Risk of injuries when disassembling under voltage If you do not switch off voltage supply before disassembling the product, you may get injured or the control block or system components may be damaged. ff Always switch off the power supply to the relevant system component before assembling the product.

WARNING

10.1 Required tools


Tools suitable for the fastenings specified on the Installation drawing Detergents: Whetstone or oil rubber Permanent marker for marking control block sections Clean drain tray to collect leaking hydraulic fluid.

10.2 Preparing for disassembly


Decommission the entire system as described in the overall machine manual. Prepare the disassembly of the control block as follows:

10.3 Disassemble the control block from the machine


1. Switch off drive motor and switch all valves of the control block used for pressure relief to their end position. 2. Place drain tray for the collection of leaking hydraulic fluid beneath the controlblock. 3. Lower any load. There is still hydraulic fluid in the control block!

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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Disassembly and replacement

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.

10.4 Replacing components of the control block


Proceed as follows to disassemble the control block: 1. Number the block elements with permanent marker and begin with mono block or input element. 2. Place control block in the clean drain tray to collect resides of escaping hydraulic fluid.
Fig. 5: Disassemble control block elements

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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Disassembly and replacement

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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Extension and conversion

12 Extension and conversion


Do not retrofit the control block.

12.1 Retrofit and conversion


Retrofit and/or conversion of the control block may be required for certain applications. ff Coordinate the procedure with Bosch Rexroth. The Bosch Rexroth warranty applies only to the delivered configuration and extensions considered in this configuration. After an extension or a conversion exceeding the conversions and extensions described here, the warranty will forfeit. If the as-delivered state of the control block is changed, all changes must be documented. If necessary, the details on the name plate must be adjusted to the new construction state of the control block.

12.2 Optional accessories


Available accessories are listed in the Technical data sheet as well as in the Spare parts list, see Table 1 on page 5.

12.2.1 Contact person for accessories


Accessories are available at the machine manufacturer (specialty retailer), see operating instructions of the machine where the Rexroth control block is installed at your Bosch Rexroth specialty retailer.

12.2.2 Ordering addresss for accessories


Please refer to www.boschrexroth.com and to chapter 15.6 Address directory on page 42 for addresses offoreign subsidiaries.

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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.

13.1.1 Malfunction table


The control block is not sensitive to faults if the specified operating conditions are met, particularly the quality of the hydraulic oil.
Table 9: Malfunction table Fault Hydraulic oil escapes from the control block and/or the control block sections Possible causes Control block is leaking Plug screws are leaking Remedy Tighten fastening screws applying the specified tightening torque. Tighten plug screws applying the specified tightening torque; replace copper seals, if necessary. For O-ring seals: Do not tighten up plug screw, replace seals and tighten plug screw with specified tightening torque. In case of persistent leakages: Check sealing surface/seal for damages. Replace plug screw, if necessary. Disassemble control block and/or control block section replace by a new one. Check seals and replace screwing, if necessary. Check tightening torque, see details of the manufacturer of the screwing. Replace secondary valve/plug screw.

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

Fault The supply lines to the control block are leaking

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

Hydraulic fluid escapes between the control block sections

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 does not reset or resets too slowly.

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

Performance: Hydraulic actuation

Undersupply (pump pressure too low) No control pressure

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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.

15.2 Hydraulic circuit diagrams


See Technical data sheet and Installation drawing.

15.3 Electrical schematics


See Technical data sheet.

15.4 Lubricant recommendations


Information on hydraulic fluids on mineral oil basis which is also applicable for Rexroth control blocks are available in the Technical data sheet and in ourbrochures. RE 90220 hydraulic fluids on mineral oil basis RE 90220-1 hydraulic fluids on mineral oil basis

15.5 Spare parts list


Spare parts lists are available from Bosch Rexroth on request.

15.6 Address directory


Contact person for service and spare parts Bosch Rexroth AG Service Industriehydraulik Brgermeister-Dr. Nebel-Str. 8 97816 Lohr am Main Germany Phone +49(9352)18-1164 Fax +49(9352)18-3363 http://www.boschrexroth.com/service Ordering address for accessories and control blocks Headquarters: Bosch Rexroth AG Hydraulics Zum Eisengieer 1 97816 Lohr am Main Germany Phone +49(9352)18-0 Fax +49(9352)18-40 You will find the addresses of our foreign subsidiaries on the internet at: http://www.boschrexroth.com

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Alphabetical index

16 Alphabetical index
A N

Accessories 37 Contact person for 37 Ordering address for 37

Nameplates 14

Before first commissioning 23 Bleeding the hydraulic system 25

Obligations of the operator 11 Operating temperature 25

Cleanliness class 25 Corrosion protection 16

Pressure fluid 29 contaminations 30 disposal 36 performance characteristics 29

Disposal 36 Environmental protection 36 Recycling 36

Q R

Qualification of personnel 10

E F

Electrical supply 22

Repair 31 Contact person for 31 Safety instructions 31

First commissioning 24 Flange surfaces 20, 34

Inspection and maintenance 29 Intended use 9

Spare parts Contact person for 32 Order 31 Ordering address for 32 Storage conditions 16

Leakage at the outside 29

Troubleshooting 38 Malfunction table 38

Mobile control block assembling 20 coating 20 connecting hydraulically 22 disassembling 33 fastening 20 replacing components 34 storing 16 transporting 16

Unpacking 20

Warranty 11, 14, 37

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

Subject to change without notice Printed in Germany RE 64025-B/06.2010