Control Blocks

8/12/2019 Control Blocks

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Control blocksfor mobile applications

Applies to the following types:M1

M4M6

M7

M8

M9

MOSM

SP

SX

Replaces: 06.2010

English

Operating instructions

RE 64025-B/03.2014

MO

SX

M4M1 M6

SP

M7

SM

M8 M9



The data specified above only serve todescribe the product. No statementsconcerning a certain condition or suitabilityfor a certain application can be derived fromour information. The information given doesnot release the user from the obligation of

own judgment and verification. It must beremembered that our products are subject to anatural process of wear and aging.

© This document, as well as the data,specifications and other information set forth init, are the exclusive property of Bosch RexrothAG. It may not be reproduced or given to thirdparties without its consent.

The cover shows an example configuration.The product supplied may therefore differ fromthe photo shown.

The original operating instructions were

prepared in German.



RE 64025-B/03.2014, control blocks, Bosch Rexroth AG

3/56Contents

Contents

1 About this documentation 5

1.1 Validity of the documentation 5

1.2 Required and amending documentation 5

1.3 Representation of information 7

1.3.1 Safety instructions 7

1.3.2 Symbols 8

1.3.3 Designations 8

1.3.4 Abbreviations 8

2 Safety instructions 9

2.1 General information on this chapter 9

2.2 Intended use 9

2.3 Improper use 10

2.4 Qualification of personnel 10

2.5 General safety instructions 10

2.6 Product-specific safety instructions 11

2.7 Personal protective equipment 14

3 General information on damage to property and damage to the product 15

4 Scope of delivery 18

5 About these products 19

5.1 Performance description 19

5.2 Product description 19

5.3 Product identification 19

6 Transport and storage 21

6.1 Transporting the control block 21

6.1.1 Transport by hand 21

6.1.2 Transport using lifting tools 21

6.2 Storing the control block 23

7 Assembly 25

7.1 Unpacking 25

7.2 Painting the control block 25

7.3 Installation conditions 26

7.4 Installation position 26

7.5 Assembling the control block 26

7.5.1 Required tools 26

7.5.2 Preparation 26

7.5.3 Dimensions 26

7.5.4 Fastening the control block 27

7.5.5 Completing the assembly 28

7.5.6 Connecting the control block mechanically 28

7.5.7 Connecting the control block hydraulically 29

7.5.8 Connecting the control block electrically 31

8 Commissioning 33

8.1 Before first commissioning 34

8.2 First commissioning 35

8.3 Re-commissioning after standstill 36



4/56

Bosch Rexroth AG, control blocks, RE 64025-B/03.2014

Contents

9 Operation 37

9.1 Information on the use of control blocks at low temperatures 37

10 Maintenance and repair 39

10.1 Inspection 41

10.2 Maintenance 41

10.3 Repair 41

10.4 Spare parts 42

11 Disassembly and exchange 43

11.1 Necessary tools 43

11.2 Preparing disassembly 43

11.3 Disassembling the control block from the machine 43

11.4 Preparing the components for storage/further use 43

12 Disposal 44

13 Extension and modification 45

14 Troubleshooting 46

14.1 How to proceed for troubleshooting 46

14.2 Fault table 47

15 Technical data 50

16 Index 52



About this documentation 5/56


1 About this documentation

1.1 Validity of the documentation

This documentation applies to the following products: • M1

• M4

• M6

• M7

• M8

• M9

• MO

• SM

• SP

• SX

This documentation is aimed at the machine manufacturer.

This documentation contains important information on the safe and proper

transport, assembly and disassembly, commissioning, operation, maintenance and

simple troubleshooting of the product.

▶ You should read this documentation thoroughly and in particularchapter 2 "Safety instructions" on page 9 and chapter 3 "General information

on damage to property and damage to the product" on page 15 before working

with the control block.

This documentation applies to all control blocks of the listed series irrespective of

their date of production until a new revision of this document is issued.

1.2 Required and amending documentation ▶ Do not commission the product until you have been provided with the

documentation marked with the book symbol relating to your Rexroth product

and you have understood and observed it.

Table 1: Required and amending documentation

Title Document number Document type

Open center control block MO-16, 22, 32 64354 Data sheet

Open center control block MO-40 64370 Data sheet

Open center control block MO-52 64373 Data sheet

Open center control block M1 64263 Data sheet



Open center control block SM 64122 Data sheet

Load-sensing control block M4-12 64276 Data sheet



Load-sensing control block SP-08 64139 Data sheet

LUDV control block M6-15 64321 Data sheet




LUDV control block SX 10 64132 Data sheet





6/56 About this documentation


Table 1: Required and amending documentation

Title Document number Document type

Order confirmation

Contains the order-specific technical data of your control block.

Order confirmation

Quotation drawing

Contains the external dimensions, all connections and the hydraulic circuitdiagram of your control block.

Quotation drawing

Hydraulic fluids based on mineral oils and related hydrocarbons

Describes the requirements on hydraulic fluids based on mineral

oil and related hydrocarbons for operation with Rexroth hydraulic

components and helps you to select a hydraulic fluid for your

Bosch Rexroth component.

90220 Data sheet

Environmentally compatible hydraulic fluids

Describes the requirements on environmentally compatible hydraulic fluids

for operation with Rexroth hydraulic components and helps you to select

a hydraulic fluid for your Bosch Rexroth component.

90221 Data sheet

MTTFd reliability characteristics regarding the functional safety

according to ISO 13849

MTTFd values for control blocks

90290 Data sheet

Further information is available from Rexroth and at

www.boschrexroth.de/mobilhydraulik-katalog.



About this documentation 7/56


1.3 Representation of informationConsistent safety instructions, symbols, terms and abbreviations are used in this

documentation so that you can quickly and safely work with your product. For a

better understanding, they are explained in the following sections.

1.3.1 Safety instructions

In this documentation, safety instructions are included in chapter 2.6 "Product-

specific safety instructions" on page 11 and in chapter 3 "General information

on damage to property and damage to the product" on page 15 or whenever

a sequence of actions or instructions is explained which bears the risk of personal

injury or damage to property. The hazard avoidance measures described must

be observed.

Safety instructions are set out as follows:

SIGNAL WORDType and source of danger!

Consequences in case of non-compliance

▶ Hazard avoidance measures

▶ <Enumeration>

• Warning sign: Draws attention to the danger

• Signal word: Identifies the degree of danger

• Type and source of danger: Specifies the type and source of danger

• Consequences: Describes the consequences of non-compliance

• Precaution: Specifies how the danger can be prevented

Table 2: Risk classes according to ANSI Z535.6-2006

Warning sign, signal word Meaning

DANGERIndicates a dangerous situation which will cause death or

severe personal injuries if not avoided.

WARNINGIndicates a dangerous situation which may cause death or

severe personal injuries if not avoided.

CAUTIONIndicates a dangerous situation which may cause minor or

medium personal injuries if not avoided.

NOTICE Damage to property: The product or the environment could

be damaged.



8/56 About this documentation


1.3.2 Symbols

The following symbols indicate notices which are not safety-relevant but increase the

comprehensibility 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, independent action

1.

2.

3.

Numbered instruction:

The numbers indicate that the actions must be carried out one after

the other.

1.3.3 Designations

The following designations are used in this documentation:

Table 4: Designations

Designation Meaning

Mono block Control block which is molded in one piece. Optionally, further directional

valves can be mounted to extend the functions.

Directional valve Control block element with 1 spool axis, in the following also referred to as

"control block disc".

Control spool Main spool

Actuation Type of control of the control spool

1.3.4 Abbreviations

The following abbreviations are used in this documentation:

Table 5: Abbreviations

Abbreviation Meaning

DB Pressure relief valve (Druckbegrenzungsventil)

DIN Deutsche Industrie Norm (German Industry Standard)

ISO International Organization for Standardization



Safety instructions 9/56


2 Safety instructions

2.1 General information on this chapter

The product has been manufactured according to the generally accepted codes ofpractice. However, there is still the risk of personal injury and damage to property if

you do not observe this chapter and the safety instructions in this documentation.

▶ Read this documentation completely and thoroughly before working with

the product.

▶ Keep this documentation in a location where it is accessible to all users at

all times.

▶ Always include the required documentation when you pass the control block on

to third parties.

2.2 Intended use

Control blocks are hydraulic components and are therefore neither covered bythe scope of completely nor partly completed machinery in the sense of the EU

Machinery Directive 2006/42/EC. The component is exclusively intended to be

assembled together with other components to form partly completed or complete

machinery. The component may only be commissioned if it has been integrated

in the machine for which it is designed and if the safety of the overall system was

established according to the requirements of the Machinery Directive.

The control blocks specified in chapter 1.1 have been developed for the control of

different hydraulic actuators in mobile machines.

Any deviating use is only permitted after consultation with Bosch Rexroth.

The product can be used as safety-relevant 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 safety-

related part of the control must be specified by the system manufacturer or system

planner. Further information is available in the standards for functional safety such

as ISO 13849, IEC 62061 or specific professional guidelines.

▶ Comply with the technical data, application and operating conditions and

performance limits according to data sheet and order confirmation. For

information on the permitted hydraulic fluids, see the respective data sheet.

The control block is not a piece of safety equipment.

Intended use includes having read and understood this documentation completely,

especially chapter 2 "Safety instructions" on page 9.



10/56 Safety instructions


2.3 Improper useAny use deviating from the intended use is improper and thus not admissible.

The valve is not suitable for being operated in explosive environments.

Bosch Rexroth AG does not assume any liability for damage caused by improper use.

The user assumes all risks involved with improper use.

2.4 Qualification of personnelThe activities described in this documentation require basic knowledge of mechanics,

electrics and hydraulics as well as knowledge of the appropriate technical terms.

For transporting and handling the product, additional knowledge of how to handle

lifting tools and the necessary attachment devices is required. Experts are those who

can recognize potential dangers and apply the appropriate safety measures due to

their technical training, knowledge and experience, as well as their understanding

of the relevant provisions pertaining to the work to be undertaken. An expert must

observe the relevant specific professional rules and have the necessary hydraulic

expert knowledge.

Hydraulic expert knowledge means, amongst others:

• Reading and understanding hydraulic schemes

• Having knowledge of the function and interaction of hydraulic components

Bosch Rexroth offers measures supporting the training in specific fields. Please

find an overview of the training contents on the Internet at:

http://www.boschrexroth.de/didactic

2.5 General safety instructions

•

Observe the valid regulations on accident prevention and forenvironmental protection.

• Observe the safety regulations and provisions of the country where the product is

implemented/used.

• Exclusively use Rexroth products in technically perfect condition.

• Observe all notices on the product.

• Persons who assemble, operate, disassemble or maintain Rexroth products must

not be under the influence of alcohol, drugs or pharmaceuticals that may affect

their ability to respond.

• Only use original Rexroth accessories and spare parts.

• Comply with the technical data and environmental conditions indicated in the

product documentation. • The installation or use of inappropriate products in safety-relevant applications

could result in uncontrolled operating conditions during operation. This may

cause injuries and/or damage to property. Therefore, only use a product for

safety-relevant applications if this use is expressly specified and permitted in the

documentation of the product, e.g. in explosion-protected areas or in safety-related

parts of control systems (functional safety).







• Do not commission the product until you can be sure that the end product (for

example a machine/system) in which the Rexroth products are to be installed

comply with the country-specific provisions, safety regulations and standards of

the application.

2.6 Product-specific safety instructionsThe following safety instructions apply to chapters 6 to 14.

WARNINGUnintended pressure build-up/pressure reduction!

Danger to life, risk of injury, damage to property!

The control block may block in an undefined position due to internal contamination,

e.g. polluted hydraulic fluid, abrasion or residual dirt from system components.

As a result, the driven actuator is no longer under the operator’s control.

▶ Secure the machine against rolling (away) and unintended movements according

to the machine manufacturer's specifications. ▶ Comply with the specified cleanliness class for the hydraulic fluid according to

the data sheet.

Hydraulic fluid leaking through cracks in the housing, leaks between control

block and/or attachment parts due to the use of an inadmissible pressure

medium, adjustment work at seal lock nuts, cleaning with solvents and thus

destruction of seals!

Danger to life and risk of injury due to injection of a pressurized oil jet! Risk of

burning due to escaping oil!

▶ Access to the control blocks during operation must be limited in such a way

that hazards to persons caused by the bursting during operation is avoided by

suitable safeguards.

▶ Depressurize the control block and repair the leak.

Pressurized machine!

Danger to life, risk of injury, severe injury when working at machines that have not

been stopped! Damage to property!

▶ Secure the overall system according to the manufacturer's instructions.

▶ Make sure that the control block has been depressurized. For doing so, observe

the specifications of the machine manufacturer.

▶ Do not disconnect lines, connections or components as long as the control

block is under pressure.

▶ Observe the specifications of the machine manufacturer regardingmachine shut-down.





WARNINGDanger due to suspended loads!

Danger to life, risk of injury, damage to property!

In case of improper transport, the control block may fall down and cause injuriese.g. crush injuries or fractures and/or damage to the product.

▶ Make sure that the lifting capacity of the forklift and/or the lifting tool

is sufficient.

▶ Never step or reach below suspended loads.

▶ Provide for a stable position during transport.

▶ Use your personal protective equipment (e.g. safety goggles, protective gloves,

suitable working clothes, safety shoes).

▶ Use suitable lifting tools for the transport.

▶ Observe the prescribed position of lifting straps.

▶ Comply with the national laws and regulations regarding occupational health

and safety and transport.Leaking oil mist!

Explosion hazard, risk of fire, allergic reactions, inhalation, environmental pollution!

▶ Depressurize the control block and repair the leak.

▶ Keep open fire and ignition sources away from the control block.

▶ If control blocks are positioned close to ignition sources or powerful heat

radiators, screening to ensure that potentially leaking hydraulic fluid cannot be

ignited and the hose lines are protected against early aging.

Electrical voltage!

Danger to life, risk of injury and damage to property due to electric shock!

▶ Always de-energize the mating connectors before assembling the product or

when connecting and disconnecting connectors.

▶ Secure the machine according to the manufacturer's instructions.

Incorrect energy supply!

Danger to life and risk of injury due to uncontrolled valve positions! These may

cause unexpected behavior of the control block.

▶ Always connect the earthing connection of the control block with the

appropriate earthing system of your installation.

▶ Only use a power supply unit with protective isolation. Always consider the

country-specific regulations.





CAUTIONRisk of injury due to sharp edges and rough surfaces!

When working at the control block and transporting it, there is a risk of injury, e.g.

due to sharp edges at the valve housing, at threads or at attachment parts. ▶ Wear safety shoes with steel toe caps.

▶ Wear protective gloves and suitable working clothes as protection against injuries.

Risk to limbs due to crushing and impact!

There is a risk of injury in the gap between the actuation element and the

valve housing.

▶ Keep your limbs away from the gap between the actuation element/hand lever

and the valve housing.

High noise development during operation!

Danger of hearing damage, deafness!

The noise emission of control blocks is e.g. dependent on operating pressure and

installation conditions. Under normal application conditions, the sound pressure

level may exceed 70 dBA.

▶ Always protect yourself by wearing ear protection when working close to

running control blocks.

Hot surfaces at the control block!

Risk of burning!

▶ Allow the control block to cool down sufficiently before touching it.

▶ Wear heat-resistant protective clothing, e.g. gloves.

Cold surfaces at the control block!

Sticking skin to and frostbites caused by contact with the cold valve housing!

▶ Wear personal protective clothing, e.g. cold protection gloves.

Improper laying of cables and lines!

Risk of stumbling and damage to property!

▶ Lay cables and lines in such a way that they cannot be damaged and no one can

trip over them.

Contact with hydraulic fluid!

Health hazard/impairment of health, e.g. eye injuries, skin lesions, poisoning due

to inhalation!

▶ Avoid contact with hydraulic fluids.

▶ When dealing with hydraulic fluids, you must imperatively observe the safety

instructions of the lubricant manufacturer. ▶ Use personal protective equipment (like e.g. safety goggles, protective gloves,

suitable working clothes, safety shoes).

▶ If hydraulic fluid comes into contact with the eyes or enters the bloodstream or

is swallowed nevertheless, consult a doctor immediately.





CAUTIONEscaped hydraulic fluid due to leakage!

Slip hazard!

▶ Pay attention to escaped hydraulic fluid on the ground around the machine. ▶ If hydraulic fluid has leaked, use an oil binding agent.

▶ Dispose of the hydraulic fluid in accordance with the applicable national

regulations in your country.

2.7 Personal protective equipmentThe user of the control block is responsible for the personal protective equipment.

Observe the safety regulations and provisions in your country.

Bosch Rexroth recommends using the following personal protective equipment when

using the product:

•

Heat-resistant protective clothing, e.g. protective gloves for working at thecontrol block

• Safety shoes, protective gloves, safety goggles, ear protection and suitable working

clothes for working at the control block



General information on damage to property and damage to the product 15/56


3 General information on damage to

property and damage to the product

The warranty only applies to the delivered configuration.The claim to warranty expires in case of:

• Incorrect assembly, commissioning and operation

• Improper use

• Removal of protection caps and lead seals (e.g. for pressure adjustments)

• Alteration of the factory settings

• Modifications and attachments

• Opening the valve

• Improper handling

• Using third party spare parts

The following safety instructions apply to chapters 6 to 14.

NOTICE Danger due to improper handling!

The product may be damaged!

▶ Do not apply any inadmissible mechanical, hydraulic or electrical loads to

the product.

▶ Never use the product as a handle or step.

▶ Do not transport the control block on sensitive attachment parts (e.g. actuation

elements, sensors, solenoids or valves).

▶ Put the control block carefully onto the contact surface in order not to damage

it and secure it against falling down. ▶ Do not place/put any objects on top of the product.

▶ Do not place/put the control block on the actuation elements.

▶ Avoid impacts against sensitive attachment parts (e.g. sensors, solenoids or

actuation elements).

▶ Avoid impacts against sealing surfaces (e.g. at the working connections).

▶ Do not remove the protective covers from the control block before connecting

the lines.

▶ Disconnect all electrical connector plugs prior to painting.

▶ Make sure that the electronic components (e.g. sensors) are not electrostatically

charged (e.g. during painting).

Control block falling down!

The surface coating may be damaged and attachment parts may come off or bend.

Impaired functionality.

▶ Use a suitable lifting, putting down and moving technique.

▶ Place the product on a clean, bearing surface.

Intrusion of fluids and foreign particles due to missing seals and caps!

Loss of the protection class and risk of short circuit!

▶ Before assembly, ensure that all seals and caps of the plug-in connections

are tight



16/56 General information on damage to property and damage to the product


NOTICE Mixing hydraulic fluids!


▶ Drain all liquids from the control block prior to installation to avoid mixing withthe hydraulic fluid used for the machine.

▶ Any mixing of hydraulic fluids by different manufacturers and/or of different

types by the same manufacturer is generally not admissible.

Contamination of the hydraulic fluid!

The cleanliness of the hydraulic fluid has a considerable impact on the cleanliness

and life cycle of the hydraulic system as a whole. Early wear and malfunctions!

▶ It is imperative that the working environment at the site of installation is free of

dust and foreign substances in order to prevent foreign particles (e.g. welding

beads or metal chips) from getting into the hydraulic lines and causing

product wear or malfunctions. The control block must be protected from dirt

during installation. ▶ Only use clean connections, hydraulic lines and attachment parts (e.g.

measuring devices).

▶ No contamination must enter when closing the connections.

▶ Before commissioning, ensure that all hydraulic connections are tight and

that all seals and caps of the plug-in connections are correctly installed and

undamaged in order to prevent fluids and foreign particles from penetrating

the product.

▶ During filling, filter the hydraulic fluids using a suitable filter system in order to

minimize the solid particle contamination and water in the hydraulic system.

Improper cleaning!


▶ Cover all openings with appropriate safeguards in order to prevent cleaning

agents from penetrating the control block.

▶ Never use solvents or aggressive cleaning agents. Use water and mild cleaning

agents, if necessary, to clean the control block.

▶ Do not point high-pressure washers at sensitive components, e.g. rubber

components (bellows), electrical connections (solenoids, sensors) and

actuation elements.

▶ Use fiber-free cleaning cloths for cleaning.

Environmental pollution caused by incorrect disposal!

Careless disposal of the control block, the hydraulic fluid and the packagingmaterial may lead to environmental pollution!

▶ Dispose of the control block, the hydraulic fluid and the packaging in

accordance with the applicable national regulations in your country.



General information on damage to property and damage to the product 17/56


NOTICE Leaking or spilt hydraulic fluid!

Environmental pollution and pollution of the ground water!

▶ When draining the hydraulic fluid, always put a collecting pan underthe control block.

▶ If hydraulic fluid is spilled, use an oil binding agent.

▶ Dispose of the hydraulic fluid in accordance with the applicable national




18/56 Scope of delivery


4 Scope of delivery

The scope of delivery includes:

• Control block according to order confirmation

Upon delivery, the following parts are additionally mounted depending on the model:

• Protective covers

• Protective plugs/plug screws

• Attachment point(s) for transport, e.g. ring bolt



About these products 19/56


5 About these products

5.1 Performance description

Please find technical data, operating conditions and limitations of use of the controlblocks in the data sheet and the order confirmation.

The assignment of the control blocks to the data sheets is available in

chapter 1.2 "Required and amending documentation" on page 5.

5.2 Product descriptionFor the description of the set-up and function as well as instructions on the project

planning of the individual control blocks, refer to the data sheet.

The assignment of the control blocks to the data sheets is available in Table 1

"Required and amending documentation" on page 7.

5.3 Product identificationUse the name plate to identify the control block.

The details on the name plate apply to the control block in the condition as

supplied. If modifications have been carried out at the control block as compared

to the condition as supplied, the name plate information may possibly not be true

for the present control block.

▶ Take care not to damage the existing name plates.

▶ Compare the material number of the control block indicated on the name plate

with the details on the quotation drawing to make sure that the operating

instructions apply to the product available to you.If in doubt, contact Bosch Rexroth.

1 2

8910

3

4

5

6

7

MNR: R90xxxxxxx

SN: XXXX

708AMade in Germany

M4-G12345-20/5M4-12J_W2_MV01

123456789

FD: 12W20

1

7

10

6

411 3

MNR: R90xxxxxxx

Made in France

123456789

2

Fig. 1: Example name plate M4 Fig. 2: Example name plate SX

1 Word mark (manufacturer)

2 Material number of the control block

3 Date of production

4 Serial number

5 Material short text

6 Customer material number (optional)

7 Area/works number

8 Installation stamp

9 Test stamp

10 Designation of origin

11 DataMatrix code



20/56 About these products


Depending on the order, there might be deviations from the name plates shown

above. On customer-specific name plates, the Rexroth logo can be replaced by a

customer logo, for example.

Further labels on the product are intended for internal Bosch Rexroth

purposes only.

If the control block is supplied without name plate, the identification can be

found on the connection or end plate.



Transport and storage 21/56


6 Transport and storage

▶ Always comply with the required environmental conditions with regards to

transport and storage, see chapter 6.2 "Storing the control block" on page 23.

Failure to comply causes premature aging of components and reduces the

life cycle.

For unpacking instructions, see chapter 7.1 "Unpacking" on page 25.

6.1 Transporting the control blockDepending on the weight and transport duration, there are the following

transport possibilities:

• Transport by hand

• Transport using lifting tools (ring bolt or lifting strap)

The dimensions and weights vary according to the model. For the values applicable

to your control block, see the quotation drawing and the data sheet.

6.1.1 Transport by hand

Control blocks with a weight of up to 15 kg can be transported by hand for a short

time, if necessary.

CAUTION! Danger due to heavy loads!

When carrying control blocks, there is a risk of health hazards.

▶ Use a suitable lifting, putting down and moving technique.

▶ Use your personal protective equipment (like e.g. safety goggles, protectivegloves, suitable working clothes, safety shoes).

▶ Do not transport the control block using sensitive attachment parts (e.g. sensors

or valves).

▶ Put the control block carefully onto the contact surface in order not to damage it.

6.1.2 Transport using lifting tools

For the transport, the control block can be connected to a lifting tool using the

attachment points at the housing or using a lifting strap. Possible attachment

points are

• mounting threads of the connection flanges • attached ring bolts.

▶ Ensure that the lifting tool is sufficiently dimensioned for the control block.

▶ Hang a chain or any other suitable lifting gear into the attachment points at the

housing of the control block.



22/56 Transport and storage


WARNING! Danger due to suspended loads!

During transport using a lifting strap, the control block may tilt out of the loop and

cause personal injuries.

▶ Use the broadest lifting strap possible.

▶ Make sure that the control block is properly secured with the lifting strap.

▶ You may only guide the control block by hand for fine positioning and in order to

avoid swinging.

▶ Never step or reach below suspended loads.

▶ Put the lifting strap around the control block in such a way that it does not run

over attachment parts (e.g. valves) and ensure that the control block is not

suspended at attachment parts.

Fig. 3: Transport using a lifting strap

Transport using

a lifting strap



Transport and storage 23/56


6.2 Storing the control block • The storage facilities must be free from corrosive substances, fumes and gases.

• In order to avoid damage to seals, do not operate any ozone-generating devices in

the storage facilities, such as mercury vapor lamps, copiers, printers, high-voltage

devices, electric motors, electric radio sources and/or discharges.

• The storage facilities must be dry and free from dust.

• Optimum storage temperature: +5 °C to +20 °C.

• Minimum storage temperature: –20 °C.

• Maximum storage temperature: +40 °C.

• UV protection: 100 %

Avoid high light irradiation (e.g. bright windows or direct neon light).

• Relative air humidity (no condensation): Max. 65 %.

• Store the control block in such a way that it is protected from shocks, do not stack it.

• Do not store the control block on sensitive attachment parts, e.g. actuation

elements, sensors, solenoids or valves.

• Do not remove any protective covers and protective plugs.

▶ Check the correct storage of the control block on a monthly basis. The maximum

admissible storage time is two years.

As a standard, the control blocks are coated with a priming (single coat paint) or

protected against corrosion by electroplating at the factory.

Mineral oil is used for internal corrosion protection of closed valves. Surfaces of

the control block that are not coated or electroplated (e.g. flange surfaces) are not

protected against corrosion.

Delayed commissioning, long transport and storage times or the decommissioning of

Rexroth control blocks for a longer period of time may lead to corrosion. In order toprevent this, additional corrosion protection measures have to be taken.

The claim to warranty expires in case of non-compliance with the requirements

and storage conditions or after expiry of the maximum storage time.

Recommended procedure following an extended storage time:

1. Check the complete control block for damage and corrosion prior to installation.

2. In a test run, check the control block for correct function and leak-tightness.

3. External seals of control blocks which have been stored for more than 12 months

must be checked for damage before assembly and must be replaced, if necessary.

4. If the storage time of two years is exceeded, outward facing seals have tobe exchanged.

After expiry of the maximum storage time, we recommend having the control

block checked by your competent Bosch Rexroth service.

Requirements

Following delivery



24/56 Transport and storage


For questions regarding repair and spare parts, contact your local Bosch Rexroth

service or the service department of the control block manufacturer's factory, see

chapter 10.4 "Spare parts" on page 42.

If a dismounted control block is to be stored, it has to be preserved for the time of

storage to protect it against corrosion.

The following instructions only refer to control blocks that are operated with

a hydraulic fluid on mineral oil basis. Other hydraulic fluids require preservative

measures that are specifically designed for them. In this case consult the Bosch

Rexroth service, for the address see chapter 10.4 "Spare parts" on page 42.

Bosch Rexroth recommends the following procedure:

1. Clean the control block.

2. Drain the control block.

3. Close all connections air tightly.

4. Wet the unpainted flange-mounting surfaces and exterior seals of the control

block with mineral oil.

5. Protect sensitive attachment parts (e.g. actuation elements, sensors, solenoids or

valves) using suitable measures as in the condition as supplied.

6. Pack the control block with a suitable desiccant air-tightly in corrosion

protection film.

7. Store the control block in such a way that it is protected from shocks. For further

conditions, see section "Requirements" on page 23 in this chapter.

8. If required, send the control block to the Bosch Rexroth service for repair.

Following disassembly



Assembly 25/56


7 Assembly

Prior to installation, make sure the following documents are at hand:

• Quotation drawing (installation drawing) of the control block (available from your

contact at Bosch Rexroth) • Hydraulic circuit diagram of the control block (see the quotation drawing)

• Hydraulic circuit diagram of the machine (available from the machine manufacturer)

• Order confirmation (contains the order-specific technical data of your

control block)

• Data sheet of the control block (contains the admissible technical data)

7.1 Unpacking

CAUTION! Danger due to falling parts!

If the packaging is opened improperly, parts may fall out and be damaged or even

cause injuries! ▶ Put the packaging on level ground with sufficient load carrying capacity.

▶ Only open the packaging from above or at the intended place.

1. Remove the control block packaging.

2. Check the control block for transport damage and completeness, see

chapter 4 "Scope of delivery" on page 18.

3. Dispose of the packaging in accordance with the currently applicable national

provisions in your country.

4. Return reusable packaging material to the sending Bosch Rexroth plant.

7.2 Painting the control block

CAUTIONEscape of aerosols during painting!

Risk of inhaling harmful substances.

▶ Wear inhalation protection and protective clothing during painting.

Complete the following steps if the control block is to be painted prior to

installation:

▶ Completely protect the hydraulic ports against paint application by screwing-in

plastic screw-in plugs beforehand.

▶ Protect the mounting threads against paint application by screwing-in bolts.

▶ Mask the flange surfaces of the control blocks as well as the connection and end

plates carefully before coating to prevent dirt or paint from entering.

▶ Avoid paint application to the contacts of the electrical connections and make

sure not to cause any damage to the connector.



26/56 Assembly


▶ Protect attachment parts (e.g. actuation elements, sensors, solenoids) against

paint application.

▶ Protect plastic and rubber parts against paint application.

▶ When removing the plastic screw-in plugs after painting, make sure that no paint

chips get into the control block.

▶ Protect name plates against paint application using a foil which can be removed

after coating.

7.3 Installation conditionsThe installation position determines the installation and commissioning procedure

(e.g. bleeding of the control block).

▶ Mount the control block in such a way that the forces and torques to be expected

can be transmitted without risk. The machine manufacturer is responsible for the

design of the mounting elements and screw connections.

▶ Ensure that the control block is bled and filled with hydraulic fluid during

commissioning and operation. The control block must not drain hydraulically in

case of standstill.

▶ It is imperative that the working environment at the site of installation is free

of dust and foreign substances. The control block must be protected from dirt

during installation. Contamination of the hydraulic fluid may considerably impair

the function and life cycle of the control block.

7.4 Installation positionIf not indicated otherwise in the technical documents, the control block can be

installed in any position.

7.5 Assembling the control block

7.5.1 Required tools

Installation can be carried out using standard tools. No special tools are required.

Also observe the instructions of the manufacturers of the other hydraulic

components when selecting the required tools.

7.5.2 Preparation

1. Compare the material number and the designation (type key) with the details in

the order confirmation.

If the material number of the control block does not match the number in theorder confirmation, contact the Bosch Rexroth service for clarification. For the

address, refer to chapter 10.4 "Spare parts" on page 42.

2. Drain the control block prior to installation to avoid mixing with the hydraulic

fluid used for the machine.

7.5.3 Dimensions

The quotation drawing contains the dimensions for all connections at the

control block.



Assembly 27/56


7.5.4 Fastening the control block

For mounting, the control block is provided with mounting bores which can be seen

in the quotation drawing and the data sheet. The required mounting hole image

(dimensions and tolerances) for the mounting bores on the machine can also be

found in the quotation drawing or on the data sheet. Select the tightening torques

according to the usual standard values for each bore size and bolt property class.

Excessive tightening torque might cause the control spool to jam. If this is the case,

reduce the mounting torque accordingly. Observe the adequate residual clamping

force of the screws.

1. Observe the contact surface requirements from the quotation drawing.

2. Check the levelness of the flange surface in the machine (tolerance: 0.5 mm)

3. Always fasten the control block at all mounting points provided. Depending on

the type of mounting, use screws and/or hexagon nuts with one of the property

classes listed in Table 6 according to EN ISO 4762 or EN ISO 4014.

4. Tighten the screws with the respective tightening torques specified in

the standard.

Bosch Rexroth recommends using a screw connection with the following parameters:

Table 6: Mounting screws

Series Dimension Property class Tightening

torque [Nm]

Screw-in depth

[mm]

M1-16 M8 8.8 / 10.9 27 / 40 1)

M1-25 M10 8.8 / 10.9 54 / 79 10

M1-32 M12 8.8 / 10.9 93 / 37 1)

M4-12 M10 8.8 / 10.9 41 / 60 12 … 15

M4-15 M10 8.8 / 10.9 54 / 79 10M4-22 M16 8.8 / 10.9 230 / 338 1)

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

M8-35 M16 8.8 / 10.9 230 / 338 1)

M9-20 M16 8.8 / 10.9 230 / 338 16

M9-25 M16 8.8 / 10.9 230 / 338 16

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 1)

MO-52 M20 8.8 / 10.9 464 / 661 20

SP-08 M8 8.8 / 10.9 25 / 30 10 … 141)



28/56 Assembly


Series Dimension Property class Tightening

torque [Nm]

Screw-in depth

[mm]

SM 12 M8 8.8 / 10.9 27 / 40 101)

SX 10 M8 8.8 / 10.9 27 / 40 1)

SX 12 M10 8.8 / 10.9 54 / 79 1)

SX 14 M10 8.8 / 10.9 54 / 79 1)

¹) Through hole in the housing; the screw-in depth depends on the nut thread material.

7.5.5 Completing the assembly

1. Remove transport aids which might have been attached.

CAUTION! Operation with protective plastic plugs!

Operating the control block with protective plugs may cause injuries or damage to

the control block.

▶ Prior to commissioning, remove all protective plugs and replace them by line

connections or suitable pressure-resistant metal plug screws.

2. Remove the transport protection.

The control block is delivered with protective covers and protective plugs, where

appropriate. These components are not pressure-resistant and therefore have to be

removed prior to connection. Use suitable tools to avoid damage to the sealing and

functional surfaces. If the sealing or functional surfaces are damaged, contact your

Bosch Rexroth service or the service department of the control block manufacturer.

Line connectors are equipped with protective plugs or plug screws that serve as

transport protection. All connections required for the function have to be

connected. Non-compliance may lead to mulfunctions or damage. Connections

that are not connected have to be closed with plug screws as the protective plugs

are not pressure-resistant.

7.5.6 Connecting the control block mechanically

Please see the quotation drawing for the connection of the actuation elements

incl. tolerances. Select the tightening torques according to the actuation elements.

The actuation must be free of transverse forces!

▶ Before commissioning, make sure that the tongue is in zero position (control

spool in central position).



Assembly 29/56


7.5.7 Connecting the control block hydraulically

CAUTIONDangerous motion of the hydraulic actuators!

Risk of injury caused by incorrect pin assignment or mixed up cable connectors dueto unintended actuator movement!

▶ Make sure that all pipes and/or hoses are connected to the correct control block

port and do not mix them up in any case.

▶ After completion of the connections, check the correct assignment of the cable

connectors to each control block solenoid.

NOTICE Damage caused by incorrect assembly!

During operation, hydraulic lines and hoses installed under mechanical stress

create additional mechanical forces. This reduces the life cycle of the control blockand the complete machine.

▶ Assemble lines and hoses without stress.

The machine manufacturer is responsible for the design of the lines. The control

block has to be connected to the remaining hydraulic system according to the

hydraulic circuit diagram of the machine manufacturer.

The connections and the mounting threads are designed for the peak pressure

indicated in the data sheet. The machine manufacturer has to make sure that the

connection elements and lines comply with the intended application conditions

(pressure, flow, hydraulic fluid, temperature) including the required safety factors.

Only connect hydraulic lines that match the control block connection (pressure

level, size, system of units).

Observe the following instructions regarding the installation of hydraulic lines.

• Lines and hoses have to be installed without preload so that there are no

additional mechanical forces during operation that reduce the life cycle of the

control block and possibly the entire machine.

• If necessary, remove any resinification caused by incorrect storage.

• Use suitable seals as sealants.

–Observe the compatibility of seals with the hydraulic fluid used.

–Use the provided seal at each hydraulic connection.

–Make sure that the connections are clean and intact.

• Make sure that the connections and connection elements are air-tight.

• Pressure lines

–Only use pipes, hoses and connection elements as pressure lines that are rated

for the operating pressure range indicated in the data sheet. They also have to be

pressure-resistant with respect to the external air pressure.

• Tank line

Instructions on the

installation of lines



30/56 Assembly


– Always install tank lines in such a way that the control block is always filled with

hydraulic fluid and cannot drain hydraulically in case of an extended standstill.

The control blocks are used in fields of application with metric and US system

of units.

Both the system of units and the size of the threaded hole and the screw-in stud

(e.g. plug screw) must match.

Due to little visual differences, there is a risk of confusion. In this regard, observe

the specifications in the quotation drawing. The SI units usually apply, unless

stated otherwise.

WARNING! Leaking or ejected screw-in studs!

If a screw-in stud whose system of units and size do not match the threaded hole is

pressurized, it may come loose and even be ejected with high speed from the hole.

This may cause serious injuries and damage to property. Hydraulic fluid may escape

from this leakage point.

▶ Use the drawings (quotation drawing) to check the required screw-in stud for

all fittings.

▶ Make sure that there is no confusion when installing fittings, mounting screws

and plug screws.

▶ Use a screw-in stud with the same system of units and the right size for the

respective threaded hole.

For an overview of the line connections, see the respective data sheet and the

quotation drawing.

Risk of confusion with

threaded connections

Connection overview



Assembly 31/56


Observe the specifications in standards and/or the manufacturer's specifications for

the screw-in studs, fittings, armatures, plug screws, etc. used. In addition, keep in

mind that tightening torques may also depend on the admissible pressure and

temperature range and on the application conditions.

Connecting the control block to the hydraulic system:

1. Remove the protective plugs and/or plug screws from the connections that are to

be connected according to the hydraulic circuit diagram.

2. Make sure that the sealing surfaces of the hydraulic connections and functional

surfaces are not damaged.

3. Only use clean hydraulic lines or rinse them prior to installation.

4. Connect the lines according to the quotation drawing and the machine diagram.

Check if all connections are piped or closed with plug screws.

5. Correctly tighten the fittings (observe the tightening torques!). Mark all correctly

tightened fittings, e.g. with a permanent marker.

6. Check all pipes and hose lines and all combinations of connection pieces,

couplings or connection points with hoses or pipes for their operational safety.

7.5.8 Connecting the control block electrically

NOTICE Functional impairment caused by wrong plug-in connections!

Only the plug-in connections listed in the data sheet/quotation drawing may be

used for the electrical connection.

▶ Comply with the assembly instructions of the plug-in connection manufacturer.

▶ Before commissioning, check the power supply as to whether the voltagecomplies with the details of the quotation drawing and whether the total

of the currents to be expected is less than or equal to the capacity of the

power supply.

▶ The plug-in connections may only be contacted when deenergized. The assembly

process must not be repeated more than 10 times.

The machine manufacturer is responsible for the design of the electric control.

Electrically controlled control blocks have to be connected according to the electric

circuit diagram of the machine.

Regarding control blocks with electric adjustment device and/or attached sensors,

observe the specifications in the data sheet and the quotation drawing, e.g.: • The admissible voltage range

• The admissible current

• The correct pin assignment

Tightening torques

Procedure



32/56 Assembly


For details on the correct connection assignment, the connector, the protection

class and the matching mating connector, see the data sheet and the quotation

drawing. The mating connector is not included in the scope of delivery.

Connecting the control block to the machine electronics:

1. De-energize the plug-in connections of the control block.

2. Prior to connection, check that the connector and all its seals are intact.

3. Connect the control block to the electrical system (12 V or 24 V).

If required, change the position of the connector by turning the solenoid body (coil).

This does not depend on the connector model.

Proceed as follows:

1. Loosen the mounting nut (1) of the solenoid using a suitable tool. For this

purpose, turn the mounting nut (1) by one turn in counterclockwise direction.

2. Turn the body of the solenoid (2) in the desired position.

3. Re-tighten the mounting nut with a tightening torque of 4+1 Nm.

Procedure

Changing the

connector position

1

2



Commissioning 33/56


8 Commissioning

WARNINGDanger due to working in the danger zone of a machine!

Danger to life, risk of injury or severe injury!

▶ Pay attention to potential sources of danger and remove them before

commissioning the control block.

▶ When commissioning, comply with the instructions of the

machine manufacturer.

CAUTIONCommissioning an incorrectly installed product!

Confusing the connections or cable connectors causes unexpected functions

and/or irreparable damage to the control block and thereby endangers personsand equipment!

▶ Make sure that all electrical and hydraulic connections are either connected

correctly or closed.

▶ Prior to the functional test, check if the required piping was installed according

to the hydraulic circuit diagram.

▶ Check that the cable connectors are correctly assigned to the respective

electric components.

▶ Commission the product only if it is installed completely.

Risk of injury caused by entrapped air

Air entrapped in the control block might cause components to vibrate during

operation in such a way that they hit the end stops hard and are damaged.

Unexpected movements of the actuators may cause injuries.

▶ Before commissioning, make sure that entrapped air is completely removed

from the control block. This can e.g. be done by a small amount of hydraulic

fluid q ≤ 20 % qpump flowing through in all switching positions. If the control

block is not equipped with a self-bleeding function at the covers, it may be

necessary to bleed the covers by means of the bleed screw.

▶ In any case, observe the instructions on bleeding in the operating instructions

of the machine.

NOTICE Product damage and impaired functionality resulting from a lack of hydraulic fluid!

Commissioning the control block without or too little hydraulic fluid will damage or

even destroy the control block immediately.

▶ When commissioning or re-commissioning a machine, you should ensure that the

housing area, as well as the suction and working lines of the control block are

filled with hydraulic fluid and that they remain filled during operation.



34/56 Commissioning


8.1 Before first commissioning ▶ 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.

▶ Check the operating instructions for the machine to find out in which machine

the Rexroth control block must be installed and carry out a visual inspection

to check whether commissioning of the hydraulics might result in uncontrolled

and dangerous motions. If necessary, also observe the hazard analysis/risk

assessment of the machine.

▶ Take respective precautions if risks are to be expected, e.g. make sure that the

cylinder piston rod can be extended without any risk.

▶ Secure the load to be lifted additionally with a lifting tool/load lifting device.

▶ Check whether the electrical control of the machine allows for 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.

▶ Develop a sequence program for the commissioning process and file it in the

technical documents as annex to the operating instructions.

▶ Divide the functional circuit diagram in sub-circuits which can be commissioned

one after the other.

▶ Read the functional circuit diagram and clarify ambiguous facts

and representations.

▶ Determine in which spool position the control blocks must be switched and how

the control blocks must be adjusted.

▶ Apply important mandatory signs, prohibition signs, information signs and check

whether the meaning of these signs is explained in the operating instructions.

▶ Observe the following order for commissioning: –Pump circuit

–Parts of the control: e.g. pressure cut-off and switch-over, free circulation,

pressure reduction, etc.

▶ Make sure that pipes and/or hoses are connected to all ports and/or that the

ports are closed with plug screws.

▶ Ensure that the cap nuts and flanges on pipe fittings and flanges are tightened

according to the standard.

▶ Switch pressure and flow control valves, pump controls, and sensors such as

pressure switches, position switches and thermostats to the switching positions

and settings specified in the sequence program.



Commissioning 35/56


8.2 First commissioningFor Bosch Rexroth, the first commissioning is the first examination and release of

the product.

We recommend accepting points 1 up to and including 7 for the series production of

the hydraulic system.

For all commissioning works on the control block observe the general safety

instructions and the intended use in chapter 2 "Safety instructions" on

page 9.

▶ Let the control block acclimatize itself for several hours before commissioning,

as otherwise water may condense in the housing.

▶ Make sure that all electrical and hydraulic connections are either used or closed.

Commission the control block only if it is completely installed.

▶ Avoid temperature shocks. There must not be temperature differences of more

than 20 °C between the control block and the hydraulic fluid. Otherwise, there is

a risk of jammed spools. At temperatures below –20 °C, the control block has to

be warmed up.

▶ Only use hydraulic fluid that complies with the following requirements:

For information on admissible hydraulic fluids, refer to the relevant data sheet of

the product, see Table 1 "Required and amending documentation" on page 5.

For first commissioning of the control block, proceed as follows:

1. Completely fill the control block and, if available, the pilot control circuit, with

admissible hydraulic fluid (see data sheet).

2. Ensure the hydraulic supply of the control block.

3. If available, ensure the power supply of the control block.4. Check the electrical connections of the control block.

Electrical connections must be checked for their proper condition by or under the

guidance and supervision of a specialized electrician before first commissioning

or any re-commissioning.

Observe the operating instructions of the machine where the control block

is installed.



36/56 Commissioning


5. Bleeding the control block.

–Before the actual operation, you must switch the control block several times

under operating pressure in each direction of actuation and with reduced

velocity. This will expel any remaining air from the control block. Mechanical

damage due to inadmissibly high acceleration of the hydraulic fluid and the

control spool is thus avoided and the control block's life cycle is increased.

– If automatic bleeding of the cover is not sufficient, bleeding can also be

carried out by means of the bleed screws potentially available at the cover

(series specific).

Procedure:

ATTENTION! When loosening the bleed screw, hydraulic fluid may leak!

▶Loosen the bleed screw of the cover by up to two rotations to ensure that the

air can escape through the thread and the seal of the bleed screw.

▶Switch the valve several times in order to completely bleed the cover.

▶Fastening the bleed screw considering the valid tightening torque.

–Also observe the instructions on bleeding in the operating instructions of

the machine.

Carry out a leak test.

Ensure that no hydraulic fluid leaks at the control block and at the connections

during operation. If hydraulic fluid leaks, see Table 8 "Fault table" on page 47.

6. Carry out a 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 the pressure and stop the functional test immediately in case of leakage!

7. Check the hydraulic fluid temperature of the control block after several hours

of continuous operation. Check whether the measured temperature lies within

the product-specific limits. If the temperature lies outside the determined limits,

the Bosch Rexroth warranty will forfeit.

8. Have a hydraulic fluid sample analytically tested for the required cleanliness class

after initial commissioning. Replace the hydraulic fluid if the required cleanliness

class is not achieved. If the hydraulic fluid is not tested in the laboratory after

initial commissioning, the following applies: Replace the hydraulic fluid.

8.3 Re-commissioning after standstillRe-commissioning is necessary if the control block has been out of operation for a

period of more than 12 months.

▶ Carry out the re-commissioning as described in chapter 8.2 "First commissioning"

on page 35.

Also observe the instructions for (re-)commissioning after standstill in the

machine operating instructions.



Operation 37/56


9 Operation

The product is a component which does not require any settings or modifications

during operation. As a result, this chapter of the instructions does not contain any

information on adjustment options. Only use the product within the performancerange provided in the technical data. The machine manufacturer is responsible for

the correct project planning of the hydraulic system and its control.

▶ Avoid temperature shocks. There must not be temperature differences of more

than 20 °C between the control block and the hydraulic fluid. Otherwise, there is

a risk of jammed spools. With temperatures below –20 °C, the control block has

to be warmed up.

9.1 Information on the use of control blocks at low temperatures • Minimum ambient temperature –40 °C

• Warm-up phase with little load from –40 °C

• Operation with load from –25 °C

• For use under –25 °C, seals deviating from the standard are used. Differing limits

of use are specified in the Technical Customer Documents (TKU) of the control

block.

• Avoid humidity in the environment of the control blocks as potential condensation

at the movement seals may lead to freezing of the control spools during standstill.

This may also lead to the destruction of the seal ring if the control spool is

actuated.

• The viscosity limits specified in the control blocks data sheets must be complied

with over the entire operating period by selecting a suitable hydraulic fluid, both in

winter and in summer with warmer temperatures. • For boundary conditions, the following values apply:

νmin = 5 mm²/s

(shortly at a max. admissible temperature of θ max = 115 °C/90 °C)

Note that the max. hydraulic fluid temperature of 115 °C (90 °C for perbunan) must

not be exceeded locally, e.g. at the pressure reducing valve, either.

νmax = 2000 mm²/s

(shortly in case of cold start, n ≤ 1000 min-1, θ min = –40 °C)

• Especially the start-up viscosity must be observed.

• If new components are installed into a cold machine, they must be filled at higher

temperatures in advance to ensure sufficient lubrication in all areas.

• Coordinate the measures for filters, cylinders, gears etc. with the manufacturers.

Boundary conditions

General information



38/56 Operation


• Control units, amplifiers, sensors, encoders, solenoids

– Minimum storage temperature –50 °C

– Installation and full function from –40 °C

• Devices with displays (unless specified in more detail)

– Minimum storage temperature –20 °C

– Installation and full function from –20 °C

• With switching and proportional solenoids, possible increases in the hysteresis

and/or extended switching times due to increasing operating medium viscosity

with decreasing temperature are to be expected.

1. Heat up all components to at least –40 °C.

2. Start the drive motor.

3. Warm up the pump according to the specification (see data sheet 90300-03-B)

4. Warm-up phase of the open hydraulic system

–Pump starts up with Diesel motor and should be operated with idle speed of

the Diesel motor for at least 10 minutes in order to ensure self lubrication.

–The pump must be in pressure-reduced circulation (max. 50 bar and max. 50 %

delivery volume).

–Loading of the open circuit, e.g. by means of separate preload valve, generates

a circulation pressure of approx. 50 bar at the pump. Maintain this operating

state until –25 °C are reached in the system. The Diesel speed must not

be increased.

–Afterwards, operate all machine functions slowly and several times at minimum

load in order to heat up the entire machine as evenly as possible. In this

connection, the tank temperature is to be observed which will decrease again

due to the return flow of the cold hydraulic fluid.

5. Warm-up phase of the closed hydraulic system

–Set the pump to neutral position without flow.

–The pump starts up with Diesel motor and should be operated with idle speed

of the Diesel motor for at least 10 minutes.

–Afterwards, slowly swivel out the pump. All machine functions must be

operated slowly and several times without load until –25 °C are reached in the

entire machine.

6. Valves that are used at low temperature enable flushing from the pump to the

tank in order to sufficiently heat the control block.

7. The covers in hydraulically pilot operated valves are flushed with tank oil via the

flushing channels.

8. After completed pump warm-up, slowly operate all actuators without load inorder to exchange the cold oil contained in the actuators by warm oil.

9. The flushing should remain functional during operation in order to keep actuators

which are only operated occasionally at operating temperature.

10.Permanent flushing is necessary in all components in order to avoid temperature

shocks. The max. admissible temperature difference between operating medium

and the individual components is 20 °C.

11.Our control blocks may be loaded from a circuit temperature of ≥ –25 °C in

the machine.

Information on

the electronics

Procedure



Maintenance and repair 39/56


10 Maintenance and repair

CAUTIONRisks caused by reduced safety during maintenance works

Experience has shown that the number of accidents during maintenance is

higher than during normal operation. Therefore, we would ask you to observe the

following safety instructions in the interest of your safety.

▶ Regularly check the safety equipment – if any – for correct functionality.

▶ Complete all maintenance in due time, properly and completely and document it.

▶ Adequately secure the maintenance area before starting maintenance.

▶ Pay attention to cleanliness in order to avoid malfunctions caused by pollution.

Paint residues on sealing surfaces must be removed before assembly. Make

sure that paint residues do not enter control block openings as this may lead

to malfunctions.

▶ Operate the hydraulic product in maintenance mode with increased alertness as

it may possibly require disassembly of certain protective devices. Switch off the

hydraulic product and secure it against unintended re-activation.

▶ The user is not allowed to change the settings of safety valves. Re-adjustments

may only be carried out by authorized testing authorities.

▶ Wear protective goggles, protective gloves and safety boots.

Depressurize the hydraulic product and properly unload available pressure

accumulators, if applicable.

▶ Let system sections and pressure lines which can be opened cool down before

starting maintenance.

▶ Open slowly any segments that are still pressurized.

▶ Please observe that the hydraulic system might still be pressurized even after

it has been disconnected from the actual pressure supply if there are check

valves in the pressure lines above the pumps. Move all cylinders to the safe

end position.

▶ Lower all loads. Provide for an external safeguard if the load cannot be lowered.

Maintenance must not be carried out at lifted units without external safeguard.

▶ Switch off all pumps.

▶ Support vertical cylinders mechanically against sinking.

▶ Only new, structurally identical and tested components, spare parts and

lubricants in original equipment quality are admitted for replacement/use.

▶ 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 re-commissioning.

▶ After the completion of all work, remove all tools and devices used for

maintenance from the hydraulic product.



40/56 Maintenance and repair


CAUTIONPersonal injury caused by non-functional spare parts

Spare parts that do not meet the technical requirements specified by

Bosch Rexroth may cause personal injuries. ▶ Only use original Rexroth spare parts.

NOTICE Penetrating dirt and fluids will cause malfunctions!

Safe function of the control block is no longer ensured.

▶ Always ensure absolute cleanliness when working at the control block.

▶ Cover all openings with appropriate protective equipment in order to prevent

cleaning agents from penetrating the system.

▶ Ensure that all seals and caps of the plug-in connections are firmly attached so

that no humidity can penetrate the control block during cleaning.

▶ Dust accumulation on the control block has to be removed at regular intervals.

Damage to the surface from solvents and aggressive cleaning agents!

Aggressive cleaning agents may damage the seals of the control block and

accelerate ageing.

▶ Never use solvents or aggressive cleaning agents (cleaning agents on a

solvent base).

▶ Only clean the control block using a damp, lint-free cloth. Only use water and,

if necessary, a mild cleaning agent.

Damage to the hydraulic system and seals!

The water pressure of a high-pressure washer may damage the hydraulic systemand the seals of the control block. The water displaces the oil from the hydraulic

system and seals.

▶ Do not use high-pressure washers for cleaning.

Delayed inspections and maintenance works!

Damage to property!

▶ Perform the prescribed inspection and maintenance works at the control block

at the intervals specified in these instructions.

Also observe the instructions for maintenance and repair in the machine

operating instructions.



Maintenance and repair 41/56


10.1 InspectionFor reliable operation of the control block, Bosch Rexroth recommends checking

the control block on a regular basis and recording and archiving the following

operating conditions:

Table 7: Inspection plan

Works to be carried out at the control block Interval

Check the operating temperature weekly

Hydraulic fluid analysis: Viscosity, time deterioration

and contamination

annually or all 2000

operating hours

Check the control block for external leakage (visual inspection). daily

Check the control block for the development of strange noises. daily

Check the mounting elements for tight seat.

All mounting elements have to be checked when the control block

is depressurized, de-energized and cool.

monthly

10.2 MaintenanceIf used as intended, the control block is low-maintenance.

The life cycle of control block decisively depends on the quality of the applied

hydraulic fluid. We therefore recommend exchanging the hydraulic fluid at least

once per year or every 2000 operating hours (whichever occurs first) or to have it

analyzed for further usability by the hydraulic fluid manufacturer or a laboratory.

Observe the following general rule:

From a hydraulic fluid temperature of > 70 °C, the aging speed doubles with every

10 °C temperature increase.

For the maximum admissible degree of contamination of the hydraulic fluid,

see the data sheet in chapter "Technical data".

Also observe the information on the hydraulic fluid in the operating instructions

of the machine.

10.3 RepairBosch Rexroth offers a wide range of repair services for Rexroth control blocks.

The control block may only be repaired by Bosch Rexroth certified service centers or

by the machine manufacturer.

▶ Exclusively use Rexroth original spare parts to repair the Rexroth control blocks.

Otherwise, the functional safety of the control block is no longer ensured and you

lose your claim to warranty.

For questions regarding repair, contact your local Bosch Rexroth service

or the service department of the control block manufacturer's factory, see

chapter 10.4 "Spare parts" on page 42.



42/56 Maintenance and repair


For repair works, the control block may only be disassembled to the extent

described in these operating instructions.

10.4 Spare parts

CAUTIONUse of unsuitable spare parts!

Spare parts that do not meet the technical requirements specified by

Bosch Rexroth may cause personal injuries and damage to property.

▶ Exclusively use Rexroth original spare parts to repair the Rexroth control blocks.

Otherwise, the function of the control block is no longer ensured and you lose

your claim to warranty.

Spare parts lists are available from your local Bosch Rexroth representative.

Indicate the material and serial numbers of the control block as well as the material

numbers of the spare parts when ordering spare parts.

In case of questions regarding spare parts, please contact your local Bosch Rexroth

service or the service department of the control block manufacturer's factory.

Bosch Rexroth AG

Zum Eisengießer 1

97816 Lohr am Main, Germany

Phone: +49 (0) 9352 18-40 50 60

[email protected]

For the addresses of our sales and service network, seewww.boschrexroth.de/adressen.



Disassembly and exchange 43/56


11 Disassembly and exchange

11.1 Necessary tools

•

Tools suitable for the fastenings specified in the quotation drawing • Permanent marker for marking the control block plates

• Clean collecting pan for collecting leaking hydraulic fluid

11.2 Preparing disassembly1. Decommission the overall system as described in the machine

operating instructions.

– Depressurize and unload the hydraulic system as described by the

machine manufacturer.

– Ensure that the control block is depressurized and de-energized.

2. Secure the overall system according to the manufacturer's instructions.

11.3 Disassembling the control block from the machine

If the component to be exchanged (e.g. screw-in cartridge valve) is freely

accessible from the outside, the control block does not have to be disassembled

from the machine.

Proceed as follows to disassemble the control block:

1. Let the control block cool down so that it can be disassembled without risks.

2. Make sure that no hydraulic fluid can escape unintentionally from the system dueto the disassembly of the control block.

3. Place a clean collecting pan below the control block to collect any escaping

hydraulic fluid residues.

4. Disconnect the lines and collect any escaping hydraulic fluid residues in the

collecting pan.

5. Disassemble the control block according to the machine

manufacturer’s specifications.

6. Place the product on a clean, bearing surface.

7. Drain the control block completely.

8. Close all openings in order to prevent the deposition of dirt.

11.4 Preparing the components for storage/further use ▶ Proceed as described in chapter 6.2 "Storing the control block", section "After

disassembly" on page 24.



44/56 Disposal


12 Disposal

CAUTIONSpring preloaded components!

Risk of injury due to ejected components when the valve is disassembled into its

individual components!

▶ Slowly loosen screw-in parts and spring preloaded components and secure

them until the compression spring is unloaded.

Careless disposal of the control block, the hydraulic fluid and the packaging material

may lead to environmental pollution.

For the disposal of the control block, comply with the following instructions:

1. Drain the control block completely.

2. Dispose of the control block and the packaging material in accordance with the

applicable national regulations in your country.3. Dispose of the hydraulic fluid in accordance with the currently applicable national


4. Disassemble the control block into its individual components in order to

recycle them.

5. Separate for example:

–Steel

–Aluminum

–Non-ferrous metal

–Electrical and electronic parts (solenoids, sensors, coils)

–Plastic

–Rubber (seals, bellows, pedal rubber)



Extension and modification 45/56


13 Extension and modification

Modifications as well as changes in settings at the control block are not admissible.

The Bosch Rexroth warranty applies only to the configuration supplied. Followingan extension or a modification, the claim to warranty expires.

Adjusting the settings causes the claim to warranty to expire. If you require the

settings to be changed, contact your local Bosch Rexroth service, for the address

see chapter 10.4 "Spare parts" on page 42.

For available accessories, see the respective data sheet.

Accessories are available from your Rexroth specialist dealer. For addresses of our

sales and service network, see www.boschrexroth.de/adressen.

Optional accessories

http://www.boschrexroth.de/adressen

http://www.boschrexroth.de/adressen





Troubleshooting 47/56


14.2 Fault tableThe control block is not sensitive to faults if the specified application conditions are

met. This particularly applies to the quality of the hydraulic fluid and the maximum

admissible pressure values.

Table 8: Fault table

Fault Possible causes Remedy

Hydraulic fluid leaks at

the control block and/or the

control block plates

Control block is leaking Tighten the mounting screws applying the specified

tightening torque.

Plug screws are leaking Tighten the plug screws applying the specified tightening

torque; replace copper seal rings, if necessary.

For O-ring seals:

Do not tighten up plug screw, replace seals and tighten

plug screw with specified tightening torque.

If leakage persists:

Check sealing surfaces/seal for damage.

Where appropriate, replace the plug screw.

Control block housing and/or control block

plate is leaking

Disassemble the control block and/or the control block

plate and replace by a new one.

Connections leading to the actuator (screw

necks, fittings) are leaking

Check seals and replace the fittings, if necessary.

Check tightening torques, see details of the

fitting manufacturer.

Valve housing at the secondary valve/plug

screw is leaking

Replace secondary valve/plug screw.

Hydraulic fluid leaks

from the supply lines to

the control block

Piping or hose lines damaged

The piping or hose lines are loose

Replace piping or hose lines.

Tighten screwing and fittings according to the assembly

instructions applicable for fittings. All assembly

instructions are available from the machine manufacturer.

Hydraulic fluid escapes

between the control

block plates

Seals in the flange surface are damaged Replace seals, see "Installation drawing".

Deposition of dirt during assembly of

the control block

Disassemble control block, clean flange surface.

Control block housing leaking at the

flange surface

Replace control block plate.

Tightening torque of the tie rods too low Check tightening torques, see "Technical data sheet".

Residual oil from assembly/test of

the control block

Remove oil and dirt from the control block. Do not use

any cleaning agents which are aggressive against plastic

or metal, change the properties of plastic, react with

metal or generate residues.

Working movement

not constant

There is air in the hydraulic fluid Bleed the hydraulic system, see page 36.



48/56 Troubleshooting




Version:

Mechanical actuation:

The control spool cannot be

controlled mechanically

Tie rod screwed with too much/different

tightening torque

Loosen tie rod nuts and tighten with specified

tightening torque.

Oil temperature too high and/or

temperature difference between hydraulicfluid and control block too high, thus

blocking of control spool and control block

as a result of different thermal expansion

Check cooler function, oil supply and pump pressure in

neutral position.Avoid temperature shock, for related information see

"Technical data sheet".

Dirt or foreign matter deposited during the

assembly of the connectors leading to the

actuator jam the control spool

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 solenoid or tweezers. Replace

valve housing in case of jammed foreign matter.

The control spool does not

reset or resets too slowly.

The control spool jams See fault above "Control spool cannot be

controlled mechanically".

Control spool is retained due to the flow

force which is caused by too much oil flow

Reduce oil flow from the actuator to the tank.

Version:Electro-hydraulic actuation

Control spool shows no

reaction or delayed reaction

to electric control

No solenoid current or solenoid currenttoo low, wrong operating point (solenoid

current not correctly adjusted to oil flow)

Check voltage supply and operating point Q/I, see"Technical data sheet". Check plug-in connections.

Pilot control valve and/or solenoid valve

does not work

Replace pilot control valve and/or solenoid valve.

Undersupply (pump pressure too low).

Provide minimum pump pressure,

see "Technical data sheet".

Undersupply (pump pressure too low). Provide minimum

pump pressure, see "Technical data sheet".

Pilot oil supply jams Disassemble pilot oil supply and replace by a new one.

Pilot control valves are contaminated Replace pilot control valve.

Version:

Hydraulic actuation

Undersupply (pump pressure too low) Provide minimum pump pressure, see "Technical

data sheet".

No pilot pressure Check pilot oil supply

For valves in parallel

operation: No pressure and/

or no oil flow at the actuator

with deflected control

spool, considerably delayed

pressure build-up

Oil flows to the actuator with minimum

pressure due to undersupply

Increase pump oil flow by applying higher speed or

larger pump, and/or reduce actuator volume using a

volume throttle.

Neutral circulation pressure

too high

No load-sensing unloading

(only for M4, M6, M7, SP,SX)

Control spool not in neutral position For tongue: Check projection, see "Technical data sheet".

Pressure in the control covers too high (check control).

Return flow pressure too high Separate return flow from mutual return line, use

separate return line or increase line cross-section.

Inlet pressure compensator jams Replace inlet plate.

Motion at the actuator

despite neutral position

Control spool not in neutral position Pressure in the control covers too high (check control).

Secondary pressure relief valve is leaking

and/or set too low

Check set pressure at the secondary pressure relief valve.

Leakage at control spool too large Leakage values see data sheet.

Install leakage-free lowering brake valve.



Troubleshooting 49/56




No detent function Return force in the actuating element too

high compared to the detent force (spring)

Disassemble and clean the detent.

Detent unit worn out Replace the detent unit.

Detent release forcetoo high

The control spool jams See "Control spool cannot be deflected" under "Controlspool is jammed" at the top of this table.

Detent unit damaged Replace the detent unit.

Detent force too high Clean and grease detent unit. Replace detent unit if

malfunction cannot be removed.

Following faults due to contamination, it is – in addition to the repair – essential to

check the quality of the hydraulic fluid and to improve it, if necessary, by suitable

measures such as flushing, replacement or the additional installation of filters.



50/56 Technical data


15 Technical data

For the admissible technical data of the control blocks, see the respective data

sheet. The assignment of the control blocks to the data sheets is available in Table 1

"Required and amending documentation" on page 5.

The data sheets are available on the Internet at

www.boschrexroth.com/various/utilities/mediadirectory

For further information, refer to the online product catalog

Mobile hydraulics: www.boschrexroth.de/mobilhydraulik-katalog

The order-specific technical data of your control block are available in the

order confirmation.



Technical data 51/56




52/56 Index


16 Index

▶ A

Abbreviations 8Accessories 45

Assembly 25

– Completing 28

– preparing 26

▶ B

Bleeding 36

▶ C

Commissioning 33

– first 35Connecting

– electrical 31

– hydraulically 29

Corrosion protection 23

▶ D

Designations 8

Disassembly 43

– implementing 43

– preparing 43

Disposal 44

▶ F

Fault table 47

Functional test 36

▶ H

Hydraulic fluid 35

– Disposal 44

– exchange 41

▶ IIdentification 19

Inspection 41

Installation conditions 26

Installation position 26

Intended use 9

▶ L

lifting strap 22

Lifting tool 21

▶ M

Maintenance 41Modification 45

▶ N

Name plate 19

▶ O

Operation 37

▶ P

Performance description 19

Product description 19

▶ Q

Qualification of personnel 10

▶ R

Re-commissioning

– after standstill 36

Repair 41

Required documentation 5

▶ SSafety instructions 9

– General 10

– Product-specific 11

– Signal word 7

Scope of delivery 18

Settings 45

Solenoid position

– change 32

Spare parts 42

Storage time 23

Storing 23Symbols 8

▶ T

Technical data 50

Tools 26, 43

Transport 21

– by hand 21

– using a lifting strap 22

– using lifting tools 21



Index 53/56


Troubleshooting 46

– Fault table 47

▶ U

Unpacking 25

▶ W

Warranty 15, 23, 45

Weight 21



54/56 Index




Index 55/56




Bosch Rexroth AG

Mobile Applications

Zum Eisengießer 1

97816 Lohr am Main

Germany

Phone +49 9352 18-0

[email protected]

www.boschrexroth.com

For your local contact, please refer to:

www.boschrexroth.de/adressen