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Bosch Rexroth MCR 30 Series, Instruction Manual

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Bosch Rexroth MCR 30 Series Instruction Manual Download Page 47

 

Maintenance and repair 47/56

 

RE 15215-01-B/11.2015, MCR Series 30, 31, 32, 33 and 41, 

Bosch Rexroth AG

  

10.4 Repair

Bosch Rexroth offers a comprehensive range of services for the repair of Rexroth 
radial piston motors.
Repairs to Rexroth radial piston motors should only be carried out by authorized and 
qualified staff at service centers certified by Bosch Rexroth.

 

▶

Only original spare parts supplied by Bosch Rexroth should be used to repair 
Rexroth radial piston motors. Failure to do so will invalidate the warranty and may 
result in unsatisfactory performance and component failure.

In the event of questions regarding repairs, contact your responsible Bosch Rexroth 
Service partner or the service department of the manufacture‘s plant for the radial 
piston motor, see chapter 10.5 "Spare parts" on page 47.

10.5 Spare parts

 CAUTIOn

Use of unsuitable spare parts!

Spare parts that do not meet the technical requirements specified by Bosch 
Rexroth may cause personal injury or property damage!

 

▶

Only original spare parts supplied by Bosch Rexroth should be used to repair 
Rexroth radial piston motors. Failure to do so may result in unsatisfactory 
performance and possible component failure.

The spare parts lists for radial piston motors are order specific. When ordering spare 
parts, quote the material and serial number of the radial piston motor as well as the 
material numbers of the spare parts.
Address all questions regarding spare parts to your responsible Bosch Rexroth 
Service partner or the service department of the manufacturer‘s plant for the radial 
piston motor.

Bosch Rexroth Limited 
Viewfield Industrial Estate 
Glenrothes, Fife 
Scotland, KY6 2RD 
United Kingdom 
Phone  +44 1592 631777

For general inquiries please contact [email protected]

For the addresses of foreign subsidiaries, please refer to 

www.boschrexroth.com/addresses

Summary of Contents for MCR 30 Series

Page 1: ... Ersetzen Sie diese Abbildungsfläche durch Ihre Produktabbildung Instruction manual RE 15215 01 B 11 2015 Replaces 08 09 English Radial piston motor MCR Series 30 31 32 33 and 41 ...

Page 2: ...own judgment and verification Our products are subject to a natural wear and aging process 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 an example application The product delivered may differ from the image on the cover The ...

Page 3: ...ance description 16 5 2 Product description 16 5 2 1 Section of the radial piston motor 16 5 2 2 Functional description 17 5 3 Product identification 22 5 4 Product variants 23 6 Transport and storage 24 6 1 Transporting the radial piston motor 24 6 1 1 Transporting by hand 25 6 1 2 Transporting with lifting device 25 6 2 Storing the radial piston motor 27 7 Installation 28 7 1 Unpacking 28 7 2 In...

Page 4: ... Operation 43 9 1 Manual brake release in case of emergency 44 10 Maintenance and repair 45 10 1 Cleaning and care 45 10 2 Inspection 45 10 3 Maintenance 46 10 4 Repair 47 10 5 Spare parts 47 11 Removal and replacement 48 11 1 Required tools 48 11 2 Preparing for removal 48 11 3 Removing the radial piston motor 48 11 4 Preparing the components for storage or further use 48 12 Disposal 49 13 Modifi...

Page 5: ...st the installation drawing via your contact person at Bosch Rexroth Installation drawing Radial piston motor for wheel drives MCR F Radial piston motor for heavy duty wheel drives MCR W Radial piston motor for frame integrated drives MCR A Radial piston motor for integrated drives MCR H Radial piston motor for track drives MCR T Radial piston motor for hydraulic drive assist MCR R series 32 Radia...

Page 6: ...nal word identifies the degree of the danger Type and source of danger identifies the type and source of the danger Consequences describes what occurs if the safety instructions are not complied with Precautions states how the danger can be avoided Table 2 Danger classes in accordance with ANSI Z535 6 Safety sign signal word Meaning DANGER Identifies a dangerous situation that will result in death...

Page 7: ...for compact drives MCR D MCR E Radial piston motor for industrial applications Threaded plug Metal screw pressure resistant Protective plug Made out of plastic not pressure resistant only for transportation 1 3 4 Abbreviations This documentation uses the following abbreviations Table 5 Abbreviations Abbreviation Meaning ATEX EU directive for explosion protection Atmosphère explosible DIN Deutsche ...

Page 8: ...lowing use The radial piston motor converts hydrostatic flow into mechanical rotation It is certified for use as a hydraulic motor in hydrostatic drives Observe the technical data application and operating conditions and performance limits as specified in data sheets 15195 15196 15197 15198 15199 15200 15221 15222 or 15223 and in the order confirmation Information about approved hydraulic fluids c...

Page 9: ...s due to their professional training knowledge and experience as well as their understanding of the relevant regulations pertaining to the work to be done Qualified personnel must observe the rules relevant to the subject area and have the necessary hydraulic knowledge Hydraulic knowledge means for instance reading and fully understanding hydraulic plans fully understanding in particular the inter...

Page 10: ...h application Please contact your Bosch Rexoth sales partner Danger from excessively high pressure Danger to life or risk of injury damage to equipment Changing the factory pressure settings can cause pressure to increase beyond the permissible maximum Operating the unit above the permissible maximum pressure can cause component failure and hydraulic fluid to escape under high pressure Changes to ...

Page 11: ...protect hose lines from premature aging Electrical voltage Risk of injury due to electric shock or damage to equipment Always set up the relevant part of the machine system so that it is free of electrical voltage before you install the product or when connecting and disconnecting plugs Protect the machine system against being energized Presence of strong magnets only in specific motor types e g M...

Page 12: ...ct with hydraulic fluid Hazard to health health impairment e g eye injuries skin damage toxication during inhalation Avoid contact with hydraulic fluids When working with hydraulic fluids strictly observe the safety instructions provided by the lubricant manufacturer Use your personal protective equipment e g safety glasses safety gloves suitable working clothes safety shoes If hydraulic fluid sho...

Page 13: ...s Damage to equipment due to improper lubrication Product can be damaged or destroyed Never operate the radial piston motor with insufficient hydraulic fluid Make sure in particular that the rotary group has sufficient lubrication When commissioning a machine system make sure that the case interior and the service lines of the radial piston motor are filled with hydraulic fluid and remain filled d...

Page 14: ...e damaged Plug all openings with the appropriate protective equipment in order to prevent detergents from entering the hydraulic system Never use solvents or aggressive detergents Use only water and if necessary a mild detergent to clean the radial piston motor Do not point the power washer at sensitive components e g shaft seal electrical connections and components Use lint free cloths for cleani...

Page 15: ...L Included in the delivery contents are Radial piston motor as per order confirmation The following ports are protected with protective plug threaded plug and protective covers Standard main ports A and B drain port L Where applicable brake port Z 2 speed port X filler port F metal plug Fig 1 Radial piston motors with various port protection ...

Page 16: ...circuit the hydraulic fluid flows from the reservoir to the hydraulic pump from where it is transported to the hydraulic motor From the hydraulic motor the hydraulic fluid flows directly back to the reservoir The output direction of rotation of the hydraulic motor can be changed e g by a directional valve In the closed circuit the hydraulic fluid flows from the hydraulic pump to the hydraulic moto...

Page 17: ...is torque is transferred to the output shaft 6 via the splines in the cylinder block 4 If the torque exceeds the shaft load the cylinder block turns causing the pistons to stroke working stroke Once the end of a stroke is reached the piston is returned to its bore by the reaction force at the cam return stroke and the fluid is fed to the motor outlet port in the rear case The output torque is prod...

Page 18: ...gives the potential for cost and efficiency improvements The motor maximum speed remains unchanged Rexroth has developed a special spool valve to allow smooth switching to reduced displacement whilst on the move This is known as soft shift and is a standard feature of 2W motors The spool valve requires either an additional sequence valve or electro proportional control to operate in soft shift mod...

Page 19: ... schematic Notice Danger from improper use of the holding brake Product can be damaged The holding brake is designed solely for static use and should not be applied whilst the motor is rotating Fig 7 Holding brake section As a safety requirement in mobile applications a parking brake may be provided to ensure that the motor cannot turn when the machine is not in use The brake is mounted by the way...

Page 20: ...e Danger from improper use of the holding brake Product can be damaged The holding brake is designed solely for static use and should not be applied whilst the motor is rotating Fig 8 Holding brake section MCR T The brake is mounted by the way of the front case 2 and drive shaft 16 A disc pack 11 with alternate discs splined to the drive shaft and front case is compressed by the force of a disc sp...

Page 21: ...nsor 14 may be fitted as an option giving a two channel output of phase displaced square waves and enabling detection of speed and direction A toothed target disc 15 is fitted to the motor cylinder block 4 and the sensor fitted to a port in the rear case produces a pulse on each channel as each tooth passes in front of it The frequency of the pulses is proportional to the rotational speed Versions...

Page 22: ...e applicable 3 Motor serial number 4 Barcode of motor serial number 5 Internal plant designation 6 Manufacture date yrWwk 7 Motor description 8 Barcode of motor part number 9 Motor part number Additionally the motor serial number 3 along with the manufacture date 6 is stamped on either the front case rear case or the end cover of the radial piston motor The cam part number along with the displacem...

Page 23: ...otor code The main visual differences relate to Frame size Front case Front shaft Brake Auxiliary functions such as 2 speed flushing speed sensor valve block Examples are MCR A MCR F with holding brake MCR D MCR F with dynamic brake MCR H MCR E MCR W MCR T Fig 12 Examples of different MCR motor types For full details please refer to the motor code in the relevant data sheet ...

Page 24: ...fting device ring screw or lifting strap The weight specification may vary depending on the motor type and configuration Table 6 Dimensions and weights motors without brakes Frame size MCR 3 5 6 10 15 20 Weight kg MCR F 1L 21 38 65 95 2WL 26 46 70 95 MCR W 1L 28 53 65 2WL 30 46 MCR A 1L 23 43 70 2WL 28 50 MCR H 1L 12 23 36 54 76 2WL 18 30 40 54 76 MCR T 1L 58 84 2WL 63 66 93 MCR R series 32 1L 33 ...

Page 25: ...e bolt a hook or a lifting sling WARNING Danger from suspended loads Danger to life or risk of serious injury when working with suspended loads Damage to equipment Never stand or position any part of the body below a suspended load Always wear correct PPE personal protective equipment Ensure all equipment used in the lifting operation is of sufficient capacity for the load Never leave a suspended ...

Page 26: ...ated in Fig 14 During lifting operations the motor must be manually supported to ensure it cannot slip from the hook Fig 14 Hoisting a motor with a hook WARNING Danger from suspended loads Ensure the sling is of sufficient load capacity for the motor being lifted Use the widest possible lifting sling Ensure the radial piston motor is securely held within the sling by positioning it in such a way t...

Page 27: ...umulative storage time from original manufacture date for a radial piston motor is 6 years after which it should be scrapped Entitlement to warranty will be rendered void if storage conditions and inspection measures are not complied with If a removed radial piston motor is to be stored it must be preserved against corrosion for the duration of storage The following instructions only refer to radi...

Page 28: ...ations of your country 7 2 Installation conditions The location and position of the radial piston motor essentially determine the procedures during installation and commissioning Make sure that the case of the radial piston motor is filled with hydraulic fluid prior to operation This will happen automatically where the motor is fitted with a flushing valve It should also be noted that following lo...

Page 29: ...r installation means that the radial piston motor installation is below the minimum fluid level of the reservoir L L1 1 2 L L1 3 4 L L1 L L1 F F F F Fig 16 Below reservoir installation MCR with installation position 1 4 L Drain port F Filler port L1 Air bleeding Note L1 is part of the external piping The oil filling of the case should always take place via the filler port F and the air bleeding vi...

Page 30: ...L L1 L L1 F F F F 0 5 bar 0 5 bar Fig 17 Above reservoir installation MCR with installation position 7 12 L Drain port F Filler port L1 Air bleeding Note L1 is part of the external piping The oil filling of the case should always take place via the filler port F and the air bleeding via port L1 in the drain line Where a check valve is fitted to the drain line it should be sized to ensure the motor...

Page 31: ...l chapter 5 3 Letter L in code or no designation means counter clockwise rotation Letter R in code means clockwise rotation 7 4 2 Dimensions The installation drawing specifies the dimensions of the mountings and ports of the radial piston motor 7 4 3 General instructions During installation and removal of the radial piston motor observe the following general instructions and handling instructions ...

Page 32: ...d the nuts must be tightened to the following torque values Table 7 Wheel nut tightening torques Stud Flat Nm Spherical Nm M14 140 180 M18 300 380 M20 420 610 M22 560 780 The shaft connection to the wheel must use all mounting holes or wheel studs specified on the drive shaft Protect the spline from frictional corrosion by application of a suitable lubricant WARNING Risk of damage and injury When ...

Page 33: ...o this could result in insufficient bearing lubrication and premature failure of the bearing Protect the sprocket on the drive shaft from frictional corrosion by providing adequate lubrication The installation drawings for the MCR H and MCR R specifies all relevant data such as spline connection bearing loads and sealing arrangements 7 4 5 Assembly of the speed sensor Where a radial piston motor i...

Page 34: ...all transportation plugs and replace with metal plugs of a suitable pressure rating 2 Remove the transport protection The radial piston motor is delivered with protective covers and plugs These are not pressure resistant and must be removed prior to connection Use a suitable tool for this to prevent damage to the sealing and functional surfaces If sealing or functional surfaces are damaged contact...

Page 35: ...y safety factors Observe the following notes when routing the boost pressure drain and control lines Lines and hoses must be installed without any mechanical pre tension to ensure additional motor loads are not created during operation Ensure correct sealing materials are used appropriate for the fluid type and operating conditions Pressure boost line For the pressure boost lines use only pipes ho...

Page 36: ...nut tightening torques on page 32 Table 8 Tightening torques for threaded holes and filler plug Thread size at ports Minimum thread engagement mm Maximum permissible tightening torque of the threaded holes Nm Tightening torque for filler plug Nm G 1 4 ISO 228 1 9 5 70 G 3 8 ISO 228 1 9 5 110 G 1 2 ISO 228 1 13 0 200 60 G 3 4 ISO 228 1 13 0 330 7 16 20 UNF ISO 11926 9 0 40 9 16 18 UNF ISO 11926 10 ...

Page 37: ...stallation drawing and the machine or system schematic Check whether all ports are connected or plugged with threaded plugs of a sufficient pressure rating 5 Tighten the fittings correctly note tightening torques 6 Check all pipes hose lines connecting pieces and couplings to ensure they are in condition for safe working 7 5 Peforming flushing cycle In order to remove foreign particles from the sy...

Page 38: ...issioning of an incorrectly installed product Risk of injury and damage to equipment Make sure that all electrical and hydraulic ports are connected or plugged Only commission a completely installed fault free product with original accessories from Bosch Rexroth 8 1 First commissioning During all work for commissioning the radial piston motor observe the general safety instructions and intended us...

Page 39: ...adial piston motor The radial piston motor must not be operated while it is being filled Use an approved hydraulic fluid The machine or system manufacturer can provide precise details of the hydraulic fluid Details of minimum requirements for mineral oil based hydraulic fluids environmentally acceptable hydraulic fluids or HF hydraulic fluids for the radial piston motor are contained in the relate...

Page 40: ... deceleration under maximum load For information on troubleshooting see chapter 14 Troubleshooting on page 50 To test the hydraulic fluid supply 1 Allow the pump to run at low speed and without load Pay attention to leakage and noise 2 Check the case drain line during the test The case drain fluid should not contain any bubbles 3 Check the case drain pressure of both pump and motor Refer to the da...

Page 41: ...00 C Allow the brake to cool To remove residue brake gently 2 times each in the forward and reverse directions For the caliper disc brake the following procedure should be carried out Brake the machine hard until the disc temperature reaches 250 C Allow to cool To remove residue brake gently 2 times The bearings and sliding surfaces are subject to a running in phase The increased friction at the s...

Page 42: ...ng brake release pressure 15 bar and 30 bar standard specification or exact values as stated on the installation drawing for all non standard specifications SO versions 2 speed switching pressure For minimum and maximum 2 speed switching pressures refer to the appropriate motor installation drawing Case drain oil temperature 85 C For operation above this temperature please consult Rexroth engineer...

Page 43: ...erature and fluid viscosity are within current data sheet recommendations see also section 8 4 Final checks on page 42 Fluid cleanliness within data sheet limits Motor is still securely mounted running at normal sound level and free from external leakage Fluid is changed per the machine manufacturer s recommendation Where applicable check bearing lubrication is still effective For higher loading o...

Page 44: ... a puller into the tapped hole in the brake piston 15 Table 9 Required puller size for emergency brake release Motor type Screw size Minimum screw length Approx release torque MCR3 M12 30 mm 60 Nm MCR5 M16 30 mm 120 Nm MCR10 M16 40 mm 160 Nm MCR15 M20 45 mm 230 Nm MCR20 M20 50 mm 340 Nm Alternatively if the plug is not present or a suitable puller is not available the brake may be released by loos...

Page 45: ...y a mild detergent to clean the radial piston motor Never use solvents or aggressive detergents Remove coarse external dirt and keep sensitive and important components such as solenoids valves indicators and sensors clean 10 2 Inspection In order to ensure long and reliable operation of the radial piston motor Bosch Rexroth recommends regular monitoring of the hydraulic system and radial piston mo...

Page 46: ...ery 2000 operating hours which ever occurs first or having it analyzed by the hydraulic fluid manufacturer or a laboratory to determine its suitability for further use The service life of the radial piston motor is limited by the service life of the bearings fitted The service life can be requested from the responsible Bosch Rexroth Sales partner or by contacting Bosch Rexroth Engineering Departme...

Page 47: ...TION Use of unsuitable spare parts Spare parts that do not meet the technical requirements specified by Bosch Rexroth may cause personal injury or property damage Only original spare parts supplied by Bosch Rexroth should be used to repair Rexroth radial piston motors Failure to do so may result in unsatisfactory performance and possible component failure The spare parts lists for radial piston mo...

Page 48: ...ed as follows to remove the radial piston motor 1 Ensure the hydraulic system is depressurized 2 Ensure the radial piston motor has been allowed to cool down 3 For below reservoir installation before disconnecting the radial piston motor isolate the connection to the reservoir or drain the reservoir 4 Place a drip tray under the radial piston motor to collect any hydraulic fluid that may escape 5 ...

Page 49: ...radial piston motor into its individual parts and properly recycle these parts 5 Separate the parts into Cast parts Steel Aluminum Non ferrous metal Electronic waste Plastic Seals 13 Modification and adjustments There are no facilities for end users to carry out modifications or adjustments to the radial piston motor The only exception to this is the fitting of an optional speed sensor see chapter...

Page 50: ...in conjunction with the entire system Confirm that the product was working properly in conjunction with the entire system before the fault occurred Try to determine if there were any recent changes made to the system in which the product is integrated Were there any changes to the product s application conditions or operating range Has maintenance work recently been carried out Is there an inspect...

Page 51: ...frame Check installation of lines per machine manufacturer s specifications Internal damage to radial piston motor Strip down and inspect motor Replace defective parts or complete motor as necessary Air intake Completely bleed hydraulic system Check tightness of all connections Brake release pressure too low causing brake where fitted not to be fully released Check brake release pressure versus ma...

Page 52: ...tted jammed in a partially or fully shifted position Strip 2 speed valve and check all components including bore in motor housing Remove any contamination and replace components or motor housing as necessary Brake release pressure too low causing brake where fitted not to be fully released Check brake release pressure versus machine manufacturer s specification and adjust repair or replace pressur...

Page 53: ...us machine specification If too high reset pump and or engine speed Motor case drain pressure too high causing integrated flushing valve where fitted to close Check case pressure versus machine specification If too high check drain line for blockages Pump charge pressure below opening pressure of integrated flushing valve where fitted Check charge pressure versus machine specification Reset charge...

Page 54: ...ke run in procedure per motor data sheet Brake does not release Brake release pressure too low disc brake Check brake release pressure versus machine manufacturer s specification and adjust repair or replace pressure source as necessary If pressure source OK strip down brake and check and replace brake seal as necessary Brake piston or seals damaged disc brake Replace brake piston or seals as requ...

Page 55: ...able 1 Required and supplementary documentation on page 5 The data sheets can be found on the internet under www boschrexroth com various utilities mediadirectory index jsp language en GB Further information can be found in the online product catalog Mobile Hydraulics www boschrexroth com radial piston motors The order related technical data of your radial piston motor can be found in the order co...

Page 56: ...Viewfield Industrial Estate Glenrothes Fife Scotland KY6 2RD United Kingdom Phone 44 1592 631 777 www boschrexroth com Subject to change Printed in Germany RE 15215 01 B 11 2015 Your local contact can be found at www boschrexroth com addresses ...

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