Bosch rexroth M1 Instruction Manual Download Page 1

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Instruction manual

RE 64025-B/2021-08-12, replaces: 04.2019, EN

Control blocks for

mobile applications

RCS

Summary of Contents for rexroth M1

Page 1: ...Instruction manual RE 64025 B 2021 08 12 replaces 04 2019 EN Control blocks for mobile applications M1 M8 M9 MO SM RCS M4 SP M6 M7 RS SX ...

Page 2: ...concerning a certain condition or suitability for a certain application can be derived from our information The information given does not release the user from the obligation of own judgment and verification It must be remembered that our products are subject to a natural process of wear and aging The cover shows an example application The product delivered may differ from the image on the cover ...

Page 3: ... 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 with lifting devices 21 6 2 Storing the control block 23 7 Installation 25 7 1 Unpacking 25 7 2 Painting the control block 25 7 3 Installation conditions 26 7 4 Installation position 26 7 5 Installing the control block 26 7 5 1 Required...

Page 4: ... 2 Inspection 40 10 3 Maintenance 41 10 4 Repair 41 10 5 Spare parts 42 11 Removal and replacement 43 11 1 Required tools 43 11 2 Preparing for removal 43 11 3 Removal of the control block from the machine 43 11 4 Preparing the components for storage or further use 43 12 Disposal 44 13 Extension and conversion 45 14 Troubleshooting 46 14 1 How to proceed for troubleshooting 46 14 2 Malfunction tab...

Page 5: ... damage on page 15 before you start work with the control block 1 2 Required and supplementary documentation Only commission the product if the documentation marked with the book symbol is available understood and complied with Table 1 Required and supplementary documentation Title Document number Document type Technical data sheet Contains the permissible technical data Please bear in mind that d...

Page 6: ...confirmation Contains the order related technical data of the control block Order confirmation Offer drawing Contains the outer dimensions all connections and the hydraulic circuit diagram of the control block Offer drawing Hydraulic fluids based on mineral oils and related hydrocarbons Describes the requirements for hydraulic fluids on mineral oil basis and related hydrocarbons for operation with...

Page 7: ...with the use of this product Safety instructions are set out as follows SIGNAL WORD Type and source of danger Consequences of noncompliance Danger prevention measure Warning sign draws attention to the danger Signal word identifies the degree of the danger Type and source of danger indicates the type and source of the danger Consequences describes what occurs if safety instructions are disregarded...

Page 8: ...ons Table 4 Designations Designation Meaning Mono block A control block that has been cast from a single piece Optionally other directional valves can be mounted to extend the functions Control block in sandwich plate design A control block that has been assembled from one or several directional valves Directional valve A control block segment with 1 spool axis also referred to below as a valve se...

Page 9: ... the machine for which it is intended and the required safety of the entire system has been established in accordance with the machinery directive The control blocks have been developed to control various hydraulic consumers on mobile and standalone working machines Deviating use is only permitted following consultation with Bosch Rexroth The product can be employed as a safety relevant part of a ...

Page 10: ...14 34 EU 2 4 Personnel qualifications The activities described in this documentation require a basic understanding of mechanics electricity and hydraulics as well as familiarity with associated technical terms For transporting and handling the product knowledge regarding the use of lifting gear and lifting devices is required The term skilled personnel refers to persons who possess the professiona...

Page 11: ...sion protection areas or in safety related parts of a control system functional safety Only commission the product if it has been determined that the end product e g machinery or system in which the Rexroth products are installed corresponds to the country specific provisions safety regulations and standards for the application Use tools appropriate for the work being performed and wear appropriat...

Page 12: ... shield must be erected to ensure any escaping hydraulic fluid cannot be ignited and to protect hose lines from premature aging Electrical voltage Danger to life or risk of injury due to electric shock or property damage Always disconnect the voltage supply to the relevant machine system part before installing the product and or connecting or disconnecting the connector Protect the machine system ...

Page 13: ...njury Do not move any limbs into the gap between the actuation element hand lever and the valve housing High noise development during operation Danger of hearing damage or hearing loss Among others the noise emission of control blocks depends on the working pressure and the installation conditions The sound pressure level may rise to above 70 dBA under specific application conditions Always wear h...

Page 14: ...t or if you swallow it accidentally Escaping hydraulic fluid through leaking machine system components Risk of burning and risk of injury due to escaping hydraulic fluid jet Depressurize the relevant machine system component and repair the leak Never attempt to block or seal the leak or hydraulic fluid jet with a cloth Danger from improper handling Slip hazard When using the control block as climb...

Page 15: ...the actuation elements Do not hit sensitive assembled parts e g sensors solenoids or actuation elements Do not hit sealing surfaces e g on the work connections Leave the protective covers on the control block until you connect the lines Disconnect all electric connectors before any painting operations Ensure that the electronic components e g sensors are not electro statically charged e g during p...

Page 16: ...ticles e g welding beads or metal cuttings from entering the hydraulic lines and lead to wear and malfunctions in the product The control block must be installed in a clean condition Only use clean ports hydraulic lines and assembled parts e g measuring devices When plugging the ports no contamination may ingress Before commissioning ensure that all hydraulic connections are tight and that all sea...

Page 17: ...corrosive environmental conditions Leakage or spilling of hydraulic fluid Environmental pollution and contamination of the ground water When filling and draining hydraulic fluid always place a drip tray under the control block Use a suitable binding agent if hydraulic fluid is spilled Observe the parameters in the safety data sheet for the hydraulic fluid and the specifications provided by the mac...

Page 18: ...5 B 2021 08 12 4 Scope of delivery Included in the scope of delivery Control block as per order confirmation The following parts are also assembled prior to delivery according to version Protective covers Protective plugs threaded plugs Attachment point for transportation e g an eye bolt ...

Page 19: ...d instructions on the project planning of individual control blocks refer to the data sheet For the assignments of control blocks to data sheets refer to Table 1 Required and supplementary documentation on page 5 5 3 Product identification The control block is to be identified on the name plate The parameters on the name plate apply to the control block as delivered If modifications have been made...

Page 20: ...r number at the customer optional 11 Area plant number 12 Data Matrix code 13 Identification number 4 digits of the notified body 14 CE conformity sign optional Make sure that the name plates in place are not damaged By comparing the material number of the control block on the respective name plate to the parameters in the offer drawing check that this instruction manual refers to the product in q...

Page 21: ...ions in your country CAUTION Danger due to heavy loads When carrying control blocks there is a danger of health damage Only manually transport the control block for a short period of time Observe the national regulations in your country for manual transport Always use appropriate lifting lowering and moving techniques Use your personal protective equipment e g safety goggles safety gloves suitable...

Page 22: ... widest possible lifting strap Make sure that the control block is securely fixed with the lifting strap Only guide the control block by hand for fine positioning and to avoid vibrations Never step or grip under suspended loads Place the lifting strap around the control block such that it does not pass over the assembled parts e g valves or that the control block is hung on assembled parts Fig 3 T...

Page 23: ...g at the factory Mineral oil in plugged valves provides internal corrosion protection Non painted or coating surfaces on the control block not provided with a galvanized coating e g flange surfaces are not protected against corrosion Delayed commissioning long freight and storage times or a prolonged decommissioning of Rexroth control blocks leads to rust formation Take additional corrosion protec...

Page 24: ...h Rexroth recommends the following procedure 1 Clean the control block 2 Drain the control block 3 Plug all ports so they are airproof 4 Moisten the unpainted flange surfaces and external seals of the control block with mineral oil 5 Protect sensitive assembled parts e g actuation elements sensors solenoids or valves with appropriate measures as in the delivery state 6 Package the control block wi...

Page 25: ...damage and completeness see chapter 4 Scope of delivery on page 18 3 Dispose of the packaging in accordance with the regulations in your country 4 Return any reusable packaging to the corresponding sending Bosch Rexroth plant 7 2 Painting the control block Perform the following steps if the control block is to be painted before installation First protect the hydraulic ports by completely screwing ...

Page 26: ...osition of the control block is arbitrary 7 5 Installing the control block 7 5 1 Required tools Installation can be performed with standard tools No special tools are necessary Also observe the manuals provided by the manufacturers of the other hydraulic components when selecting the required tools 7 5 2 Preparation 1 Check the parameters on the name plate to see if the control block is correct 2 ...

Page 27: ...ired tightening torques depend on various factors e g screw material and coating operation forces material of the tensioned components Generally it is herewith referred to the parameters provided by the system supplier Bosch Rexroth recommends a screw connection with the following parameters Table 6 Mounting bolts Series Dimension Property class Tightening torque Nm Screw in depth mm M1 16 M8 8 8 ...

Page 28: ...e control block may be delivered with protective covers and protective plugs They are not pressure resistant and have to 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 your Bosch Rexroth service partner or the service department of the manufacturer s plant for the control blo...

Page 29: ...in the data sheet The machine manufacturer must ensure that the connecting elements and lines correspond to the specified application conditions pressure flow hydraulic fluid temperature with the necessary safety factors Only connect hydraulic lines that are appropriate for the control block port pressure level size system of units Observe the following notices when routing hydraulic lines Lines a...

Page 30: ...em of units and of the correct size For an overview of line connections refer to the respective data sheet and the offer drawing Observe the parameters in the standards or the manufacturer s specifications for the stud ends fittings and threaded plugs on hydraulic ports Apart from this be aware that tightening torques can also depend on the permissible pressure and temperature range and the applic...

Page 31: ...signation Control block Pressure relief feed valve with pressure sequencing stage Pressure relief feed valve with pressure cut off stage Valve housing Inner valve support Lock nut Einstellspindel Lock nut Adjustment screw with hydraulic port The pressure relief feed valve consists of the visible components to To avoid an unintentional change of the pressure setting the screw connections to each ot...

Page 32: ...emove the protective plug or screw plug from the adjustment screw 2 Make sure that the sealing surfaces of the fitting are not damaged 3 Turn the screw fitting clockwise into the thread of the adjustment screw When doing so counter the lock nut and the adjustment screw with an open end wrench 4 Tighten the screw fitting correctly observe tightening torque Procedure ...

Page 33: ...trical control and or mounted sensors please comply with the parameters given in the data sheet and the offer drawing e g Permissible voltage range Permissible current Correct pin assignment Exact parameters on the correct assignment of the connector the type of protection and the appropriate mating connector can also be found in the data sheet and the offer drawing The mating connector is not inc...

Page 34: ... and hydraulic ports are connected or plugged correctly Before the functional test check whether the piping specified in the hydraulic circuit diagram has been installed Make sure that the cable connectors are correctly assigned to the respective electrical components Only commission a completely installed product Risk of injury due to entrapped air In operation air that is entrapped in the contro...

Page 35: ... control to carry out the internal functional test of the hydraulic system Work out a sequence program for the commissioning and archive this in the technical documentation as an annex to the instruction manual Divide the functional circuit diagram into partial circuits which can be commissioned in stages Read the functional circuit diagram and clarify any ambiguous statements or representations S...

Page 36: ...a sheet of the product see Table 1 Required and supplementary documentation on page 5 During commissioning monitor the temperature of the hydraulic fluid in the reservoir to ensure that it lies within permissible viscosity limits To commission the control block for the first time proceed as follows 1 Completely fill the control block and the pilot circuit if present with permissible hydraulic flui...

Page 37: ... The functional test must be performed according to the parameters provided the machine manufacturer see machine instruction manual Applicable for each case Always increase the pressure slowly if a leakage occurs stop the functional test immediately 8 Check the control block hydraulic fluid temperature after it has been running in continuous operation for several hours Check whether the measured t...

Page 38: ...For applications below an ambient temperature of 20 C non standard seals are used Different application limits are specified in the control block s Technical Customer Documents TKU Avoid moisture in the area surrounding the control blocks since possible moisture on the moving seals may freeze the seal to the control spool when at a standstill When moving the control spool it is not possible to rul...

Page 39: ...s reached in the system While doing this the diesel engine speed must not be increased After this slowly actuate all of the machine functions several times at the lowest load to heat up the machine as evenly as possible When doing this monitor the reservoir temperature which drops again as a result of the cold hydraulic fluid that flows back 5 For operation at low temperatures it is recommend that...

Page 40: ...only water and if necessary a mild cleaning agent to clean the control block Never use solvents or aggressive cleaning agents Remove major external contamination and keep clean sensitive and important components such as solenoids valves indicators and sensors 10 2 Inspection In order to enable long and reliable operation of the control block Bosch Rexroth recommends testing the hydraulic system an...

Page 41: ...es From a hydraulic fluid temperature of 70 C the aging speed doubles with every 10 C of temperature increase The maximum permissible degree of contamination of the hydraulic fluid can be seen in the data sheet in Chapter Technical data Please also observe the parameters on hydraulic fluid in the machine s instruction manual 10 4 Repair Bosch Rexroth offers a comprehensive range of services for th...

Page 42: ...arts quote the material and serial number of the control block as well as the material numbers of the spare parts Address all queries about spare parts to your responsible Bosch Rexroth Service partner or the service department of the manufacturer s plant for the control block Bosch Rexroth AG Zum Eisengießer 1 97816 Lohr am Main Germany Phone 49 0 9352 18 40 50 60 service svc boschrexroth de Bosc...

Page 43: ...hine To remove the control block proceed as follows 1 Make sure you have the appropriate tools and wear personal protective equipment 2 Allow the control block to cool down until it can be removed without danger 3 Make sure that no hydraulic fluid can escape from the system accidentally due to the control block being removed 4 Place a clean collecting pan under the control block to collect any hyd...

Page 44: ...posal of the control block the hydraulic fluid and the packaging material can result in environmental pollution For the disposal of the control block observe the following points 1 Drain the control block completely 2 Dispose of the control block and the packaging material in accordance with the national regulations of your country 3 Dispose of the hydraulic fluid in accordance with the regulation...

Page 45: ...d configuration The warranty will be voided if the unit is modified or extended Changing the settings will void the warranty If you need to change settings contact your Bosch Rexroth service partner for the address see Chapter 10 5 Spare parts on page 42 Available accessories can be found in the respective data sheet Accessories are available from your Rexroth specialist dealer Addresses of our co...

Page 46: ...m Find out whether or not the control block rendered the required function in the entire system before the fault occurred Collect the changes to the entire system in which the control block is installed Have there been any changes to the application conditions or operating range of the product Has maintenance work recently been carried out Is there an inspection or maintenance log Have any changes...

Page 47: ...ug The seals of assembled parts are leaking Renew the seals refer to the spare parts list The system pressure is too high Comply with the pressure limit Hydraulic fluid leaks from the supply lines on the control block Pipe or hose lines damaged Replace pipe or hose lines Pipelines or hose lines are loose Tighten the threaded joints and the fittings in accordance with the installation instructions ...

Page 48: ...h the valve several times by actuating the hand lever or the pilot control Carry out a visual inspection of the ports to the actuator and remove the foreign particles using a solenoids and a tweezers If foreign particles are jammed renew the valve housing Control spool not operating or goes back too slowly Control spool is jammed In the case of a malfunction see Not possible to deflect control spo...

Page 49: ... pressure relief valve leaking or set too low Check the setting pressure on the secondary pressure relief valve The control spool leakage is too great Refer to the data sheet for the leakage values Install a leak free lowering brake valve No detent function Restoring force in the direction of actuation is too great compared to the detent force spring Remove the detent and clean it Detent unit is w...

Page 50: ...e assignments of control blocks to data sheets refer to Table 1 Required and supplementary documentation on page 5 The data sheets can be found online under www boschrexroth com various utilities mediadirectory Additional information can be found in the online product catalogue Mobile hydraulics www boschrexroth com mobile hydraulics catalog The order related technical data of your control block c...

Page 51: ...RE 64025 B 2021 08 12 Bosch Rexroth AG Technical data Control blocks for mobile applications 51 54 ...

Page 52: ... Installation 25 Completion 28 Preparation 26 Installation conditions 26 Installation position 26 Intended use 9 L Lifting devices 21 Lifting strap 22 M Maintenance 41 Malfunction table 47 N Name plate 19 O Operation 38 P Performance description 19 Personnel qualifications 10 Product description 19 R Recommissioning after standstill 37 Removal 43 Performance 43 Preparation 43 Repair 41 Required do...

Page 53: ...ontrol blocks for mobile applications 53 54 T Technical data 50 Tools 26 43 Transport 21 by hand 21 with eye bolt 21 with lifting devices 21 with lifting strap 22 Troubleshooting 46 Malfunction table 47 U Unpacking 25 W Warranty 17 23 45 Weight 21 ...

Page 54: ...E 64025 B 2021 08 12 Bosch Rexroth AG Zum Eisengießer 1 97816 Lohr am Main Germany Tel 49 93 52 18 0 info ma boschrexroth de www boschrexroth com Your local contact person can be found at https addresses boschrexroth com ...

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