Bosch Rexroth WS290 Operating Instructions Manual Download Page 80

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Hydraulics training system WS290 | RE 00225-B/2.15

Help in case of faults

This chapter summarizes information which may help you should any faults

occur on the WS290 training system.

Table 10:

Faults

Situation

Possible causes

Recommended remedy

Electric motor switched on
by means of "ON" switch
but the motor does not
start up.

Hydraulic power unit at
the electric control box
not connected.

Operate the
OFF pushbutton

Establish the
cable connection

Repeat the switch-on

Automatic circuit breaker
has been triggered
EMERGENCY OFF
pushbutton is operated

Do not repeat the switch-on
Commission a qualified,
specialized electrician with
the examination and remedy

Electric motor switched on
by means of "ON" switch
but no flow can
be identified.

Filling level in the tank is
too low

Immediately stop the
hydraulic power unit
Refill hydraulic fluid

Wrong direction of rotation
of the motor

Immediately stop the
hydraulic power unit
Commission a qualified,
specialized electrician with
the examination and remedy

Coupling damage between
electric motor and pump

Immediately stop the
hydraulic power unit
Commission a qualified,
specialized electrician with
the examination and remedy

There is permanently foam
in the measuring glass.

Leakage in the suction
range

Immediately stop the
hydraulic power unit
Inform the Bosch Rexroth
service

If it is not possible to identify and remedy fault causes, please contact the

responsible Bosch Rexroth service department.

Summary of Contents for Rexroth WS290

Page 1: ...RE 00225 B 12 15 Operating instructions Replaces 02 15 English Hydraulics training system WS290 ...

Page 2: ...he user from the obligation of own judgment and verification Our products are subject to a natural process of wear and aging This document as well as the data specifications and other information set forth in it are the exclusive property of Bosch Rexroth AG It may not be reproduced or given to third parties without its consent The cover page shows an example configuration The product supplied may...

Page 3: ...al protective equipment 14 2 8 Obligations of the machine end user 14 2 9 Safety equipment 15 2 10 Operator workplaces 16 3 General warnings of damage to property and damage to the product 16 4 Scope of delivery 18 5 Information on this product 19 5 1 General 19 5 2 Product description 20 5 3 Base frame device carrier 21 5 4 Hose storage 24 5 4 1 Hose storage for 9 hoses 24 5 4 2 Hose storage for ...

Page 4: ...ilding 59 8 2 2 Transportation between two buildings 60 8 3 Storage 61 9 Set up installation and commissioning 62 9 1 Setting the WS290 training system up 62 9 2 Checking the hydraulic supply 63 9 3 Filling the oil tank 63 9 4 Electric installation 65 9 5 Checking the functions 66 9 5 1 Checking the EMERGENCY OFF circuit 66 9 5 2 Checking the direction of rotation of the electric motor the pump 67...

Page 5: ... 81 12 2 Maintenance and control plan 82 13 Maintenance works 84 13 1 General information 84 13 2 Maintenance schedule 85 13 2 1 Supplies auxiliary materials tools and measuring devices 87 13 2 2 Exchanging parts 87 13 2 3 Hydraulic oil maintenance 88 13 2 4 Performing the oil exchange 88 13 2 5 Exchanging the filter element 90 13 2 6 Exchanging hydraulic hose lines 92 14 Disposal 94 15 Hydraulic ...

Page 6: ...fety instructions before working with the product 1 2 In these instructions the following signs and symbols are used Activity symbol The text following this symbol describes activities that are to be completed in the specified order from top to bottom 1 3 Required and amending documentation In addition to these operating instructions for the ready for use WS290 training system there is also the fo...

Page 7: ...cates a dangerous situation which may cause death or severe personal injuries if not avoided CAUTION Indicates a dangerous situation which may cause minor or medium personal injuries if not avoided NOTICE Indicates damage to property The product or the environment could be damaged 1 4 2 Symbols The following symbols indicate notices which are not safety relevant but increase the comprehensibility ...

Page 8: ...ut this documentation 1 4 3 Abbreviations The following abbreviations are used in this documentation Table 3 Abbreviations Abbreviation Meaning LS control block Load sensing control block WS290 training system Hydraulics training system WS290 Hy power unit Hydraulic power unit ...

Page 9: ...g For the set up of control circuits and simulations only the devices and device sets approved for the WS290 training system may be used The operation is only admissible under the operating conditions indicated in chapter 5 The product is only intended for professional use and not for private use Intended use includes having read and understood this documentation completely especially the chapter ...

Page 10: ...or persons participating in further training are supposed to install control circuits at the WS290 training system check the installation and functional effects of the control circuit for a safe sequence before switching on the system answer questions in a clear and comprehensible manner To supervise the WS290 training system during the exercises trained personnel may also be used These are qualif...

Page 11: ...he valid regulations on accident prevention and for environmental 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 assembling operating disassembling or maintaining Rexroth products must not be under the influence of alcohol other...

Page 12: ...c power units in IT networks Only operate the WS290 training system in a grid with functional FI protective earthing conductor or a protective earthing Manipulated and or non functioning safety equipment and safeguards Risk of serious injury Stop the system immediately The fault or manipulation has to be promptly remedied by specialist personnel Never change the pressure setting at the safety valv...

Page 13: ...se lines Look out for loose unfastened set ups Do not work without safety goggles there is the risk of eye injuries Slip hazard due to oily surfaces Risk of injury Protect and mark the danger zone Use an oil binding agent in order to bind the leaked hydraulic oil Provide binding material already before filling refilling or changing hydraulic oil Remove and dispose of the contaminated oil binding a...

Page 14: ...s sufficiently load bearing and even and horizontal Ensures that the accident prevention regulations the safety regulations of the professional unions as well as further internal local requirements are observed They instruct their employees and or those of third party companies on possible dangers at the place of set up The machine end user has to make available sufficient lighting at the place of...

Page 15: ... stroke control and sealed with red painting at the setscrew At the pump a so called standby pressure of 15 bar has been pre set and sealed The maximum operating pressure is limited by means of a load sensing pressure relief valve to 50 bar industrial hydraulics or to 60 bar mobile hydraulics To monitor the pressure of practice circuits during teaching the corresponding pressure gauges and or pres...

Page 16: ...r of persons Set up 3 Operation 2 A maximum number of three persons may work at the WS290 training system during set up at the same time During operation a maximum of two persons plus instructor may work at the system 3 General warnings of damage to property and damage to the product Training places NOTICE Pressurized and live system Damage to property Ensure that the drive module has been complet...

Page 17: ...in switch Incorrect setting of the pressure relief valves and the pressure switches of the hydraulic components Damage to property Only operate the hydraulic components with the pressure values prescribed Hazard for the electrical equipment due to high electric currents Damage to property Make sure that excess current protection equipment is available Secure the mains socket by pulling the mains p...

Page 18: ...n Unit Value Dimensions Length mm 2100 Width mm 1000 Height mm 2360 1 5 4 2 3 Fig 2 Box with marking The following information is affixed to the box 1 Transport instructions or warnings as required 2 Shipping number bar code 3 Shipping note in plastic bag 4 Imprint Gross weight possibly net weight 5 Imprint Packaging according to IPPC standard The scope of delivery of the WS290 training system enc...

Page 19: ...g sections of these operating instructions illustrate as an example a variant of the WS290 training system and its components A selection of attachments and device sets is available for the WS290 training system These components turn the WS290 training system into a complete customer specific training and further education system with practical orientation ...

Page 20: ... hoses 5 Installation container 6 LS Hy power unit Versions Double pump 230 V 50 Hz or 60 Hz 1 5 kW or 400 V 50 Hz 2 2 kW Variant Hy power unit Versions Single pump 230 V 50 Hz 1 5 kW or 400 V 50 Hz 2 2 kW Double pump 230 V 50 Hz 1 5 kW or 400 V 50 Hz 2 2 kW 7 Oil pan 8 Control box versions 230 V 50 Hz or 400 V 50 Hz 2 x Emergency Off 3 sockets with or without FI 9 P T distributor with depressuriz...

Page 21: ...s 3 They are used to collect drip losses at training set ups 2 1 3 5 4 6 8 7 Fig 4 WS290 base frame 1 Device carrier with mounting frame 2 Transport rollers maneuverable and lockable 3 Oil tight pans for the grids 4 Mounting frame grid 5 Writing surface 6 Oil drip sheet 7 Installation container 8 Oil pan The mounting frame is used to accept 2 grids The device kits required for the exercises are cl...

Page 22: ... units are necessary Fig 5 Oil drip sheet The writing surfaces are inserted into the oil tight pans of the base frame instead of the drip sheets Fig 6 Writing surface The oil pan for the WS290 substructure made of powder coated sheet steel is used to collect drip losses at the power unit The hydraulic power unit is fixedly mounted on the base frame Fig 7 Oil pan Oil drip sheet Writing surface Oil ...

Page 23: ...h Rexroth AG 23 104 Information on this product The installation container is equipped with a front side lock and easy running tracks and fixedly screwed to the base frame next to the hydraulic power unit Fig 8 Installation container Installation container ...

Page 24: ...side frame of the base frame and is used to hold up to 9 hose lines The hose lines are hooked into the lower profile 5 4 2 Hose storage for 50 hoses Fig 10 Hose storage for 50 hoses The hose storage is attached to the side frame of the base frame and is used to hold up to 50 hose lines The hose lines are hooked into the lower profiles At the top an oil pan for the storage of small parts has moreov...

Page 25: ...nstruction height of 3HE or 2x3HE are intended for the installation of electronic components into 19 inch installation technology They are used to control electrically switching valves and proportional technology Fig 11 Rack one row Fig 12 Rack two row Free slots at the 19 rack are to be provided with covers in order to prevent objects from being put down Fig 13 19 rack ...

Page 26: ...short circuit proof 24 VDC output are integrated into the side frame of the base frame They are connected to the control box socket by means of a connection cable The power supply unit is used to supply the control and measuring electronics of the electric components in the 19 rack Power supply unit available with 230 V or 115 V input voltage Fig 14 Power supply unit ...

Page 27: ...upply and the cable connection are designed according to the customer specifications and the country specifications Fig 15 Control box 1 EMERGENCY OFF pushbutton 2 Housing 3 Coded socket for the current supply of the hydraulic power unit 4 FI circuit breaker optional 5 Automatic circuit breakers for 16 A socket 6 Automatic circuit breakers for coded 16 A socket 7 Connection cable with connector 8 ...

Page 28: ...cuit diagram HY power unit with single pump Item no Assembly Item no Assembly 1 0 Oil tank 3 0 Return flow filter 1 1 Oil level and temperature display 3 1 Clogging indicator optical 1 2 Filling and breathing filters 4 01 P T manifold 2 0 Three phase current motor 4 1 Coupling connector 2 1 Vane pump 4 21 Threaded coupling 2 2 2 3 2 31 Hose line 5 0 Switch housing 2 32 Pressure relief valve 5 2 Po...

Page 29: ...se lines serve as connection between the individual components of the hydraulic power unit The sealed pressure relief valve secures the pump circuit with 70 bar The check valve blocks the flow in the one direction and opens against a spring in the other direction In this connection the spring force corresponds to a certain pressure During operation the oil flows via the check valve to the LS contr...

Page 30: ...at the hydraulic power unit The control box with protective motor switch is connected to the control box at the base frame of the WS290 training system by means of a coded connector The measuring glass mounted at the base frame is directly connected to the oil tank by means of a return flow hose Control box consisting of 5 0 switch housing and 5 2 power switch 6 0 Measuring glass ...

Page 31: ...15 Bosch Rexroth AG 31 104 Information on this product 5 9 Hydraulic power unit with double pump 5 9 1 General The hydraulic power unit with double pump is used to supply two workplaces Fig 17 Hydraulic circuit diagram Hy power unit with double pump ...

Page 32: ...tank comprises the following assemblies Filling breathing cap Inspection glass Thermometer Oil drain plug The oil drain plug G1 2 fastened at the side of the oil tank is used to empty the oil tank Before opening of the oil drain plug the power unit is to be decommissioned By means of the visual filling level indicator inspection glass you can visually check the filling level If the system is switc...

Page 33: ...tion from the hydraulic oil The filter consisting of the filter housing with a filter element 20 µm filters the hydraulic fluid to the tank If the filter element is contaminated and has to be exchanged this is visually displayed by the clogging indicator Via the coupling connectors of the P T distributor hose lines are connected with the vane pump The generated pressure p is available at port P of...

Page 34: ...places Fig 18 Hydraulic circuit diagram LS Hy power unit with double pump Item no Assembly Item no Assembly 1 0 Oil tank 2 6 2 7 Check valve 1 1 Oil level and temperature display 3 0 Return flow filter 1 2 Filling and breathing filters 3 1 Clogging indicator optical 2 0 Three phase current motor 5 0 Switch housing 2 1 Vane pump 5 2 Power switch 2 2 2 31 2 4 2 51 Hose line 6 0 Measuring glass 2 5 l...

Page 35: ...bar The hose lines serve as connection between the individual components of the hydraulic power unit The sealed pressure relief valves secure the pump circuit with 70 bar The check valves block the flow in the one direction and open against a spring in the other direction In this connection the spring force corresponds to a certain pressure During operation the oil flows via the check valves to th...

Page 36: ...oth AG Hydraulics training system WS290 RE 00225 B 2 15 Information on this product The measuring glass mounted at the base frame is directly connected to the oil tank by means of a return flow hose 6 0 Measuring glass ...

Page 37: ...ns of an angle Fig 19 P T distributor with depressurized circulation circulation circuit At the P T distributor 2 hose couplings for P pump and T tank are in each case provided for the connection of hose lines for diverse set ups and functions Upon switch on hydraulic power units with a power of 1 5 kW require almost unloaded start up for the pump With the P T distributor with depressurized circul...

Page 38: ...ntrol block 3 hose couplings for P pump and 2 hose couplings for T tank are in each case provided for the connection of hose lines for diverse set ups and functions If the LS pressure is taken from port P1 the pump behaves like a pressure controlled pump The regulated pump pressure is set to 50 bar using the LS pressure relief valve The 3 2 way ball valve allows for the depressurized unloading of ...

Page 39: ... glass contains 2 5 l and is equipped with scale vent valve overflow protection and ball valve Fig 22 Measuring glass The measuring glass is attached to the WS290 base frame by means of an assembly console It is used for the Depressurized limited recording of the hydraulic fluid for flow measurements Verification of the oil circulation ...

Page 40: ...ulics training system WS290 RE 00225 B 2 15 Information on this product Fig 23 Measuring glass 1 Measuring glass with scale 2 Return line connection 3 Shut off cock 4 Vent valve 5 Overflow line 6 Discharge line 7 Fastening console ...

Page 41: ...24 Load simulator rotatable The rotatable load simulator is attached to the side frame of the base frame It is height adjustable and can be rotated by means of the handles and a safety rotating mechanism The bottom clearance dimension X should be at least 80 100 mm The load simulator is intended for exercises with simulated load The load simulator will be rotated depending on whether pulling or pu...

Page 42: ...using 2 Window protective cover 3 Mounting flange for assembly at the lateral frame 4 Swiveling device with stopping and locking lever 5 Handle top bottom 6 Mass part 7 Hydraulic cylinder 8 Hose couplings 9 Clamping console for sensors 10 Transport lock clamping lever Optional as accessory 2 hose lines for exercise set ups X Chassis clearance ...

Page 43: ...C 60 Place of installation Closed room Ambient temperature C 10 25 Max relative air humidity 90 at 20 C Max installation height m 1000 above sea level Pneumatics Max operating pressure bar 8 Hydraulics Max operating pressure bar 50 Tank volume l 40 Oil type DIN 51524 HLP VG22 Cleanliness ISO 4406 Class 20 18 15 Flow l min 8 Mains connection Connection operating voltage V 230 230 For D and Europe F...

Page 44: ...re C 10 25 Max relative air humidity 90 at 20 C Max installation height m 1000 above sea level Pneumatics Max operating pressure bar 8 Hydraulics Max operating pressure Industrial Mobile Hydraulics bar 50 60 Safety pressure bar 70 Standby pressure bar 15 Tank volume l 40 Oil type DIN 51524 HLP VG22 Cleanliness ISO 4406 Class 20 18 15 Flow l min 8 Mains connection Connection operating voltage V 230...

Page 45: ...5 Bosch Rexroth AG 45 104 Technical data and dimensions 6 2 Dimensions of the hydraulics training system WS290 A 1350 1810 265 800 A 200 1240 250 320 195 S S center of gravity A support point forklift Fig 26 WS290 dimensions in mm and support points ...

Page 46: ...0 training system are indicated here To identify the WS290 training system e g when ordering spare parts the following information is required from the name plate The MATERIAL NO and the TYPE AUFTRAGS NR BAUWOCHE MATERIAL NR TYP SCHALTPLAN NR TANK INHALT CAPACITY l ltr GEWICHT WEIGHT kg CIRCUIT NO MATERIAL NO ORDER NO PROD WEEK TYPE Made in Germany Rexroth F D 05W19 TS DS 4 1 R G2U09V2A0E 07MO S O...

Page 47: ...there is a danger to persons and machines you may switch off the WS290 training system by using the pushbutton Triggering the EMERGENCY OFF pushbutton interrupts the power supply to the sockets All work processes are immediately brought to a hold and dangerous control circuits hydraulic drive and the control are switched off The mains voltage continues to be applied in the control box Do not use t...

Page 48: ...th connector 7 Start pushbutton 8 230 V socket The current connection to the control box of the hydraulic power unit is effected via a coded connector connection The circuit breaker serves as residual current safeguard and interrupts the current supply to the control box in case of a residual current the switch is set to 0 0 position current supply interrupted 1 position current supply is availabl...

Page 49: ...s to be laid in a way that it cannot be crushed rolled over bent tensioned or concealed The Start pushbutton with lock is used to release the mains power supply to the sockets and to the protective motor switch of the hydraulic power unit The current connection to the 24 VDC power supply units is effected by means of separate power cables via these sockets The power cable is to be laid in a way th...

Page 50: ...y range of the operating temperature goes from 20 ºC to max 80 ºC The clogging indicator provides information on the degree of contamination of the filter cartridge of the return flow filter The display instrument shows the following color ranges Green OK Yellow Exchange filter Red Exchange oil and filter 7 4 P T distributor with depressurized circulation circulation circuit Fig 30 P T distributor...

Page 51: ...et ups 2 x hose couplings T tank for the return flow at exercise set ups 1 x hose coupling P for the connection to the P T distributor power unit operating pressure 1 x hose coupling T for the connection to the P T distributor power unit return flow into the oil tank Fig 31 P T distributor hose connections Hose couplings WARNING Danger due to pressurized hose lines Risk of serious injury Before de...

Page 52: ...Vertical position rest position Horizontal position operating position The 3 way ball valve allows for the depressurized unloading of the system to the leakage oil with simultaneous blocking to the pump At the LS control block there are hose couplings for the connection of hose lines for diverse set ups and functions see fig 33 In the project manuals the designation connection block is used in ord...

Page 53: ...n from port P1 the pump behaves like a pressure controlled pump The regulated pump pressure is set to 50 bar using the LS pressure relief valve WARNING Danger due to pressurized hose lines Risk of serious injury Before decoupling the hoses always depressurize the hydraulic circuit see chapter 13 2 6 Exchanging hydraulic hose lines ...

Page 54: ...urized recording of the hydraulic fluid for volume measurements By means of a scale at the measuring glass the corresponding filling level can be read off At the measuring glass two connection couplings for connecting hose lines are provided At the return flow port of the measuring glass there is a shut off cock If it is opened the hydraulic fluid from the measuring glass can flow back into the oi...

Page 55: ...a separate power cable It is connected to the socket at the control box at the coded mains socket The power cable is to be laid in a way that it cannot be crushed bent tensioned or concealed Using the illuminated switch Power the power supply unit is activated if 24 VDC is required as output voltage for electronic set ups The illuminated switch serves as operating switch OFF position 0 ON position...

Page 56: ... Fig 36 WS290 load simulator rotatable in pulling position 1 Swiveling device with locking mechanism 2 Handle 3 Transport lock The swiveling device is fixed in the two end positions with two locking pins which are engaged by means of a spring Never pull out both locking pins simultaneously The locking pins are set at the factory and must not be adjusted The end position of the load simulator must ...

Page 57: ...ss part The screw must not be fixed for operation It must be possible for the mass part to move freely Before transportation or shutdown of the training system and or for the removal of the load simulator this transport lock is to be activated CAUTION Danger of uncontrolled tipping of the load simulator Risk of minor injury Before swiveling retract the cylinder into its lower end position During s...

Page 58: ...e of them properly Dispose of the pallet and the wooden box properly or keep them properly for later storage The WS290 training system may now be brought to its place of use Possible damage during transportation and defects shall be promptly recorded and notified in writing by way of a notification of claim Required tool CAUTION Risk of tilting of the WS290 training system The center of gravity is...

Page 59: ... guide rollers On a slope secure with several people Push the WS290 training system to the new location using the 4 guide rollers Place the WS290 training system on solid and level ground Lock the locking devices of the guide rollers The WS290 training system may be stored see chapter 8 3 Storage or reconnected to the energy supply see chapter 9 4 Electric installation When putting the system down...

Page 60: ...ruck Secure the WS290 training system by means of belts or plastic straps against falling possibly use the original transport box Protect the WS290 training system from humidity Transport the pallet with the WS290 training system by means of a forklift Place the WS290 training system on solid and level ground At the allocated location carefully lift the WS290 training system out of the transport b...

Page 61: ...device sets not required beforehand Do not exceed the max admissible load bearing capacity of the rollers max 450 kg total weight Tighten the transport lock at the load simulator Ensure before transportation that no mineral oil can leak drain the tank if necessary Transportation to the other building has to be effected according to chapter 8 2 2 You should store the WS290 training system as follow...

Page 62: ...here required rework the area or choose another set up location Make sure that an electrical connection is available Make sure that there is sufficient lighting at the set up location Observe the following aspects for the set up Check the alignment of the WS290 training system at the place of installation spirit level Lock the locking devices of the guide rollers to secure them against rolling awa...

Page 63: ... or an authorized mineral oil supplier Prerequisites to be met for filling Ensure that the hydraulic power unit is switched off and that the mains plug is pulled out Make sure that the hydraulic system is depressurized Provide a filter funnel for new filling re filling or for oil exchange In this connection filling by means of a filter filling pump is most suitable Provide suitable cleaning cloths...

Page 64: ... level glass see fig 38 Wait for about 15 minutes until the hydraulic fluid settled down in the tank This is also valid if you only refill partial quantities Close the tank filler with the filler and breather cap Remove any leaking hydraulic oil by means of the cleaning cloths Always dispose of contaminated cleaning cloths properly The oil tank is now filled Filling the hydraulic power unit CAUTIO...

Page 65: ...rks at the electric equipment of the training system have only been performed by a specialized electrician How the hydraulic power unit is installed Check whether the coded connector for the power supply of the hydraulic power unit is plugged in at the control box The protective motor switch must still be in Off position 0 If this is not the case set the switch to 0 and plug the connector in Check...

Page 66: ... appropriate unlock the EMERGENCY OFF pushbutton Operate the ON switch at the control box of the hydraulic power unit Operate the START switch at the control box of the WS290 training system The pump drive motor starts up Operate the EMERGENCY OFF pushbutton 1 The pump drive motor keeps on running There is a faulty installation or a defective EMERGENCY OFF pushbutton Proceed as follows Immediately...

Page 67: ... box Inform a specialized electrician Direction of rotation at the motor corresponds to the arrow indicating the direction of rotation The result is ok the test is completed 9 5 3 Checking the pump circulation For the functional tests of the hydraulic power unit pump delivers oil you need a measuring glass and hose lines from the WS290 training system device program Alternatively you have got the ...

Page 68: ... of the pump the pump properly delivers the hydraulic fluid through the measuring glass Particularly with cold oil the measuring glass may overflow as the pump delivers more oil than it can flow back into the oil tank via the hose 5 Restoring the initial condition Bring the 3 way ball valve with depressurized circulation into circulation operation horizontal position see chapter 7 4 P T distributo...

Page 69: ...osed pump circuit as set up in section 9 5 3 is maintained Close the shut off cock at the measuring glass Operate the ON switch at the power unit Approx 3 seconds after start up of the pump hydraulic fluid must flow into the measuring glass Only fill approximately half of the measuring glass Immediately operate the OFF switch at the power unit Particularly with cold oil the measuring glass may ove...

Page 70: ...te the OFF switch at the power unit Exchange the hydraulic fluid before the commissioning 4 Leaky There is leakage in the suction range Interrupt the further operation Stop the hydraulic power unit Prevent the further operation of the WS290 training system Inform the Bosch Rexroth service Restoring the initial condition Bring the 3 way ball valve into circulation operation horizontal position see ...

Page 71: ...ake effect as soon as the maximum admissible operating pressure of 50 bar is reached The zero stroke controller limits the flow to the value 0 The specified zero stroke pressure must not increase any further Ensure that the hydraulic power unit is ready for operation i e all preceding tests have been carried out as prescribed and without errors Keep a hose line with Minimess connection 2 and a pre...

Page 72: ...re test of the zero stroke control with a constant pressure system Switch on the hydraulic pump at the ON switch The pump must start up At the P T distributor set the switch over lever to the operating position vertical position Check the zero stroke pressure The pointer in the pressure gauge is constant Read off the value WARNING Danger of bursting of the hydraulic system or of attachment compone...

Page 73: ...form the Bosch Rexroth service 3 Pressure ok The zero stroke control is ok if the displayed pressure lies between 50 bar and 55 bar Repeat the test for the second pump circuit The pressure test is completed Restore the initial condition 9 5 7 Pressure test in circulation operation At the P T distributor the circulation operation is set up as follows At the P T distributor with depressurized circul...

Page 74: ...llation container or the hose storage The operating pressure is ok the WS290 training system is ready for operation 9 5 8 Standby pressure test at the load sensing system How the pressure measurement is carried out Connect the pressure gauge to MP1 Switch on the hydraulic pump at the ON switch Bring the ball valve in operating position horizontal position Check the pressure at MP1 The displayed pr...

Page 75: ...e locking devices of the transport rollers are locked The max admissible total weight of the WS290 training system in the operating state incl attachments and device sets is 500 kg If the WS290 training system is moved the max total weight is limited to 450 kg 9 6 2 How to commission the hydraulic power unit Upon switch on of the pump drive the hydraulic power unit with 1 5 kW drive power generall...

Page 76: ...ox by means of the On switch Switch on of the pump motor triggers the oil delivery Ensure that port P is connected to port T Filter the hydraulic fluid for approx 10 minutes through the return flow filter by means of pump operation also in case of refilling with partial quantities Observe the clogging indicator at the return flow filter Switch the hydraulic power unit off again Check the oil level...

Page 77: ... for the power supply of the WS290 training system is connected Ensure that the coded connectors for the 24 V power supply units are connected to the 230 V sockets and the coded connector for the hydraulic power unit to the coded socket of the control box Where appropriate unlock all EMERGENCY OFF pushbuttons Where appropriate set fuses and FI switches at the control box to ON Press the Start push...

Page 78: ... lie between 15 and 60 bar 10 2 Switch off With the constant pressure system set the ball valve horizontally to circulation position With the load sensing system set the ball valve vertically to rest position Switch off the ON OFF switch at the 24 V power supply unit and pull the connector out of the socket if applicable Set the motor switch at the hydraulic power unit to 0 Where required e g when...

Page 79: ...ond EMERGENCY OFF pushbutton After the EMERGENCY OFF pushbutton has been unlocked again the mains power supply has to be restored using the Start pushbutton at the control box The Start pushbutton at the control box is used to release the power supply for the sockets and to the ON OFF switch at the hydraulic power unit Before re activation of the mains power supply by means of the Start pushbutton...

Page 80: ...ed specialized electrician with the examination and remedy Electric motor switched on by means of ON switch but no flow can be identified Filling level in the tank is too low Immediately stop the hydraulic power unit Refill hydraulic fluid Wrong direction of rotation of the motor Immediately stop the hydraulic power unit Commission a qualified specialized electrician with the examination and remed...

Page 81: ...amp cloth Only use water and if necessary a mild cleaning agent without any chemical additives Never use solvents or aggressive cleaning agents Before using any cleaning agent obtain information about the usability and possible dangers by referring to the user instructions and the DIN safety data sheet Never blow off the training system with compressed air as the sensors and valves of the function...

Page 82: ...act with the hydraulic fluid may cause dry and chapped skin Wash your hands after contact with hydraulic fluid Wear working safety shoes as protection against parts falling down When What Where Comments Daily prior to any use EMERGENCY OFF pushbutton Check the function Always before starting the works Overall training system Clean the surrounding of the training system Clean the worktops and keep ...

Page 83: ...ble damage Check for leakage and visible damage Have any damage removed immediately Overall training system Check the electric connection cables and lines for visible damage abrasions cracks cuts Promptly have any damage remedied by a specialized electrician Check electrical devices control boxes and switches buttons for visible damage cracks Promptly have any damage remedied by a specialized elec...

Page 84: ...ng shall be observed in any case Take the training system out of operation without any undue delay Determine the cause and remedy the defects Replace the defective component Where appropriate do not put the WS290 training system back into operation Store and dispose of any supplies and auxiliary materials spilled and used as prescribed pursuant to the legal provisions In case of doubt obtain infor...

Page 85: ...raulic fluid in case of Turbidity black coloring acid smell Return flow filter Check filter contamination Color sector of the pressure gauge display green yellow red In case the display is in the YELLOW range Exchange filter element Clean oil In case the display is in the RED range Exchange filter element Exchange the oil When exchanging filters only use original spare parts Fittings Check for ext...

Page 86: ...nt pressure system Check circulation pressure Max 12 bar Min 5 bar Load sensing system Check standby pressure 15 bar Pressure measurement Check the circulation operation See chapter 9 5 7 Overall training system Check the electric connection cables and lines for visible damage abrasions cracks cuts Promptly have any damage remedied by a specialized electrician Protective motor switch hydraulic pow...

Page 87: ... Oil binding agent recommended Type AVILUB SUPER 5ORB art no 0844108 company Bantleon Ulm Germany Further data is contained in the supplier s DIN safety data sheet Cleaning cloths Tarpaulin Container to dispose of lubricants waste Test and maintenance record writer 1 set open end wrenches including size 36 1 set hexagon socket wrenches 1 set screwdrivers 1 elastic hammer rubber hammer Caliper Pres...

Page 88: ...xchanging the filter element Check for residues in the empty tank in case of Extreme contamination of the hydraulic fluid Or if the clogging indicator had been in the red range for a longer period of time An oil exchange is required if strong contamination is visible at the exiting hydraulic fluid or in case of oil sludge In this case inform the Bosch Rexroth service by all means 13 2 4 Performing...

Page 89: ...ter and filter effect Measure required GREEN 0 2 bar Bypass valve closed Continuous filtration of the flowing hydraulic fluid Not applicable YELLOW 2 3 bar Bypass valve partially open Only partial filtration of the flowing hydraulic fluid Exchange the filter element Clean the hydraulic fluid RED 3 10 bar Bypass valve completely open No filtration of the flowing hydraulic fluid Exchange the filter ...

Page 90: ... filter element Container to dispose of lubricants waste Provide appropriate cleaning cloths The hydraulic power unit is switched off and the mains plug is not connected The hydraulic system must be depressurized To exchange the filter element proceed as follows Screw off the cover of the return flow filter using an open end wrench size 36 see fig 44 Fig 44 Removing the cover Pull the contaminated...

Page 91: ...luid if required and or re fill it completely see chapter 9 3 Set up the circulation operation see chapter 9 5 7 Switch the hydraulic power unit on Operate the unit with circulation operation for some minutes in order to check the proper assembly of the return flow filter and to fill the filter Carry out a visual inspection for leak tightness at the return flow filter Observe the clogging indicato...

Page 92: ...eration The hose couplings P and T are connected with each other and thus the pending pressure in the hose lines is discharged 2 LS power unit see chapter 7 5 Load sensing control block Bring the switching lever of the ball valve into the horizontal operating position Use a hose line to connect pump P and the tank T Set the switching lever to the vertical position rest position The pending pressur...

Page 93: ...button at the control box Switch the hydraulic power unit on again by pressing the ON pushbutton Provide for depressurized circulation of the hydraulic oil in the hydraulic system Check all hose connections for leak tightness Check the oil level at the oil sight glass as the new hoses are filled with hydraulic oil the oil level in the tank decreases and refill hydraulic oil if necessary The exchan...

Page 94: ...sed of Dispose of the training system according to the local and legal provisions Any water polluting substances such as hydraulic oil and cleaning liquids containing solvents must not infiltrate the ground and reach the sewage system According to the legal provisions supplies and auxiliary materials have to be kept stored transported collected and disposed of in suitable containers In case of dou...

Page 95: ...Hydraulics training system WS290 RE 00225 B 12 15 Bosch Rexroth AG 95 104 Hydraulic oil data sheet 15 Hydraulic oil data sheet ...

Page 96: ...96 104 Bosch Rexroth AG Hydraulics training system WS290 RE 00225 B 2 15 Hydraulic oil data sheet ...

Page 97: ...Hydraulics training system WS290 RE 00225 B 12 15 Bosch Rexroth AG 97 104 Hydraulic oil data sheet ...

Page 98: ...98 104 Bosch Rexroth AG Hydraulics training system WS290 RE 00225 B 2 15 Hydraulic oil data sheet ...

Page 99: ...Hydraulics training system WS290 RE 00225 B 12 15 Bosch Rexroth AG 99 104 Hydraulic oil data sheet ...

Page 100: ...100 104 Bosch Rexroth AG Hydraulics training system WS290 RE 00225 B 2 15 Hydraulic oil data sheet ...

Page 101: ...Hydraulics training system WS290 RE 00225 B 12 15 Bosch Rexroth AG 101 104 Hydraulic oil data sheet ...

Page 102: ...102 104 Bosch Rexroth AG Hydraulics training system WS290 RE 00225 B 2 15 Declaration of conformity 16 Declaration of conformity ...

Page 103: ...Hydraulics training system WS290 RE 00225 B 12 15 Bosch Rexroth AG 103 104 Declaration of conformity ...

Page 104: ...nted in Germany RE 00225 B 12 2015 Mat no R961003776 Bosch Rexroth AG Drive Control Academy Bahnhofplatz 2 D 97070 Würzburg Germany Phone 09352 18 1920 Fax 09352 18 6882 trainingsystems boschrexroth de www boschrexroth com academy ...

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Bosch Rexroth WS290, Operating Instructions Manual

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