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About this manual

Bosch Rexroth AG

, M4-12, RE 64276-01-R/10.2017

1 About this manual

This repair manual is made up of the following parts:

Part 01

Basic document

Part 10

Control block assembly

Part 20

Repairing the directional valve

Part 30

Repairing the electro-proportional pressure relief system

Part 40

Repairing the electronics (EPM2)

Part 41

Repairing the electronics (CPM)

Part 50

Repairing the inlet plate

Part 51

Repairing the inlet plate for safety-related applications

1.1 Validity of the documentation

This documentation applies to the following products:

•

Load sensing control block M4-12

This manual is aimed at vehicle manufacturers, assemblers and service technicians,
as well as authorized specialist companies and dealers.
This documentation contains important information on the safe and proper repair of
the control block.

▶

Read this documentation in its entirety and in particular the sections 2 “Safety
instructions” page 7 and 3 “General notes on damage to equipment and the
product” on page 12 before working with the product.

1.2 Required and supplementary documentation

▶

Only commission the product if the documentation marked with the book
symbol

is available to you and you have understood and observed it.

Table 1: Required and supplementary documentation

Title

Document number Document type

Control blocks for mobile applications

Contains important information for safely and professionally transporting, installing,
commissioning, servicing and removing the Load sensing control block M4-12.

64025-B

Operating
instructions

Load sensing control block M4-12 for safety-related applications

Contains important information for safely and professionally transporting, installing,
commissioning, servicing and removing the Load sensing control block M4-12 for
safety-related applications.

64276-01-B

Operating
instructions

Load sensing control block M4-12

Contains the permissible technical data.

64276

Data sheet

Load sensing control block M4-12

Contains the spare parts available to order.

64276-E

Spare parts list

Related documents for the assembly and repair can be found in Table 21 on page
25 and can be obtained where necessary via

www.boschrexroth.com/mobile-hydraulics-catalog

Documents relating to the general circuit diagram of the machine are available
from the vehicle manufacturer.

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Содержание Rexroth M4-12

Страница 1: ...Repair manual RE 64276 01 R 10 2017 Replaces 10 2014 English Load sensing control block M4 12 Basic document ...

Страница 2: ...cerning 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 An example configuration is shown on the title page The product delivered may therefore differ from tha...

Страница 3: ...l block segments 17 4 4 1 Inlet plate 17 4 4 2 Directional valves M4 12 general 18 4 4 3 Directional valves M4 12 with purely mechanical actuation 19 4 4 4 Directional valves M4 12 with hydraulic actuation 20 4 4 5 Directional valves M4 12 with electrohydraulic actuation 21 4 4 6 Directional valves M4 12 with on board electronics 22 4 4 7 Directional valves M4 12 with servohydraulic actuation 23 4...

Страница 4: ...ired and supplementary documentation Only commission the product if the documentation marked with the book symbol is available to you and you have understood and observed it Table 1 Required and supplementary documentation Title Document number Document type Control blocks for mobile applications Contains important information for safely and professionally transporting installing commissioning ser...

Страница 5: ...fety instructions are set out as follows Signal word Type and source of danger Consequences of non compliance Measures to avert danger Warning sign draws attention to the danger Signal word identifies the degree of danger Type and source of the hazard identifies the type and source of the danger Consequences describes what will happen if the safety instructions are not complied with Precautions st...

Страница 6: ...tanding White circle with black number Item or assembly with a reference to the parts list and to the graphics within a section White circle with black letters Assembly with reference to the parts list and the graphics within a section White circle with black Roman numeral Variants Views 1 3 3 Designations This documentation uses the following designations Table 4 Designations Designation Meaning ...

Страница 7: ...sional training and experience Are able to evaluate the work assigned to them Can identify potential dangers Can implement the measures required in order to eliminate dangers Are aware of the potential health risks posed by hydraulic fluids Have the necessary knowledge to carry out repair and assembly work Specialist knowledge of hydraulics means Reading and fully understanding hydraulic diagrams ...

Страница 8: ...ire system and secure it against being restarted as specified by the machine manufacturer Make sure that all relevant components of the hydraulic system are depressurized Please follow the machine manufacturer s instructions Note that the hydraulic system may still may be under pressure even after the pressure supply itself has been disconnected Do not disconnect any line connections ports and com...

Страница 9: ...aulic fluid leaking or fly away parts Danger to life or risk of injury If fasteners without sufficient high pressure resistance are used they can cause rupturing and leakage of hydraulic fluid and or fly away parts The ports and fastening threads of the control block are designed for the specified maximum pressure Only ever connect connecting elements and lines that match the ports of the control ...

Страница 10: ... control block Risk of burns Allow the control block to cool down sufficiently before touching it Wear heat resistant protective clothing e g gloves Cold surfaces on the control block Sticking skin frostbite by touching the cold valve housing Wear personal protective clothing e g cold resistant gloves Improper routing of cables and lines Risk of stumbling and property damage Improper routing of ca...

Страница 11: ... Never use the control block for grabbing or climbing Check how to safely get on top of the machine 2 4 Personal protective equipment The personal protective equipment is the responsibility of the user of the control block Observe the safety regulations and provisions in your country All pieces of personal protective equipment must be intact Bosch Rexroth recommends that personal protective equipm...

Страница 12: ...ts with new ones after removing The housing and parts must be clean and undamaged Damaged housings and parts may no longer be used Reworking threads is not permissible Reworking holes is not permissible Prevent dirt from entering holes and threads Adhesion forces may act between the flange surfaces during disassembly Remove soiling with a sharpening stone and clean with an oil soaked cleaning clot...

Страница 13: ... you connect the lines Disconnect all electrical connectors before starting painting operations Make certain that the electronic components e g sensors do not become electrostatically charged e g during painting operations Risk of property damage due to improper lubrication Product can get damaged or destroyed Always commission the control block with sufficient hydraulic fluid When commissioning a...

Страница 14: ... solid impurities and water in the hydraulic system Improper cleaning Product can get damaged Plug all openings with appropriate protective equipment to prevent cleaning agents from entering the control block Never use solvents or corrosive cleaning agents Clean the control block using only water and a mild cleaning agent if necessary Do not point the high pressure cleaner at sensitive components ...

Страница 15: ...ace a drip tray under the control block Use an oil binding agent if hydraulic fluid is spilled Dispose of the hydraulic fluid according to the national regulations in your country Danger from hot components Nearby products can get damaged Components which heat up e g solenoids can cause damage to nearby products if they are too close during installation When installing the control block check the ...

Страница 16: ...0 5M4 12J_W2_MV01 123456789 FD 12W20 1 Word mark manufacturer 2 Material number 3 Production date 4 Serial number 5 Material description 6 Customer material number 7 Area plant number 8 Installation stamp 9 Inspection stamp 10 Designation of origin 4 2 Connection designation Table 6 Connections Designation Port for A Consumer B Consumer LS LS signal T Tank or return P Pump Y Tank or pilot oil retu...

Страница 17: ...e IP for fixed displacement pump FDP IP for variable pump VP Multiple M4 12 directional valves can be arranged The end plate closes off the control block 4 4 1 Inlet plate Table 7 Internal functions Item Designation Primary pressure relief valve Pilot oil supply cartridge Pressure compensator Fig 2 Inlet plate for fixed displacement pump Inlet plate IP Directional valves M4 12 End plate EP ...

Страница 18: ...e side A Valve side B Service line port Service line port Secondary pressure relief valve hole optional Secondary pressure relief valve hole optional LS pressure relief valve hole optional LS pressure relief valve hole optional LS port optional LS port optional Table 9 Internal functions Item Designation Shuttle valve Pressure compensator Y LS port X pilot oil port X pilot oil supply Fig 4 Directi...

Страница 19: ... Guide on the pilot spool Bearing block Hand lever Cover side B with adjustable stroke limitation and setting shaft Table 11 Internal functions Item Designation Cover side A Cover side A with locking unit Secondary pressure relief valve not adjustable or plug Secondary pressure relief valve adjustable Cover for LS components Cover side A with spring centering and stroke limitation ...

Страница 20: ...tation and setting shaft hand lever Hydraulic actuation port A Hydraulic actuation port B Proportional pressure relief valve type KBPS Table 13 Internal functions Item Designation Cover side B with adjustable stroke limitation Cover side A with adjustable stroke limitation Secondary pressure relief valve or plug Plate for electro proportional pressure relief Unloading valve Plate for switchable di...

Страница 21: ...ing shaft hand lever Electrohydraulic actuation port A Electrohydraulic actuation port B Proportional pressure relief valve type KBPS Table 15 Internal functions Item Designation Cover side B with adjustable stroke limitation Cover side A with adjustable stroke limitation Secondary pressure relief valve or plug Plate for electro proportional pressure relief Unloading valve Plate for switchable dir...

Страница 22: ...signation Cover side B with adjustable stroke limitation and setting shaft hand lever EPM2 or CPM Proportional pressure relief valve type KBPS Table 17 Internal functions Item Designation Cover side B with adjustable stroke limitation Cover side A for EPM2 or CPM Secondary pressure relief valve or plug Plate for electro proportional pressure relief Unloading valve ...

Страница 23: ... External connections Item Designation Cover side A with servo adjusting unit Table 19 Internal functions Item Designation Cover side A for servo adjusting unit Cover side B with adjustable stroke limitation Secondary pressure relief valve not adjustable or plug 4 4 8 End plate Table 20 External connections Item Designation M Measuring port ...

Страница 24: ...actuation with guide hand lever Fig 7 Servohydraulic actuation Fig 8 Hydraulic actuation Fig 9 Electrohydraulic actuation Fig 10 Electrohydraulic actuation with on board electronics Control blocks in the M4 12 series have a modular structure They can be combined to provide the perfect solution for the application at hand The pictures shown are example configurations ...

Страница 25: ...30 R Repairing the electronics EPM2 64276 40 R Repairing the electronics CPM 64276 41 R Repairing the inlet plate 64276 50 R Repairing the inlet plate for safety related applications 64276 51 R 5 1 Screw connection for hydraulic connections Pipe thread in accordance with ISO 2281 Lightly grease the screw connection 5 2 Screw connection on the control block segment Torque wrench 1 Use the screw con...

Страница 26: ...ce 0 1 mm 1 Align the control block with the fixing threads facing the fixing through holes 2 Screw the screws into the fixing threads clockwise and by hand 3 Pre tension the screws with a torque of 5 1 Nm 4 Tighten the fixing screws clockwise using a torque wrench in accordance with Table 22 Table 22 Tightening torques Screw Tightening torque Minimum screw in depth of the thread Through hole diam...

Страница 27: ...valve or a control block tests must be performed to ensure that the modification will not impede the function of the application or cause it to work incorrectly Follow the instructions in the corresponding instruction manual See Table 1 Required and supplementary documentation on page 4 In the event of malfunctions see the section 7 Fault finding on page 28 ...

Страница 28: ...ghtening torque Flange surface damaged Replace the control block segment with a new one F4 Fluctuations in pressure and oil flow Pressure fluctuations in the system Vent the control block segments Vent the hydraulic system Dirt or foreign particles in the control block segment Clean the insides of the control block segments Check that the oil meets the specified oil cleanliness F5 Temperature on t...

Страница 29: ... for accessories and spare parts Accessories and spare parts are available From the vehicle manufacturer specialist dealer From your Bosch Rexroth specialist dealer Rexroth sales partners can be found on the Internet at www boschrexroth com addresses For questions relating to repair and spare parts contact your responsible Bosch Rexroth Service team Bosch Rexroth AG Bürgermeister Dr Nebel Straße 8...

Страница 30: ...30 32 Accessories and spare parts Bosch Rexroth AG M4 12 RE 64276 01 R 10 2017 ...

Страница 31: ...Accessories and spare parts 31 32 RE 64276 01 R 10 2017 M4 12 Bosch Rexroth AG ...

Страница 32: ...sengießer 1 97816 Lohr am Main Germany Tel 49 9352 18 0 info ma boschrexroth de www boschrexroth com Subject to change Printed in Germany RE 64276 01 R 10 2017 Your local contact can be found at www boschrexroth com addresses ...

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