Industrial Hydraulics
Trainer‘s manual
Foreword Bosch Rexroth AG I RE 00845/04.07
Foreword
In July 2004 the Federal Minister for Economics and Labor passed the new regulations for
vocational training in industrial metalworking professions.
Basic training for the entire field of professions, the structure and objectives of vocational train-
ing are set out in paragraph § 3. Skills and knowledge (qualifications) are to be imparted with
reference to practical needs. To be capable of carrying out qualified work, the trainees are to
be trained in particular in independent planning, execution and checking as well as acting in
the overall operative context.
Specialist Profession-specific specialist qualifications, e.g. the manufacture, assembly and disassembly of
qualification assemblies and systems are to imparted in conjunction with core qualifications, e.g. planning
Core qualification and organizing of the related work and the evaluation of work results.
The training contents for the profession-specific specialist qualification include, among others,
business processes and quality assurance systems in the relevant field of activity.
Project Manual The present Project Manual Industrial Hydraulics is intended as accompanying and exercise
book to help trainers and technical instructors to impart knowledge through project work.
BIBB In line with the exercises compiled by the Bundesinstitut for berufliche Bildung in Berlin BIBB
(Federal Institute for Vocational Training in Berlin BIBB) project tasks are described, which are
oriented towards the restructured industrial metalworking and electrical engineering profes-
sions.
Practice-oriented With all practice-oriented project tasks core and specialist qualifications are imparted in an
project tasks integrated form involving independent planning, execution and checks.
The training course was structured in a way that the project manager/trainer explains the project
order first and also supports the trainees during their project work.
In the course of the further project tasks, the information and assistance provided by the proj-
ect manager is reduced. In this way the trainees learn to actively proceed in line with project
management requirements.
Foreword Bosch Rexroth AG I RE 00845/04.07
Notes
Introduction Bosch Rexroth AG I RE 00845/04.07
1987 2004
3,5 3,5
Profession-specific
Subject Subject specialized training
Qualification requirements
The requirements for core qualification are met by solving tasks set in the form of project
steps, which involve informing, planning, decision-making, executing, checking and assess-
ing. Mastering and internalizing the multitude of qualifications finally results in the professional
competence to act.
Field of
activities
ns
ns
ist
ifi
Sp
al
context of profession-
Co
Fields of activities
specific business
processes
Framework The project tasks and project work described in the Project Manual Industrial Hydraulics pro-
curriculum vide trainers and trainees with information and instruments that will help them comply with the
demands made on the transfer of specialist know-how in the field of hydraulics.
The sub-objectives listed below, which are taken from the framework curriculum for vocational
training of industrial mechanics, are matched with the regulations for vocational training in
industrial metalworking professions dated 09.07.2004 (BGBl. I. S. 1502). The sub-objectives
listed refer to training objectives given for hydraulic control technology.
Industrial mechanics
• plan and organize work sequences, check and assess work results,
• verify mechanical and physical variables,
• assemble and disassemble machines, equipment, fixtures and systems,
• commission systems and plants, including open and closed-loop control equipment, and
instruct customers,
• carry out maintenance work and ensure the operability of technical systems,
• prepare technical documentation,
• apply standards and regulations for safeguarding the process and product quality and
contribute to continuing improvements in the work sequences in the company.
Fields of activities Industrial mechanics are mainly assigned to professional activities in the field of production,
assembly, maintenance and automation of technical systems. The fields of activities mentioned
before are dealt with in individual training sections. Within the fields of activities, the training
sections of the individual training years are based on each other.
Training sections In training section-oriented lessons the solutions required for project handling are not imparted
like in conventional lessons. The solution of the task set is worked out alternately in systematic,
technical and situation- or case-related training. In the course of the project work it should
be envisaged that the trainee can handle the projects on his/her own and under his/her own
responsibility and, whenever possible, in a team.
This brings the training contents closer to the trainee's real world of experience, which enables
and simplifies imparting the professional competence to act in the lessons.
To solve a more complex project task, it may be required to impart the basic principles for this
project in systematic technical training.
Introduction Bosch Rexroth AG I RE 00845/04.07
The starting point of didactic-methodical structuring of the training situation in the individual
training sections is to be the business and work process in the vocational field of activities. This
is reflected in the formulation of objectives in the individual training sections. The objectives of
the training sections are the decisive factors for the structuring of the lessons and represent
the minimum scope together with supplementary contents.
Training schedule The technical contents of the individual training sections are formulated generally and are not
listed in a differentiated way. The individual contents of the training sections are coordinated
with the training curriculum for in-company training.
According to § 7 of the regulations for vocational training in industrial metalworking professions
deviations from the training curriculum are permitted in terms of technical contents and time
schedule, in particular, where practical requirements necessitate this deviation.
The project tasks described in the Project Manual Hydraulics are structured so that the trainee
achieves the training objectives described in the project definition in 6 project steps:
• Informing,
• Planning,
• Deciding,
• Executing,
• Checking,
• Evaluating.
Introduction Bosch Rexroth AG I RE 00845/04.07
Specialist The objectives described are geared to the development of competence to act. The trainee will
competence develop his or her competence to act from the capability and willingness to solve tasks and
problems and evaluate results in a target-oriented manner, skillfully, methodically and indepen-
dently on the basis of technical knowledge and skills.
Professional The projects described in the project definition are oriented towards practical needs and are
competence to act characterized by a high level of conformity with customer orders from industry and trade. Cus-
tomer orders represent complete activities and develop and promote the trainee's professional
competence.
As mentioned before, the trainee is to work off the project task or the project order in 6
steps.
1. Informing
Based on the project definition, the trainee is to get a clear idea of the finished solution, including
any required details. This is achieved through a systematic analysis of the project documenta-
tion and, if required, by asking questions.
Possible questions: • What is to be done?
• Have I understood the task completely?
• Which hydraulic component/system is to be dealt with?
2. Planning
Planning means the theoretical preparation and anticipation of the concrete execution. In detail,
planning requires competence to handle the project order and to organize the project handling
steps.
Possible questions: • How to proceed?
• What knowledge is required?
• Which aids are available?
• Are there comparable applications in my company?
3. Decision-making
After the planning stage, the trainee determines the aids to be used, e.g. which data sheets are
required for coping with the project task. He/she decides on the sequence and the interrela-
tionships of the individual project steps. Moreover, a decision should be made as to whether it
would be easier to solve the project task in a team.
Possible questions: • Which hydraulic components will be used?
• How can you know that technical data sheets are up to date?
• Have I utilized all available sources of information?
• Are the prescribed safety instructions at hand?
4. Executing:
The order is to be executed according to the work instructions given in the chapter "order execu-
tion", taking all safety notes into account. After a thorough preparatory phase, the trainee is to
carry out the project order largely on his/her own. After the solution was worked out in writing,
it should be verified or questioned, whether the right attempt at a solution was selected.
Depending on the project order, the possibilities of execution may be limited. This is valid, for
example, in the case of costly work in the field of information technology.
Possible questions: • Have I chosen the correct sequence?
5. Checking:
The trainee must check intermediate results as early as during the execution stage, and finally
the result of the customer requirement. In some cases, the result can be compared with the
manufacturer's documents. In the case of measuring exercises, it must be checked, whether the
measured results are realistic. The documentation should also be finally corrected, improved
and completed. This also includes the preparation of a final report. After completion, the trainer
makes a final check.
Introduction Bosch Rexroth AG I RE 00845/04.07
6. Evaluating:
In the final evaluation phase, an external or self-evaluation is to be carried out on the basis of
a comparison of project order documents, the installed control and results of measurements
and checks.
Faults, if any, and their causes must be analyzed and possibilities discussed as to how faults
can be avoided in the future.
The trainee must learn to assess his/her strengths and weaknesses and develop objective quality
standards for his/her acting, which ultimately leads to personal competence. The evaluation can
be finalized in a technical discussion, possibly also in a discussion with the customer.
General notes:
For didactic reasons, we refer exclusively to trainees and trainers in the present manual. We
expressly point out that these terms include all persons involved in the basic and advanced
training: Instructors, teachers, project managers, etc., whether male or female.
Procedural In this manual, we do not give notes on procedural knowledge (explanatory knowledge). It is
knowledge the knowledge of how to achieve a certain result with which measures, procedures or pro-
cesses - in this case, how the learning target can be reached.
The present manual must be understood as a tool for providing the required core and special-
ist qualification that must be imparted in an integrated form through independent planning,
executing and checking according to the regulations for vocational training in industrial met-
alworking professions.
Pictogram The pictograms, which are used as recurrent symbols, are to transfer important information
as quickly as possible in the form of a simplified graphical representation and independently
of languages.
Introduction Bosch Rexroth AG I RE 00845/04.07
Project
Project designation Project content BIBB
no.
Component selection for hydraulic
01 Hydraulic power unit A1
power unit
Hydraulic variable displacement
02 Pump characteristic curve A2
pump
Safety aspects with regard to pres-
03 Single-rod cylinder/pressure B 1.1
sure intensification
Commissioning, troubleshooting,
21 Commissioning H1
maintenance
Introduction Bosch Rexroth AG I RE 00845/04.07
Component matrix
The matrix below provides an overview of the components, which are required for the individual project exercises.
Project 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21
Component designation
ZY 1.3
1 1 1 1 1 1 1 1 1 1
Double-acting cylinders
ZY 1.Load
1 1 1
Double-acting cylinders with load
DM 2.N
1 1 1 1 1
Hydraulic motor
DW 3E
1 1 1 1 1 1 1
4/2 directional valve C
DW 4E
1 1
4/3 directional valve G
DW 10E
1 1
4/3 directional valve J
DW 13E
1 1 1 1 1 1 1 1 1 1
4/3 directional valve E
DS 2.1
1 1
Check valve
DS 1.1
1 1 1
Check valve, pilot operated
DZ 2.1
1 1
Shut-off valve
DD 1.1
1 1 2 1 2 2 2 2 2 1 2 2 1 1 1 1 1 1
Pressure relief valve
DD 2
1
Pressure reducing valve
DF 1.2
1 1 1 1 1 1 1 1
Throttle valve
DZ 2.2
1 1
Throttle check valve
DF 3
1 1 1 1
Flow control valve
DD 6.E
1 1
Pressure switch
DZ 3.2
1
Hydraulic accumulator
DE 2
2
Limit switch
DZ 4.1
2 1 1 1 3 3 2 1 2 1 2 3 1 1 1 2 2
Distributor plate
DZ 1.4
1 3 3 4 3 3 3 4 3 4 1 3 3 3 1 2 3 3 3 4
Pressure gauge/minimess connection
DZ 25.1
1 4 3 3 3 4 3 4 1 3 3 3 1 1 3 3 3 4
Hydraulic hose/minimess connection
Overview of components
Double-acting cylinder
ZY 1.3
with single-sided piston rod
Double-acting cylinder
ZY 1.Load
with single-sided piston rod with load
Hose VSK 1
Introduction 12 Bosch Rexroth AG I RE 00845/04.07
Flow-meter DZ 30
Tachometer
1)
red
black
Limit switch, inductive DE 2.2
blue
1)
Stopwatch
1)
No symbol according to DIN ISO 1219
Introduction 13 Bosch Rexroth AG I RE 00845/04.07
Safety aspects
Safety and the economic use of resources are essential demands that are placed on modern
plant and machinery and serve to protect people. These two requirements have in common
that they have to be taken into account as early as possible, that is, at the product concept
stage. Only in this way can optimized and low-priced solutions be found. Safe machines with
low consumption demonstrate that the manufacturer masters his processes; they are a quality
feature.
In order that hazards to plant and machinery can be recognized, safety regulations, product
information brochures and operating instructions must be observed. Corresponding notes on
the handling of electrohydraulic components and systems of Bosch Rexroth can be found in:
• General product information on hydraulic products
RE 07008/02.05
• Operating instructions for hydraulic systems
AB 01-01.02
• Hydraulic cylinders of tie rod/mill-type design (operating instructions)
RE 07100-B/10.04
• Operating instructions DS4 – 1X
RE 00225-B/05.05
The safety notes and product information in the above documentation are exclusively valid for
Bosch Rexroth hydraulic products.
Only when operating instructions, safety notes and product information are observed can the
trouble-free operation of Rexroth products be ensured.
The present Project Manual Industrial Hydraulics includes warning notes, which precede in-
structions for activities that involve a risk of personal injury or damage to property. The described
precautions for averting risks must be taken.
Conventions
This symbol refers to imminent danger that, if not avoided, can lead to sever-
est injuries or death.
Warning
This symbol refers to a potential risk, which can lead to light or serious injuries
or damage to property.
Caution
Note:
The electrohydraulic components and systems described in this Project Manual are technical
equipment, which is not intended for private use.
The use for the intended purpose also includes that the safety regulations, product information
and operating instructions described in the following are read and understood.
Introduction 14 Bosch Rexroth AG I RE 00845/04.07
Qualification of Installation, commissioning and operation, disassembly, upkeep and maintenance require fun-
personnel damental knowledge of mechanics and electrohydraulics as well as the knowledge of related
technical terms. In order to ensure operational safety, these activities may only be carried out by
a corresponding specialist or by an instructed person under the supervision of a specialist.
A specialist is, who, due to his/her professional training, his/her knowledge and experience and
the knowledge of relevant regulations, can asses the duties assigned to him/her, recognize po-
tential risks and take suitable precautions. A specialist must observe relevant technical rules.
Consequently, this means that the trainer must point out potential risks to the trainees and
provide information on how to avert such risks.
Liability In the case of damage resulting from improper use and unauthorized interventions, which are
not provided in the Project Manual Industrial Hydraulics, any liability claims for defects or other
liability claims vis-à-vis Bosch Rexroth AG become void.
If Projects 01 to 21 described in the Project Manual Industrial Hydraulics are carried out on
training stands and with electrohydraulic components that were not delivered by Rexroth, that
is, products of competitors' make, any defect or liability claims vis-à-vis Bosch Rexroth AG shall
be void as well.
When using competitors' products, observe the safety notes of the manufac-
turer and make sure that the components and systems comply with currently
valid EU Directives.
For this reason, commissioning is prohibited until it was established that the
electrohydraulic components and systems to be used meet the stipulations
Warning of all relevant EU Directives.
Note:
The required safety regulations, product information documents* and operating instructions
must be handed over or be accessible to the trainee in their latest issue.
In the Project Manual Industrial Hydraulics we do not refer in detail to the correct handling of
hydraulic fluids in the project exercises 01 to 21. The corresponding information can be found
in the safety data sheet.
The correct handling of hydraulic fluids and possible risks as well as measures for averting
risks are described in a separate topic "Hydraulic fluids" in the following.
* Rexroth product information sheets are valid exclusively for hydraulic products, which are
operated with hydraulic fluids based on mineral oil, unless the use of other hydraulic fluids
is expressly permitted in the operating instructions.
Basic principles of hydraulics Bosch Rexroth AG I RE 00845/04.07
Tension force by
spring
Energy transmis- Pipes and hoses Pipes and hoses Electric cables Mechanical parts:
sion elements Levers, shafts, etc.
Magnetic field
Energy carriers Fluids Air Electrons Rigid and elastic
bodies
Force density High Relatively low Low High
(power density)
High pressures Low pressures cf. power/weight Volume and assign-
ratio of el. motor to ment of required
Large forces hydraulic motor 1:10 installation space is
often less favorable
Small installation than with hydraulics
space requirement
Smooth control Excellent via pres- Good via pressure Good to excellent Poor
(accelerating, sure and flow and flow
decelerating) Electrical open and
closed-loop control
Motion types of Linear and rotary Linear and rotary Mainly rotary move- Linear and rotary
drives movements can eas- movements can eas- ments movements
ily be achieved with ily be achieved with
hydraulic cylinders pneumatic cylinders
and hydraulic motors and pneumatic mo-
tors
System planning The specific advantages of hydraulic technology over other technologies such as pneumatics,
electrics and mechanics, can only be utilized to the full extent, if the system planner knows the
typical features offered by hydraulic control technology.
Features of hy- • Transmission of large forces within a minimum of space;
draulic systems • High energy density
• Storing of energy is possible
• Stepless changes in motion variables such as velocities, forces and moments
• Good monitorability of occurring forces
• Swift reversing operation due to small masses (low moments of inertia) of the drive ele-
ments
• High switching dynamics
• Good transmission ratio
• Simple conversion of rotary movements into linear movements or vice versa
• Constructive flexibility in the arrangement of components
• Physical separation of input and output through pipes and hoses
• Possibility of automating all types of movements and auxiliary movements by means of pilot
control valves and electronic command transmission
• Usability of standard components and assemblies
• Simple overload protection
• Low wear, since hydraulic components are lubricated by the operating medium
• Long service life
• Possibility of energy recovery
• Pressure and flow losses (fluidic friction) in line systems and control elements
• Dependence of viscosity of the hydraulic fluid on temperature and pressure
• Leakage problems; therefore risk of accidents and risk of fire
• Compressibility of the hydraulic fluid
Basic principles of hydraulics Bosch Rexroth AG I RE 00845/04.07
Energy conversion Hydraulic systems convert mechanical energy into hydraulic energy, transport it in this form in
an open or closed-loop controlled way and then re-convert it into mechanical energy.
For the conversion of energy, hydraulic pumps are used on the primary side, and hydraulic
cylinders and hydraulic motors on the secondary side.
Hydraulic energy and hence the transmitted power can be influenced in pressure and flow by
hydraulic pumps, and in its magnitude and direction of action by open and closed-loop control
valves.
The hydraulic fluid that is directed via pipes, hoses and bores in control blocks or manifolds
assumes, among others, the energy transport.
For storing and maintaining the hydraulic fluid, additional equipment such as reservoirs, filters,
coolers, heaters, measuring and testing instruments are required.
Electric energy,
thermal energy, Hydraulic energy Mechanical energy
mechanical energy
Energy conversion in a hydraulic system
As illustrated in the schematic above, an oil-hydraulic system firstly converts mechanical energy
into hydraulic energy, transports it in an open or closed-loop controlled way, and then converts
it into mechanical work. The components used in hydraulics can be classified according to
their function.
Basic principles of hydraulics Bosch Rexroth AG I RE 00845/04.07
The figure below schematically shows the components of a simple hydraulic system.
Hydraulic cylinder
Throttle
check valve
Directional valve
Pressure relief
Check valve valve
Hydraulic pump
Instead of sectional drawings, standardized symbols according to DIN ISO 1219 part 1 are
used in hydraulic circuit diagrams. More detailed information is provided in the next chapter
"Symbols".
Graphical symbols help to identify the function in circuit diagrams of fluid power technology.
They can also be attached to the components themselves for this purpose.
DIN ISO 1219-1 The symbols included in standard DIN ISO 1219 should preferably be used, but their use does
in no way rule out the use of symbols commonly applied in other technical areas for identifying
pipes and hoses.
The followings lists are not complete, but must be regarded as working aid for the preparation
or completion of project-related circuit diagrams.
The graphical symbols used in the manual comply with DIN ISO 1219 - fluid power technology;
graphical symbols and circuit diagrams; part 1: Graphical symbols.
DIN ISO 1219-2 The basic rules for the preparation of hydraulic circuit diagrams are determined in part 2 of
standard DIN ISO 1219. Circuit diagrams are a tool to simplify the planning and description of
a hydraulic system in order to prevent - through a standardized representation - uncertainties
and faults at the planning stage, during production, installation, and servicing.
Basic symbols
Supply line, return flow line, frames for com-
ponents and symbols
Hose
Adjustability of a pump/motor
Overview of
symbols Directional valves Pressure control valves Flow control valves
Directional poppet valve Pressure reducing valve Two-way flow control valve
Hydraulic circuit In the field of hydraulics, we differentiate between three circuit systems:
systems
• Open circuit,
• closed circuit,
• semi-closed circuit.
Open circuit In an open circuit, the hydraulic pumps usually aspires hydraulic fluid through the suction pipe,
which is installed below fluid level. The hydraulic fluid is directed by directional valves to the
actuator and fed back to the storage reservoir; this means, there is no connection between the
suction pipe of the hydraulic pump and the hydraulic fluid returning from the actuator.
Input speed
Schematic n = constant
diagram
Lifting speed
v = constant
Flow
qV = constant
The open circuit is employed, for example, in machine tools, handling systems, press controls,
winch drives, and gears for mobile applications. The actuators can be hydraulic cylinders and
hydraulic motors.
Basic principles of hydraulics Bosch Rexroth AG I RE 00845/04.07
Closed circuit In a closed circuit, the hydraulic fluid returning from the actuator is directly re-fed to the hydraulic
pump. The high-pressure side of the system is protected by a pressure relief valve. The pressure
is unloaded to the low-pressure side, that is, the hydraulic fluid remains in the circuit.
The design-inherent permanent, internal leakage of the hydraulic pump and the hydraulic mo-
tor is compensated for by a separate auxiliary pump, which is flange-mounted to the hydraulic
pump in most of the cases.
Schematic Flow
diagram Auxiliary pump for qV = variable
leakage compensation
Output speed
n = variable
Cooler
The closed circuit is used almost exclusively in mobile applications, e.g. for powering a wheel
loader travel drive. The hydraulic pumps and hydraulic motors used are in most of the cases
axial piston units.
Basic principles of hydraulics 10 Bosch Rexroth AG I RE 00845/04.07
Semi-closed circuit The semi-closed circuit is a combination of the open and the closed circuit and is used, if the
volume must be balanced by means of anti-cavitation valves, for example, when a single-rod
cylinder is employed in a mobile machine.
drive and control The schematic illustration "drive and control / driving - controlling - and moving" on the next
page shows the task set to a hydraulic cylinder or hydraulic motor as machine element.
• The travel speed of the actuator is realized by the hydraulic pump flow.
• The direction, start and stop are controlled by directional valves.
• The required force can be varied by adjustable pressure control valves.
• The specified travel speed of the actuator can be influenced by means of a flow control
valve.
• Optimized system technology includes monitoring elements such as pressure switches and
pressure gauges. Hydraulic accumulators can be provided for realizing faster movements.
Heat exchangers optimize the oil quality and hence the availability of the system.
Basic principles of hydraulics 11 Bosch Rexroth AG I RE 00845/04.07
* Rexroth-specific statement
Pumps
Driving and controlling
Flow +
hydraulic cylinders and motors
storage tank
Hydraulic fluids
The second relationship lies in the size of the area (A), onto which the force acts.
The smaller the area, the higher the pressure; and, of course, vice versa, the greater the area,
the smaller the pressure.
Consequently, the pressure is dependent on the amount of the effective force (F) and the size
of the area (A) onto which this force acts.
Pascal's law: F
p=
A
or: F
A=
p
F = pA
p A
In pressure calculations, the unit Dekapascal (daPa) is often used, where one Dekapascal
corresponds to 0.1 mbar.
100 Pa = 10 daPa = 1 haPa = 1 mbar
100,000 Pa = 0.1 MPa = 1 bar = 1,000 mbar
1.000.000 Pa = 1 MPa = 10 bar = 1 N/m2
Basic principles of hydraulics 13 Bosch Rexroth AG I RE 00845/04.07
Force transmis- In a closed system with two cylinders of different size, only one pressure (p) can prevail. If both
sion cylinders are to be held in balance and the areas (A1 - A2) have different sizes, the loads (F)
acting on the areas must consequently be different.
F1
Cylinder 1 means: p=
A1
F2
Cylinder 2 means: p=
A2
F1 F2
If p is identical in both cylinders, this means: =
A1 A2
A2
Rearranged by force: F1 = F2
A1
A2
is the area ratio of the cylinders and is identified by letter ϕ.
A1
Consequently: F1 • ϕ = F2
A2
Example: Solution: F1 = F2
Area A1 = 50 cm2 A1
Area A2 = 750 cm2
Weight force F1 = 1.000 daN 750 cm2
1.000 daN = 15.000 daN
Weight force F2 = ? 50 cm2
A2 750
or with ϕ = = = 15
A1 50
F1 • ϕ = F2
1.000 daN 15 = 15.000 daN
This means that cylinder 1 with a force of 1,000 daN, which corresponds to a mass of 1,000 kg,
can hold cylinder 2 with a load of 15,000 kg or 15 t.
F1 F2
A1 A2
Basic principles of hydraulics 14 Bosch Rexroth AG I RE 00845/04.07
Pressure intensifi- The extending speed of a piston is to be adjustable by means of a meter-out throttle.
cation
Which risk arises, when the throttle is completely closed, e.g. due to dirt?
Example:
pK = 100 bar
ϕ = 2 : 1
AK
ϕ=
AR
Solution:
pK ϕ = pR
2
100 bar = 200 bar
1
pR = 200 bar
Conclusion:
Meter-out throttling involves the risk of pressure intensification!
AK ASt AR
pK pR
Basic principles of hydraulics 15 Bosch Rexroth AG I RE 00845/04.07
Flow The flow is the amount of fluid (nominal volume) that moves in a hydraulic systems within a
certain time.
If in the schematic diagram below the lever of the pump is shifted to the right, the piston dis-
places fluid into the system. If there is no counterforce (counterpressure), almost no pressure
will consequently build up in the pump. The fluid is fed to the system at zero pressure.
Only when the displacement is opposed by a resistance (directional valve, throttle, cylinder
piston or similar elements), can a counterforce be generated. The pump continues to displace
fluid and compresses the fluid. Pressure builds up, which depends on the resistance not gen-
erated by the pump.
qV in l/min
s
t in s in mm
A in cm2
qV in l/min
V As
qV = =
t t
qV = A v 6 in l/min
A in cm2
s
v = = Velocity in m/s
t
s in mm
A in cm2
v in m/s
In technical data sheets, the size of the pump is given in cm3/revolution. The following formula
is applied for determining the power:
Vg n
qV = in l/min
1.000
Vg = displacement in cm3/rev
n = speed of the pump shaft in min-1
Flow law The identical volumes flow through a pipe with different cross-sections within the same time.
This means that the flow velocity of the fluid must increase at the narrow point.
As
If A • s is subsituted for V, q is then given by qV =
t
s
Distance s divided by time t provides velocity v v=
t
Flow q hence equals the product from the cross-sectional area of pipe A multiplied by the
velocity of the fluid v qv = A • v.
Flow
Flow q in L/min is the same at any point in a pipe. If the pipe has two cross-sections A1 and A2,
corresponding velocities must occur at the two cross-sections.
q1 = q2
q1 = A1 • v1
q2 = A2 • v2
Hydraulic fluids
General In a hydraulic system, the fluid assumes the task of force transmission. This means that certain
demands must be placed on the fluid.
Environmentally friendly
Neutral against seals, plastics, paint
Corrosion protection
Temperature stability
Requirements of None of the fluids offered on the market today can meet all of the requirements listed on the
the market previous page. Even in view of ongoing discussions about environmental compatibility of hy-
draulic fluids and in spite of all concerns, mineral oil is still the most common hydraulic fluid
used in hydraulic systems.
Selection criteria Being an important design element and machine element, the hydraulic fluid must be taken
into account at the planning stage, and during engineering and commissioning of hydraulic
systems.
The hydraulic fluid to be used is selected according to the prevailing operating conditions such as:
• Operating temperature range
• Concept of the hydraulic system
• Hydraulic pump type
• Working pressure and environmental requirements
• Operating time and availability
• Economic and ecological factors
Viscosity Viscosity is the most important criterion for the selection of the hydraulic fluid. Viscosity data
indicate whether a pressure medium is light or viscous at a certain temperature and hence
whether friction between the fluid layers is smaller or greater.
The viscosity is measured in the SI unit mm2/sec. It changes as temperature changes. In a
diagram with a double logarithmic scale for the viscosity axis, the representation in the change
in viscosity in dependence upon temperature T shows a straight line.
Manufacturer's For determining the application limits of a hydraulic system and consequently for the selection
data of the hydraulic fluid, it is important to take minimum and maximum viscosity values into account
that are given by the manufacturer in his documentation for the hydraulic components used.
The component manufacturer Rexroth, for example, indicates the data for the selection of the
hydraulic fluid in the technical data sheet of the component - RE data sheet - in the section
Technical data, hydraulic. Here, you can find details about the hydraulic fluid, hydraulic fluid
temperature and viscosity range.
Basic principles of hydraulics 19 Bosch Rexroth AG I RE 00845/04.07
Classification of
hydraulic oils
ATF HA
HN
Hydraulic oils based on Flame-retardant hydraulic Fast bio-degradable Hydraulic oils compatible
mineral oils oils hydraulic oils with foodstuffs
7. Lux. report,
ISO 6743/4, ISO/CD VDMA sheet 24568, ISO FDA, USDA and NSF
DIN 51 502, ISO 6743/4
12922, DIN 51 502, 6743/4 and ISO 15380 classification
Factory Mutual - USA
Classification of
hydraulic fluids
based on mineral
oil
Mineral oils with active additives Hydrostatic drives with high ther-
to increase the resistance to mal stress, good water separation
HL HL
aging and to improve corrosion capacity
protection -10 to 90 °C
Classification of
flame-retardant
hydraulic fluids
and water-free,
fast bio-degrad-
able hydraulic
fluids
Viscosity/ 10.000
temperature
Viscosity mm2/s
diagram
1.000
* Max. permitted
12
10
9
8
IS
7
O SO
VG V
6
10
IS
0
O
G
IS
5
V G
68
O
46
VG VG
IS
3
O
4
2
2 2
IS
O
3,0
VG
15
-40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 120 140
Temperature °C
Comparison of
different SAE classes ISO - VG SAE classes
viscosity classes (DIN 51519)
100 68
30
49
68
20, 20 W 36
46
25
10 W 32
5W 22 16
(15)
9
10
Basic principles of hydraulics 23 Bosch Rexroth AG I RE 00845/04.07
Additives No hydraulic fluid can meet all requirements. Thanks to additives, certain properties of the
hydraulic fluid can be optimized to suit the requirements of specific applications.
For example:
• for improving:
– corrosion protection
– pressure resistance
– resistance to aging
– viscosity/temperature behavior
• for reducing:
– the pour-point
– foaming
– wear
Basic principles of hydraulics 24 Bosch Rexroth AG I RE 00845/04.07
Practical notes
Effects of air Air can be present in hydraulic oils in the following forms: as dissolved air (invisible), as surface
in the oil foam (visible), and as undissolved, dispersed air (visible). While dissolved air and minor surface
foam hardly show any adverse effects, dispersed air can cause severe problems. Since the oil
contains very small air bubbles, which are finely dispersed and can rise to the surface only very
slowly, the following troubles can occur:
• Uneven or jerky movements of hydraulic spools, vibration in the system due to increased
compressibility, changed actuating times of servo-valves
• Pump noise
• Damage to pumps, lines and seals caused by cavitation
• Accelerated aging of the oil
• Micro-diesel effect, a form of thermal cracking due to high temperatures in compressed air
bubbles
Environmental Hydraulic systems are closed systems. When hydraulic systems are used properly, hydraulic fluid
aspects does therefore not get into the environment. Care must be taken that power units are leak-free
and maintenance/repairs are carried out in due time. Especially hydraulic hoses and hose con-
nections must be intensively observed and inspected. Oil changes must be made properly and
thoroughly; waste oil must be disposed of in accordance with all relevant legal stipulations.
Safety aspects Hydraulic fluids based on mineral oil are water-endangering and inflam-
mable. Pressure fluids may only be used, if the corresponding safety data
Danger
sheet of the manufacturer is at hand and all precautions prescribed therein
are observed.
If leakage on the hydraulic product can lead to the contamination of water
and soil, the hydraulic product must be placed in a suitable oil drip tray.
Basic principles of hydraulics 25 Bosch Rexroth AG I RE 00845/04.07
Critical tolerances
for hydraulic
components Gear pump
J1 from 0.5 to 5 μm
J2 from 0.5 to 5 μm
Vane pump
J1 from 0.5 to 5 μm
J2 from 5 to 20 μm
J3 from 30 to 40 μm
Piston pump
J1 from 5 to 40 μm
J2 from 0.5 to 1 μm
J3 from 20 to 40 μm
J4 from 1 to 25 μm
Valve
J1 from 5 to 25 μm
Servo-valve
J1 from 0.5 to 8 μm
J2 from 100 to 450 μm
J3 from 20 to 80 μm
Basic principles of hydraulics 27 Bosch Rexroth AG I RE 00845/04.07
Causes and
sources of
contamination
1 External contamination
2 Installation + repair
3 Fresh oil
4 Abrasion in the pump
5 Abrasion of seals
Basic principles of hydraulics 28 Bosch Rexroth AG I RE 00845/04.07
Arrangement of The task of filters is directly related to their arrangement in the system.
filters in the open Filters perform certain tasks depending on their location in the system.
circuit
1
8
10 6 Off-line filtration
3
2
5 9
Advantages
– Low cost
– Ease of maintenance
– Can be fitted with clogging indicator
– Provides fine filtration
– No pump cavitation
Disadvantages
– A by-pass valve is required
– Lets dirt particles through the open by-pass valve in the case of pressure peaks and cold
start conditions
The filter shown below is mounted to the tank cover using a mounting flange. The housing with
the filter connection protrudes directly into the tank. A great advantage of this filter design is
good accessibility and consequently maintenance-friendliness.
The filter element can be quickly and easily taken out by removing the cover.
An important feature is that a strainer encloses the filter element. When the filter element is taken
out, the strainer is pulled out as well, thus preventing dirt already settled from flowing into the
hydraulic tank. The filters are generally provided with a connection for a clogging indicator.
Basic principles of hydraulics 30 Bosch Rexroth AG I RE 00845/04.07
Advantages
– Can be installed directly upstream of sensitive components
– No pump cavitation
Disadvantages
– Element must be provided for a high differential pressure
Basic principles of hydraulics 31 Bosch Rexroth AG I RE 00845/04.07
Symbol for filler and breather filter without (on the left-hand Filler and breather filter with and without filling filter
side) and with by-pass valve (on the right-hand side)
In the past minor importance had been attached to these filters in hydraulic systems. However,
according to latest findings, they are one of the most important elements for the filtration of
hydraulic fluids in hydraulic systems. A significant part of contaminants gets into hydraulic
systems through unsuitable venting equipment. Design measures such as pressurization of oil
tanks are often uneconomical when compared with the highly efficient breather filters offered
on the market today.
Depending on the required cleanliness class, breather filters are equipped with replaceable
elements of different filtration ratings. The filters should be fitted with a connection for clogging
indicators (2).
Filler and breather filters basically consist of an air filter (1) for filtering the air flowing into the
tank and a filling strainer (3) for retaining coarse particles when the system is filled with fluid.
The air filters are available with different filtration ratings so that CETOP standard RP 70 can
be complied with, which prescribes the same filtration rating for system filters and air filters.
The requirements for this filter type are laid down in DIN 24557.
Basic principles of hydraulics 32 Bosch Rexroth AG I RE 00845/04.07
Filtration media For the filtration methods described, various filter media or a combination of filter media are
used.
a) Surface filtration
With surface filters, the particles are separated directly at the surface of the filter media.
Particles that get into the filter medium due to their small diameter can pass through the filter
without any hindrance. However, the filter resistance increases as the surface is clogged.
The filter cake built up on the surface can result in a reduction in the filtration rating.
For surface filtration, diaphragm filters of filter materials made of wire mesh, metal edges or
Dutch weave are used.
b) Deep filtration
The fluid to be filtered penetrates the filter structure. The particles to be removed are also
retained in the deeper layers of the filter. As more and more particles are retained by the
filter, the flow resistance increases so that the filter element has to be replaced. For these
filters, filter media are used, which are made of
– impregnated cellulose materials (organic filter material),
– glass fiber material (inorganic filter material),
– sintered metal meshpacks,
– porous, sintered metal.
Basic principles of hydraulics 33 Bosch Rexroth AG I RE 00845/04.07
Classification The solid particle content in the hydraulic fluid is determined with the help of classification
systems for the systems (standardized cleanliness classes).
degree of con-
tamination of the The most common standards today are NAS 1638 (National Aerospace Standard) and DIN
hydraulic fluid ISO 4406.
Particle size in µm
Contamina-
tion class
5 - 15 15 - 25 25 - 50 50 - 100 > 100
00 125 22 4 1 0
0 250 44 8 2 0
1 500 89 16 3 1
2 1000 178 32 6 1
3 2000 356 63 11 2
640000 1300000 27
320000 640000 26
160000 320000 25
80000 160000 24
40000 80000 23
20000 40000 22
10000 20000 21
5000 10000 20
2500 5000 19
1300 2500 18
640 1300 17
320 640 16
160 320 15
80 160 14
40 80 13
20 40 12
10 20 11
5 10 10
2.5 5 9
1.3 2.5 8
0.64 1.3 7
0.32 0.64 6
0.16 0.32 5
0.08 0.16 4
0.04 0.08 3
0.02 0.04 2
0.01 0.02 1
0.00 0.01 0
Basic principles of hydraulics 36 Bosch Rexroth AG I RE 00845/04.07
Filter clogging Inside the clogging indicators, each change in pressure is recorded as change in travel by means
indicators of metering pistons or diaphragms. A piston with attached magnet is moved against the force
of a spring inside the clogging indicator. On visual clogging indicators, a unipolar magnet is
mounted in the indicator head. The closer the poles come to each other, the greater becomes
the repulsive force between the magnets, until finally the red indictor button pops out.
For a permanent indication of the element contamination electronic clogging indicators were
developed. Through the use of these indicators, maintenance intervals become foreseeable.
With these fully electronic clogging indicators, the differential pressure building up as a result
of contamination of the element is converted contact-free into an analog electrical output
signal with the help of a sensor. A pressure peak suppression and cold start suppression are
additionally integrated.
The trainer must make the required documents available to the trainee. When competitors' prod-
ucts are used, the safety notes of the relevant manufacturer are applicable, and it must be ensured
that the components and systems comply with currently valid, relevant EU Directives.
For this reason, commissioning is prohibited until it was established that the
electrohydraulic components and systems to be used meet the stipulations
Warning of all relevant EU Directives.
Fundamental, ge-
neral safety notes
Warning
Observe
• danger signs and safety notes on the machine
• instructions, which prescribe the behavior during operation in order to prevent accidents
and health damage and must be prepared by the operator/employer on the basis of, for
example, regulations for the prevention of accidents,
• operating instructions, which ensure the proper use of the hydraulic system in accordance
with its intended purpose.
The operating instructions are intended for information purposes and for the
prevention of risks when hydraulic components are being installed in a system
- in this case mounting of electrohydraulic components on the training stand
-, and include information and notes on transport, storage and maintenance
(inspection, servicing, corrective maintenance) of the hydraulic system.
Only when the operating instructions are strictly observed can accidents
and damage to property be avoided and the trouble-free operation of the
hydraulic system be ensured.
Moreover, observing the operating instructions helps to:
• reduce downtimes and repair costs
• prolong the service life of the hydraulic system.
Hydraulic oil based on mineral oil is water-endangering and inflammable. It may only be used
when the corresponding safety data sheet is available and all precautions prescribed therein
were taken.
The hydraulic system may only be operated when in technically perfect condition.
The use for the intended purpose, performance data and operating conditions must not be
changed.
Protective equipment / components must not be rendered inoperable, e.g. by bridging limit
switches, valves or other control components.
If protective equipment must be bridged to allow servicing work to be carried out, precau-
tions must be taken to ensure that no dangerous situation can arise. The higher-order machine
operating instructions must be observed.
Safety notes Bosch Rexroth AG I RE 00845/04.07
Uncontrolled access by external persons to the direct operating area of the hydraulic system
is prohibited (even in case that the hydraulic system is at rest).
Note:
These are the fundamental safety regulations that must be observed for every project task.
Project 01:
Hydraulic power unit Bosch Rexroth AG I RE 00845/04.07
Hydraulics as technology can be assigned to drive technology. The task of drive engineering
is to provide a drive for a machine or system that ensures optimum performance of the tech-
nological function. This is equally valid for the engine of a passenger car as for the drive of the
projects described in this project manual such as the drive of:
• feed equipment for the vertical transport of workpieces,
• rope winches for lifting loads,
• lifting gear for the horizontal transport of loads,
• conveyor belts for transporting loads,
• feed carriages for tool transport,
• punching equipment for punching perforated metal sheets,
• rotary drives for relocating workpieces, and
• pressing equipment for workpiece pressing.
The drive power is made available by an electric motor or combustion engine. The output
torque of the motor or engine is converted by a convertor into a rotary or linear movement as
required by the machine. This task is assumed by a transmission - in this case, the hydraulic
component such as a hydraulic cylinder or a hydraulic motor. The power is transmitted by the
hydraulic fluid.
The components of a hydraulic system listed above can be designed as individual components
or, to form a compact assembly, combined in a hydraulic power unit (without consumers). The
valves such as directional, pressure and flow control valves are in most of the cases installed
separately into a machine.
In the following Project 01 you can impart knowledge of the general structure of a hydraulic
power unit.
In the project order, the trainee sets up the required components on the basis of the given
requirements. In this project task, he or she is to understand the following:
• A hydraulic system consists of a fluid flow generator and a fluid flow consumer (actuator),
open and closed-loop control devices and accessories.
• In a hydraulic power unit, hydraulic components are grouped to form a compact assembly.
Project 01:
Hydraulic power unit Bosch Rexroth AG I RE 00845/04.07
01
• The required drive elements and the accessories such as control and monitoring devices as
well as maintenance equipment can be mounted on top or to the hydraulic fluid reservoir.
• The size of the power unit, e.g. the capacity of the reservoir, depends on the given conditions
and customer requirements.
In this project task, the trainee is to set up a power unit on the basis of the conditions listed
below and draw a sketch of a schematic diagram:
• Hydraulic pump in the form of a pilot operated, variable vane pump with a displacement of
qV = 20 l/min;
• electric motor for a maximum system pressure of p = 80 bar,
• reservoir according to the displacement (3 - 5 times qV),
• carrier components,
• hydraulic filter with visual, mechanical clogging indicator,
• filler and breather filter,
• level monitor and
• drain valve for changing the hydraulic fluid.
A hydraulic accumulator is not provided.
01
Project definition
In a hydraulic system for driving lifting equipment for heavy loads, a hydraulic power unit with
a variable displacement pump powered by an electric motor and associated accessories is to
be used.
The customer wishes to get information about the structure of a hydraulic power unit with pilot
operated vane pump. In the list of the hydraulic power unit components he requests the provi-
sion of short information about the selected components, including a schematic diagram of the
hydraulic system and a parts list.
Fig. 01.1 Practical example: Hydraulic power unit with hydraulic pump/el. motor and
accessories
Project tasks
• Independent understanding of the task and its putting into practice using hydraulic control
technology
• Planning and organizing the customer requirement (core qualification)
• Analyzing the technical data sheet for a standard power unit with pilot operated vane pump
(technical qualification)
• Handling of hydraulic components in line with functional needs
Project 01:
Hydraulic power unit Bosch Rexroth AG I RE 00845/04.07
01
Project steps
• Informing: Accepting and understanding the order, among others, through discussions
with the customer.
• Planning: Planning and organizing the execution of the customer order; among oth-
ers, through the selection of power unit construction parts from a technical
data sheet (RE 91098 / modular standard power units).
• Evaluating: Are there further possibilities of meeting the customer requirement or simpler
ways of project execution? Have unforeseeable problems occurred?
Notes
Project 01:
Hydraulic power unit Bosch Rexroth AG I RE 00845/04.07
01
Hydraulic schematic diagram
Measuring glass
Item 6.0
Item 2.0
Item 8.0
Item 3.0
01
Component selection with parts list
4 KW/1450 rev/
4.0 1 Electric motor
min.
Table 01.1 Parts list for hydraulic circuit diagram Fig. 01.2
01
Safety notes
Notes
Project 01:
Hydraulic power unit Bosch Rexroth AG I RE 00845/04.07
01
Execution of the order
In the project order, only simple rules for the rating of power units can be applied. For this,
formulas from physical basic principles can be applied (see Fig. 01.3). Any power losses are
not considered.
p = pressure in bar
A = area in mm2
Velocity
s
v=
t
m
Flow control valve v = velocity in
s
Change in velocity s = travel in m
t = time in s
01
Factors that have an influence on the rating of a power unit
01
Hydraulic pump:
qV = ? l/min., i.e. which volume is the pump to provide within which time.
Since manufacturers usually indicate only the sizes in technical data sheets (how much is
displaced during one revolution of the pump?), the speed of the drive/electric motor must be
known. In industrial applications, motors of approx. 1,500 rev/min. are employed. For converting
the displacement into power per unit of displacement the following formula can be applied:
Vg n
qV = in l/min
1.000
Because no manufacturer will be able to offer a hydraulic pump with exactly the requested
power, the next larger size is usually selected.
Electric motor:
For rating the electric motor, the possible maximum system pressure must be known apart from
the displacement of the hydraulic pump in l/min.
Also here, the next larger frame size of the manufacturer's electric motor is selected. Typical
frame sizes are, e.g. 3 kW, 4 kW, 5.5 kW, 7.5 kW, etc.
The selection of the required carrier components such as coupling, pump mounting bracket
and damping elements will not be considered here and are not part of the order execution.
Hydraulic fluid reservoirs are selected on the basis of practical experience such as:
Reservoir size = displacement of the hydraulic pump • 5
Whenever possible, standard reservoirs of standardized sizes should be used. The topic of
cooling is not dealt with in this simple engineering task. The provision of a drain valve is always
recommended for changing the hydraulic fluid.
Accessories:
In this project task, required accessories for a hydraulic fluid reservoir are a return flow filter, a
filler/breather filter and a level control device. For the selection, please refer to technical data
sheets of the manufacturers.
When selecting the return flow filter, the actual flow required for operating a single-rod cylinder
must in any case be taken into account, i.e. how much oil returns from the hydraulic cylinder to
the filter (see Project 04).
The factors that have an influence on the selection of a return flow filter are listed on the previ-
ous page.
Project 01:
Hydraulic power unit 11 Bosch Rexroth AG I RE 00845/04.07
01
As additional aid for rating a hydraulic power unit we recommend the use of a hydraulic slide
rule.
For the simplified rating of a return flow filter, see technical data sheet RE 50081.
Detailed notes on the engineering and design of hydraulic systems can be found in The Hydraulic
Trainer Volume 3/Bosch Rexroth AG.
General note:
In contrast to the following project tasks, this order execution does not involve any practical
work on the training system.
A component arrangement drawing and a general layout of the training system are therefore
not provided.
• A hydraulic system consists of a fluid flow generator and a fluid flow consumer, valves and
accessories.
• A hydraulic power unit accommodates the hydraulic components to form a compact unit.
• The required drive elements and reservoir accessories such as control and monitoring and
maintenance devices can be mounted to or on top of the reservoir.
• The size and design of the hydraulic power unit depends on the given conditions and the
requirements of the customer.
Project 01:
Hydraulic power unit 12 Bosch Rexroth AG I RE 00845/04.07
Notes
01
Project 01:
Hydraulic power unit 13 Bosch Rexroth AG I RE 00845/04.07
01
Project schedule: Project 01 Q. Public, John
………………………………………………………………………………………
Last name, first name
– System rating/calculation
……………………………………………………………………………………………………………
Identifiy components
……………………………………………………………………………………………………………
……………………………………………………………………………………………………………
Sources of information
Project manager
……………………………………………………………………………………………………………
Data sheets
……………………………………………………………………………………………………………
Internet
……………………………………………………………………………………………………………
Hydraulics supplier
……………………………………………………………………………………………………………
Make calculations
……………………………………………………………………………………………………………
……………………………………………………………………………………………………………
Deciding on
……………………………………………………………………………………………………………
Decision-making and selecting components;
…………………………………………………………………………………………………………… complementing the circuit
diagram and parts list.
……………………………………………………………………………………………………………
(Overleaf)
Project 01:
Hydraulic power unit 14 Bosch Rexroth AG I RE 00845/04.07
01
Summarize the information obtained
……………………………………………………………………………………………………………
……………………………………………………………………………………………………………
……………………………………………………………………………………………………………
Execution
……………………………………………………………………………………………………………
Execution of the order Set-up of the electrohy-
…………………………………………………………………………………………………………… draulic control and acqui-
sition of required data.
……………………………………………………………………………………………………………
Special points?
……………………………………………………………………………………………………………
……………………………………………………………………………………………………………
……………………………………………………………………………………………………………
……………………………………………………………………………………………………………
……………………………………………………………………………………………………………
……………………………………………………………………………………………………………
……………………………………………………………………………………………………………
Checking
……………………………………………………………………………………………………………
Quality check Are all customer require-
…………………………………………………………………………………………………………… ments met?
……………………………………………………………………………………………………………
Evaluating
Optimize project steps
………………………………………………………………………………………………………………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………………………………………………………………………………………………………………
Project 01 ……………………………………………………………………………………………………………………………………………………………
Note of completion by confirmation of the project manager/place, date, signature
Project 02:
Hydraulic variable displacement pump Bosch Rexroth AG I RE 00845/04.07
In a hydraulic system, fluid flow generators/hydraulic pumps convert the mechanical energy
02
of a drive motor (torque, speed) into hydraulic power (flow, pressure).
The hydraulic pump usually aspires the hydraulic fluid from a storage tank (suction side) and
displaces it to the pump outlet (pressure side). In terms of construction, hydraulic pumps can
be differentiated as follows:
Hydraulic pumps are displacer pumps, the displacement of which can be either fixed or variable.
Hydraulic pumps that feature an adjustable displacement are called variable displacement pumps.
The displacement/flow is adjusted by means of mechanical or electronic control systems.
In the following Project 02 you can impart knowledge of the interrelationship between the
hydraulic variable displacement pump, the displacement and pressure build-up through resist-
ances in the hydraulic system.
In the project order, the trainee is made familiar with the characteristic curves of a pilot operated
variable displacement vane pump and the direct relationship between the displacement and the
system pressure. This project task is to help the trainee to understand the following:
• With hydraulic variable displacement pumps, the flow is almost reduced to zero when the
system pressure has been reached.
• Due to the design of a variable displacement pump, internal leakage oil occurs, which is
refed to the reservoir through an external leakage oil line.
• The leakage oil flow increases as the resistance rises, which opposes the displacement in
the pressure line of the pump
• The drained leakage oil flow is the power loss of the hydraulic pump.
With the help of the control set up on the training system, the trainee can recognize that when
the system pressure increases as resistance at the pressure port of the hydraulic pump, the
total displacement reduces. The resistance is realized by means of a hand lever valve, with the
system pressure being steplessly variable via a pressure relief valve operated in parallel.
Project definition
In a hydraulic power unit, the hydraulic energy is to be provided by a variable, pilot operated
02
vane pump. The power that can be generated by the hydraulic pump is to be measured in an
experiment set-up.
The customer wishes detailed information about the pros and cons of this vane pump, including
a flow characteristic curve, from which the relationship between increasing system pressure
and losses of the vane pump can be seen.
Project tasks
• Independent understanding of the task and its putting into practice using hydraulic control
technology
• Planning and organizing the customer requirement (core qualification)
• Analyzing the technical data sheet for a pilot operated vane pump (technical qualifica-
tion)
• Handling of hydraulic components in line with functional needs
Project 02:
Hydraulic variable displacement pump Bosch Rexroth AG I RE 00845/04.07
Project steps
• Informing: Accepting and understanding the order, among others, through discussions
02
with the customer.
• Planning: Planning and organizing the execution of the customer order; among
others, through the selection of components from a technical data sheet
(RE 10515 vane pump, pilot operated).
• Executing:: Working out the set-up of a hydraulic control on the training system, docu-
menting the characteristic curve required by the customer and providing
explanations with regard to the characteristic curves and power losses.
• Evaluating: Are there further possibilities of meeting the customer requirement or simpler
ways of project execution? Have unforeseeable problems occurred?
Notes
Project 02:
Hydraulic variable displacement pump Bosch Rexroth AG I RE 00845/04.07
Item 1.1
Item 1.2
Item 0.1
Measuring
glass
Item 1.0
1 Stopwatch
Table 02.1 Parts list for hydraulic circuit diagram Fig. 02.2
Component arrangement
02
Measuring glass
Connection block
D Note:
In the case of connection
elements marked with “D”, the
components can be connected
directly with each other.
Fig. 02.3 Recommended component arrangement with component designation for parts list table 02.1 and hydraulic circuit diagram Fig. 02.2
Note:
The designations of components in the parts list and the component arrangement are Rexroth-
specific designations. Also the grid layout is Rexroth-specific and adapated for use on the
training system.
Notes
Project 02:
Hydraulic variable displacement pump Bosch Rexroth AG I RE 00845/04.07
Safety notes
Flow measurement
5. Open shut-off valve item 1.2. 02
6. Open throttle valve item 1.1 until a pressure of 15 bar is present at measuring point M1.
7. Flow measurement by means of the measuring glass; to this end, close shut-off valve item
1.2, close the measuring glass, open shut-off valve item 1.2 for 10 s.
Record the filling quantity and enter the measured value in Table 02.2.
8. Take flow measurements as described in points 6. to 7. at pressure values of 30 bar,
40 bar, 45 bar and 50 bar and enter the recorded measured values in Table 02.2.
After completion of practical work, switch the hydraulic pump on the training
system off! Turn pressure relief valve item 1.0 back to minimum pressure.
Caution Open throttle valve item 1.1 completely. No pressure gauge may indicate a
pressure!
9. Calculate the measured oil flow/time and enter it as flow in qV = l/min in Table 02.2.
Enter the individual values as points in Diagram 02.3 and connect the individual points with
a line to create a curve.
The resulting curve is the typical characteristic curve of the pilot operated, variable vane
pump.
Measured values
Pressure p bar 15 30 40 45 50
Time t s 10 10 10 10 10
Volume V l 1.32 1.25 1.20 1.10 0
Flow qV l/min 7.92 7.50 7.20 6.60 0
Table 02.2 Evaluation of the measured oil volumes
02
Flow qV in l/min
Notes
02
Project 03:
Single-rod cylinder / pressure intensification Bosch Rexroth AG I RE 00845/04.07
If in a hydraulic system the hydraulic force, which is converted into mechanical energy, is to be
transmitted to an actuator in the form of a linear (straight) movement, a hydraulic cylinder is
used. We distinguish hydraulic cylinders by their design principles: 03
Plunger, single-rod and double-rod cylinders.
The hydraulic cylinder as output element forms the link between the hydraulic circuit and the
working element/tool in a technological system. Lifting, lowering, locking and transporting loads
are typical applications of hydraulic cylinders.
Neglecting friction, the possible maximum cylinder force F in kN depends on the possible
maximum system pressure p and the effective piston area A of the hydraulic cylinder, i.e.
F = p • A in dN m2
p in bar; A in cm
The piston velocity v in m/s of the hydraulic cylinder is determined by the pump flow supplied.
Flow control valves are used to change, i.e. reduce, the piston velocity. When throttling, for
example, the piston extension velocity, important physical laws must be taken into account.
In the following Project 03 knowledge can be imparted with regard to the use of single-rod
cylinders as machine elements.
In the project order, the trainee is to work out the physical basic principles of pressure inten-
sification with single-rod cylinders. On the basis of this project task, he/she is to understand
the following:
• The hydraulic cylinder performs a straight movement and transmits the supplied piston pres-
sure in the form of force.
• Double-acting hydraulic cylinders with different piston areas are pressure intensifiers.
• Due to adhesive friction in the hydraulic cylinder the pressure actually transmitted via the
piston area or through the differences in areas is reduced.
• Forces and velocities can be kept constant over the entire stroke.
Biased on the control set up on the training system the trainee is to learn that the use of a meter-
out throttle on the piston rod side involves a risk of pressure intensification. When the hydraulic
pump is switched on, the piston of the single-rod cylinder extends. The extension velocity can
be varied by means of a throttle valve. Retracting of the single-rod cylinder is accomplished
with the help of a 4/2 directional valve.
Project definition
Project tasks
• Independent understanding and execution of the task set through application of hydraulic
control technology
• Planning and organizing the customer requirement (core qualification)
• Analyzing the technical data sheet of a hydraulic cylinder (specialist qualification)
• Handling of hydraulic components in line with functional needs
Project 03:
Single-rod cylinder / pressure intensification Bosch Rexroth AG I RE 00845/04.07
Project steps
• Informing: Accepting and understanding the order, among others, through discussions
with the customer.
• Planning: Planning and organizing the execution of the customer order; among oth-
03
ers, through the selection of hydraulic components from the data sheet
collection (RE 17039 Hydraulic cylinders, tie rod design).
• Executing: Set-up of the hydraulic control on the training system. Working out and
documenting the system parameters required by the customer and expla-
nations with regard to pressure intensification on the basis of a calculation
example.
• Evaluating: Are there further possibilities of meeting the customer requirement or simpler
ways of project execution? Have unforeseeable problems occurred?
Notes
Project 03:
Single-rod cylinder / pressure intensification Bosch Rexroth AG I RE 00845/04.07
Item 1.0 03
Item 1.3
Item 1.1
Measuring
Item 0.1 glass
Item 1.2
03
Retraction
-Single-rod cylinder-
Note:
The single-rod cylinder
extends automatically
when the hydraulic pump is
switched on.
Double-acting cylinder
03
1.0 1 ZY 1.3
with single-sided piston rod
Hose VSK 1
Table 03.1 Parts list for hydraulic circuit diagram Fig. 03.2
Project 03:
Single-rod cylinder / pressure intensification Bosch Rexroth AG I RE 00845/04.07
Component arrangement
03
Measuring glass
Connection block
D Note:
In the case of connection
elements marked with “D”, the
components can be connected
directly with each other.
Fig. 03.4 Recommended component arrangement with component designations for parts list Table 03.1 and hydraulic circuit diagram Fig. 03.2
Note:
The designations of components in the parts list and the component arrangement are Rexroth-
specific designations. Also the grid arrangement is Rexroth-specific and adapted for use on
the training system.
Notes
Project 03:
Single-rod cylinder / pressure intensification Bosch Rexroth AG I RE 00845/04.07
Safety notes
6. Switch the hydraulic pump off and wait until the system is depressurized. Close throttle
valve Item 1.3. To this end, turn in the adjustment element counter-clockwise to the limit
stop.
7. Switch the hydraulic pump on. The piston of the hydraulic cylinder cannot extend, because
the counterforce on the piston rod side is greater than the force on the piston side, since
the throttle valve is closed. Pressure gauge M3 indicates the value of pressure intensifica-
03
tion. Note the measured values and enter them in Table 03.2.
After having completed practical work on the training system switch the
hydraulic pump off! Turn pressure relief valve Item 1.2 back to minimum
Caution
pressure. No pressure gauge may indicate a pressure!
Measured values
Calculation of the pressure intensification on the basis of given hydraulic cylinder values.
4,91 cm2
= 2,07 : 1
2,54 cm2
FK = FR
pK AK = pR AR
2,07
pR = 50 bar = 103,5 bar
1,00
Project 03:
Single-rod cylinder / pressure intensification 10 Bosch Rexroth AG I RE 00845/04.07
• Hydraulic cylinders perform linear movements and transmit the piston pressure in the form
of force.
• Double-acting hydraulic cylinders with different areas are called single-rod cylinders. 03
• Single-rod cylinders are pressure intensifiers.
• Velocities can be kept constant over the entire stroke.
Project 04:
Single-rod cylinder/flow Bosch Rexroth AG I RE 00845/04.07
If a hydraulic cylinder in a hydraulic system is not only to transmit the force, but also work in the
form of piston velocity, double-acting hydraulic cylinders are used such as:
single-rod and double-rod cylinders.
Due to the different areas, single-rod cylinders feature different piston velocities, even if the
pump flow provided remains unchanged. Here, the load force generated by the moved workpiece
often has an influence on the piston velocity (see Project 09 - 10). Due to the area ratio of the
04
piston side to the piston rod side, different flows occur during extending and retracting of the
cylinder. To prevent high flow velocities in the connected hoses and pipes, the latter must be
selected taking into account the given flow supplied by the hydraulic pump and the area ratio
of the single-rod cylinder.
AK AR AK
=ϕ
AR
40 10 e.g. qV = 20 l/min
Values in l/min ϕ = 2 : 1
20 20
The following Project 04 is intended to impart knowledge of the use of single-rod cylinders as
machine element, in particular with reference to the piston velocities and flows.
In this project order, the trainees are to be made familiar the velocity behavior during the exten-
sion and retraction of the cylinder piston of single-rod cylinders. Through this project task, they
are to understand the following:
• The piston velocity of a double-acting cylinder - single-rod cylinder - depends on the cylinder
size and the supplied flow.
• The different piston areas result in different flow velocities, which have an influence on the
selection of connection elements, the line system and power unit accessories such as filtra-
tion and cooling systems.
• In the case of double-rod cylinders, the forces transmitted and the piston velocities are
identical in both directions of action of the piston.
On the basis of the control set up on the training system the trainees are to recognize that the
cylinder piston retracts and extends at different velocities. When the hydraulic pump is switched
on, the piston of the single-rod cylinder extends. Controlled by a 4/2 directional valve, the pis-
ton of the hydraulic cylinder retracts. The extension and retraction velocity can be changed by
means of a throttle valve on the piston rod side.
Project definition
The customer observes that with an open throttle valve the piston velocities during extending
and retracting of the cylinder are different. Apart from the technical documentation, he wishes
04
to obtain an explanation with regard to the different piston velocities of the single-rod cylinder.
He also requests details about the filling volume of the hydraulic cylinder used.
Fig. 04.1 Practical example: Schematic illustration of flow velocities in the single-rod cylinder
Project tasks
• Independent understanding of the task and its putting into practice using hydraulic control
technology
• Planning and organizing the customer requirement (core qualification)
• Analyzing the technical data sheet of a hydraulic cylinder (specialist qualification)
• Handling of hydraulic components in line with functional needs
Project 04:
Single-rod cylinder/flow Bosch Rexroth AG I RE 00845/04.07
Project steps
• Informing: Accepting and understanding the order, among others, through discussions
with the customer.
• Planning: Planning and organizing the execution of the customer order; among others,
through the selection of hydraulic components from the data sheet collection
(RE 17039 Hydraulic cylinders of tie rod design). 04
• Deciding: Preparation of a schematic diagram sketch and selection of components.
• Executing: Set-up of the hydraulic control on the training system. Prepration and docu-
mentation of the information and explanations with regard to the single-rod
cylinder as demanded by the customer.
• Evaluating: Are there further possibilities of meeting the customer requirement or simpler
ways of project execution? Have unforeseeable problems occurred?
Notes
Project 04:
Single-rod cylinder/flow Bosch Rexroth AG I RE 00845/04.07
Item 1.0
04
Item 0.2 Item 0.3
Item 1.1
04
Retraction
-Single-rod cylinder-
Note:
The single-rod cylinder
extends automatically
when the hydraulic pump
is switched on.
Hose VSK 1
1 Stopwatch
1 Flowmeter DZ 30
Table 04.1 Parts list for hydraulic circuit diagram Fig. 04.2
Project 04:
Single-rod cylinder/flow Bosch Rexroth AG I RE 00845/04.07
Component arrangement
������
�������
�������
04
Measuring glass
������ ������
�����
�
�
������
Note:
The component arrangement
shows the optional variant with
����� ����� electronic flow measurement
�
Connection block
�����
������
�
D Note:
� � In the case of connection
������
�
Fig. 04.4 Recommended component arrangement with component designations for parts list Table 04.1 and hydraulic circuit diagram Fig. 04.2
Note:
The designations of components in the parts list and the component arrangement are Rexroth-
specific designations. Also the grid arrangement is Rexroth-specific and adapted for use on
the training system.
Notes
Project 04:
Single-rod cylinder/flow Bosch Rexroth AG I RE 00845/04.07
Safety notes
7. Measure the pressures at measuring points M1, M2, M3 during extending, retracting and
at the relevant end position of the cylinder and enter the values in Table 04.2.
Establish the time required for extending and retracting by means of a stopwatch and enter
the values also in Table 04.2.
After having completed practical work on the training system switch the
Caution
hydraulic pump off! Turn all pressure valves of the electrohydraulic control
back to minimum pressure. Completely open throttle valves, if installed. No
04
pressure gauge may indicate a pressure!
Measured values
Hydraulic Position M1 M2 M3 t v V
cylinder 4/2 directional p in bar p in bar p in bar in s in m/s in l
Piston position valve
Extending b 49 0 0 5 0.051 -
Extended b 50 49 0 - - 0.098
Retracting a 49 0 6 3.2 0.073 -
Retracted a 50 0 49 - - 0.058
Table 04.2 Values of velocity/flow measurement
Calculation of the filling volume of the single-rod cylinder used for the execution of the order
(enter calculated values in Table 04.2).
Fill: V = A • s A in cm2
s in mm
V in l
• The extension and retraction velocity of a single-rod cylinder piston depends on the supplied
hydraulic pump flow and the cylinder areas.
• With double-rod cylinders with identical piston rods on both sides, the piston velocities are
identical in both directions.
04
Project 05:
Hydraulic motor Bosch Rexroth AG I RE 00845/04.07
If the hydraulic force is to be transmitted via a rotary movement to an actuator in a hydraulic sys-
tem, a hydraulic motor is used. Hydraulic motors are distinguished by their design principle:
In functional terms, a hydraulic motor is the inversion of a hydraulic pump. Hydraulic pumps
convert the mechanical energy, which is fed to the pump via a drive shaft, into hydraulic energy.
Hydraulic motors convert hydraulic energy into mechanical energy. 05
In principle, a hydraulic motor is a hydraulic pump, which works in the opposite direction and
with which both directions of rotation are possible. If you connect a hydraulic pump directly to a
hydraulic motor in a closed circuit you get a hydrostatic gearbox, which is steplessly adjustable
by means of appropriate control systems.
The following Project 05: Hydraulic motor is intended to gain knowledge of the operating
principle and the use of hydraulic motors.
In the project order, the trainee is to get familiar with the operating features of a hydraulic motor.
Through this project task, he/she is to understand the following:
• Hydraulic motors convert hydraulic energy into torque and speed.
• The direction of rotation or the direction of flow of hydraulic motors can be controlled by
means of a directional valve.
• The speed of the hydraulic motors is determined by the flow provided and by the swept
volume of the hydraulic motors.
• The torque of hydraulic motors is determined by the differential pressure between the inlet
and the outlet and by the swept volume.
By the control to be set up on the training system, the trainee can recognize the operating
principle of a hydraulic motor. 4/3 directional valves can be used to implement clockwise and
counter-clockwise running of the hydraulic motor. The speed of the hydraulic motor can be
changed by means of a meter-in throttle. For a positioned standstill of the hydraulic motor the
return line (T) of the 4/3 directional valve is pre-loaded by means of a pressure relief valve.
Project definition
Heavy loads are to be lifted and lowered by means of a rope winch. The velocity of the rope
winch is to be adjustable. For space reasons, the use of a hydraulic cylinder is impossible, i.e.
the rope winch must be powered by a hydraulic motor. Also an electrical solution is not desir-
able due to changing loads.
In order that the customer can understand the hydraulic solution proposed, he requires technical
documentation such as a hydraulic circuit diagram with parts list and the required measured
data such as an evaluation of the differential pressure across the hydraulic motor at different
flows. 05
Project tasks
• Independent understanding of the task and its putting into practice using hydraulic control
technology
• Planning and organizing the customer requirement (core qualification)
• Analyzing the technical data sheet of a hydraulic motor (specialist qualification)
• Handling of hydraulic components in line with functional needs
Project 05:
Hydraulic motor Bosch Rexroth AG I RE 00845/04.07
Project steps
• Informing: Accepting and understanding the order, among others, through discussions
with the customer.
• Planning: Planning and organizing the execution of the customer order; among others,
through the selection of hydraulic components from the data sheet collection
(RE 91001 Axial piston motor).
• Evaluating: Are there further possibilities of meeting the customer requirement or simpler
ways of project execution? Have unforeseeable problems occurred?
Notes
Project 05:
Hydraulic motor Bosch Rexroth AG I RE 00845/04.07
Item 1.0
05
Item 1.1
Item 0.4
Item 1.4
Item 1.3
05
Stop
Rotation Rotation
-Hydraulic motor-
Fig. 05.3 Wiring diagram for hydraulic circuit diagram Fig. 05.2
Project 05:
Hydraulic motor Bosch Rexroth AG I RE 00845/04.07
Hose VSK 1
1 Stopwatch
1 Tachometer
1 Flowmeter DZ 30
Table 05.1 Parts list for hydraulic circuit diagram Fig. 05.2
Project 05:
Hydraulic motor Bosch Rexroth AG I RE 00845/04.07
Component arrangement
05
Measuring glass
Connection block
D Note:
In the case of connection
elements marked with “D”, the
components can be connected
directly with each other.
Fig. 05.4 Recommended component arrangement with component designations for parts list Table 05.1 and hydraulic circuit diagram Fig. 05.2
Note:
The designations of components in the parts list and the component arrangement are Rexroth-
specific designations. Also the grid arrangement is Rexroth-specific and adapted for use on
the training system.
Notes
Project 05:
Hydraulic motor Bosch Rexroth AG I RE 00845/04.07
Component arrangement/optional
Note:
The component arrangement
shows the optional variant with
electronic flow measurement
05
Measuring glass
Connection block
D Note:
In the case of connection
elements marked with “D”, the
components can be connected
directly with each other.
Fig. 05.6 Recommended component arrangement with component designations for parts list Table 05.1 and hydraulic circuit diagram Fig. 05.2
Note:
The designations of components in the parts list and the component arrangement are Rexroth-
specific designations. Also the grid arrangement is Rexroth-specific and adapted for use on
the training system.
Notes
Project 05:
Hydraulic motor Bosch Rexroth AG I RE 00845/04.07
Safety notes
In the next working step the hydraulic motor rotates. Take care that clothes,
hair, etc. cannot get caught by the motor plate.
Caution
5. By actuating push-button S4 solenoid Y1b of 4/3 directional valve Item 1.1 is energized.
Hydraulic motor Item 1.0 rotates clockwise.
While the hydraulic motor is rotating, adjust preload pressure M4 to 20 bar by means of
pressure relief valve Item 1.4.
6. Close throttle valve Item 1.3, then open it by � turn (the first value given in Table 05.2).
7. By actuating push-button S2 solenoid Y1a of 4/3 directional valves Item 1.1 is energized. 05
The hydraulic motor rotates counter-clockwise.
Use the measuring glass and a stopwatch or optionally an electronic flow measuring system
to acquire the flow qV in l/min and enter the values in Table 05.2. Also measure pressures
M1, M2, M3, M4 and enter them in Table 05.2.
8. Continue to set throttle valve Item 1.3 to the values given in Table 05.2 and enter the mea-
surement result in Table 05.2.
Measure all specified values for the clockwise direction of rotation.
After having completed practical work on the training system switch the
hydraulic pump off! Turn pressure relief valve Item 1.2 back to minimum
Caution pressure, completely open throttle valve Item 1.3. No pressure gauge may
indicate a pressure!
Measured values
Additional tasks:
Calculation of the output power at maximum speed using the formulas below.
∆ p • qV P = output power in kW
P= in kW p = pressure in bar
600
qV = swept volume in l/min
V = content of the measuring glass in l
V t = measuring time in s
qV = • 60
t n = drive speed in min-1
n=
qV • ηvol
• 1000
hvol = volumetric efficiency of the motor
Vg = geometric swept volume (displacement) of the 05
motor in cm3/rev
Vg
hvol = 0.8
Vg = 4.93 cm3/rev - DM2
Notes
05
Project 06:
4/3 directional valve Bosch Rexroth AG I RE 00845/04.07
If the travel, direction, start, and stop of a hydraulic cylinder is to be controlled in a hydraulic
system, a directional valve must be used. Directional valves are differentiated as follows:
Directional spool valves, direct operated, pilot operated and directional poppet valves.
Directional valves are elements that assume the task of opening, closing or changing the flow
paths in hydraulic systems.
The spool of a directional valve is installed with a certain clearance. This clearance causes a
continuous leakage oil flow. This leakage, which is not externally visible, results in a flow loss
that increases as the pressure rises. When a directional valve is used for controlling a hydraulic
cylinder, pressure/force losses occur on the hydraulic cylinder when the fluid flows through
the valve. 06
Possible applications and the operating characteristics of the directional valve are determined
by, among others, the selection of the valve spool. The valve spool also determines the form
of the symbol.
The following Project 06: 4/3 directional valve is intended to gain knowledge of the operating
principle and the possible applications of direct operated directional valves.
In the project order the trainee is to work out and document the following:
• The spool shape determines the symbol, and all directional spool valves feature internal
leakage for design reasons caused by the clearance of the spool in the valve housing.
• With a valve being in the blocked position:
– a connected single-rod cylinder can extend due to internal leakage of the valve while the
valve is in its rest position and the pump is running.
– the total flow of a fixed displacement pump flows via the pressure relief valve to the tank
when the set system pressure is reached while the pump is running and the valve is in its
rest position, i.e. high power losses incur and the oil heats up.
– the working pressure utilized last slowly decreases via the clearance of the spool when
the hydraulic pump is switched off and the valve is in its rest position.
• With a valve being in the circulation position:
– when the valve is in its rest position and the pump is switched on the total pump flow
flows almost at zero pressure to the tank; the backpressure and hence the power loss
is determined by the pressure differential across the valve;
– energy is saved while the pump is running and the valve is in its rest position. This feature
cannot be installed in controls, where the system pressure is required by further actua-
tors.
With the help of the control set up on the training system the trainee gets familiar with the pos-
sible application of a 4/3 directional valve. A hydraulic cylinder is to be controlled alternately by
a 4/3 directional valve with different spool shapes (blocked and circulation position). The trainee
can recognize the special features of different symbols by measuring the different pressure dif-
ferentials across the 4/3 directional valve. Internal leakage can be recognized by the horizontal
arrangement of the single-rod cylinder, on which no external forces act.
Project definition
A single-rod cylinder is to shift and position tools horizontally in a fixture. When in the rest posi-
tion the hydraulic cylinder must not move, and the fixed displacement pump is to be spared
and thus energy saved.
The customer wants to be informed about the pros and cons of the various spool shapes, in
particular blocked and circulation position. In order that the customer can understand your
proposed solution, he requires technical documentation such as the hydraulic circuit diagram
with parts list, and the required measured data for the spool shapes/symbols.
06
Project tasks
• Independent understanding of the task and its putting into practice using hydraulic control
technology
• Planning and organizing the customer requirement (core qualification)
• Analyzing the technical data sheet of a directional valve (specialist qualification)
• Handling of hydraulic components in line with functional needs
Project 06:
4/3 directional valve Bosch Rexroth AG I RE 00845/04.07
Project steps
• Informing: Accepting and understanding the order, among others, through discussions
with the customer.
• Planning: Planning and organizing the execution of the customer order; among oth-
ers, through the selection of hydraulic components from the data sheet
collection (RE 23178/4/3 directional valve).
• Executing: Set-up of the hydraulic control on the training system. Working out and
documenting the system parameters as required by the customer. 06
• Checking: Are all customer requirements met?
• Evaluating: Are there further possibilities of meeting the customer requirement or simpler
ways of project execution? Have unforeseeable problems occurred?
Notes
Project 06:
4/3 directional valve Bosch Rexroth AG I RE 00845/04.07
Item 1.0
06
Item 1.1
Circulation
06
Extension Retraction
-Single-rod cylinder-
Fig. 06.3 Wiring diagram for hydraulic circuit diagram Fig. 06.2
Project 06:
4/3 directional valve Bosch Rexroth AG I RE 00845/04.07
Item 1.0
06
Item 1.2
Stop
06
Retraction Extension
-Single-rod cylinder-
Fig. 06.5 Wiring diagram for hydraulic circuit diagram Fig. 06.4
Project 06:
4/3 directional valve Bosch Rexroth AG I RE 00845/04.07
Double-acting cylinder
1.0 1 ZY 1.3
with single-sided piston rod
06
and central position P - T, A, B
Hose VSK 1
1 Flowmeter DZ 30.N
Table 06.1 Parts list for hydraulic circuit diagrams Fig. 06.2 and 06.04
Project 06:
4/3 directional valve Bosch Rexroth AG I RE 00845/04.07
Component arrangement/task 1
Note:
The component arrangement
shows the optional variant with
Measuring glass
06
Connection block
D Note:
In the case of connection
elements marked with “D”, the
components can be connected
directly with each other.
Fig. 06.6 Recommended component arrangement with component designations for parts list Table 06.1 and hydraulic circuit diagram Fig. 06.02
Note:
The designations of components in the parts list and the component arrangement are Rexroth-
specific designations. Also the grid arrangement is Rexroth-specific and adapted for use on
the training system.
Notes
Project 06:
4/3 directional valve 10 Bosch Rexroth AG I RE 00845/04.07
Component arrangement/task 2
Note:
The component arrangement
shows the optional variant with
Measuring glass
06
Connection block
D Note:
In the case of connection
elements marked with “D”, the
components can be connected
directly with each other.
Fig. 06.8 Recommended component arrangement with component designations for parts list Table 06.1 and hydraulic circuit diagram Fig. 06.4
Note:
The designations of components in the parts list and the component arrangement are Rexroth-
specific designations. Also the grid arrangement is Rexroth-specific and adapted for use on
the training system.
Notes
Project 06:
4/3 directional valve 11 Bosch Rexroth AG I RE 00845/04.07
Safety notes
After having completed practical work on the training system switch the
hydraulic pump off! Turn pressure relief valve Item 1.3 back to minimum
Caution pressure. No pressure gauge may indicate a pressure!
Task 2 6. Modify the hydraulic control according to hydraulic circuit diagram 06.4. Proceed as de-
scribed in task one, steps 1 and 2.
Check the electrical control for correct wiring.
7. Switch the hydraulic pump on and inspect the set up control for leakage. No pressure gauge
06
may indicate a pressure.
8. Set the system pressure on pressure relief valve Item 1.3 to 30 bar.
9. By actuating push-button S4 solenoid Y1b of 4/3 directional valve Item 1.2 is ener-
gized. The piston of hydraulic cylinder Item 1.1 extends.
By actuating push-button S2 the piston of the hydraulic cylinder retracts.
In contrast to task 1, positions "a“ and "b“ of the 4/3 directional valve are exchanged due
to the spool shape/symbol.
Measurements for task 2:
10. Measure the specified values in the end positions of the hydraulic cylinder and in the rest
position (central position) of the 4/3 directional valve as listed in Table 06.3 and enter the
values in Table 06.3.
After having completed practical work on the training system switch the
hydraulic pump off! Turn pressure relief valve Item 1.3 back to minimum
Caution
pressure. No pressure gauge may indicate a pressure.
06
The values were measured at an oil temperature of approx. 20 °C.
The values measured by the trainees can deviate by 10 %.
• With a 4/3 directional valve with circulation position the total flow of the hydraulic pump is
fed back to the tank almost at zero pressure when the directional valve is in its rest/central
position. The pressure differential, and hence the power loss, is determined by the spool
shape of the directional valve and by line resistances in the return line.
• With a 4/3 directional valve with circulation position, energy is saved due to the pressureless
circulation in der central position, but this valve can not be used, if further actuators are to
be controlled by an additional directional valve.
• With a 4/3 directional valve with blocked position, the total flow of a fixed displacement
hydraulic pump is fed via the pressure relief valve to the tank in the rest/central position of
the directional valve when the system pressure is reached. The hydraulic fluid heats up and
a high power loss incurs.
• With a 4/3 directional valve with blocked position a connected single-rod cylinder can
extend due to internal leakage oil while the directional valve is in its rest position and the
fixed displacment pump is running.
The working pressure utilized last slowly decreases via the clearance between spool/
housing.
Project 06:
4/3 directional valve 14 Bosch Rexroth AG I RE 00845/04.07
Notes
06
Project 07:
Check valve Bosch Rexroth AG I RE 00845/04.07
If the flow in hydraulic system is to be blocked in one direction, a check valve is required.
Check valves are available as seat valves, with ball or poppet as closing element. They are
subdivided as follows:
Check valves, pilot operated check valves.
Through the installation of a check valve it is possible to prevent, for example, the load pressure
from driving a hydraulic pump reversely when the electric motor is switched off. Also pressure
peaks, e.g. upstream of filters or coolers, can be reduced by means of a check valve installed
in a by-pass.
However, the use of a check valve also results in additional resistance in the system so that a
greater power must be installed.
The following Project 07 can be used to impart knowledge of the operating principle and the
use of a check valve.
07
In the course of the project order the trainee is to understand the operating principle of a check
valve installed in a by-pass. Through this project tasks he/she is to recognize the following:
• Fluid can only flow through a check valve in one direction.
• A check valve results in additional hydraulic resistance in the system.
• Pressure peaks can be reduced with the help of a check valve installed in a by-pass.
• When loads are secured by a check valve on the piston rod side, there is a risk of pressure
intensification.
On the basis of the control set up on the training system the trainee is to understand the oper-
ating principle of a check valve. A hydraulic cylinder under load, which is secured by a check
valve, can be lowered by operating a shut-off valve. The cylinder velocity can be adjusted by
means of a throttle.
To provide protection against pressure intensification a pressure relief valve is to be installed
on the piston rod side.
Project definition
In order that the customer can understand your proposed solution, he requires technical docu-
mentation.
In addition, he wants to know whether particular problems could arise, if a check valve is installed
on the piston rod side.
07
Project tasks
• Independent understanding of the task and its putting into practice using hydraulic control
technology
• Planning and organizing the customer requirement (core qualification)
• Analyzing the technical data sheet of a check valve (specialist qualification)
• Handling of hydraulic components in line with functional needs
Project 07:
Check valve Bosch Rexroth AG I RE 00845/04.07
Project steps
• Informing: Accepting and understanding the order, among others, through discussions
with the customer.
• Planning: Planning and organizing the execution of the customer order; among oth-
ers, through the selection of hydraulic components from the data sheet
collection (RE 20375 Check valve).
• Executing: Set-up of the hydraulic control on the training system. Working out and
documenting the system parameters requred by the customer.
Notes
Project 07:
Check valve Bosch Rexroth AG I RE 00845/04.07
Item 1.0
Item 0.3
Item 1.6
Item 0.2
Item 1.5
07
Item 1.3 Item 1.4
Item 1.1
Fig. 07.2 Hydraulic circuit diagram: Control of a vertical cylinder with suspended load
Project 07:
Check valve Bosch Rexroth AG I RE 00845/04.07
07
(Emergency stop)
Stop
Retraction
-Single-rod cylinder-
* Solenoid Y1.b
is not energized
Double-acting cylinder
1.0 1 with single-sided piston rod with ZY 1.Last
load
Hose VSK 1
Table 07.1 Parts list for hydraulic circuit diagram Fig. 07.2
Project 07:
Check valve Bosch Rexroth AG I RE 00845/04.07
Component arrangement
Measuring glass
07
Connection block
D Note:
In the case of connection
elements marked with “D”, the
components can be connected
directly with each other.
Fig. 07.4 Recommended component arrangement with component designation for parts list Table 07.1 and hydraulic circuit diagram Fig. 07.2
Note:
The designations of components in the parts list and the component arrangement are Rexroth-
specific designations. Also the grid arrangement is Rexroth-specific and adapted for use on
the training system.
Project 07:
Check valve Bosch Rexroth AG I RE 00845/04.07
Safety notes
2. Switch the hydraulic pump on and inspect the set up control for leakage. No pressure gauge
may indicate a pressure.
3. Set the system pressure on pressure relief valve Item 1.2 to 50 bar plus one turn (in
pressure line M1).
Project 07:
Check valve Bosch Rexroth AG I RE 00845/04.07
4. By actuating push-button S2 solenoid Y1a of 4/3 directional valve Item 1.1 is energized,
i.e. the cylinder retracts. Opening of shut-off valve Item 1.4 causes the cylinder to extend.
5. Safety valve setting against pressure intensification on the piston rod side:
Starting position of the cylinder: B.D.C. (bottom dead center, cylinder extended).
Close shut-off valve Item 1.4. Set pressure relief valve Item 1.5 on the piston rod side to
maximum pressure (spring tensioned - 1 turn).
Move the cylinder to the U.D.C. by operating push-button S2. Move directional valve Item
1.1 by manual operation to position Y1b while opening pressure relief valve Item 1.5 on
the piston rod side until pressure gauge M3 indicates a pressure of 80 bar (safety setting
against pressure intensification on the piston rod side).
Check the set value by extending the cylinder again.
6. Check lowering of the load in the de-energized condition by opening shut-off valve Item 1.4.
The lowering velocity can be adjusted by means of throttle valve Item 1.6.
The pressure that builds up when the cylinder supports on the counterforce of pressure
07
relief valve Item 1.5 on the piston rod side is called load holding pressure. To determine
the load holding pressure, the cylinder must be at the U.D.C. While the shut-off valve is
closed, slowly open the pressure relief valve until the cylinder starts to lower. M3 indicates
the load holding pressure. On the basis of the load holding pressure and the dimensions of
the hydraulic cylinder the weight of the load can be calculated.
Note:
To prevent pressure intensification, a safety valve (pressure relief valve) is used in practi-
cal applications, e.g. in a welding fixture. The upward stroke is accomplished via a check
valve installed in parallel.
After having completed practical work on the training system switch the
hydraulic pump off! Set the throttle valve and the pressure relief valves to
minimum pressure. For the disassembly, the load must be lowered. No pres-
Caution
sure gauge may indicate a pressure!
Notes
07
Project 08:
Check valve, pilot operated Bosch Rexroth AG I RE 00845/04.07
In contrast to simple check valves, pilot operated check valves can also be opened in the direc-
tion opposite to the direction of flow (direction of closure).
Pilot operated check valves can be installed for isolating pressurized working circuits (hydraulic
isolation of a hydraulic cylinder) or for providing protection against lowering of a load in the
event of a line rupture.
In the following Project 08 you can impart knowledge of the operating principle and the use of
a pilot operated check valve.
In the project order, the trainee has to make himself/herself familiar with the operating principle
of a pilot operated check valve, when it is opened by an additional hydraulic control signal. With
the help of a practice-oriented experiment set-up on the training system he/she is to undertand
the following:
• Fluid can only flow through a hydraulically pilot operated check valve in the checking direc-
tion, if it is opened by means of a hydraulic control signal.
• The check valve can only be closed when the pilot line is depressurized.
08
• The check valve can only close properly, if the fluid can freely flow from the closing element
to the reservoir.
• To prevent decompression shocks when the check valve opens, components are used that
feature a pre-opening function of the main poppet.
With the help of a control set up on the training system for a lifting apparatus, the trainee can
see the operating principle of a pilot operated check vave. A hydraulic cylinder under load
(vertical cylinder with suspended load) is secured by a pilot operated check valve. This pilot
operated check valve is opened by means of a 4/2 directional valve. The lowering speed can
be adjusted with a throttle. A pressure relief valve on the piston rod side provides a pressure
relief function for pressure intensifications.
Notes on the detailed technical information about the direct operated pressure relief
valve:
• The Hydraulic Trainer Volume 1, Bosch Rexroth AG
Basic principles and components, chapter 10
• Technical data sheet RE 21460
Check valve
Project 08:
Check valve, pilot operated Bosch Rexroth AG I RE 00845/04.07
Project definition
A cylinder in a rig (gripper) is to be protected against lowering by a pilot operated check valve. The
hydraulic control from Project 07 is to be modified according to the customer requirements.
In order that the customer can understand your proposed solution, he requires the modified
technical documentation.
As the lowering speed should also be adjustable here, the customer wants to know, at which
position the throttle valve can be installed. Moreover, he wants to know at which pilot pressure
the pilot operated check valve opens.
08
Fig. 08.1 Practical example: Hydraulically pilot operated check valves in a rig (gripper)
Project tasks
• Independent understanding of the task and its putting into practice using hydraulic control
technology
• Planning and organizing the customer requirement (core qualification)
• Analyzing the technical data sheet for a pilot operated check valve (technical qualifica-
tion)
• Handling of hydraulic components in line with functional needs
Project 08:
Check valve, pilot operated Bosch Rexroth AG I RE 00845/04.07
Project steps
• Informing: Accepting and understanding the order, among others, through discussions
with the customer.
• Planning: Planning and organizing the execution of the customer order; among oth-
ers, through the selection of hydraulic components from the data sheet
collection (RE 21460 / pilot operated check valve).
• Evaluating: Are there further possibilities of meeting the customer requirement or simpler
ways of project execution? Have unforeseeable problems occurred?
08
Notes
Project 08:
Check valve, pilot operated Bosch Rexroth AG I RE 00845/04.07
Item 1.0
Item 0.3
Item 1.6
08
Item 1.1
Measuring
Item 0.1 glass
Item 1.2
Fig. 08.2 Hydraulic circuit diagram: Check valve, hydraulically pilot operated
Project 08:
Check valve, pilot operated Bosch Rexroth AG I RE 00845/04.07
Stop
08
Note:
Extension = Y1.b + Y2
1.2/1.5 2
Direct operated pressure relief
valve; the cracking pressure can be DD 1.1
08
adjusted by means of a spring
Hose VSK 1
Table 08.1 Parts list for hydraulic circuit diagram Fig. 08.2
Project 08:
Check valve, pilot operated Bosch Rexroth AG I RE 00845/04.07
Component arrangement
Measuring glass
08
Connection block
D Note:
In the case of connection
elements marked with “D”, the
components can be connected
directly with each other.
Fig. 08.4 Recommended component arrangement with component designations for parts list Table 08.1 and hydraulic circuit diagram Fig. 08.2
Note:
The designations of components in the parts list and the component arrangement are Rexroth-
specific designations. Also the grid layout is Rexroth-specific and adapated for use on the
training system.
Project 08:
Check valve, pilot operated Bosch Rexroth AG I RE 00845/04.07
Safety notes
08
Only operate S3; turn in pressure relief valve completely, then turn pressure
relief valve out until 80 bar is applied at M3. The cylinder is to come to a
Caution standstill.
5. The actuation of pushbutton S3 causes 4/3 directional valve item 1.1 to be operated, i.e.
pressure is supplied to the the piston side of the hydraulic cylinder. The piston cannot ex-
tend.
Measure the pressures in M1, M2 and M3 and enter the values in Table 08.2.
6. Only when pushbutton S4 is operated additionally is port X of pilot operated check valve
item 1.4 controlled via 4/2 directional valve item 1.3 and the check valve opens. Fluid can
now flow at zero pressure from the piston rod side via 4/3 directional valve item 1.1 to the
reservoir.
Measure the pressures at M1, M2 and M3 during operation and enter the values in Table
08.2.
While the throttle is open and the piston is lowering, the movement of the
piston may be very jerky. The piston can advance due to the load on the ver-
Caution
tical cylinder. This causes underpressure in the piston chamber and hence 08
an absence of pilot pressure at port X of the pilot operated check valve, i.e.
the valve closes abruptly. When pressure is built up again on the piston side,
port X on the check valve is again supplied with pilot pressure. The check
valve opens abruptly.
7. Set the lowering speed of the cylinder to a lowering time of approx. 5 s on throttle valve
item 1.6.
Before converting the circuit for the further execution of the order, switch
the hydraulic pump off!
Caution
Notes
Project 08:
Check valve, pilot operated 10 Bosch Rexroth AG I RE 00845/04.07
Measured values
M1 M2 M3
Measuring point
p in bar p in bar p in bar
Lower cylinder via the pressure relief valve 45 45 70
08
After having completed the practical work on the training system, switch the
hydraulic pump off! Set the throttle valve and the pressure relief valves to mini-
Caution mum pressure. No pressure gauge may indicate a pressure!
• Fluid can only flow through a hydraulically pilot operated check valve in the checking direc-
tion, if it was opened by means of a hydraulic control signal.
• The pilot operated check valve can only close, when the pilot line is depressurized.
• The pilot operated check valve can only close properly, when the fluid can freely flow away
from the closing element.
• To prevent decompression shocks during opening of the check valve, components with a
pre-opening feature of the main poppet are used (development of theoretical knowledge).
Project 09:
Throttle valve, adjustable Bosch Rexroth AG I RE 00845/04.07
In hydraulic systems the piston velocity of a hydraulic cylinder or the revving speed of a hydraulic
motor should often be adjustable. The flow provided by the hydraulic pump can be controlled
with the help of flow control valves. Flow control valves are classified in:
Throttle - fine throttle/orifice and flow control valve.
In the following Project 09 knowledge is to be imparted with regard to the operating principle
and the use of throttle valves. The task of a throttle valves is to offer a flow resistance by chang-
ing the flow cross-section. As a result of the pressure drop, Dp across the throttling point, the
flow and consequently the speed of the actuator changes.
In the project order the trainee is to work out and document the characteristic curve of a throttle.
By changing the throttle settings, he/she is to understand that:
• the differential pressure Dp rises while the flow increases and the throttling cross-section
remains constant,
• the differntial pressure Dp rises in proportion to the reduction in the throttling cross-section
while the flow remains constant,
• the flow is independent of the pressure level when the pressure differential Dp is con-
stant.
09
The control set up on the training system allows the trainee to measure various differential pres-
sures across the throttle valve at certain flows. A load can be simulated by installing a pressure
relief valve in the return line of the 4/3 directional valve.
Project definition
In the plant of the customer, a conveyor belt, on which unchanged loads are transported, is
powered by a hydraulic motor. The drive speed of the hydraulic motor is to be adjustable in
both directions of travel.
In order that the customer can understand the proposed solution, he requires technical docu-
mentation.
As an option, he wants to know whether the drive speed changes when loads of different
weights are transported.
09
Fig. 09.1 Practical example: Conveyor belt for transporting printed-circuit boards
Project tasks
• Independent understanding of the task and its putting into practice using hydraulic control
technology
• Planning and organizing the customer requirement (core qualification)
• Analyzing the technical data sheet of a throttle valve (specialist qualification)
• Handling of hydraulic components in line with functional needs
Project 09:
Throttle valve, adjustable Bosch Rexroth AG I RE 00845/04.07
Project steps
• Informing: Accepting and understanding the order, among others, through discussions
with the customer.
• Planning: Planning and organizing the execution of the customer order; among oth-
ers, through the selection of hydraulic components from the data sheet
collection (RE 27219 Throttle check valve).
• Executing: Set-up of the hydraulic control on the training system. Working out and
documenting the system parameters requred by the customer.
• Evaluating: Are there further possibilities of meeting the customer requirement or simpler
ways of project execution?
09
Notes
Project 09:
Throttle valve, adjustable Bosch Rexroth AG I RE 00845/04.07
Item 1.5
Item 1.4 09
Load pressure
Stop
09
Rotation Rotation
-Hydraulic motor-
Fig. 09.3 Wiring diagram for hydraulic circuit diagram Fig. 09.2
Project 09:
Throttle valve, adjustable Bosch Rexroth AG I RE 00845/04.07
Hose VSK 1
1 Stopwatch
1 Flowmeter DFF 1
Table 09.1 Parts list for hydraulic circuit diagram Fig. 09.2
Project 09:
Throttle valve, adjustable Bosch Rexroth AG I RE 00845/04.07
Component arrangement
Measuring glass
Connection block
D Note:
In the case of connection
elements marked with “D”, the
components can be connected
09
directly with each other.
Fig. 09.4 Recommended component arrangement with component designation for parts list 09.1 and hydraulic circuit diagram Fig. 09.2
Note:
The designations of components in the parts list and the component arrangement are Rexroth-
specific designations. Also the grid arrangement is Rexroth-specific and adapted for use on
the training system.
Notes
Project 09:
Throttle valve, adjustable Bosch Rexroth AG I RE 00845/04.07
Safety notes
While directional valve Y1b is operated, the load pressure can be adjusted to 20 bar on
pressure relief valve Item 1.4, which is installed in the return line of the 4/3 directional valve,
and the pressure value read off from pressure gauge M3.
6. The flow measurement can be taken with the help of a measuring glass in liters/time or
optionally using flowmeter Item 1.5. Measure the pressure differential ∆p across throttle
valve Item 1.3 using pressure gauges M2 and M3 and enter the values in Table 09.2.
7. While the throttle position remains unchanged (1st position) increase the load pressure
to 25 bar, 30 bar, 35 bar, 40 bar and 42 bar.
Throttling process 2:
8. Throttle valve Item 1.3, � turn opened (2nd position).
Follow the instructions in points 6 to 8 and enter the values in Table 09.2.
Throttling process 3:
9. Throttle valve Item 1.3, 1� turns opened (3rd position).
Follow the instructions in points 6 and 7 and enter the measurement result in Table 09.2.
After having completed practical work on the training system, switch the
hydraulic pump off! Open the throttle valve and set the pressure relief valves
Caution
to minimum pressure. No pressure gauge may indicate a pressure!
09
10. Optional: Carry the measured values over in a Diagram 09.1.
Measured values
M3
20 25 30 35 40 50
p in bar
Throttle M2
46 46 47 47 47 48
Item 1.3 p in bar
1st M2 - M3
26 21 17 12 7 2
position ∆p in bar
q
1.98 1.74 1.47 1.20 0.87 0
in l/min
M3
20 25 30 35 40 50
p in bar
Throttle M2
44 45 45 46 47 48
Item 1.3 p in bar
2nd M2 - M3
24 20 15 11 7 2
position ∆p in bar
q
3.64 3.22 2.77 2.26 1.71 0
in l/min
M3
20 25 30 35 40 50
p in bar
Throttle M2
39 41 43 44 45 48
Item 1.3 p in bar
3rd M2 - M3
19 16 13 9 5 2
position ∆p in bar
q
6.40 5.82 5.09 4.20 3.18 0
in l/min
Table 09.2 Measurement results from execution of the order
Project 09:
Throttle valve, adjustable 10 Bosch Rexroth AG I RE 00845/04.07
30
Differential pressure ∆p in bar
25
20
15
10
5
09
0
0 1 2 3 4 5 6 7
Flow qV in l/min
If a given velocity is to be adjustable, a throttle valve can be used. If the traversing speed is to
be adjustable in only one direction, a throttle check valve is used.
Like a throttle valve a throttle check valve is a variable throttle with the disadvantages dealt with
in Project 09 such as temperature and dependence on the differential pressure.
In the following Project 10 knowledge of the operating principle and the use of a throttle check
valve can be imparted. The task of a throttle check valve is to throttle a given flow in only one
direction of rotation. The actuator to be controlled moves with flow throttling in one direction
and almost unthrottled in the opposite direction.
If the throttle is used, for example, on a single-rod cylinder, meter-in or meter-out throttling can
be provided.
In the project order, the trainee is to get familiar with the typical characteristics of a meter-in or
meter-out throttle. By installing the throttle valve differently, he/she is to understand that:
• a throttle check valve is a combination of a throttle and a check valve
• with a throttle check valve the piston velocity of a single-rod cylinder can be adjusted in only
one direction,
• in the case of meter-out throttling the single-rod cylinder is hydraulically isolated, but pres-
sure intensification can occur on the piston rod side,
• the use of a meter-in throttle can result in jerky movements of the single-rod cylinder (slip
stick). 10
On the basis of the control set up on the training system for powering a horizontally installed
single-rod cylinder, the trainee can recognize the pros and cons of meter-in and meter-out throt-
tling by taking measurements on the piston and on the piston rod side.
Project definition
In a machining station (bending of a roll seam) the hydraulic advance velocity is to be adjust-
able.
The return stroke is to be performed at maximum velocity.
As in Project 09, the customer requires technical documentation in order to be able to under-
stand the proposed solution. In addition, measurements of meter-in and meter-out throttling
are required.
10
Fig. 10.1 Practical example: Tool advance for roll seam bending
Project tasks
• Independent understanding and solving of the task set by applying hydraulic control tech-
nology
• Planning and organizing the customer requirement (core qualification)
• Analyzing the technical data sheet of a throttle check valve (specialist qualification)
• Handling of hydraulic components in line with functional needs
Project 10:
Throttle check valve Bosch Rexroth AG I RE 00845/04.07
Project steps
• Informing: Accepting and understanding the order, among others, through discussions
with the customer.
• Planning: Planning and organizing the customer order with the help of, among others,
the technical data sheets RE 27219 and RE 27506.
• Executing: Set-up of the hydraulic control on the training system. Working out and
documenting the system parameters required by the customer.
• Evaluating: Are there further possibilities of meeting the customer requirement or simpler
ways of project execution? Have unforeseeable problems occurred?
10
Notes
Project 10:
Throttle check valve Bosch Rexroth AG I RE 00845/04.07
Item 1.0
Item 1.3
Item 1.1
10
Measuring
Item 0.1 glass
Item 1.2
Fig. 10.2 Hydraulic circuit diagram: Meter-in throttle - extending a single-rod cylinder
Project 10:
Throttle check valve Bosch Rexroth AG I RE 00845/04.07
Item 1.0
Item 1.3
Item 1.1
10
Measuring
Item 0.1 glass
Item 1.2
Fig. 10.3 Hydraulic circuit diagram: Meter-out throttle - extending a single-rod cylinder
Project 10:
Throttle check valve Bosch Rexroth AG I RE 00845/04.07
Item 1.0
Item 1.3
Item 1.1
10
Measuring
Item 0.1 glass
Item 1.2
Fig. 10.4 Hydraulic circuit diagram: Meter-in throttle - retracting a single-rod cylinder
Project 10:
Throttle check valve Bosch Rexroth AG I RE 00845/04.07
Item 1.0
Item 1.3
Item 1.1
10
Measuring
Item 0.1 glass
Item 1.2
Fig. 10.5 Hydraulic circuit diagram: Meter-out throttle - retracting a single-rod cylinder
Project 10:
Throttle check valve Bosch Rexroth AG I RE 00845/04.07
Stop
10
Retraction Extension
-Single-rod cylinder-
Fig. 10.6 Wiring diagram for hydraulic schematic diagrams Fig. 10.2 to 10.5
Project 10:
Throttle check valve Bosch Rexroth AG I RE 00845/04.07
Double-acting cylinder
1.0 1 ZY 1.3
with single-sided piston rod
10
1 Distributor plate with four ports DZ 4.1
Hose VSK 1
Table 10.1 Parts list for hydraulic circuit diagrams 10.2 to 10.5
Project 10:
Throttle check valve 10 Bosch Rexroth AG I RE 00845/04.07
Component arrangement 1
Measuring glass
Connection block
D Note:
In the case of connection
elements marked with “D”, the
components can be connected
directly with each other.
10
Fig. 10.7 Recommended component arrangement with component designation for parts list Table 10.1 and hydraulic circuit diagram 10.2
Note:
The designations of components in the parts list and the component arrangement are Rexroth-
specific designations. Also the grid arrangement is Rexroth-specific and adapted for use on
the training system.
Notes
Project 10:
Throttle check valve 11 Bosch Rexroth AG I RE 00845/04.07
Component arrangement 2
Measuring glass
Connection block
D Note:
In the case of connection
elements marked with “D”, the
components can be connected
directly with each other.
10
Fig. 10.8 Recommended component arrangement with component designation for parts list Table 10.1 and hydraulic circuit diagram Fig. 10.3
Note:
The designations of components in the parts list and the component arrangement are Rexroth-
specific designations. Also the grid arrangement is Rexroth-specific and adapted for use on
the training system.
Notes
Project 10:
Throttle check valve 12 Bosch Rexroth AG I RE 00845/04.07
Component arrangement 3
Measuring glass
Connection block
D Note:
In the case of connection
elements marked with “D”, the
components can be connected
directly with each other.
10
Fig. 10.9 Recommended component arrangement with component designation for parts list Table 10.1 and hydraulic circuit diagram Fig. 10.4
Note:
The designations of components in the parts list and the component arrangement are Rexroth-
specific designations. Also the grid arrangement is Rexroth-specific and adapted for use on
the training system.
Notes
Project 10:
Throttle check valve 13 Bosch Rexroth AG I RE 00845/04.07
Component arrangement 4
Measuring glass
������
Connection block
D Note:
In the case of connection
elements marked with “D”, the
components can be connected
directly with each other.
10
Fig. 10.10 Recommended component arrangement with component designation for parts list Table 10.1 and hydraulic circuit diagram 10.5
Note:
The designations of components in the parts list and the component arrangement are Rexroth-
specific designations. Also the grid arrangement is Rexroth-specific and adapted for use on
the training system.
Notes
Project 10:
Throttle check valve 14 Bosch Rexroth AG I RE 00845/04.07
Safety notes
Before making any conversion for further order processing, switch the hy-
draulic pump off! No pressure gauge may indicate a pressure!
Caution
After having completed practical work on the training system switch the
hydraulic pump off! No pressure gauge may indicate a pressure! Open the
Caution throttle check valve.
Project 10:
Throttle check valve 16 Bosch Rexroth AG I RE 00845/04.07
Measured values
M2 M3
Measuring points →
p in bar p in bar
Meter-in throttle, piston side
2 3
→ extending
Meter-out throttle, piston rod side
50 77
→ extending
Meter-in throttle, piston rod side
2 4
← retracting
Meter-out throttle, piston side
27 50
← retracting
10
Safety note from accident prevention regulations:
If there is a riks of pressure intensification on the piston rod side, protection
Warning must be provided in the form of an additional pressure relief valve.
Setting: 10 % above system pressure; the system operator must secure the
setting against unauthorized changes by providing a lead seal.
• The customer requirement can be met by means of a throttle check valve, i.e. the traversing
speed of the advance carriage is adjustable in one direction.
• A throttle check valve is a combination of devices comprising a throttle valve and a check
valve.
• The advance cylinder can be hydraulically isolated during extended, but on the piston rod
side there is a risk of pressure intensification. Depending on the area ratio of the single-rod
cylinder the intensified pressure can reach, e.g. 2 : 1, which is the double system pres-
sure.
• To provide protection against pressure intensification a pressure relief valve can be in-
stalled.
• The flow through a throttle check valve depends on the differential pressure ∆p.
Project 11:
Flow control valve Bosch Rexroth AG I RE 00845/04.07
If the velocity of a hydraulic cylinder or the speed of a hydraulic motor is to be kept constant
independently of pressure fluctuations, a flow control valve is used, e.g. in conjunction with a
hydraulic cylinder, which is to lift and lower different loads, but is to move at the same travers-
ing velocity.
A flow control valve comprises a control loop and consists of an adjustable orifice and an up-
stream or downstream pressure compensator. Due to a continuous comparison of the pressures
upstream and downstream of the adjustable orifice, the set flow is kept constant.
In the following Project 11 you can impart knowledge of the operating principle and use of flow
control valves. The task of the flow control valve used is to maintain the speed of a hydraulic
motor constant despite varying loads.
In the project order, the trainee has to work out and record the characteristic curves of a 2-way
flow control valve. By making various adjustments to the flow control valve and changing the
loads on the hydraulic motor, he/she is to recognize that:
• the flow remains constant at varying load pressures,
• at varying inlet pressures, the flow remains constant,
• a flow control valve features a closed hydraulic control loop,
• flow qV eff. drops below a minimum pressure differential.
With the help of the control set up on the training system for driving a hydraulic motor, the trainee
can recognize the different flow rates under changing loads. The load can be simulated with the
help of a pressure relief valve installed in the return line of the 4/3 directional valve. 11
Notes on the detailed technical information about the flow control valve:
• The Hydraulic Trainer Volume 1/Bosch Rexroth AG
Basic principles and components, chapter 13
• Technical data sheet RE 28163/2-way flow control valve
Project 11:
Flow control valve Bosch Rexroth AG I RE 00845/04.07
Project definition
In a machining station, a hydraulic rotary drive is to swivel a drum from the horizontal to the
vertical position after a welding process. The movement is to be performed by a hydraulic mo-
tor. Despite varying loads, the motor speed must remain constant.
Applying the knowledge that was gained in Project 09, a load-independent throttle valve is to
be used in the velocity control.
In order that the customer can understand the solution, he requires, apart from the technical
documentation for the use of different workpiece weights, a flow/pressure differential curve for
varying loads and falling system pressures.
11
Project tasks
• Independent understanding of the task and its putting into practice using hydraulic control
technology
• Planning and organizing the customer requirement (core qualification)
• Analyzing the technical data sheet for a flow control valve (technical qualification)
• Handling of hydraulic components in line with functional needs
Project 11:
Flow control valve Bosch Rexroth AG I RE 00845/04.07
Project steps
• Informing: Accepting and understanding the order, among others, through discussions
with the customer.
• Planning: Planning and organizing the execution of the customer order; among others,
by dealing intensively with data sheet RE 28163.
• Deciding: Using the sketches of the circuit diagrams from Project 10: Throttle check
valve, selection of the relevant sketch with selection of the hydraulic com-
ponents.
• Executing: Set-up of the hydraulic control on the training system and preparation and
documentation of the system parameters requested by the customer.
• Evaluating: Are there further possibilities of meeting the customer requirement or simpler
ways of project execution? Have unforeseeable problems occurred?
Notes 11
Project 11:
Flow control valve Bosch Rexroth AG I RE 00845/04.07
Item 1.1
Item 0.4
Item 1.4
Load pressure
11
Measuring
Item 0.1 glass
Item 1.2
Fig. 11.2 Hydraulic circuit diagram: Load-independent speed control of a tool spindle
Project 11:
Flow control valve Bosch Rexroth AG I RE 00845/04.07
Stop
11
Rotation Rotation
-Hydraulic motor-
Fig. 11.3 Wiring diagram for hydraulic circuit diagram Fig. 11.2
Project 11:
Flow control valve Bosch Rexroth AG I RE 00845/04.07
Hose VSK 1
1 Stopwatch
Component arrangement
Measuring glass
Connection block
D Note:
In the case of connection
elements marked with “D”, the
components can be connected
directly with each other.
11
Fig. 11.4 Recommended component arrangement with component designations to parts list Table 11.1 and hydraulic circuit diagram Fig. 11.2
Note:
The designations of components in the parts list and the component arrangement are Rexroth-
specific designations. Also the grid layout is Rexroth-specific and adapated for use on the
training system.
Notes
Project 11:
Flow control valve Bosch Rexroth AG I RE 00845/04.07
Safety notes
the training system according to the prepared circuit diagram.
Connect the hydraulic control according to hydraulic circuit diagram Fig. 11.2 by means of
11
hoses.
For connections, to which pressure gauges with minimess line DZ 1.4 are to be connected,
use hydraulic hoses DZ 25.1. Hand-tighten the pressure gauge measuring lines hand tight
at the relevant minimess connection of the hydraulic hose.
The proper and tight fit of hose connections of components can be easily checked by
slightly turning the hoses.
Make sure that pipes or hoses are connected to all connections - in this case
also to minimess lines, or that the connections are plugged by means of plug
screws or protective caps. Leakage oil may drip through open connections
Warning
and cause a slipping risk.
Before commissioning the hydraulic control, i.e. before switching the hydrau-
lic pump on, check, whether all pressure control valves are set to minimum
Caution
pressure (spring unloaded) and all throttle valves are open.
Wire the electrical control according to wiring diagram Fig. 11.3.
2. Switch the hydraulic pump on and inspect the set up control for leakage. No pressure gauge
may indicate a pressure.
Task 1 Determining the flow/pressure differential curve with rising load pressure
3. Set the system pressure on pressure relief valve item 1.2 to 45 bar.
4. Turn flow control valve item 1.3 to scale position 2.
5. Operate pushbutton S4; the hydraulic motor rotates clockwise; adjust the load pressure on
pressure relief valve item 1.5 in the return flow line to 10 bar (pressure gauge M4). Enter
the pressure values M2 (upstream of DF 3) and M3 (downstream of DF 3) in measurement
table 11.2. Calculate the pressure differential Dp (M2 - M3) and enter it in the measure-
ment table.
Project 11:
Flow control valve Bosch Rexroth AG I RE 00845/04.07
Measured values
42 40 15 27 25 0.47 1.92
42 40 20 22 20 0.46 1.90
42 40 25 17 15 0.46 1.90
42 40 30 12 10 0.45 1.86
42 40 35 7 5 0.31 1.30 11
42 42 40 2 2 0 0
Table 11.2 Values measured during the execution of the order, increasing load pressure
2,5
2
Flow qV in l/min
1,5
0,5
0
0 5 10 15 20 25 30 35 40
Pressure differential Dp in bar
Diagram 11.1 Flow/pressure differential curve, increasing load pressure
Project 11:
Flow control valve 10 Bosch Rexroth AG I RE 00845/04.07
After completion of the practical work on the training system, switch the hy-
draulic pump off! Set the throttle valve and pressure relief valves to minimum
Caution pressure. No pressure gauge may indicate a pressure!
Measured values
11
Measuring point M1 Measuring point M3 Pressure differential Flow
p in bar p in bar Dp in bar qV in l/min
40 5 35 0.5
35 5 30 0.5
30 5 35 0.5
25 5 20 0.5
20 5 15 0.5
15 5 10 0.5
10 5 5 0.4
0,6
0,5
0,4
Flow qV in l/min
0,3
0,2
0,1
0 10 15 20 25 30 35 40
Pressure differential ∆p in bar
Diagram 11.2 Flow/pressure differential curves, system pressure falling
11
Notes
11
Project 12:
Pressure relief valve, direct operated Bosch Rexroth AG I RE 00845/04.07
The limitation of the system pressure protects system components such as pipes and hoses,
connections, control blocks, pump housings, etc. against destruction. Pressure relief valves are
also used to provide protection against, e.g. pressure peaks. In the special machinery construc-
tion sector, e.g. in presses, pressure relief valves are also used as load holding valves.
To be able to assess the characteristics of a direct operated pressure relief valve, the charac-
teristic curves of the pressure/flow relation must be known.
In the following Project 12 knowledge of the operating principle, use and adjustment options
of direct operated pressure relief valves is to be gained. Pressure relief valves are used to limit
the system pressure of a hydraulic control.
In the project order, the trainee is to get to know the characteristic curves of a direct oper-
ated pressure relief valve. By making various settings on the pressure relief valve, he/she is to
recognize that:
• the characteristic curve of a pressure relief valve shows the dependence of pressure p on
flow qV;
• despite an open pressure relief valve a resistance (line and valve resistance) can be ob-
served;
• in the case of a parallel connection of throttle and pressure relief valves the flow is di-
vided;
• pressure relief valves can be used, for example, as overload protection. 12
On the basis of the set up control the trainee can work out the characteristic curves of a pres-
sure relief valve by changing the system pressure and the resistance installed in parallel. The
resistance is provided by an adjustable throttle valve.
Notes on detailed technical information about the direct operated pressure relief valve:
• The Hydraulic Trainer Volume 1/Bosch Rexroth AG
Basic principles and components, Chapter 12
• Technical data sheet RE 25402/Pressure relief valve, direct operated
Project 12:
Pressure relief valve, direct operated Bosch Rexroth AG I RE 00845/04.07
Project definition
On a lifting platform, the system pressure is to be reduced due to the use of lower weights.
The new setting is to save energy.
The customer requires work instructions in order that he can adjust the pressure without re-
quiring expert help. Moreover, he is interested in the pressure/flow relationship characteristic
curves of pressure relief valves.
12
Project tasks
• Independent understanding of the task and its putting into practice using hydraulic control
technology
• Planning and organizing the customer requirement (core qualification)
• Analyzing the technical data sheet of a pressure relief valve (specialist qualification)
• Handling of hydraulic components in line with functional needs
Project 12:
Pressure relief valve, direct operated Bosch Rexroth AG I RE 00845/04.07
Project steps
• Informing: Accepting and understanding the order, among others, through discussions
with the customer.
• Planning: Planning and organizing the customer order, among others, by dealing
intensively with technical data sheets RE 25402.
• Executing: Set-up of the hydraulic control on the training system. Working out and
documenting the system parameters required by the customer.
• Evaluating: Are there further possibilities of meeting the customer requirement or simpler
ways of project execution? Have unforeseeable problems occurred?
Notes
12
Project 12:
Pressure relief valve, direct operated Bosch Rexroth AG I RE 00845/04.07
Item 1.1
Item 1.5
Item 0.1
Measuring
glass
Item 1.0
Fig. 12.2 Hydraulic circuit diagram: Determination of technical data of a pressure relief valve, direct operated
Project 12:
Pressure relief valve, direct operated Bosch Rexroth AG I RE 00845/04.07
Hose VSK 1
12
1 Stopwatch
1 Flowmeter DZ 30
Table 12.1 Parts list for hydraulic circuit diagram Fig. 12.2
Project 12:
Pressure relief valve, direct operated Bosch Rexroth AG I RE 00845/04.07
Component arrangement
Measuring glass
Connection block
D Note:
In the case of connection
elements marked with “D”, the
components can be connected
directly with each other.
Fig. 12.3 Recommended component arrangement with component designation for parts list Table 12.1 and hydraulic circuit diagram Fig. 12.2
Note: 12
The designations of components in the parts list and the component arrangement are Rexroth-
specific designations. Also the grid arrangement is Rexroth-specific and adapted for use on
the training system.
Notes
Project 12:
Pressure relief valve, direct operated Bosch Rexroth AG I RE 00845/04.07
Safety notes
4. Open throttle valve Item 1.1 in individual steps (5 bar increments). The pressure is shown
on pressure gauge M1. Enter the M1 measurement results and flow qV in Table 11.2.
5. Carry over the measurement results from Table 12.2 to Diagram 12.1.
After having completed practical work on the training system switch the
hydraulic pump off! No pressure gauge may indicate a pressure! Open the
throttle check valve.
Caution
Measured values
Flow
System pressure M1 qV in l/min
Throttle valve
p in bar through pressure relief
valve
Closed 30 7.6
25 4.3
20 1.8
15 0 12
Open 10 0
35
30
System pressure M1 p in bar
25
20
15
10
0
0 1 2 3 4 5 6 7 8
Flow qV across the pressure relief valve in l/min
Diagram 12.1 Pressure/flow characteristic curves, falling system pressure
Notes
12
Project 13:
Pressure relief valve control Bosch Rexroth AG I RE 00845/04.07
If three different pressures are to be realized in a hydraulic circuit, pressure relief valves
The following Project 13 can be used to acquire knowledge of the practical use and adjustment
options of direct operated pressure relief valves.
In the project order, the trainee has to develop and record the adjustment options of parallel
and series circuits with the help of experiment set-ups on the training system. As preparation
to the practical experiment, the trainee has to become familiar with the theoretical principles
of the circuits.
By controlling the pressure relief valves in different ways by means of a 4/3 directional valve,
he/she is to recognize that:
• Pressure relief valves can be used for pre-selecting various system and pilot pressures via
pressure stage circuits,
• in the case of pressure relief valves controlled in parallel, the lowest set pressure becomes
effective,
• in the case of pressure relief valves controlled in series, the pressures add up.
With the help of the controls set up on the training system, the trainee is to understand the
typical features of the controls by operating pressure relief valves connected in parallel and in
series. With the help of a 4/3 directional valve he/she can control pressure relief valves option-
ally connected in parallel or in series.
Notes on the detailed technical information about the direct operated pressure relief
valve:
• The Hydraulic Trainer Volume 1/Bosch Rexroth AG
Basic principles and components, chapter 12
13
• Technical data sheet RE 25402/Pressure relief valve, direct operated
Project 13:
Pressure relief valve control Bosch Rexroth AG I RE 00845/04.07
Project definition
On a punching rig, three, electrically controllable pressures are to be callable for different tools
and different working sequences.
The customer wishes solution proposals for the simple realization of a pressure control and
requires technical documentation with the necessary system parameters.
13
Fig. 13.1 Practical example: Punching equipment
Project tasks
• Independent understanding of the task and its putting into practice using hydraulic control
technology
• Planning and organizing the customer requirement (core qualification)
• Analyzing the technical data sheet for a pressure relief valve (technical qualification)
• Handling of hydraulic components in line with functional needs
Project 13:
Pressure relief valve control Bosch Rexroth AG I RE 00845/04.07
Project steps
• Informing: Accepting and understanding the order, among others, through discussions
with the customer.
• Planning: Planning and organizing the execution of the customer order, among others,
by dealing intensively with data sheet RE 25402.
• Evaluating: Are there further possibilities of meeting the customer requirement or simpler
ways of project execution? Have unforeseeable problems occurred?
Notes
13
Project 13:
Pressure relief valve control Bosch Rexroth AG I RE 00845/04.07
Item 0.3
Item 1.2
Item 0.2
Item 1.1
Item 1.0
Measuring
Item 0.1 glass
13
System
Item 0.3
Item 1.2
Item 0.2
Item 1.1
Item 1.0
Measuring
Item 0.1 glass
13
System
Item 1.0
Measuring
Item 0.1 glass
System
Circulation
13
Fig. 13.5 Wiring diagram for hydraulic circuit diagrams Fig. 13.2 and 13.4
Project 13:
Pressure relief valve control Bosch Rexroth AG I RE 00845/04.07
Hose VSK 1
Table 13.1 Parts list for hydraulic circuit diagrams Fig. 13.2 to 13.4
13
Project 13:
Pressure relief valve control Bosch Rexroth AG I RE 00845/04.07
Component arrangement 1
Measuring glass
Connection block
D Note:
In the case of connection
elements marked with “D”, the
components can be connected
directly with each other.
Fig. 13.6 Recommended component arrangement with component desgnations for parts list Table 13.1 and hydraulic circuit diagram Fig. 13.2
Note:
The designations of components in the parts list and the component arrangement are Rexroth-
specific designations. Also the grid layout is Rexroth-specific and adapated for use on the
training system. 13
Notes
Project 13:
Pressure relief valve control 10 Bosch Rexroth AG I RE 00845/04.07
Component arrangement 2
Measuring glass
Connection block
D Note:
In the case of connection
elements marked with “D”, the
components can be connected
directly with each other.
Fig. 13.7 Recommended component arrangement with component designations for parts list Table 13.1 and hydraulic circuit diagram Fig. 13.3
Note:
The designations of components in the parts list and the component arrangement are Rexroth-
specific designations. Also the grid layout is Rexroth-specific and adapated for use on the
training system. 13
Notes
Project 13:
Pressure relief valve control 11 Bosch Rexroth AG I RE 00845/04.07
Component arrangement 3
Measuring glass
Connection block
D Note:
In the case of connection
elements marked with “D”, the
components can be connected
directly with each other.
Fig. 13.8 Recommended component arrangement with component designations for parts list Table 13.1 and hydraulic circuit diagram Fig. 13.4
Note:
The designations of components in the parts list and the component arrangement are Rexroth-
specific designations. Also the grid layout is Rexroth-specific and adapated for use on the
training system. 13
Notes
Project 13:
Pressure relief valve control 12 Bosch Rexroth AG I RE 00845/04.07
Safety notes
4. Operate directional valve item 1.0 by actuating pushbutton S2. Set the system pressure
on pressure relief valve item 1.2 at port A to 20 bar (pressure gauge M3).
Enter the measured values (pressure gauge M1, M2, M3) in Table 13.2.
Before converting the circuit for the further execution of the order, switch the
hydraulic pump off! No pressure gauge may indicate a pressure!
Caution
Before converting the circuit for the further execution of the order, switch the
hydraulic pump off! No pressure gauge may indicate a pressure!
Caution
After completion of the practical work on the training system, switch the
hydraulic pump off! No pressure may indicate a pressure! Open the throttle
Caution
check valve.
13
Notes
Project 13:
Pressure relief valve control 14 Bosch Rexroth AG I RE 00845/04.07
Measured values
• In a 3-stage pressure circuit, direct operated pressure relief valves can be controlled via a
directional valve and consequently three different, pre-selected system pressures can be
realized.
• In the case of pressure relief valves connected in parallel, the lowest pressure set is effec-
tive.
• In the case of pressure relief valves connected in series, the set pressures add up.
Project 14:
Pressure reducing valve Bosch Rexroth AG I RE 00845/04.07
In contrast to the pressure relief valve, which limits the input pressure, the pressure reducing
valve influences the output pressure (actuator pressure). The pressure that can be set on a
pressure reducing valve is always lower than the system pressure.
The following Project 14 is intended to impart knowledge of the operating principle and the
use of a pressure reducing valve. The task of a pressure reducing valve is to keep the output
pressure constant and lower than the input pressure.
In the project order the trainee is to get familiar with the typical characteristics of a pressure
reducing valve with the help of a practice-oriented experiment set up on the training system.
This project task is to help him/her understand that:
• with the help of a pressure reducing valve a secondary actuator can be controlled at a pres-
sure which is lower than the system pressure,
• excess pressure in port A is discharged via port T of the pressure reducing valve to the
tank,
• a pressure reducing valve without by-pass check valve operates as pressure relief valve
when controlled via port A.
The control set up on the training system (two actuators are controlled simultaneously at dif-
ferent pressures via a 4/3 directional valve) is to make the characteristics of a 3-way pressure
reducing valve clear to the trainee.
Project definition
The customer wishes a solution with which the control can easily be realized and requires the
associated technical documentation with the necessary system parameters. In addition, he
needs information about the setting options and wants to know, why a by-pass check valve is
required.
14
Fig. 14.1 Practical example: Swiveling/clamping unit
Project tasks
• Independent understanding of the task and its putting into practice using hydraulic control
technology
• Planning and organizing the customer requirement (core qualification)
• Analyzing the technical data sheet of a pressure reducing valve (specialist qualification)
• Handling of hydraulic components in line with functional needs
Project 14:
Pressure reducing valve Bosch Rexroth AG I RE 00845/04.07
Project steps
• Informing: Accepting and understanding the order, among others, through discussions
with the customer.
• Planning: Planning and organizing of the customer order by, among others, dealing
intensively with technical data sheet RE 26564.
• Executing: Set-up of the hydraulic control on the training system. Preparation and
documentation of the measured data.
• Evaluating: Are there further possibilities of meeting the customer requirement or simpler
ways of project execution? Have unforeseeable problems occurred?
Notes
14
Project 14:
Pressure reducing valve Bosch Rexroth AG I RE 00845/04.07
Item 2.1
Item 1.4
Item 1.1
Measuring
Item 0.1 glass
Item 1.2
14
Power unit limit
Stop
14
Retraction Extension
-Single-rod cylinder-
Clockwise rotation
-Hydraulic motor-
Fig. 14.3 Wiring diagram for hydraulic circuit diagram Fig. 14.2
Project 14:
Pressure reducing valve Bosch Rexroth AG I RE 00845/04.07
Double-acting cylinder
1.0 1 ZY 1.3
with single-sided piston rod
Hose VSK 1
Table 14.1 Parts list for hydraulic circuit diagram Fig. 14.2
Project 14:
Pressure reducing valve Bosch Rexroth AG I RE 00845/04.07
Component arrangement
Measuring glass
Connection block
D Note:
In the case of connection
elements marked with “D”, the
components can be connected
directly with each other.
Fig. 14.4 Recommended component arrangement with component designation for parts list Table 14.1 and hydraulic circuit diagram Fig. 14.2
Note:
The designations of components in the parts list and the component arrangement are Rexroth-
specific designations. Also the grid arrangement is Rexroth-specific and adapted for use on
the training system.
14
Notes
Project 14:
Pressure reducing valve Bosch Rexroth AG I RE 00845/04.07
Safety notes
For the connections, to which pressure gauges with minimess line DZ 1.4 are to be con-
nected, use hydraulic hoses DZ 25. Hand-tighten the pressure gauge measuring lines at
the relevant minimess connection of the hydraulic hose.
The correct and proper fit of the component connections with hoses can be checked
by slightly turning the hoses.
Make sure that all ports - in this case also minimess lines - pipes and hoses
are connected or that the ports are blocked with plug screws or protective
Warning
caps. Leakage oil can drop through open ports on the floor and cause a risk
of slipping.
Before commissioning the hydraulic control, i.e. before switching the hydrau-
lic pump on, check, whether all pressure control valves are set to minimum
Caution
pressure (spring unloaded) and all throttle valves are open.
Wire the electrical control according to wiring diagram Fig. 14.3.
Project 14:
Pressure reducing valve Bosch Rexroth AG I RE 00845/04.07
Measured values
• A pressure reducing valve can supply a secondary actuator with a lower pressure than the
14
system pressure.
• The system pressure must always be higher than the secondary pressure.
• When the pressure rises in port A of the pressure reducing valve (e.g. pressure peaks/
changes in the load by the secondary actuator), the pressure increase is reduced to the
tank via port T of the pressure reducing valve.
• When controlled via channel A, a pressure reducing valve operates as pressure relief
valve.
• When controlled from T to P the pressure relief valve on the hydraulic motor operates as
check valve.
Project 15:
Pressure switch Bosch Rexroth AG I RE 00845/04.07
The switching elements integrated in a piston-type pressure switch make or break an electrical
circuit.
In the following Project 15 knowledge can be imparted with regard to the operating principle
and use of a piston-type pressure switch. Pressure switches assume switching and monitoring
functions in a hydraulic control.
In the project order the trainee is to get familiar with the typical characteristics and the setting
options of a piston-type pressure switch with the help of a practice-oriented experiment set-up
on the training system. The following knowledge is to be gained with this project task:
• Piston-type pressure switches issue an electrical control signal.
• The hydraulic pressure is used to switch an electrical signal via a micro-switch.
• In the case of a piston-type pressure switch the pressure must exceed or fall below the set
value in order that a switching process in initiated.
Based on the control set up on the training system the trainee is to understand the possible
applications of a piston-type pressure switch. A cylinder is to be controlled by means of a 4/2
directional valve, and the pressure on the piston side controlled by a piston-type pressure switch.
When the set pressure is reached, the return stroke is to be initiated.
Project definition
Two hydraulic workpieces are to be pressed together in a fixture by means of a hydraulic cylin-
der. After the pressing pressure was reached, the hydraulic cylinder is to retract automatically.
The pressing velocity is to be adjustable.
The customer wishes to obtain a proposed solution for an automatic, hydraulic pressing pro-
cess. In the event of a fault of pressure monitoring, it should be possible to release the pressing
fixture electrically. The customer also wants to know the settable minimum pressing pressure.
For his technical documentation, the customer requires a circuit diagram with parts list and
functional description.
15
Fig. 15.1 Practical example: International pressure indications on pressure switches for system monitoring
Project tasks
• Independent understanding of the task and its putting into practice using hydraulic control
technology
• Planning and organizing the customer requirement (core qualification)
• Analyzing the technical data sheet of a piston-type pressure switch (specialist qualification)
• Handling of hydraulic components in line with functional needs
Project 15:
Pressure switch Bosch Rexroth AG I RE 00845/04.07
Project steps
• Informing: Accepting and understanding the order, among others, through discussions
with the customer.
• Planning: Planning and organizing of the customer order by, among others, dealing
intensively with technical data sheet RE 50060.
• Executing: Set-up of the hydraulic control on the training system. Working out the set-
ting options of the pressure switch at different, given system pressures.
• Evaluating: Are there further possibilities of meeting the customer requirement or simpler
ways of project execution? Have unforeseeable problems occurred?
Notes
15
Project 15:
Pressure switch Bosch Rexroth AG I RE 00845/04.07
Item 1.0
Item 0.2
Item 1.3
Item 1.4
Item 0.3
Item 1.1
15
Control 4/2 directional valve
Extension
-Single-rod cylinder-
Note:
Retracting of the single-rod cylinder
can additionally be controlled
by means of push-button S1.
Fig. 15.3 Wiring diagram for hdraulic circuit diagram Fig. 15.2
Project 15:
Pressure switch Bosch Rexroth AG I RE 00845/04.07
Double-acting cylinder
1.0 1 ZY 1.3
with single-sided piston rod
Hose VSK 1
Table 15.1 Parts list for hydraulic circuit diagram Fig. 15.2
Project 15:
Pressure switch Bosch Rexroth AG I RE 00845/04.07
Component arrangement
������
����� �������
������ ������
������
������
Measuring glass
�����
�
������
�������
�����
�����
�
Connection block
�����
������
�
D Note:
� � In the case of connection
������
�
Fig. 15.4 Recommended component arrangement with component designation for parts list Table 15.1 and hydraulic circuit diagram Fig. 15.2
Note:
The designations of components in the parts list and the component arrangement are Rexroth-
specific designations. Also the grid arrangement is Rexroth-specific and adapted for use on
the training system.
Notes
15
Project 15:
Pressure switch Bosch Rexroth AG I RE 00845/04.07
Safety notes
3. Check that the pressing cylinder extends and retracts correctly while the throttle check valve
is open. Actuate push-button S2 to operate directional valve Item 1.1. Adjust the extension
velocity of the pressing piston to a forward speed of 0.05 m/s by means of throttle check
valve Item 1.4. To this end, calculate the velocity as a function of the measured extension
time and the stroke length.
4. Adjust the pressing pressure on piston-type pressure switch Item 1.3 (release spring)
so that the pressing cylinder piston retracts automatically. To this end, extend the pressing
piston to the end position.
5. Set the pressures given in Table 15.2 and verify whether the cylinder retracts automati-
cally.
Enter the results in Table 15.2.
Measured values
28 No
30 Yes
32 Yes
40 Yes
After having completed practical work on the training system switch the
hydraulic pump off! No pressure gauge may indicate a pressure! Open the
15
Caution throttle check valve.
Notes
15
Project 16:
Pressure switch hysteresis Bosch Rexroth AG I RE 00845/04.07
The switching point at increasing pressure and at falling pressure varies due to friction. The
difference in the values is called hysteresis (Greek hysteros: later).
SP
Hysteresis
rP
1
0 Hno (normally open)
1 Hnc (normally closed)
0
Diagram 16.1 Hysteresis
In the following Project 16 knowledge can be imparted of the practical effects of hysteresis on
a piston-type pressure switch.
In the project order the trainee is to get familiar with the hysteresis of a piston-type pressure
switch through a practical experiment set-up on the training system. Through this project task,
the trainee is to gain the following knowledge:
• A piston-type pressure switch always has a hysteresis.
• Hysteresis is the difference of switching points at rising and falling pressure.
• Hysteresis can have different amounts, which can be attributed to the individual design. 16
• On certain pressure switches, hysteresis can be adjustable.
On the basis of the control set up on the training system, the trainee is to get to know the hys-
teresis of a piston-type pressure switch. With the help of a 24 V bulb, which serves as control
unit, and a pressure relief valve installed in a by-pass, he/she can set given values and measure
the hysteresis by way of the hydraulic pressure.
Project definition
max.
Pressure stage 100 bar
Switching pressure differential in bar →
Scatter
min.
16
Project tasks
• Independent understanding of the task and its putting into practice using hydraulic control
technology
• Planning and organizing the customer requirement (core qualification)
• Analyzing the technical data sheet of a piston-type pressure switch (specialist qualification)
• Handling of hydraulic components in line with functional needs
Project 16:
Pressure switch hysteresis Bosch Rexroth AG I RE 00845/04.07
Project steps
• Informing: Accepting and understanding the order, among others, through discussions
with the customer.
• Planning: Planning and organizing the customer order using, among others, technical
data sheet RE 50060.
• Executing: Set-up of the hydraulic control on the training system. Working out the
hysteresis of a piston-type pressure switch at various, given system pres-
sures.
• Evaluating: Are there further possibilities of meeting the customer requirement or simpler
ways of project execution? Have unforeseeable problems occurred?
Notes
16
Project 16:
Pressure switch hysteresis Bosch Rexroth AG I RE 00845/04.07
Item 1.1
Item 1.2
Item 0.1
Measuring
glass
Item 1.0
16
16
Note:
The pressure switch is
supplied with voltage via
push-button S1.
Fig. 16.3 Wiring diagram for hydraulic circuit diagram Fig. 16.2
Project 16:
Pressure switch hysteresis Bosch Rexroth AG I RE 00845/04.07
Hose VSK 1
Table 16.1 Parts list for hydraulic circuit diagram Fig. 16.2
16
Project 16:
Pressure switch hysteresis Bosch Rexroth AG I RE 00845/04.07
Component arrangement
Measuring glass
Connection block
D Note:
In the case of connection
elements marked with “D”, the
components can be connected
directly with each other.
Fig. 16.4 Recommended component arrangement with component designation for parts list Table 16.1 and hydraulic circuit diagram Fig. 16.2
Note:
The designations of components in the parts list and the component arrangement are Rexroth-
specific designations. Also the grid arrangement is Rexroth-specific and adapted for use on
the training system.
Notes
16
Project 16:
Pressure switch hysteresis Bosch Rexroth AG I RE 00845/04.07
Safety notes
For connections, to which pressure gauges with minimess line DZ 1.4 are to be connected,
use hydraulic hoses DZ 25. Hand-tighten the pressure gauge measuring lines at the relevant
minimess connection of the hydraulic hose.
The correct and proper fit of the component connections with hoses can be checked
by slightly turning the hoses.
Make sure that all ports - in this case also minimess lines - pipes and hoses
are connected or that the ports are blocked with plug screws or protective 16
caps. Leakage oil can drop through open ports on the floor and cause a risk
Warning
of slipping.
Before commissioning the hydraulic control, i.e. before switching the hydrau-
lic pump on, check, whether all pressure control valves are set to minimum
Caution
pressure (spring unloaded) and all throttle valves are open.
Wire the electrical control according to wiring diagram Fig. 16.3.
2. Switch the hydraulic pump on and inspect the set up control for leakage. No pressure gauge
may indicate a pressure.
3. Set piston-type pressure switch Item 1.1 to 30 bar; to this end, set pressure relief valve
Item 1.0 to 30 bar. To this end, close throttle Item 1.2 and operate push-button S1.
4. Set the system pressure to 25 bar on pressure relief valve Item 1.0.
Project 16:
Pressure switch hysteresis Bosch Rexroth AG I RE 00845/04.07
Slowly increase the system pressure to 30 bar while observing indicator lamp H1 on the
electrical control.
When the pressure rises to 30 bar, lamp H1 goes on.
Increase the system pressure by further 5 bar to 35 bar. During this, lamp H1 must not go
out.
5. Slowly reduce the system pressure until lamp H1 goes out. The pressure indicated by the
pressure gauge should be 27.5 bar.
This switching difference is called hysteresis.
Note:
The value given under point 5 can deviate by 1 - 2 bar.
After having completed practical work on the training system switch the
hydraulic pump off! No pressure gauge may indicate a pressure! Open the
Caution
throttle check valve.
16
Project 16:
Pressure switch hysteresis 10 Bosch Rexroth AG I RE 00845/04.07
Notes
16
Project 17:
Hydraulic accumulator Bosch Rexroth AG I RE 00845/04.07
If, in a hydraulic control, a cylinder should be operable also in the event of a failure, for example
of the hydraulic pump, the energy required for this can be taken from a hydraulic accumulator.
Depending on their design, hydraulic accumulators are classified as:
Piston-type, bladder-type and diaphragm-type accumulators.
A hydraulic accumulator is a pressure vessel with a separating element, in which energy is stored.
Hydraulic accumulators are used for storing energy, for damping, for leakage oil compensation,
for holding pressures constant and for vehicle suspension.
Safety notes
(Excerpt from currently valid safety regulations - not exhaustive).
Pressure accumulators may only be installed, repaired and put into service
by specialist personnel trained in the field of hydraulics.
In the project order the trainee is to understand the behavior of a hydraulic cylinder in the event
of a hydraulic pump failure and the withdrawal of energy from a diaphragm-type accumulator
in a practical experiment set-up on the training system. Through this project task, the following
knowledge is to be acquired:
• Due to the compressibility of the filled-in gas, a diaphragm-type accumulator can be used
for storing energy.
• The oil volume that can be stored in the hydraulic accumulator depends on the size of the 17
accumulator, the nitrogen pre-charge pressure and the system pressure.
• The amount of oil available for withdrawal depends on the accumulator size, the nitrogen
pre-charge pressure and the pressure difference between the minimum and maximum work-
ing pressure.
• If the system pressure falls below the nitrogen pre-charge pressure, the hydraulic accumula-
tor is completely discharged.
On the basis of the control set up on the training system the trainee is to work out the pos-
sible application of a hydraulic accumulator as energy storage. The usable oil volume can be
calculated on the basis of a hydraulic cylinder that is controlled by a 4/3 directional valve at
different system pressures.
Project 17:
Hydraulic accumulator Bosch Rexroth AG I RE 00845/04.07
Project definition
In a fixture, a tool is to be moved by means of a hydraulic cylinder into and out of the machining
area. In the event of a hydraulic pump failure, the tool most be extended by means of stored
energy.
Since the customer has never utilized an accumulator before, he would like to know whether he
selected the correct accumulator size, i.e. whether the usable accumulator volume is sufficient.
He uses various system pressures and therefore requires documents that describe the usable
volume. In addition, he is interested in test documents such as a table that shows the various
system pressures and the usable oil volume.
17
Fig. 17.1 Practical example: Bladder and diaphragm-type accumulators with accumulator safety block
Project 17:
Hydraulic accumulator Bosch Rexroth AG I RE 00845/04.07
Project tasks
• Independent understanding of the task and its putting into practice using hydraulic control
technology
• Planning and organizing the customer requirement (core qualification)
• Analyzing the technical data sheet of a hydraulic accumulator (specialist qualification)
• Handling of hydraulic components in line with functional needs
Project steps
• Informing: Accepting and understanding the order, among others, through discussions
with the customer.
• Planning: Planning and organizing the customer order by, among others, working out
the topic of hydraulic accumulators (The Hydraulic Trainer - Basic Principles)
and the technical data sheet RE 50130/Accumulator safety block.
• Executing: Set-up of the hydraulic control on the training system and calculation of
the usable oil volume at different, given system pressures, and of the pre-
charge pressure.
• Evaluating: Are there further possibilities of meeting the customer requirement or simpler
ways of project execution? Have unforeseeable problems occurred?
17
Project 17:
Hydraulic accumulator Bosch Rexroth AG I RE 00845/04.07
Item 0.2
Item 1.0
Item 1.4
Lead-
sealed
Item 1.1
Item 0.1
17
Circulation
Retraction Extension
-Single-rod cylinder- 17
Fig. 17.3 Wiring diagram for hydraulic circuit diagram Fig. 17.2
Project 17:
Hydraulic accumulator Bosch Rexroth AG I RE 00845/04.07
Double-acting cylinder
1.0 1 ZY 1.3
with single-sided piston rod
0.1 - 0.2 2
Pressure gauge with hose
and quick release coupling DZ 1.4 17
without check valve
Hose VSK 1
Table 17.1 Parts list for hydraulic circuit diagram Fig. 17.2
Project 17:
Hydraulic accumulator Bosch Rexroth AG I RE 00845/04.07
Component arrangement
Measuring glass
Connection block
D Note:
In the case of connection
elements marked with “D”, the
components can be connected
directly with each other.
Fig. 17.4 Recommended component arrangement with component designation for parts list Table 17.1 and hydraulic circuit diagram Fig. 17.2
Note:
The designations of components in the parts list and the component arrangement are Rexroth-
specific designations. Also the grid arrangement is Rexroth-specific and adapted for use on
the training system.
Notes
17
Project 17:
Hydraulic accumulator Bosch Rexroth AG I RE 00845/04.07
Safety notes
After having completed practical work on the training system switch the
hydraulic pump off! No pressure gauge may indicate a pressure! Unload the
Caution hydraulic accumulator via the accumulator safety valve (rotary knob T).
Evaluating
On the basis of the total number of strokes of the hydraulic cylinder the useful volume of the
hydraulic accumulator can be calculated according to the following formula. 17
( a • s + x ) + (d )
d K2 • π
V =
4 K
2
- d St2 •
π
4
(
• e • s • z ) dm3
After having calculated the useful volume, prepare a characteristic curve (Diagram 17.1)
0,6
0,5
Useful volume V in l
0,4
0,3
0,2
0,1
0
0 10 20 30 40 50
Charging pressure M2 p in bar
Diagram 17.1 re Table 17.2
• Due to the compressibility of the filled in gas, diaphragm-type accumulators can be used as
energy storage.
• The oil volume stored in the hydraulic accumulator depends on the accumulator size, the
nitrogen pre-charge pressure and the system pressure.
• The effective useful volume of the hydraulic accumulator depends on the accumulator size,
the nitrogen pre-charge pressure and the pressure difference between minimum and maxi-
mum working pressure.
• If the system pressure falls below the nitrogen pre-charge pressure, the hydraulic accumula-
tor is completely unloaded.
• The hydraulic accumulator is charged when the system pressure is higher than the nitrogen
pre-charge pressure. 17
Project 17:
Hydraulic accumulator 12 Bosch Rexroth AG I RE 00845/04.07
Notes
17
Project 18:
Regenerative circuit Bosch Rexroth AG I RE 00845/04.07
In the following Project 18 knowledge can be imparted of how to increase the velocity without
enlarging the pump displacement.
In the project order the trainee is to work out the behavior of a hydraulic cylinder, when the oil
volume of the piston rod side is directly fed to the piston side during extending. On the basis
of a practical experiment set-up on the training system, the trainee is to gain the following
knowledge:
• For a single-rod cylinder the area ratio can be calculated on the basis of the piston area and
the annulus piston area.
• In the case of a regenerative circuit, the volume of the piston rod side is directly fed to the
piston side.
• With a regenerative circuit, the required pump displacement can be reduced.
With the help of the control set up on the training system the trainee is to get familiar with the
typical behavior of a regenerative circuit. The hydraulic cylinder is controlled by a 4/2 directional
valve. During extending, the oil volume of the piston rod side is directly fed to the piston side.
The piston velocity is to be adjustable by means of a flow control valve.
18
Project 18:
Regenerative circuit Bosch Rexroth AG I RE 00845/04.07
Project definition
On a machine tool the velocity of a feed cylinder is to be increased and thus the cycle time of
the system shortened without changing the pump flow. The advance velocity (extending time
of the hydraulic cylinder) is to be adjustable independently of the load.
In order that the customer can understand the circuit structure of the control, he requires the
associated documentation such as the hydraulic circuit diagram with parts list. He also requires
a table of the travel times of the hydraulic cylinder with different flow control settings.
Moreover, the customer wants to know which effect the increase in the cycle time has on the
advance force.
Fig. 18.1 Practical example: Control block with hydraulic components such as directional, pressure and flow control
valve
18
Project tasks
• Independent understanding of the task and its putting into practice using hydraulic control
technology
• Planning and organizing the customer requirement (core qualification)
• Analyzing the technical data sheet for velocity controls (specialist qualification)
• Handling of hydraulic components in line with functional needs
Project 18:
Regenerative circuit Bosch Rexroth AG I RE 00845/04.07
Project steps
• Informing: Accepting and understanding the order, among others, through discussions
with the customer.
• Planning: Planning and organizing the customer order by, among others, working out
the technical data sheets relating to velocity controls.
• Executing: Set-up of the hydraulic control on the training system. Preparation of a table
of travel times and velocities and a comparison of pros and cons.
• Evaluating: Are there further possibilities of meeting the customer requirement or simpler
ways of project execution? Have unforeseeable problems occurred?
Notes
18
Project 18:
Regenerative circuit Bosch Rexroth AG I RE 00845/04.07
Item 1.0
Item 1.1
Item 1.2
18
Extension
-Single-rod cylinder-
18
Fig. 18.3 Wiring diagram for hydraulic circuit diagram Fig. 18.2
Project 18:
Regenerative circuit Bosch Rexroth AG I RE 00845/04.07
Double-acting cylinder
1.0 1 ZY 1
with single-sided piston rod
Hose VSK 1
Table 18.1 Parts list for hydraulic circuit diagram Fig. 18.2
18
Project 18:
Regenerative circuit Bosch Rexroth AG I RE 00845/04.07
Component arrangement
Measuring glass
Connection block
D Note:
In the case of connection
elements marked with “D”, the
components can be connected
directly with each other.
Fig. 18.4 Recommended component arrangement with component designation for parts list Table 18.1 and hydraulic circuit diagram Fig. 18.2
Note:
The designations of components in the parts list and the component arrangement are Rexroth-
specific designations. Also the grid arrangement is Rexroth-specific and adapted for use on
the training system.
Notes
18
Project 18:
Regenerative circuit Bosch Rexroth AG I RE 00845/04.07
Safety notes
Operate push-button S1, which causes the piston of hydraulic cylinder Item 1.0 to retract again;
enter the retraction time of the piston and pressures M3 and M2 at the end position of
hydraulic cylinder Item 1.0 in Table 18.2.
4. Set flow control valve Item 1.2 successively to scale positions 1.2, 1.4, 1.6, 1.8 and 2.0
and enter the individual measuring results in Table 18.2 as described under point 3.
5. Enter the calculated traversing velocities of the feed cylinder as characteristic curve in
Diagram 18.1.
After having completed practical work on the training system, switch the
hydraulic pump off! No pressure gauge may indicate a pressure! Open the
Caution
throttle check valve.
6. Calculation of the area ratio of single rod cylinder ZY1 used in the regenerative circuit.
A2 =
( )
D2 - d 2 • π
= 2,9 cm2
4
4, 9 cm2 : 2,9 cm2 = 1,689
3,5
3
Velocity v in cm/s
2,5
1,5
0,5
0
0 0,5 1 1,5 2 2,5
Position of flow control valve DF3
Diagram 18.1 re Table 18.2
As mentioned in the introduction, a disadvantage of the regenerative circuit is that piston force
FK counteracts annulus piston force FR, i.e. the remaining useful force is the force of piston rod
area FST.
For information, please find below notes on pressures and flows for a single-rod cylinder con-
trolled in a regenerative circuit, including the required calculation formula.
Single-rod cylinder
Note:
When neglecting the pressure drop in the lines and the directional valve, the pressure is
identical on both sides of the cylinder.
because the pump flow must only fill the space that corresponds to the piston rod area.
Project 18:
Regenerative circuit 11 Bosch Rexroth AG I RE 00845/04.07
For retracting of the cylinder with spool position … of the directional valve, the force is calcu-
lated as follows:
Fretr = pB AR – pA AK
AK
ϕ= =2
AR
qP qP qP
Vext = = = = Vretr
AK – AR 2 AR – AR AR
Vext qP AR AR
= =
Vretr (AK – AR ) qP AK – AR
where
AK
ϕ= → AK = ϕ AR
AR
consequently
Vext AR AR 1
= = =
Vretr ϕ AR – AR AR (ϕ – 1) ϕ –1
Vext 1
=
Vretr ϕ –1
18
Project 18:
Regenerative circuit 12 Bosch Rexroth AG I RE 00845/04.07
AK AR ASt
F1 (out)
F2 (back)
pA
∆pmin
qB
qA
qtotal = qB + qP
qA
qP
• The area ratio of a single-rod cylinder can be calculated on the basis of the piston area and
the annulus piston area.
18
• In a regenerative circuit, the volume displaced on the piston rod side while the piston is
extending is fed to the piston side.
• In a regenerative circuit, the required pump displacement can be reduced.
Project 19:
Rapid speed / creep speed control Bosch Rexroth AG I RE 00845/04.07
A rapid speed/creep speed control can be used in a hydraulic circuit to control the advance
velocity of a hydraulic cylinder independently of the load.
In the following Project 19 you can impart knowledge of a velocity control. Here, a flow control
valve is cut in and out on the piston rod side of the extending hydraulic cylinder. With this veloc-
ity control, pressure intensification occurs on the piston rod side.
In the project order the trainee is to work out the behavior of a hydraulic cylinder when a flow
control valve is activated by means of a directional valve while the cylinder is extending. On the
basis of a practice-oriented experiment set-up on the training system the trainee is to gain the
following knowledge:
• With a rapid speed advance control the hydraulic cylinder extends at maximum velocity
without any throttling.
• The extension velocity can be varied independently of the load by means of an electrical
limit switch by cutting in a flow control valve.
• The return stroke of the hydraulic cylinder is performed at maximum velocity.
• Pressure intensification occurs when a flow control valve is activated on the piston rod
side.
On basis of the control set up on the training system the trainee is to understand the typical
behavior of a single-rod cylinder in such a rapid speed advance control. A 4/2 directional valve
is used to control a hydraulic cylinder. With an additional 4/2 directional valve the oil volume
of the piston rod side is fed via a flow control valve to the tank. The return stroke is performed
at the maximum velocity possible.
19
Project 19:
Rapid speed / creep speed control Bosch Rexroth AG I RE 00845/04.07
Project definition
At the end of a production line, workpieces are to be lifted from a conveyor belt and put down
on a pallet. The lifting movement is to be performed using a hydraulic cylinder. To achieve
shorter cycle times, fast motion sequences are required. Due to changing workpiece weights,
the residual stroke is to be performed independently of loads at strongly reduced velocity.
The return stroke is to be performed as fast as possible.
For his documentation, the customer wishes to obtain a travel/time diagram in addition to a
hydraulic circuit diagram and a parts list.
Project tasks
• Independent understanding of the task and its putting into practice using hydraulic control
19
technology
• Planning and organizing the customer requirement (core qualification)
• Analyzing the technical data sheet of velocity controls (specialist qualification)
• Handling of hydraulic components in line with functional needs
Project 19:
Rapid speed / creep speed control Bosch Rexroth AG I RE 00845/04.07
Project steps
• Informing: Accepting and understanding the order, among others, through discussions
with the customer.
• Planning: Planning and organizing the customer order, by, among others, examining
the technical data sheet for velocity controls.
• Executing: Set-up of the hydraulic control on the training system and preparation of a
travel/time diagram.
• Evaluating: Are there further possibilities of meeting the customer requirement or simpler
ways of project execution? Have unforeseeable problems occurred?
Notes
19
Project 19:
Rapid speed / creep speed control Bosch Rexroth AG I RE 00845/04.07
Item 0.2
Item 1.0
Item 0.3
Item 1.4
Item 1.2
Item 1.1
19
red red
black black
blue blue
Fig. 19.3 Wiring diagram for hydraulic circuit diagram Fig. 19.2
Project 19:
Rapid speed / creep speed control Bosch Rexroth AG I RE 00845/04.07
Double-acting cylinder
1.0 1 ZY 1.3
with single-sided piston rod
Hose VSK 1
red
black
B1/B2 2 Limit switch, inductive DE 2
blue
Table 19.1 Parts list for hydraulic circuit diagram Fig. 19.2 19
Project 19:
Rapid speed / creep speed control Bosch Rexroth AG I RE 00845/04.07
Component arrangement
Measuring glass
Connection block
D Note:
In the case of connection
elements marked with “D”, the
components can be connected
directly with each other.
Fig. 19.4 Recommended component arrangement with component designation for parts list Table 19.1 and hydraulic circuit diagram Fig. 19.2
Note:
The designations of components in the parts list and the component arrangement are Rexroth-
specific designations. Also the grid arrangement is Rexroth-specific and adapted for use on
the training system.
Notes
19
Project 19:
Rapid speed / creep speed control Bosch Rexroth AG I RE 00845/04.07
Safety notes
After having completed the practical work on the training system, switch the
pump off! No pressure gauge may indicate a pressure! Open the throttle
Caution check valve.
Measured values
M3 p bar 50 50
Advance M2 p bar 80 80
Time t s 23 12
M3 p bar 19 19
For information, please find below the graphical representation of the piston velocity of the
single-rod cylinder.
Table 19.3 shows a function sequence chart commonly used in practice.
Travel
t
Rapid speed Advance Return stroke Time
Diagram 19.1 Travel/time diagram
• With a rapid speed advance circuit, the piston of a hydraulic cylinder extends with maximum
pump flow without throttling. 19
• With the help of an electrical limit switch, the extension velocity can be adjusted - controlled
by a directional valve - independently of the load by means of a flow control valve.
• The return stroke of the piston is performed with the maximum pump flow.
• When the flow is throttled at the piston rod side, pressure intensification occurs during
extending.
Project 20:
Valve circulation control Bosch Rexroth AG I RE 00845/04.07
A circulation control for a fixed displacement pump can be used to prevent the hydraulic fluid
from excessive overheating. Overheating would not only lead to premature wear of the hydrau-
lic fluid, but can also result in lubrication problems. If the hydraulic pump displaces hydraulic
fluid via the pressure relief valve while the hydraulic cylinder is at a standstill, more energy is
consumed.
In the following Project 20 you can impart knowledge of a valve circulation control.
In the project order the trainee is to work out the possibility of directing the pump flow via a
circulation valve. In a practice-oriented experiment set-up on the training system, the following
knowledge is to be gained through the project task:
• When the pump flow circulates, only a small pressure builds up in the hydraulic pump.
• The circulation control reduces wear of the hydraulic pump.
• Circulation helps to save electric power.
• When the hydraulic fluid circulates, the fluid is not excessively heated and its service life
extended.
Based on the control set up on the training system the trainee is to implement a circuit for
circulating the pump displacement. A hydraulic cylinder is to be controlled by means of a 4/3
directional valve with circulation position. When no hydraulic energy is required, the directional
valve is brought to the central position, i.e. to the circulation position.
In a further control circuit, the hydraulic cylinder is to be controlled by means of a 4/3 directional
valve with blocked central position. However, in this case, the system pressure can only build
up, if the flow previously discharged via a 4/2 directional valve is directed to the 4/3 directional
valve.
20
Project 20:
Valve circulation control Bosch Rexroth AG I RE 00845/04.07
Project definition
For the assembly of heavy hydraulic control blocks, a scissors lift it used for lifting and lowering
pallets. In order that the hydraulic cylinder can be stopped at any position, a 4/3 directional
valve with blocked central position is used. To spare the hydraulic pump, a solution is to be
provided, with which the pump flow is directed at zero pressure to the tank when the hydraulic
cylinder is not operated.
The customer wishes to obtain several solution proposals and for his documentation, apart from
the hydraulic circuit diagram and the parts list, a comparison of the proposed solutions.
Project tasks
• Independent understanding of the task and its putting into practice using hydraulic control
technology
• Planning and organizing the customer requirement (core qualification)
• Analyzing the technical data sheet of fixed displacement pump (specialist qualification)
20
• Handling of hydraulic components in line with functional needs
Project 20:
Valve circulation control Bosch Rexroth AG I RE 00845/04.07
Project steps
• Informing: Accepting and understanding the order, among others, through discussions
with the customer.
• Planning: Planning and organizing the customer order, among others, through dealing
with the technical data sheet for the 4/3 directional valve, RE 23178, and
in particular with the section of symbols.
• Executing: Set-up of the hydraulic control on the training system. Acquisition of mea-
sured values and preparation of a comparison table.
• Evaluating: Are there further possibilities of meeting the customer requirement or simpler
ways of project execution? Have unforeseeable problems occurred?
Notes
20
Project 20:
Valve circulation control Bosch Rexroth AG I RE 00845/04.07
Item 1.0
Item 1.1
20
Fig. 20.2 Hydraulic circuit diagram: Pressureless circulation using a 4/3 directional valve
Project 20:
Valve circulation control Bosch Rexroth AG I RE 00845/04.07
Circulation
Extension Retraction
-Single-rod cylinder-
20
Fig. 20.3 Wiring diagram for hdraulic circuit diagram Fig. 20.2
Project 20:
Valve circulation control Bosch Rexroth AG I RE 00845/04.07
Item 1.0
Item 1.1
Item 1.3
20
Fig. 20.4 Hydraulic circuit diagram: Pressureless circulation using an additional 4/2 directional valve
Project 20:
Valve circulation control Bosch Rexroth AG I RE 00845/04.07
Circulation
-Single-rod cylinder-
20
Fig. 20.5 Wiring diagram for hydraulic circuit diagram Fig. 20.4
Project 20:
Valve circulation control Bosch Rexroth AG I RE 00845/04.07
Double-acting cylinder
1.0 1 ZY 1.3
with single-sided piston rod
Hose VSK 1
Table 20.1 Parts list for hydraulic circuit diagram Fig. 20.2 and 20.4
20
Project 20:
Valve circulation control Bosch Rexroth AG I RE 00845/04.07
Component arrangement 1
Measuring glass
Connection block
D Note:
In the case of connection
elements marked with “D”, the
components can be connected
directly with each other.
Fig. 20.6 Recommended component arrangement with component designation for parts list Table 20.1 and hydraulic circuit diagram Fig. 20.2
Note:
The designations of components in the parts list and the component arrangement are Rexroth-
specific designations. Also the grid arrangement is Rexroth-specific and adapted for use on
the training system.
Notes
20
Project 20:
Valve circulation control 10 Bosch Rexroth AG I RE 00845/04.07
Component arrangement
Measuring glass
Connection block
D Note:
In the case of connection
elements marked with “D”, the
components can be connected
directly with each other.
Fig. 20.7 Recommended component arrangement with component designation for parts list Table 20.1 and hydraulic circuit diagram Fig. 20.4
Note:
The designations of components in the parts list and the component arrangement are Rexroth-
specific designations. Also the grid arrangement is Rexroth-specific and adapted for use on
the training system.
Notes
20
Project 20:
Valve circulation control 11 Bosch Rexroth AG I RE 00845/04.07
Safety notes
Task 2 Circulation
5. Mount the components required according to parts list Table 20.1 in a clearly arranged form
on the training system according to the prepared circuit diagram.
Connect the hydraulic control according to hydraulic circuit diagram Fig. 20.4 by means
of hoses.
For connections, to which pressure gauges with minimess line DZ 1.4 are to be connected,
use hydraulic hoses DZ 25. Hand-tighten the pressure gauge measuring lines at the relevant
minimess connection of the hydraulic hose.
The correct and proper fit of the component connections with hoses can be checked
by slightly turning the hoses.
Make sure that all ports - in this case also minimess lines - pipes and hoses
are connected or that the ports are blocked with plug screws or protective
Warning caps. Leakage oil can drop through open ports on the floor and cause a risk
of slipping.
Before commissioning the hydraulic control, i.e. before switching the hydrau-
lic pump on, check, whether all pressure control valves are set to minimum
Caution
pressure (spring unloaded) and all throttle valves are open.
To provide more clarity that the entire flow is fed directly to the tank via 4/2 directional valve
Item 1.3 when directional valves Item 1.2 and Item 1.3 are not operated, port T of directional
valve Item 1.3 can be connected directly to the measuring glass (option).
Wire the electrical control according to wiring diagram Fig. 20.5.
6. Switch the hydraulic pump on and inspect the set up control for leakage. No pressure gauge
may indicate a pressure.
Set the system pressure on pressure relief valve Item 1.4 to 50 bar plus one turn.
The system pressure can only be adjusted while the cylinder is at its end position.
7. Hydraulic cylinder Item 1.0 can be controlled via directional valve Item 1.2 using push-but-
tons S2 and S4. To this end, directional valve Item 1.3 must be operated before by means
of push-button S3.
Measure and note pressure M1 in the relevant end position of hydraulic cylinder Item 1.0
(S2, S4 operated) while directional valve Item 1.3 is not operated.
After having completed the practical work on the training system, switch the
pump off! No pressure gauge may indicate a pressure! Open the throttle
Caution
check valve.
20
Project 20:
Valve circulation control 13 Bosch Rexroth AG I RE 00845/04.07
Measured values
Task 1 Task 2
M1 p in bar
p in bar p in bar
Circulation 0 8 0 8
a 50 a 50
Cylinder end position
b 50 b 50
• When the pump displacement is circulated, only a small pressure builds up in the hydraulic
pump.
• The circulation circuit reduces wear of the hydraulic pump.
• Circulation saves electric power.
• Due to the circulation circuit, hydraulic fluid does not heat up excessively, and the service
life of the fluid is extended.
20
Project 20:
Valve circulation control 14 Bosch Rexroth AG I RE 00845/04.07
Notes
20
Project 21:
Commissioning, troubleshooting, maintenance Bosch Rexroth AG I RE 00845/04.07
A long service life and functional reliability of hydraulic systems and their components depend
on proper handling. The observation of system-specific installation and operating notes of
the supplier guarantee trouble-free operation. Important information can also be found in the
technical data sheets for components, power units, and their accessories.
Not only for the engineering, but also for everyday handling of modern hydraulic systems,
regulations and safety rules must be observed.
The main task of responsible persons (fitters, but also operators) is to keep systems in opera-
tion. A precondition for meeting this requirement cost-efficiently is profound knowledge. The
persons involved must be able to read and interpret not only hydraulic circuit diagrams, but also
electrical circuit diagrams. Troubleshooting in modern controls requires the skillful handling of
measuring and diagnosis devices such as pressure gauges, multi-meters, flowmeters, etc.
Repair and servicing staff must consider the entire system in examinations. Here, condition
monitoring and the determination of machine operating schedules form the basis for active
maintenance.
According to DIN 31051 maintenance includes the sum of all measures for maintaining and
restoring technical systems.
Repairs, commissioning, maintenance, and inspections may only be carried out by trained
and instructed personnel having a specific knowledge of hydraulics.
A specialist is, who, due to his/her technical training and experience, has
sufficient knowledge and is sufficiently familiar with relevant regulations
that he/she:
• can assess the work assigned to him/her,
• can recognize possible hazards,
• can take the necessary measures to eliminate risks,
• has the required knowledge with regard to repairs and assembly.
Environmental protection also plays an important role, especially for maintenance person-
nel. For example, oil-soaked cloths and paper must be properly disposed of.
In the project order the trainee is to work out commissioning of a hydraulic control and the
procedure for component adjustments. On the basis of a practice-oriented experiment set-up,
the following knowledge is to be gained in the course of the project task:
• For commissioning, system-related machine documents such as circuit diagrams, parts list,
function charts, system parameters and operating instructions are required.
• Contamination is by far the most common cause of faults in hydraulic systems.
• Improper mounting can significantly reduce the service life of hydraulic components and
leads to costly downtimes. 21
Project 21:
Commissioning, troubleshooting, maintenance Bosch Rexroth AG I RE 00845/04.07
• An indispensable tool for targeted fault analyses is the understanding of the function and
operating principle of all hydraulic components in the system.
• Target-oriented communication simplifies the analysis of faults.
• Preventive maintenance and inspection reduce failures of systems and prolong the service
life of components.
On the basis of the complex control set up on the training stand, the trainee is to work out commis-
sioning of an electrohydraulic control and the order of adjusting the individual components.
Controlled by a 4/3 directional valve, a hydraulic cylinder is to lift a load. The lifting time is to be
adjusted by means of a throttle and take approx. 5 s. A hydraulic motor (set to 1.5 l/min), which
is to rotate independently of the load by using a flow control valve, is hydraulically pre-loaded
by a 4/2 directional valve connected in parallel. Controlled by an electrical push-button, first
the cylinder is to lift the load, and then the hydraulic motor is to rotate uniformly.
21
Project 21:
Commissioning, troubleshooting, maintenance Bosch Rexroth AG I RE 00845/04.07
Project definition
Project tasks
• Independent understanding of the task and its putting into practice using hydraulic control
technology
• Planning and organizing the customer requirement (core qualification)
• Analyzing the required technical documents (specialist qualification)
• Handling of hydraulic components in line with functional needs
21
Project 21:
Commissioning, troubleshooting, maintenance Bosch Rexroth AG I RE 00845/04.07
Project steps
• Informing: Accepting and understanding the order, among others, through discussions
with the customer.
• Planning: Planning and organizing the customer order, among others, by dealing
intensively with technical data sheets.
• Executing: Set-up of the hydraulic control on the training system. Acquisition of mea-
sured values and preparation of the technical documentation requested by
the customer.
• Evaluating: Are there further possibilities of meeting the customer requirement or simpler
ways of project execution? Have unforeseeable problems occurred?
Notes
21
Project 21:
Commissioning, troubleshooting, maintenance Bosch Rexroth AG I RE 00845/04.07
Notes
21
Project 21:
Commissioning, troubleshooting, maintenance Bosch Rexroth AG I RE 00845/04.07
Item 1.0
Item 0.4
Item 2.0
Set to
1.5 l/min
Set to
Item 1.3 text = 5 sec
Stop
hose VSK 1
Table 21.1 Parts list for hydraulic circuit diagram Fig. 21.2
21
Project 21:
Commissioning, troubleshooting, maintenance Bosch Rexroth AG I RE 00845/04.07
Component arrangement
Measuring glass
Connection block
D Note:
In the case of connection
elements marked with “D”, the
components can be connected
directly with each other.
Fig. 21.4 Recommended component arrangement with component designation for parts list Table 21.1 and hydraulic circuit diagram Fig. 21.2
Note:
The designations of components in the parts list and the component arrangement are Rexroth-
specific designations. Also the grid arrangement is Rexroth-specific and adapted for use on
the training system.
21
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Commissioning, troubleshooting, maintenance 10 Bosch Rexroth AG I RE 00845/04.07
Safety notes
21
Project 21:
Commissioning, troubleshooting, maintenance 11 Bosch Rexroth AG I RE 00845/04.07
After having completed practical work on the training system switch the
hydraulic pump off! No pressure gauge may indicate a pressure! Open the
Caution throttle check valve.
Measured values
M1 48
M3 5
M1 48
M3 30
M1 48
Hydraulic motor Rotating
M4 20
Table 21.2 System parameters of machine tool control
Lifting 1 0 0
Holding 0 0 0
Rotating 0 0 1
Hydraulic
motor
Stop 0 0 0
Table 21.3 Function sequence/machine tool control Legend: 1 Valve spool energized
0 Valve spool not energized
21
Project 21:
Commissioning, troubleshooting, maintenance 13 Bosch Rexroth AG I RE 00845/04.07
no Check and, if
Lifting cylinder Item →→→ required, correct
1.0 at end position?
position
↓
yes
↓
Valve Y2 no Is the valve spool yes Check by activating
activated →→→ jammed? →→→ emergency stop
↓
yes
↓
Note:
↓
yes Possibly mechanical fault of the
↓
hydraulic motor?
↑
↑
Questions
Question 1:
Name the systematic working steps during commissioning and for adjusting the electrohydraulic
control.
• Check the electrical control for function
• Check the set-up of the hydraulic control
• Set the pressure relief valves to minimum pressure/spring unloaded
• Adjust flow control valves to adequate flow
• Switch the hydraulic pump on/Leakages?/Direction of motor rotation OK?/No excessive pressures
in the system?
• Set the system pressure to 50 bar plus one turn/DB valve Item 1.2
• Check the LIFTING/LOWERING function of the lifting cylinder/push-buttons S4 - S2
• Adjust the lifting time to 5 s/throttle Item 1.3
• Measure the operating pressures and enter them in the system parameter table
• Check the rotating function of the hydraulic motor.
• Adjust the rotary speed/close flow control valve/measure the flow by means of the measur-
ing glass/1.5 l/min.
• Set the pre-loading valve/DB valve Item 2.2 to 20 bar.
• Enter the machining pressure of the hydraulic motor in the system parameter table
Question 2:
Which 6 machine documents are indispensable for electrohydraulic systems?
• Hydraulic circuit diagram/with parts list
• Wiring diagram
• Function chart
• Operating instructions
• Machine key data/system parameters
• Measurement report of initial commissioning
Question 3:
Why should a hydraulic system be flushed prior to initial commissioning?
• The flushing process removes dirt particles from the individual components such as pipes. It
must be ensured that the permissible maximum cleanliness class to ISO 4406 KL. 21/18/15
is not exceeded for the entire system.
Question 4:
How should the hydraulic fluid be disposed of?
• The fluids must be disposed off in accordance with environmental regulations, i.e. the
contaminated fluid must be made available to approved recycling companies in suitable
containers for disposal. The notes on waste disposal given in the safety data sheet of the
hydraulic fluid must be observed.
Question 5:
Into which areas is maintenance subdivided?
• DIN 31051 classifies maintenance in the following areas:
Maintenance - Inspection - Repair
Question 6:
Which work (measures) must be carried out during an inspection?
• Check of set operating values
• Visual inspection of the complete system for external leakage, wear, damage, ...
• Check of hydraulic fluid for fluid level and appearance
21
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Commissioning, troubleshooting, maintenance 15 Bosch Rexroth AG I RE 00845/04.07
Question 7:
Which work (measures) are to be carried out during maintenance?
• Changing the filter inserts
• Checking or changing the hydraulic fluid
• Cleaning the inside of the tank, if required
• Replacing hydraulic hoses at given intervals
Question 8:
Which of the following faults are causes for malfunction that can be traced back to improper
installation and which faults occur on running systems?
• Incorrect directional valve installed
• Electric motor incorrectly connected
• Contaminated hydraulic fluid
• Hydraulic hose improperly connected
• Wear of hydraulic seals
• Filter clogged
• Cable break at the connection of the solenoid
• Pressure switch does not switch
• Hydraulic component does not operate due to a broken spring
• Throttle bore clogged on the pilot part
Question 9:
Name a systematic order for the localization and elimination of faults.
• Recognizing faults on the system and their effect
• Analyzing the cause of fault
• Planning of how to eliminate the fault
• Proper elimination of the fault
• Re-commissioning the system
• Documenting the fault and its elimination
21
Project 21:
Commissioning, troubleshooting, maintenance 16 Bosch Rexroth AG I RE 00845/04.07
• For correct commissioning, system-related machine documents are required such as circuit
diagrams, parts list, function charts, system parameters and operating instructions.
• Contamination is the most common cause of faults in hydraulic systems.
• Improper installation can shorten the service life of hydraulic components.
• Preventive maintenance and repair reduce system failures and prolong the service life of
components.
• An important precondition for target-oriented troubleshooting is the knowledge of the func-
tion and the operating principle of all hydraulic components.
21
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Notes
21
General product information on RE 07008/02.05 1/32
hydraulic products
Contents Page
1 Important basic information 4
1.1 Conventions used in this product information 4
1.2 What you need to know about this product information 4
1.3 The contents of this product information 4
Contents Page
9 Assembly and bringing into first use 18
9.1 Safety advice for assembly and bringing into first use 18
9.2 Before bringing into first use 18
9.3 Bringing into first use, subsequent bringing into use 19
10 Operation 22
11 Trouble-shooting 22
11.1 What to do in the event of a fault 22
11.2 The basic approach to trouble-shooting 22
11.3 Trouble-shooting tables 23
12 Maintenance 24
12.1 Definitions of terms 24
12.2 Safety during maintenance tasks 24
12.3 Inspection and servicing 25
12.4 Service and storage lives of hose lines 28
12.5 Topping up the pressure fluid 29
12.6 Servicing pressure accumulators 29
12.7 Repair 29
14 Hydraulic systems 31
14.1 Effects of leaks in the hydraulic system on the machine 31
4/32 Bosch Rexroth AG Hydraulics General product information RE 07008
1 Important basic information Observing the product information and Operating Instructions
Ø reduces downtimes and maintenance costs
Ø increases the service life of your hydraulic products.
1.1 Conventions used in this product
information
The Operating Instructions must be directly accessible to one
Cross-references are printed in italics. of the personnel at the hydraulic product and kept readily avail-
able at all times in a place known to the personnel.
The Operating Instructions must be read and understood and
all its provisions observed by those responsible and by the
DANGER operative personnel. We recommend that a record is made in
writing of the employees’ familiarisation with all the relevant
This symbol indicates a threat of danger which will result parts.
directly in death or very serious injury if not avoided.
The cross-references to directives, standards and regulations
contained in this product information refer to the versions cur-
rent at the time of writing of this product information, which can
WARNING be obtained from the title page of this product information.
This symbol indicates possible danger which may lead to Ø Part I, the general Operating Instructions for the relevant
minor or serious injury and/or to material damage. class of products
Ø Part II, the Technical Datasheet
If you do not have all three parts, please request the missing
1.2 What you need to know about this part from Bosch Rexroth. Only if all the information contained
product information in all parts of the three-part Operating Instructions is observed
can safe operation of Rexroth hydraulic products be ensured.
This product information applies to the following types of Specific cross-references are used to draw your attention to
hydraulic products: information that you can find in the Operating Instructions.
Ø Hydraulic components The Operating Instructions contain detailed information about
Ø Hydraulic power units the product, including
As this product information for Rexroth hydraulic products Ø Parts lists if appropriate
applies in a general sense, some of the content may not neces- Ø Information about replacement parts and accessories.
sarily apply to the hydraulic product you have purchased.
However, only by strictly observing this product information
and the Operating Instructions can accidents be prevented
and problem-free operation of your Rexroth hydraulic product
be guaranteed.
RE 07008 General product information Hydraulics Bosch Rexroth AG 5/32
2 Scope of delivery and responsibilities Installation of Rexroth hydraulic products in a machine or sys-
tem may increase this value, and if so, the manufacturer of the
machine/system must document this.
2.1 Scope of delivery and responsibilities of At or above 85 dB(A), the plant operator must make suitable
Bosch Rexroth hearing protection available to the personnel.
Rexroth hydraulic products fulfil all safety requirements applica- 2.2.2 Special points concerning the installation of
ble to fluid power systems and their components.
certain products
IMPORTANT A Rexroth hydraulic product is intended above all for installa-
For the scope of delivery and the responsibilities of tion in machines, systems and power units as a part machine
Bosch Rexroth with respect to the product, please refer to the or a component for installation into another machine or system
Product-specific Operating Instructions. and is not a complete machine in the sense of the EU directive.
In addition to the Machinery Directive, still further directives
may apply, such as the Pressure Equipment Directive or the
Explosion Protection Directive.
2.2 Responsibilities of the plant operator A wide range of dangers can arise from the combined actions
of the hydraulic product and the machine or system in which
the hydraulic product is installed. Therefore you must always
CAUTION make sure that the hydraulic product is also suitable without
restriction for the proposed application at the installation loca-
If Rexroth hydraulic products are positioned in the vicinity tion. The interfaces with the overall machine and the operat-
of sources of ignition or strong radiators of heat, protec- ing conditions are also of the greatest importance. We recom-
tion must be put in place that would prevent any escaping mend that the results of the hazard analysis (risk assessment)
pressure fluid from igniting and the hose lines from aging of the overall machine are taken into account in the design of
prematurely. the hydraulic product.
Mineral-oil-based pressure fluid is hazardous to water and The functioning of the hydraulic product is also influenced by
flammable. It may only be used if the relevant safety data- the machine or system in which it is installed.
sheet from the manufacturer is available and all the mea- For this reason, you must also always observe the Operating
sures stipulated therein have been implemented. Instructions of the overall system in which your hydraulic prod-
If there is a risk of fluid leaking from the hydraulic prod- uct is installed. It is most important for you to also consider the
uct and contaminating water or the ground, the hydraulic possible use of the hydraulic product in a potentially explosive
product in question must be placed in a suitable collect- atmosphere (see 94/9/EC).
ing trough. In connection with this, the applicable statutory
regulations must be observed. IMPORTANT
You must also observe the EU directives for the use of work Bosch Rexroth points out that, at the time of their first intro-
equipment (Directive 89/391/EC) and the associated individ- duction on to the market, hydraulic products comply with the
ual directives, especially Directive 1999/92/EC for the protection requirements of all relevant EU directives and/or their imple-
from the danger arising from potentially explosive atmospheres mentation into national legislation in Germany. If the scope of
and their implementations in national legislation. The legisla- delivery is intended to be installed in a machine or system, then
tion contains minimum requirements with respect to the making the Machinery Directive applies as appropriate – including the
available by the employer of work equipment and for the use then currently applicable amendments – in that the scope of
of work equipment by employees at work, including the regu- delivery does not necessarily comply with the requirements
lations for operating equipment requiring supervision and the of the Machinery Directive because the scope of delivery is
obligation to produce explosion protection documentation. This intended for installation in a machine or because the scope of
involves, for example, dividing areas endangered by potentially delivery is intended for combination with other machines into a
explosive atmospheres into zones and specifying suitable work machine or a hydraulic system.
equipment and procedures for these areas. The bringing into use of the scope of delivery shall there-
fore not be permitted until the machine or system in which the
scope of delivery is to be installed or of which it represents a
2.2.1 Noise protection
component complies with the requirements of all relevant EU
directives.
The A-weighted equivalent continuous sound power level of
Rexroth hydraulic products can be obtained from the relevant Details of further responsibilities can be found in
Operating Instructions. If no values are documented then it can 3 Important basic safety instructions and in the Operating
be taken that the value is less than 70 dB(A). Instructions.
6/32 Bosch Rexroth AG Hydraulics General product information RE 07008
Bosch Rexroth shall not be liable for damages that result from
non-compliance with or disregard of these and other parts of
the Operating Instructions.
Unauthorised tampering shall render the warranty null and void.
Bosch Rexroth shall only be liable if the scope of delivery was
shown to be defective. Bosch Rexroth shall not be liable if a
deficiency occurs that involves parts having been replaced by
the customer with equivalent but not identical parts as speci-
fied by the manufacturer.
Please refer to our general terms of supply or your contract for
details of the guarantee and manufacturer’s warranty.
2.4 Copyright
Ø The meanings of the safety labelling on the Rexroth prod- Ø The plant operator shall not modify the program code of
uct are explained in the Operating Instructions. programmable control systems.
Ø For a diagram of the nameplate and an explanation of the Ø Dependencies and time factors shall not be modified with-
information on it please refer to the Operating Instructions. out prior consultation.
Ø The safety devices fitted by Rexroth must be present,
properly installed and in full working order – except when
this is impractical during setting up or maintenance work.
3.3 Proper use They shall not be relocated, bypassed or rendered ineffec-
tive.
Rexroth hydraulic products are designed and constructed for
the provision, transmission, control or regulation of energy and Ø Safety components such as limit switches, valves and
signals using the flow of oil. other control components shall not be rendered inopera-
tive.
Unless otherwise agreed, the Rexroth hydraulic product satis-
fies at least safety category B in accordance with EN 954-1. Ø Tamperproof lead seals installed by the manufacturer shall
not be removed or damaged except when this is neces-
If the hazard analysis/risk assessment of the overall machine sary in the course of maintenance tasks defined in the
in which the Rexroth hydraulic product is to be installed indi- Operating Instructions.
cates that a safety category higher than category B in accor-
dance with EN 954-1 is required for the Rexroth hydraulic Ø The specified maintenance tasks in the Operating Instruc-
product, then a correspondingly higher rated hydraulic product tions shall be carried out at the intervals stated in the
can be supplied and installed only after special agreement with Operating Instructions.
Bosch Rexroth.
8/32 Bosch Rexroth AG Hydraulics General product information RE 07008
Ø Uncontrolled access by persons unfamiliar with the sys- Servicing personnel (who carry out filter and oil changes, for
tem to the immediate operating zone of Rexroth hydraulic example) shall fulfil the following requirements:
products is prohibited (even if the product in question has
Ø They have been instructed in the relevant activity.
been shut down).
Ø Specialist knowledge of hydraulics is not required to carry
Ø Rexroth hydraulic products must never be assembled,
out servicing work.
operated or maintained by persons under the influence of
alcohol, drugs or other medication which affect one’s abil-
ity to react. Repair personnel shall fulfil the following requirements:
Ø The personnel must be hydraulics experts, who have been
instructed and meet the definition given above,
3.4 Requirements for personnel, Ø Repair personnel must be familiar with the function of the
duty of care hydraulic system as a whole, from subsystems to their
interaction with the function of the entire machine.
Ø Repair personnel must be able to read hydraulic circuit
3.4.1 Qualifications of specialist personnel diagrams, interpret individual functions from their symbols
and understand function diagrams.
A specialist person is someone who, using his specialist train-
ing, knowledge and experience as well as familiarity with the Ø Repair personnel must possess knowledge of the function
relevant conditions, can and construction of hydraulic elements.
In the interests of your safety, all safety instructions shall be Ø The use of dirty (unfiltered) pressure fluid when the pres-
carefully observed, especially those in the Operating Instruc- sure fluid is changed.
tions.
In spite of the high intrinsic safety of Rexroth hydraulic prod- Contaminants lead to malfunctions, increased wear and shorter
ucts, the risk of personal injury or damage to the environment service life of the hydraulic product. This can have negative
cannot be excluded, even when the equipment is properly effects on the safety and reliability of the hydraulic product.
used. Therefore the maintenance tasks specified in the Operating
New, additional dangers may arise if the hydraulic product is Instructions shall be carried out at regular intervals and the
installed in another machine or installed with other machines utmost cleanliness is required during work on the hydraulic
in a system. This shall apply in particular to mechanical move- product.
ments generated by the hydraulic product.
Information on these additional dangers can be found in the CAUTION
overall operating manual of the supplier of the overall system in
which the hydraulic product is installed. When changing the pressure fluid, always use factory-fresh
pressure fluid and filter it before filling to remove any contami-
nants in the pressure fluid that it often contains from the pack-
aging container (drum). Flush out lines and hoses before instal-
lation.
The cleanliness class of a pressure fluid is specified in accor-
dance with ISO 4406. Detailed information can be obtained
from the relevant datasheet or the Operating Instructions.
10/32 Bosch Rexroth AG Hydraulics General product information RE 07008
In older datasheets, the cleanliness class is sometimes speci- 3.5.4 Product-specific ancillary dangers
fied in accordance with NAS 1638. The following table can
be used to convert this to an equivalent ISO 4406 cleanliness All product-specific ancillary dangers and precautions can be
class: found in the relevant Operating Instructions.
Comparison table for cleanliness classes
Earlier class to Current class to 3.5.5 Disposal
NAS 1638 ISO 4406 (c)
Class 7 Class 18/16/13 Ø Take metal, cable and plastic ducts to a recycling materi-
Class 9 Class 20/18/15 als collection centre.
Ø Dispose of electronic components as electronic waste.
Ø Dispose of back-up batteries as special waste.
3.5.3 Electrical dangers
Ø Cleaning agents, operating fluids and other materials:
When working on electrical systems:
• De-energise the hydraulic system before beginning any CAUTION
maintenance work.
Please observe the disposal regulations specified in
• Cordon off the working area with red-white safety chain
the appropriate Safety Datasheets.
and warning signs.
• Lock the main switch, remove the key and keep it in a safe
place until the work is completed.
• Attach a warning sign to the main switch.
• Check that there is no voltage using a two-pole voltage
detector.
• Earth and short-circuit the point where you are working.
• Cover neighbouring live parts.
• Clear your workplace to prevent contact with live parts as
a result of tripping or slipping. Wear safety footwear.
• Always use electrically insulated tools.
• Disconnect plugs at sensors and valves – even those with
low voltages – after the system has been de-energised.
DANGER
Even after disconnection of the electrical supply
(main switch OFF) the following supply systems/danger
areas can still give rise to life-threatening voltages:
Ø Electrics, electronics, hydraulics (e.g. accumulators,
rechargeable batteries)
Ø Main switch
Ø Power supply cables
Ø Points identified with an electric shock warning sign.
RE 07008 General product information Hydraulics Bosch Rexroth AG 11/32
IMPORTANT
4.2.1 Use in potentially explosive atmospheres
The product-specific technical data, operating limits and ambi-
ent conditions for the operation of your Rexroth hydraulic prod-
uct can be found in the Operating Instructions. DANGER
This includes the following information:
Rexroth hydraulic products shall be used in potentially
Ø Minimum flow rate for adequate cooling explosive atmospheres only if they are designed for this
Ø Permissible maximum temperature of the coolant purpose and this is expressly stated in the Operating
Instructions.
Ø Performance data
Ø Type of control and regulation functions IMPORTANT
Ø Permissible pressures, flow rates Directive 1999/92/EC of the European Parliament and Coun-
cil dated 16 December 1999 concerning the minimum require-
Ø Connections. ments for improving the safety and health protection of work-
ers potentially at risk from explosive atmospheres governs
protection from danger from potentially explosive atmospheres.
Observe the requirements contained in the regulations for
4.1 Information about pressure fluids operating equipment requiring supervision and the obligation to
produce explosion protection documentation.
Unless otherwise indicated in the Operating Instructions, the This involves, for example, dividing areas endangered by poten-
following specification applies to the pressure fluid to be used: tially explosive atmospheres into zones and specifying suitable
Ø Mineral-oil-based pressure fluid complying with the work equipment and procedures for these areas.
requirements of DIN 51524. Observe the requirements of Directive 94/9/EC of the Euro-
Ø Operating temperature range 0 °C…+80 °C pean Parliament and Council dated 23 March 1994 on the
(in tank < 72 °C). approximation of laws of the member states concerning equip-
ment and protective systems intended for use in potentially
Any deviations from this can be found in the Operating Instruc- explosive atmospheres (ATEX Product Directive) and/or the
tions. corresponding national legislation by means of which the Direc-
tive was implemented in law in the EU member states. The
IMPORTANT directive contains requirements for the use of equipment and
protective systems in potentially explosive atmospheres.
Bosch Rexroth recommends a maximum operating tempera-
ture of 55 °C, because the rate of ageing of the pressure fluid
increases and the service life of the seals and hoses is reduced
at higher temperatures.
Ø Viscosity ranges:
see RE 07075 and RE 90220
Ø Max. permissible contamination class of the pressure fluid
in accordance with ISO 4406: see 3.5.2 Malfunctions
due to contamination of pressure fluid.
The maximum permissible cleanliness class can be found in the
Operating Instructions. The following types of pressure fluids
shall be used.
IMPORTANT
Rexroth hydraulic components are tested with test oil MZ45
manufactured by ESSO (class ISO VG 46 at 40 °C),
(Viscosity η = approx. 46 mm2/s).
12/32 Bosch Rexroth AG Hydraulics General product information RE 07008
IMPORTANT
For systems with oil-air heat exchangers:
Observe the information given in the circuit diagram in the
Operating Instructions.
DANGER
Rexroth hydraulic products shall not be used in aeronau-
tical equipment, except where they have been specially
approved and appropriately labelled to this effect.
RE 07008 General product information Hydraulics Bosch Rexroth AG 13/32
CAUTION
Make sure that the leakage fluid is fed back into the tank
in a proper manner.
Dispose of leakage fluid that is not fed back into the tank
properly, in compliance with the applicable environmental
protection regulations.
CAUTION
When topping up/refilling your hydraulic system, make
sure that you use pressure fluid of the same sort and type
and from the same manufacturer.
If the fluid is heavily contaminated or prematurely aged,
then the system, including the tank must be cleaned and
flushed before refilling. New pressure fluid must always be
filtered in accordance with the required cleanliness class,
as it does not normally meet the required cleanliness class
in the as-supplied state.
RE 07008 General product information Hydraulics Bosch Rexroth AG 15/32
Hydraulic system 5
Arrangement of interconnected components for transferring
and controlling hydraulic energy.
4
3
Component
2
A single unit (e.g. a valve, filter, cylinder, motor) that consists
of one or more parts and which is a functional constituent of a 1
hydraulic system.
1 Tank
Oil preparation
2 Filter
Drive
3 Pump Energy conversion
A component that converts the energy of the hydraulic fluid
into mechanical energy (e.g. motor, cylinder). 4 Pressure limiting valve
5 Directional valve
Energy control
6 Check valve
6.2 Schematic 7 Throttle valve
8 Hydraulic cylinder
In a system operated with hydraulic oil, first of all mechani- Energy conversion
cal energy is converted into hydraulic energy, transported and 9 Hydraulic motor
controlled in this form, to finally be converted once more into
mechanical work.
The hydraulic elements are arranged in accordance with these 6.3 Safety concept
functions. The following diagram shows a schematic represen-
tation of the elements of a complete hydraulic system. Hydraulic products contain sensors and actuators, the interac-
tion of which is particularly important with regard to the fulfil-
To demonstrate their operating principle, standardised symbols
ment of technical safety functions.
(ISO 1219) are used instead of sectional diagrams of the vari-
ous devices. Line connections are represented by simple lines, Individual hydraulic products form part of an overall safety con-
as can be seen in the example. cept.
Applications required to perform safety functions are designed
using special hydraulic components that satisfy the require-
ments of the relevant directives, such as the Pressure Equip-
ment Directive and other standards.
The manufacturer of the overall machine or system defines and
bears responsibility for the safety category to EN 954-1 to be
fulfilled.
IMPORTANT
A more detailed description of the safety concept and the spe-
cific safety components installed can be found in the Operating
Instructions and the Operating Instructions of the supplier of
the overall system in which the hydraulic product is installed.
16/32 Bosch Rexroth AG Hydraulics General product information RE 07008
CAUTION
Always ensure hydraulic products are empty of pressure 8.1.2 Storage times in relation to the ambient
fluid for transportation. conditions
Rexroth hydraulic products are delivered empty of pressure
fluid. However, products may contain oil residues left over from Delays in bringing into use, long shipping and storage times or
the final inspection at our factory. long periods of non-use can lead to rust formation in Rexroth
hydraulic products. Additional corrosion protection measures
must be implemented to prevent this.
IMPORTANT
8 Storage and longer standstills If all the openings on the hydraulic products are not sealed so
as to be air-tight, this will reduce the storage life of the hydrau-
lic product by nine months.
8.1 Hydraulic systems - subsequent bringing After the specified storage time has expired, in any event not
longer than 24 months, the corrosion protection must be
into use after storage
checked and further conservation measures applied if neces-
sary.
Corrosion, especially oxidation, can cause metal surfaces to
lose the standard of surface finish required for the hydraulic
system to function properly.
Rust and other metallic and non-metallic particles lead to abra-
sive wear (erosion), which detrimentally affects the functioning
of the hydraulic system.
CAUTION
If a hydraulic system is to be brought into use again fol-
lowing a long standstill, it must first be flushed clean.
CAUTION
Seals:
Observe the requirements of ISO 2230 and/or DIN 7716
and the specific manufacturer’s data on seals.
Hoses and hose lines:
In the Federal Republic of Germany, please observe the
requirements of DIN 20066, ZH 1/74 Safety rules for
hydraulic hose lines and the specific manufacturer’s data
on hoses and hose lines.
In addition, the following conditions shall be observed:
Ø Seals, hoses and hose lines are stored in cool, dry and
dust-free conditions.
The hoses and hose lines can be enclosed in plastic foil to
ensure low-dust storage conditions. Ideal storage conditions
for hoses and hose lines are temperatures from +15 °C to
+25 °C and a relative humidity of below 65 %.
Ø Do not store elastomers below –10 °C. The ideal stor-
age conditions for seals are temperatures from +10 °C
to +20 °C and a relative humidity of between 65 % and
75 %.
Ø Store hoses and hose lines in the original packaging if
possible. Prevent the entry of air.
Ø Avoid direct sunlight and UV radiation and shield from
nearby sources of heat.
Ø Darkened storage locations are preferred.
Ø Do not use ozone-forming light sources or equipment
(e.g. fluorescent lamps, mercury-vapour lamps, copiers,
laser printers) or electrical spark-forming devices in the
vicinity of hoses and hose lines.
Ø Seals, hoses and hose lines must not come into contact
in particular with materials or vapours that could damage
them (e.g. acids, alkalis, solvents).
Ø Store seals, hoses and hose lines lying down and free
from tension. If the hoses and hose lines are coiled, take
care not to bend them to less than the smallest bending
radius specified by the manufacturer.
Maximum storage times
Ø NBR seals: 4 years
Ø FKM seals: 10 years
Ø Hoses: 4 years
Ø Hose lines: 2 years
9 Assembly and bringing into first use Bringing into (first) use shall only be done by an instructed,
authorised hydraulics expert who has the required special-
ist knowledge.
IMPORTANT
Specialist hydraulics knowledge means, among other things,
Only the permissible pressure fluids given in the Operating that the person can read and fully understand hydraulics draw-
Instructions are to be used. Information on other pressure flu- ings. In particular, he must fully comprehend the range of func-
ids can be found in the Operating Instructions or are available tions of the integrated safety components as part of the overall
on request. safety concept.
Filling the pressure fluid tank must always take place through a
suitable filter unit. Experience has shown that even new pres-
sure fluid can often have more than the maximum permissible
level of contamination. 9.2 Before bringing into first use
All information specific to assembly and bringing into first use
can be found in the Operating Instructions. 1. Check the scope of delivery for transport damage.
Pay attention to cleanliness: 2. Check that the Operating Instructions for the Rexroth
hydraulic product are present and complete.
Ø Do not use cleaning wool or cloths containing fibres for Contact us if the Operating Instructions are not there or
cleaning. are incomplete.
Depending on the condition of the system or machine, 3. Assemble the hydraulic product.
cleaning with fibre-free cloths may be sufficient. Use suit-
able liquid cleaning agents to remove lubricants and other • Observe the Operating Instructions and this product
stronger contaminants. Make sure that cleaning agent information.
does not get into the hydraulic system. • Assemble the hydraulic components, so that they are
Ø Never use hemp and putty as sealants. mounted strain-free on even surfaces.
• Tighten the fastening bolts evenly using the specified
The functional or failure behaviour of identical hydraulic prod- tightening torque.
ucts may vary due to conditions specific to the machine or sys- 4. Ensure that the interfaces of the system/machine and the
tem in which the hydraulic product is installed (mass, speed, installation conditions provide for safe operation of the
electrical triggering at setpoint values, etc.), see also Section hydraulic product. If in doubt, consult the people responsi-
11 Trouble-shooting. ble for the overall system/functional machine.
5. Check the construction of the hydraulic product against
the circuit diagrams, lists of equipment and assem-
bly drawings. If there are any differences, draw this to
9.1 Safety advice for assembly and the attention of the people responsible. If important
bringing into first use documents are missing, they can be requested from
Bosch Rexroth. Only documents issued by the bodies
authorised to do so shall be used.
DANGER 6. Based on the Operating Instructions for the system or
machine in which the hydraulic product is installed, check
Hydraulic products are generally intended for installation whether bringing the hydraulic system into use could lead
in machines/systems or devices. to uncontrolled, dangerous movements. Where appropri-
The function of the hydraulic product must therefore ate, take into account the hazard analysis/risk assessment
always be seen in relation to the function of this machine for the system or machine.
– i.e. seemingly identical hydraulic products may demon- 7. Take the precautions appropriate to the anticipated dan-
strate different functional behaviours as a result of the gers, e.g.
function of the machine in which they are installed.
• Ensure that the cylinder piston rod can move out with-
For this reason, a hydraulic drive must not be brought into out danger.
use until it has been determined that the machine in which
it is installed conforms to EU standards. • Use a hoist or other lifting device to additionally
secure lifted loads.
Do not bring hydraulic drives into use until you have famil-
iarised yourself completely, firstly with the function of the
hydraulic product and hydraulic equipment and secondly
with the hydraulically powered machine functions, and
have clarified and dealt with any possible dangers.
RE 07008 General product information Hydraulics Bosch Rexroth AG 19/32
8. As part of bringing into (first) use, check whether the elec- 9.3 Bringing into first use,
tric motors and valve solenoids can be switched manually subsequent bringing into use
using the electrical controls of the system/machine. If they
cannot be switched manually – or can but with difficulty
– you must provide a remote control (e.g. test boxes for
Rexroth proportional valves) for the internal function test of DANGER
the hydraulic system.
Before bringing into (first) use, have all pressure accumu-
IMPORTANT lators and safety systems checked by an expert or special-
ist in accordance with national regulations.
Starting up the hydraulics solely by means of emergency man-
ual operation is not recommended, as several valves at once 1. Clean the lock on the transport and storage container
cannot be switched as required in the correct sequence. before opening.
9. Draw up a sequential program for bringing into (first) use 2. Clean the hydraulic unit and all other component groups,
and store it with the technical documentation as an appen- so that no dirt can get into the hydraulic system during
dix to the Operating Instructions. bringing into (first) use.
For this you should consider the following: 3. Check the paint on the tank for integrity.
Hydraulic drives basically consist of the following func-
tional groups 4. Flush the connection lines to remove dirt, scale, chips etc.
Ø Pump circuit (generation of pressurised oil flow); 5. Pickle and flush welded pipes.
pump, electric motor, oil tank, filters, monitoring
devices, etc.
CAUTION
Ø Control system for at least one hydraulic consumer
(cylinder, motor); directional control valves, pressure Remove all residues of water and cleaning agents
and flow control valves, check valves before performing further work.
Ø Hydraulic consumers (cylinders, motors) with spe-
cially assigned valves, e.g. braking valve.
6. Clean the interior of the hydraulic components to get rid of
contaminants:
10. Divide the functional circuit diagram into separate mini-cir-
cuits that can each be started up in succession. • Clean the filler plug of the pressure fluid tank.
11. Read the functional circuit diagram and seek clarification • Remove dust and chips using an industrial vacuum
of any unclear text or diagrams. More information about cleaner, by rinsing parts or similar cleaning method.
the functioning of components, e.g. a pump regulator, is • Completely remove any oil residues left over from the
available in the Technical Datasheet. factory test.
12. Establish into which position valves are to be switched, or • Remove any gummed oil which may have formed due
how valves are to be set. to incorrect storage.
13. Put up any necessary directional, prohibitive or informative
signs and check whether the meaning of these signs are 7. Connect up all connection lines.
explained in the Operating Instructions.
14. Follow this sequence for bringing into (first) use IMPORTANT
Ø Pump circuit Observe the installation instructions from the manufacturer
of the connection components.
Ø Parts of control system:
e.g. pressure cut-off and switchover,
open centre, DANGER
pressure reduction etc.
Make sure that pipes and hoses are connected at all
Ø Cylinder and motor circuits:
ports or that the ports are sealed with screw plugs.
First move,
fill and bleed, 8. Carry out a special check to make sure that the union nuts
then finally optimise all settings. and flanges are correctly tightened at the pipe connec-
tions and flanges.
20/32 Bosch Rexroth AG Hydraulics General product information RE 07008
IMPORTANT
CAUTION
Mark all the checked connections, e.g. with paint.
Make sure that all pipes and hoses and every combination of Use oil filler units (filter units) suitable for pres-
connection pieces, couplings or connection points with hoses sure fluids.
or pipes are checked for their operational safety by someone • Do not remove the filter strainers from filler necks or the fil-
who has the appropriate knowledge and experience. ter element from filters before filling the pressure fluid tank.
13. Fill the pressure fluid tank up to the upper mark on the
9. Connect the hydraulic consumers. Dimension the connec- inspection window. Observe the maximum fluid level, tak-
tion lines in accordance with the performance data in the ing into consideration the volume in the connection lines
Circuit Diagram and the Operating Instructions. and hydraulic consumers.
10. Install the electrical system for the drive and control sys- 14. Set the pressure and flow control valves, pump regula-
tem: tor, signalling elements such as pressure switches, limit
• Check the connected loads. switches and temperature regulators to the settings and
values defined in the sequential program (see 9.2 Before
• Connect coolant water if necessary. bringing into first use).
• Check the direction of rotation of the pumps
(e.g. as indicated by attached arrow markings). DANGER
11. Check the pressure fluid to ensure that no water has Do not change the settings of valves with a safety
entered it. function, valves with a position switch or valves with
preset electronics.
12. Before filling the pressure fluid tank, please observe the
following requirements: • Set operating-pressure valves and flow control valves
to the lowest possible values.
Ø The pressure fluid must conform to the specification
in the Operating Instructions. • Set directional control valves to their basic setting.
• Reduce the setpoint values of proportional valves to
CAUTION minimum values.
• Do not remove the tamperproof lead seals. Damaged
Never fill new hydraulic products with used pressure or removed tamperproof lead seals indicate improper
fluid. use of the hydraulic product.
Ø The drums of pressure fluid must be sealed and clean 15. If applicable:
on the outside. Fill the pressure accumulator to the specified gas pre-
charge pressure and then check the pressure, see Operat-
ing Instructions.
IMPORTANT 16. Fill the pump body:
If the pressure fluid has a high level of initial contamination Use the leakage oil port to fill pump bodies that have this
(see 4 Technical data and ambient conditions): feature, see Operating Instructions.
Use a filter unit to fill the pressure fluid tank. Ensure that the fil- 17. If applicable:
ter element is clean. Open the cocks in the suction line.
18. Start the drive motors:
IMPORTANT
• With electric motor in jogging mode, allow to start
The fineness of the filter shall correspond to the cleanliness
briefly
class required by the overall system and if possible be even
finer. • Combustion engines in idle
The filter unit used shall fulfil the requirements for functional
• Pay attention to the direction of rotation.
safety and service life.
• If possible, fill the pressure fluid tank via a filling coupling,
using a return filter if possible.
RE 07008 General product information Hydraulics Bosch Rexroth AG 21/32
19. Bleed the hydraulics (valve, pump, motor, line, cylinder). 23. After bringing the machine into first use, have a sample of
the pressure fluid analysed to ensure that it achieves the
IMPORTANT required cleanliness class. Change the pressure fluid if the
required cleanliness class is not achieved.
Details on bleeding can be found in the Operating Instruc- If the pressure fluid is not tested in the laboratory after
tions. bringing the machine into first use:
• Operate the hydraulic product at low pressure until it Change the pressure fluid.
is fully bled. 24. Replace the pressure fluid filter.
• Bleed the hydraulics lines to consumers or measuring 25. Document and file all set values.
points at the highest point, if possible.
• Operate the directional valves in jogging mode.
• Next, advance and retract all hydraulic consumers DANGER
several times.
26. To ensure the safety of persons and the system, after
• Increase the load slowly. Check the pressure fluid
bringing the machine into first use, perform the following
level in the pressure fluid tank. If necessary, top it up
tests using the defined maximum values:
with pressure fluid.
• Function test
Bleeding has been accomplished fully and correctly if the pres- • Pressure test.
sure fluid in the tank does not foam, if the hydraulic consumers
do not make any jerky movements and if no abnormal noises Prepare a record of the bringing into (first) use or accep-
can be heard. tance and have it signed by the plant operator. This record
is an important document and requires to be filed.
20. Set the valves and sensors and start up the machine:
• Set the switching operations of valves with a switch- IMPORTANT
ing time adjustment/ramp in accordance with the Information on how to perform the function test and pres-
dynamic conditions, see Operating Instructions. sure test can be found in the Operating Instructions.
• Finely adjust and optimise the setting of proportional
valves without on-board electronics (OBE).
IMPORTANT
Details on fine-tuning can be found in the Operating Instruc-
tions.
21. Check the operating temperature after the machine has
been running continuously for several hours. Too high an
operating temperature indicates that there are faults that
need to be analysed and rectified.
22. Rectify any leakages, e.g. by relieving couplings from pres-
sure and then retightening.
IMPORTANT
Apart from moisture, which should not be sufficient to form one
drop, no measurable, unintentional leakage shall be found.
22/32 Bosch Rexroth AG Hydraulics General product information RE 07008
IMPORTANT
Please refer to the Operating Instructions for all information on 11.2.2 Recommended way of working when
how to operate the Rexroth hydraulic product.
trouble-shooting
A table for product-specific trouble-shooting can be found in • Try to find out whether the hydraulics performed the
the Operating Instructions. required function in the overall system prior to the occur-
rence of the fault.
If the responsible personnel are unable to rectify the problem
immediately: • Try to determine any modifications to the overall system in
which the hydraulics are installed:
• Switch off the main switch. If applicable, turn off any com-
bustion engines used as drive motors. Ø Have the operating conditions or operating range of
the hydraulics been changed?
• Secure the main switch against being unintentionally
switched on again. Ø Have modifications (e.g. retrofitted equipment)
or repairs been carried out on the overall system
• Inform the machine manufacturer. (machine/system, electrics, control system) or on the
hydraulics? If yes: What were they?
Ø Have the set values of the hydraulics been changed?
11.2 The basic approach to trouble-shooting Ø Have the hydraulics recently undergone mainte-
nance?
The information in this section is intended to help you create
the ideal conditions for carrying out trouble-shooting as effi- Ø Has the hydraulic product/machine been operated
ciently as possible. improperly?
Ø How does the malfunction manifest itself?
11.2.1 General conditions • Form a clear picture of the cause of the fault. Ask the
machine operators directly, if necessary.
Ø Is all the necessary technical documentation to hand? • Document any work undertaken, changed set values, etc.
Ø If no hydraulic circuit diagram is available: • Document any amendments/additional information that
Can a hydraulic circuit diagram be drawn using the struc- should be included in the Operating Instructions.
ture, signs and labelling of the equipment?
Ø Are there enough measuring points?
Ø Has the customer provided useful information about how
the malfunction manifests itself and about the functional
behaviour of the system/component prior to the malfunc-
tion?
RE 07008 General product information Hydraulics Bosch Rexroth AG 23/32
• Check safety devices regularly to see that they are work- • Open with care any segments that have to remain
ing properly. under pressure.
Make sure that all safety devices are properly installed and • Document and file details of any work undertaken,
have undergone a function test before bringing the system changed set values, etc.
(back) into use.
• Document and file details of any amendments/additional
• Perform welding, burning or grinding work on the hydrau- information that should be included in the Operating
lic unit or its attachments only with the approval of local Instructions.
safety authorities/fire brigade and with suitable protective
• Modifications and additions could affect the validity of the
covering to prevent ingress of contaminants.
EU Conformity Declaration/Manufacturer’s Declaration.
• When performing assembly work above your height, use Always consult Bosch Rexroth about any proposed modifi-
the steps and platforms provided by the plant operator. Do cations or additions.
not climb on any parts of the system.
• Remove all tools and materials needed for maintenance
from the hydraulic product.
• Always rectify any leakage from the hydraulic product
immediately.
• Always inform personnel before (re)starting the hydraulic
product.
IMPORTANT
The following general specifications are based on use of the
hydraulic product in central Europe and under the usual operat-
ing conditions of commercial and industrial plants.
We strongly recommend the use of an inspection and servicing
book, in which all work specific to that site, and all inspection
and servicing intervals should be defined and documented.
An inspection and servicing book is also helpful in that
Ø It provides comparison values to aid with early detection of
malfunctions
Ø It allows warranty claims to be dealt with more easily.
CAUTION
Ensure cleanliness during all work.
• Please observe the requirements for pressure fluids men-
tioned in Section 9 Assembly and bringing into first use.
• Clean the external environment of couplings/joints and
devices before disassembly. Do not use cleaning wool or
cloths containing fibres for cleaning.
• Seal all openings using protective caps.
• Bleed the hydraulic product after each item of servicing
work.
26/32 Bosch Rexroth AG Hydraulics General product information RE 07008
12.3.1 Inspection procedures and test equipment, 12.3.2 Location of testing and measuring points
general
IMPORTANT
The following are some of the typical inspection and testing
procedures that are regularly used in connection with hydraulic Please refer to the Operating Instructions for the installation
systems and components. location of filling level indicators, filling points, drainage points,
filters, testing points, strainers, solenoids, etc. that require reg-
IMPORTANT ular inspection and servicing.
Keep the indicated typical test equipment ready for this type of
work.
12.3.3 Inspection and servicing plan, hydraulic
Type of test Typical test Typical products, general
equipment testing activities
The graph illustrates the concept of wear/wear margin.
Pressure Pressure gauge Checking of The wear margin is a characteristic feature used to describe
measure- or sensor with the condition of the system for the purpose of maintenance.
• specified pressure
ment suitable measuring
range and connec- • opening pressure 5
tion pipe and con-
• pressure difference
nection coupling
before and after the ��
object under test ����
All the factors mentioned above can exert an influence on the 12.3.5 Inspection and servicing plan: electrics and
curve but this need not necessarily adversely affect the quality control system
of its information, as wear always signifies the reduction in the
wear margin, which is understood to be the primary initial vari-
able before wear commences. IMPORTANT
Consequently, this means that a sudden change in the wear The product-specific inspection and servicing plan for electrics
margin must also count as wear, and that the element of time and control systems can be found in the Operating Instruc-
on its own is not of decisive importance for wear, but is of con- tions.
siderable interest in the assessment and evaluation of such
wear.
An increase in the wear margin to over 100 % above its base-
line may be achieved through corrective maintenance, if such 12.3.6 Lubrication points, lubricants, intervals
measures entail an improvement and this increase is estab-
lished as the new desired condition for future corrective main- IMPORTANT
tenance.
The details of the specified lubricants, lubrication points and
Certain system parts may be subject to a wear margin which associated lubrication cycles can be found in the Operating
diminishes in such a way that the time available for use is insuf- Instructions.
ficient for the requirements of the plant or operation. In this
case, investigations must be carried out to ascertain whether
the introduction of suitable technical measures might counter
this reduction in the wear margin to a satisfactory extent. The
time and expenditure required for such measures must natu-
12.3.7 Set values of valves, regulators and
rally be kept in reasonable proportion to the expected degree signalling elements
of success.
Pressure and flow control valves, pump regulators and signal-
If such conditions arise, we refer to these parts as weak points. ling elements such as pressure sensors, pressure switches,
Since their elimination may provide economic and safety limit switches and temperature regulators are given their opti-
advantages, weak points require to be rectified immediately. mum setting when the system is brought into first use.
IMPORTANT Check regularly whether all values are correctly set with the aid
of the hydraulics diagram and the documented values.
The inspection and servicing plan for your particular product
can be found in the Operating Instructions.
DANGER
The set values of valves with position switches shall only
12.3.4 Inspection and servicing plan, be calibrated or readjusted at the factory.
electrohydraulic systems The set values of safety valves shall not be altered by the
user. Any readjustment shall be performed by authorised
Electrohydraulic systems with proportional valves must be ser- testing bodies only.
viced in accordance with hydraulic requirements and strate-
Too low a pressure difference between the operating pres-
gies. However, technical control components must also be
sure and the opening pressure can lead to frequent opening
incorporated in these servicing cycles.
of safety valves. This leads to increased power losses and an
On this basis, an overall strategy for system servicing must be unacceptable increase in temperature of the pressure fluid. In
developed and documented. this event, select a lower operating pressure.
IMPORTANT
The appropriate component characteristics relevant to servic-
ing can be found in the Operating Instructions.
28/32 Bosch Rexroth AG Hydraulics General product information RE 07008
IMPORTANT IMPORTANT
Only pressure fluids specified in the Operating Instructions are Repair (corrective maintenance) is the restoring of the desired
to be used. condition.
When changing or topping up the pressure fluid, fill the pres- In addition, observe the special safety instructions in
sure fluid tank on the hydraulic product as follows: 12 Maintenance and the safety instructions in the Operating
Instructions.
1. Fill the pressure fluid tank using a special filling unit with
an integral filter (min. 10 µm).
2. Drop the system pressure right down by resetting the
pump. Set the pressure setting value on the pump pres- DANGER
sure control to minimum or zero pressure.
Ensure cleanliness during all work.
3. Fill and bleed the line system of the hydraulic product from
the unit to the cylinder. To do this actuate the cylinder in • Clean the external environment of couplings/joints and
both directions, see Operating Instructions. devices before disassembly. Do not use cleaning wool or
cloths containing fibres for cleaning.
4. Top up the pressure fluid volume to the specified quantity.
• Seal all openings using protective caps.
5. Raise the pump pressure to the system pressure.
• Bleed the hydraulic product after each item of repair work.
The hydraulic product is ready for operation.
• If appropriate, follow the procedure for bringing into first
6. Carry out a test run. use, see 9.3 Bringing into first use, subsequent bringing
7. Check the level of the fluid after the hydraulic product has into use.
warmed up to the operating temperature and adjust if nec- • Document any amendments/additional information that
essary. should be included in the Operating Instructions.
IMPORTANT
Check the contamination indicator when the pressure fluid is
warm (during or immediately after operation).
If the ambient temperature is low or the pressure fluid is cold,
its high viscosity may cause clogging to be apparently indi-
cated.
DANGER
Pressure accumulators are subject to the national legisla-
tion on safety requirements for pressure vessels applica-
ble in the place of installation.
Observe the Pressure Equipment Directive 97/23/EC.
IMPORTANT
The gas precharge pressure is measured with a testing and fill-
ing device.
Details of the procedure can be found in the Operating Instruc-
tions.
Inspection and servicing
• Carry out the tests required by law.
• Test and monitor the gas precharge pressure regularly.
30/32 Bosch Rexroth AG Hydraulics General product information RE 07008
WARNING
Before installing a hydraulic system in a machine or mod-
ifying an existing hydraulic system in a machine, satisfy
yourself that
Ø the hydraulic system is suitable for its application in the
machine
Ø the ambient conditions in the machine are suitable and/or
permissible for the use of the hydraulic system
Ø other installed items on or in the machine cannot disturb
or endanger the functioning or the safe operation of the
hydraulic system.
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07008
Bosch Rexroth AG © All rights reserved, Bosch Rexroth AG, including applications for intellec-
Hydraulics tual property rights. We reserve all power of disposal, rights of reproduction
Zum Eisengiesser 1 and issue.
97816 Lohr am Main, Germany
The data specified above only serve to describe the product.
Tel. + 49 (0) 93 52 / 18-0
No statements concerning a certain condition or suitability for a certain
Fax + 49 (0) 93 52 / 18-23 58
application can be derived from our information. The given information does
documentation@boschrexroth.de
not release the user from the obligation of own judgement and verification. It
www.boschrexroth.de
must be remembered that our products are subject to a natural process of
wear and aging.
Bosch Rexroth AG
Training Systems and Teachware
Maria-Theresien-Straße 23
97816 Lohr a. Main, Germany
Phone +49 9352 18-1041
Fax +49 9352 18-1040
trainingsystems.brs@boschrexroth.de
www.boschrexroth.com
Made in Germany