Bosch Rexroth RE 07601-B User manual

Operating instructions

RE 07601-B/12.2013 English

Manifolds and modules

The data speciﬁed above serve to describe the

product. If there is also information on theuse,

it is only to be regarded as application examples

and proposals. Catalogue information does not

constitute warranted properties. Theinforma-

tion given does not release the user from the

obligation of own judgment and veriﬁcation.

Our products are subject to anatural process

ofwear and aging.

tions and other information set forth in it, are

the exclusive property of Bosch Rexroth AG.

Itmay not be reproduced or given to third par-

ties without its consent.

The cover shows an example conﬁguration.

Theproduct supplied may therefore diﬀer from

the photo shown.

The original operating instructions were pre-

pared in German.

RE 07601-B/12.2013, manifolds and modules, Bosch Rexroth AG

3/36Inhalt

Inhalt

1 About this documentation 5

1.1 Validity of the documentation 5

1.2 Required and amending documentation 5

1.3 Representation of information 5

1.3.1 Safety instructions 5

1.3.2 Symbols 6

1.3.3 Abbreviations 6

2 Safety instructions 7

2.1 General information on this chapter 7

2.2 Intended use 7

2.3 Improper use 7

2.4 Qualiﬁcation of personnel 8

2.5 General safety instructions 8

2.6 Product-speciﬁc safety instructions 9

2.7 Personal protective equipment 12

3 General information on damage to property and damage to the product 13

4 Scope of delivery 14

5 Information on this product 15

5.1 Product identiﬁcation 15

6 Transport and storage 16

6.1 Transporting the manifold/module 16

6.1.1 Transport using lifting tools 16

6.2 Storing the manifold/module 17

7 Assembly 19

7.1 Unpacking 19

7.2 Prior to assembly 19

7.3 Installation conditions 19

7.4 Necessary tools 19

7.5 Assembling the manifold/module 20

7.5.1 Mechanically assembling the manifold/module 21

7.5.2 Hydraulically connecting the manifold/module 21

7.5.3 Connecting the power supply 21

7.6 Painting the manifold/module 22

8 Commissioning 23

8.6.1 Bleeding the hydraulic system 24

9 Operation 24

10 Maintenance and repair 25

10.1 Cleaning and care 25

10.2 Repair 26

10.3 Spare parts 26

11 Disassembly and exchange 27

11.1 Necessary tools 27

11.2 Preparing for disassembly 27

11.3 Disassembling the product 27

12 Disposal 29

12.1 Environmental protection 29

4/36

Bosch Rexroth AG, manifolds and modules, RE 07601-B/12.2013

12.2 Return to Bosch Rexroth AG 29

12.3 Packaging 29

12.4 Materials used 29

12.5 Recycling 30

13 Extension and modiﬁcation 30

14 Troubleshooting 31

14.1 How to proceed for troubleshooting 31

14.2 Fault table 31

15 Technical data 31

16 Appendix 32

16.1 List of addresses 32

17 Alphabetical index 33

About this documentation 5/36

RE 07601-B/12.2013, manifolds and modules, Bosch Rexroth AG

1 About this documentation

1.1 Validity of the documentation

This documentation applies to:

•Manifolds and modules for industrial applications

This documentation is intended for assemblers, system end-users, machine and

system manufacturers.

This documentation contains important information on the safe and proper trans-

port, assembly, commissioning, operation, use, maintenance, simple troubleshoot-

ing, disassembly and disposal of the product.

▶ Read this documentation completely and particularly chapter 2 "Safety instruc-

tions" and chapter 3 "General information on damage to property and damage to

the product" before working with manifolds or modules.

1.2 Required and amending documentation

▶ The product must not be commissioned until you have been provided with the

documentation marked with the book symbol and you have understood and

observed it.

Table 1: Required and amending documentation

Title Document number Document type

Order conﬁrmation

Installation drawing with parts list Drawing

Hydraulic valves for

industrial applications

RE 07600 Operating instructions

1.3 Representation of information

Consistent safety instructions, symbols, terms and abbreviations are used so that

you can quickly and safely work with your product. For a better understanding, they

are explained in the following sections.

1.3.1 Safety instructions

In this documentation, safety instructions are given in chapter 2.6 "Product-speciﬁc

safety instructions" and chapter 3 "General information on damage to property and

damage to the product" and whenever sequences of actions or instructions are ex-

plained which bear the danger of personal injury or damage to property. The mea-

sures described for preventing these hazards must be observed.

Safety instructions are set out as follows:

SIGNAL WORD

Type and source of danger!

Consequences in case of non-compliance

▶ Hazard avoidance measures

▶ <Enumeration>

6/36 About this documentation

Bosch Rexroth AG, manifolds and modules, RE 07601-B/12.2013

•Warning sign: Draws attention to the danger

•Signal word: Identiﬁes the degree of danger

•Type and source of danger!: Speciﬁes the type and source of danger

•Consequences: Describes the consequences in case of non-compliance

•Precaution: Speciﬁes how the danger can be prevented

Table 2: Risk classes according to ANSI Z535.6-2006

Warning sign, signal word Meaning

DANGER Indicates a dangerous situation which will cause death or

severe personal injuries if not avoided.

WARNING Indicates a dangerous situation which may cause death or

severe personal injuries if not avoided.

CAUTION Indicates a dangerous situation which may cause minor or

medium personal injuries if not avoided.

NOTICE Damage to property: The product or the environment could

be damaged.

1.3.2 Symbols

The following symbols indicate notices which are not safety-relevant but increase

thecomprehensibility of the documentation.

Table 3: Meaning of the symbols

Symbol Meaning

If this information is not observed, the product cannot be used and/or

operated optimally.

▶ Individual, independent action.

Numbered instruction:

The numbers indicate that the actions must be carried out one after theother.

1.3.3 Abbreviations

The following abbreviations are used in this documentation:

Table 4: Abbreviations

Abbreviation Meaning

ANSI American National Standards Institute

EMC Electro-magnetic Compatibility

PE Protective Earth (protective earthing conductor)

Safety instructions 7/36

RE 07601-B/12.2013, manifolds and modules, Bosch Rexroth AG

2 Safety instructions

2.1 General information on this chapter

Bosch Rexroth manifolds and modules are manufactured according to the generally

accepted code of practice. However, there is still the risk of personal injury and dam-

age to property. You must therefore observe this chapter and the safety instructions

in this documentation.

▶ Read this documentation completely and thoroughly before working with the

manifolds and modules.

▶ Keep this documentation in a location where it is accessible to all users at

alltimes.

▶ Always include the required documentation when you pass the product on to

third parties.

2.2 Intended use

The product is a hydraulic system component. It is intended for use in industrial

machines and systems.

You may use the product as follows:

•To control the movement at machines and systems

•Complying with the application and environmental conditions according to the

datasheet.

•Complying with the speciﬁed performance limits.

•Use in the original condition, without damage.

•Repair by customers is not admissible.

The product is only intended for professional use and not for private use.

Intended use includes having read and understood this documentation completely,

especially the chapter 2 "Safety instructions".

2.3 Improper use

Any use deviating from the intended use is improper and thus not admissible.

Bosch Rexroth AG does not assume any liability for damage caused by improper use.

The user assumes all risks involved with improper use.

Improper use of the manifold or module includes:

•Use in explosive environments

•Incorrect transport

•Incorrect storage

•Lack of cleanliness during storage and assembly

•Incorrect installation

•Use of inappropriate/non-admissible media

•Exceedance of the speciﬁed maximum pressures

•Operation outside the approved temperature range

8/36 Safety instructions

Bosch Rexroth AG, manifolds and modules, RE 07601-B/12.2013

2.4 Qualiﬁcation of personnel

The activities described in this documentation require basic knowledge of mechan-

ics, electrics and hydraulics as well as knowledge of the appropriate technical terms.

For transporting and handling the product, additional knowledge of how to handle

lifting tools and the necessary attachment devices is required. In order to ensure

safe use, these activities may only be carried out by an expert in the respective ﬁeld

or an instructed person under the direction and supervision of an expert.

Experts are those who are able to recognize potential hazards and apply the appro-

priate safety measures due to their professional training, knowledge and experience,

as well as their understanding of the relevant conditions pertaining to the work to be

undertaken. An expert must observe the relevant speciﬁc professional rules and have

the necessary expert knowledge.

Expert knowledge means for example for hydraulic products:

•Reading and completely understanding hydraulic schemes,

•In particular, completely understanding the correlations regarding the safety equip-

ment and

•Having knowledge of the function and set-up of hydraulic components.

Bosch Rexroth oﬀers training measures in speciﬁc ﬁelds. An overview of the

training contents can be found online at: http://www.boschrexroth.com

2.5 General safety instructions

•Observe the valid regulations on accident prevention and for environmental

protection.

•Observe the safety regulations and provisions of the country where the product is

implemented/used.

•Exclusively use Rexroth products in technically perfect condition.

•Observe all notices on the product.

•Persons assembling, operating, disassembling or maintaining Rexroth products

must not be under the inﬂuence of alcohol, other drugs or medications inﬂuencing

the ability to react.

•Only use original Rexroth accessories and spare parts in order to exclude hazards

to persons due to unsuitable spare parts.

•Comply with the technical data and environmental conditions speciﬁed in the prod-

uct documentation.

•The installation or use of inappropriate products in safety-relevant applications

could result in unintended operating conditions when being used which in turn

could cause personal injuries and/or damage to property. Therefore, only use

aproduct for safety-relevant applications if this use is expressly speciﬁed and per-

mitted in the documentation of the product, e.g. in explosion protection zones or

in safety-related parts of control systems (functional safety).

•Do not commission the product until you can be sure that the end product (for ex-

ample a machine or system) where the Rexroth product is installed complies with

the country-speciﬁc provisions, safety regulations and standards of the application.

Safety instructions 9/36

RE 07601-B/12.2013, manifolds and modules, Bosch Rexroth AG

2.6 Product-speciﬁc safety instructions

WARNING

Non-compliance with functional safety!

Hydraulic manifolds and modules control movements in machines or systems.

Incase of mechanical and electric faults, e.g. failure of the energy supply, persons

may be caught by the system, kicked away or bruised due to incorrect control and

unexpected start-up.

▶ When setting up your circuit, observe functional safety e.g. according

toENISO13849.

▶ Install light barriers or protective grids, if necessary.

▶ Immediately exchange defective components.

Pressurized system parts and leaking hydraulic ﬂuid!

When working at hydraulic systems with stored pressure energy (accumulator or

cylinders working under gravity), hydraulic manifolds and modules may even be

pressurized after the pressure supply has been switched oﬀ. During assembly and

disassembly works, attached and installed components may ﬂy around and cause

personal injuries and/or damage to property. There is moreover the danger of seri-

ous injury caused by a powerful leaking hydraulic ﬂuid jet.

▶ Ensure before working at the hydraulic product that the hydraulic system is de-

pressurized and the electrical control de-energized.

▶ Completely unload the pressure at machines and systems before working at

hydraulic products.

▶ Secure the system against restarting.

Faulty fastening!

Mounting of the manifold/module using mounting bolts of reduced stability, insuf-

ﬁcient mounting or insuﬃcient stability of the mounting surfaces may cause the

product to become loose and fall down. Manifolds/modules with high weight may

bruise or kill persons.

▶ Completely assemble the manifold/module according to the assembly speciﬁca-

tions by means of suitable assembly aids.

▶ Mount the manifold/module only at suitable mounting surfaces.

▶ Comply with tightening torques and screw stabilities.

Easily inﬂammable hydraulic ﬂuid!

Fire and risk of ﬁre due to hydraulic ﬂuid and leaking oil mist.

▶ Keep open ﬁre and ignition sources away from the manifold/module.

▶ Do not use manifolds and modules in areas with open ﬁre and only at suﬃcient

distance to hot heat sources.

▶ Immediately remove leaked hydraulic ﬂuid and dispose of it properly.

10/36 Safety instructions

Bosch Rexroth AG, manifolds and modules, RE 07601-B/12.2013

WARNING

High pressure!

Risk of injury caused by pressurized leaking oil jet and parts shooting out due to

abroken system component.

▶ In case of a leaking oil jet, decommission the system and exchange the dam-

agedcomponents.

▶ Secure the pressure in the system by means of overpressure equipment.

▶ Lead the tank line to the tank freely, without reduction of the cross-section

andblocking.

▶ Use hydraulic lines and connections according to the max. operating pressure.

▶ Do not separate, open or disconnect pressurized lines and do not disassemble

pressurized components!

▶ Depressurize the system before the assembly and any other works at the mani-

folds/modules.

CAUTION

Leaking hydraulic ﬂuid!

Hydraulic ﬂuid may leak during assembly and disassembly of hydraulic components.

Consequently, persons may slip or fall!

▶ Only remove the protective caps at hydraulic manifolds/modules directly before

the assembly.

▶ After the disassembly, provide the bores containing the hydraulic ﬂuid with suit-

able closing elements.

▶ Immediately remove leaked hydraulic ﬂuid and dispose of it properly.

Harmful hydraulic ﬂuid!

Health hazard due to contact with hydraulic oil (e.g. eye injuries, skin lesions, poi-

soning when inhaled and ingested).

▶ Check the hydraulic components and lines for wear and damage on a regular basis.

▶ Wear protective gloves, safety goggles and suitable working clothes when work-

ing with hydraulic oil.

▶ If nevertheless hydraulic ﬂuid comes into contact with the eyes or penetrates

the skin, please consult a doctor immediately.

▶ When dealing with hydraulic ﬂuids, you must imperatively observe the safety

instructions of the hydraulic ﬂuid manufacturer.

Resonance or ﬂuid noises!

Hearing damage and possible damage at hydraulic valves! In case of an unfavorable

arrangement of hydraulic manifolds and modules in the system, resonance or ﬂuid

noises e.g. whistling may result.

▶ In this case, contact a service engineer.

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