Bosch Rexroth SM 12 Operating instructions

Repair Manual

RE 64122-S/06.2011

English

Mobile control block, 6-way version

sandwich plate design

SM 12

The data specified above only serve to describe

the product. No statements concerning a certain

condition or suitability for a certain application

can be derived from our information. The

information given does not release the user from

the obligation of own judgment and verification.

It must be remembered that our products are

subject to a natural process of wear and aging.

specifications and other information set forth in it,

are the exclusive property of Bosch Rexroth AG.

It may not be reproduced or given to third parties

without its consent.

The title page shows an illustration of an example

configuration. The delivered product may

therefore deviate from the illustration.

The original operating instructions were written in

French.

Subject to revision.

Contents

1 Introduction......................................................................................... 4

2 Safety instructions ............................................................................. 5

2.1 General safety instructions ............................................................ 5

2.2 Safety instructions in this document .............................................. 5

3 Troubleshooting ................................................................................. 6

4 Fundamental rules.............................................................................. 8

4.1 General information concerning control block connection ............. 8

5 Removal / installation of the SM 12 control block ........................... 8

5.1 General recommendations............................................................. 8

5.2 Removal of the SM 12 control block .............................................. 9

5.3 Installation of the SM 12 control block ........................................... 9

5.4 Starting, maximal pressure set up ................................................. 9

6 Inlet and outlet elements repair procedure .................................... 10

6.1 Primary pressure relief valve replacement................................... 10

6.2 Removal of the outlet element type K cartridge ........................... 11

6.3 Removal of the outlet element type KW adjustable flow control .. 12

6.4 Removal of the outlet element type KV check valve.................... 13

6.5 Removal of the Externe pilot oil supply block X ........................... 14

6.6 Removal of the Interne pilot oil supply block Y ............................ 15

7 Distribution element repair procedure ........................................... 16

7.1 Secondary valves replacement.................................................... 16

7.2 Removal of a spool return via a spring operation A2 Z1 or A2 G11 8

7.3 Spool stroke measurement (3 position) ....................................... 21

7.4 Removal of a mechanical detent system B2, C2, D2 or E2 ......... 22

7.5 Removal of a manual operation M1 ............................................. 25

7.6 Removal of a manual operation with encapsulated lever R5....... 26

7.7 Removal of a hydraulic operation H200 or H400 ......................... 27

7.8 Removal of a electro-hydraulic operation W200 .......................... 28

7.9 Removal of a check-valve............................................................ 29

8 Control block Disassembly / Assembly.......................................... 30

RE 64122-S/06.2011 | Type SM 12 Bosch Rexroth AG 3/30

Introduction1

This manual deals with the instructions relative to servicing and

maintenance operations for the SM 12 control blocks. For the inspections

and servicing operations associated with the hydraulic system of the

machine to which the block is connected, please consult the maintenance

manual supplied by the equipment manufacturer.

It is recommended that only qualified personnel perform the installation,

connection and maintenance of this device, and that all operations be

carried out in compliance with the technical standards in force and the

cleanliness regulations specific to this type of installation.

To ensure maximum performance and safety during maintenance

operations we advise you to READ THIS MANUAL THOROUGHLY.

All information, illustrations, instructions and characteristics contained in

this document are based on the latest product information available at

the time of publication. In its attempts to maintain a high-quality product,

BOSCH REXROTH reserves the right to make design or technical

modifications at any time and without prior notification.

Related documents

SM 12 is a system component.

Also follow the instructions for the other system components.•

Also follow the instructions in the following manuals:•

System documentation from the system manufacturer–

Service instruction manual RE64025–

Datasheet RE64122–

Spare parts manual RDEF64122-E–

4/30 Bosch Rexroth AG Type SM 12 | RE 64122-S/06.2011

Introduction

Safety instructions2

General safety instructions2.1

See service instruction manual RE64025.

Safety instructions in this document2.2

In this manual, there are safety instructions before the steps whenever

there is a danger of personal injury or damage to the equipment. The

measures described to avoid these hazards must be observed.

Safety instructions are set out as follows :

Signal words/warning signsTableau 1:

Signal word/

warning sign

Application

DANGER

Indicates an imminently hazardous

situation which, if not avoided, will

certainly result in serious injury.

WARNING

Indicates a potentially hazardous

situation which, if not avoided, could

result in serious injury.

NOTICE Indicates property or environment

damages, practices not related to

personal injury.

CAUTION Indicates a delicate operation.

Use or application hints.

DANGER

Type of risk!

Description

precautionsf

RE 64122-S/06.2011 | Type SM 12 Bosch Rexroth AG 5/30

Safety instructions

Troubleshooting3

CAUTION

BEFORE STARTING ANY PROCEDURES OF TROUBLE SHOOTING OR REMOVING THE CONTROL BLOCK,

INSPECT THE GLOBAL MACHINE’S HYDRAULIC SYSTEM TO ELIMINATE ALL POSSIBLE MALFUNCTIONS NOT

RELATED TO THE SM 12 CONTROL BLOCK.

Abnormal operation of the actuators connected to the control blockTableau 2:

Malfunction Probable cause Additional Checks Remedy

Lack of strength at all

actuators

1 - Primary pressure relief valve

defective

Take a pressure measurement

(see block specifications)

Replace primary pressure relief valve

(see § 6.1)

2 - Primary pressure relief valve

out of adjustment

Make necessary adjustments

(see § 5.4)

Lack of force on one

actuator only

1 - Secondary pressure relief

valve out of adjustment

Reset to original pressure (refer to

block specifications).

2 - Secondary pressure relief

valve blocked "open"

(return to tank)

Replace secondary pressure relief

valve (see § 7.1)

Movement performance

slow

Spool stroke incorrect Manual control: measure spool

stroke (see § 7.3)

If stroke is incorrect: replace the

distribution element (see § 8)

Lack of load hold at work Load hold check valve failure Replace check valve or distribution

element (see § 8 and 7.9)

Lack of load hold at

neutral position or relief

valve internal leak

Excessive clearance between the

housing and the spool or relief

valve internal leak

Replace the distribution element (see

§ 8) or secondary pressure relief

valve (see § 7.1)

Abnormal control block operationTableau 3:

Malfunction Probable cause Additional Checks Remedy

Detent malfunction Mechanism defective Replace mechanical detent

(see § 7.4)

Defective manual

operation type R5: no

movement

Ball joint broken Replace the operation (cf. § 7.6)

Defective manual

operation type M1 : lever

stiff

1 - Nut overtightened Adjust tightening torque (cf. § 7.5)

2 - System defective Replace the operation (cf. § 7.5)

Increase of force on

controls or spool return

defective

Control block assembly tie rods

too tight

Check tightening torque Loosen and tighten

to 18 ± 10% N.m.

CAUTION

REMOVE CONTROL BLOCK

FROM ITS FIXATION POINTS

Spool seals obsolete Replace spool seals (see § 7.2)

6/30 Bosch Rexroth AG Type SM 12 | RE 64122-S/06.2011

Troubleshooting

Visual defectsTableau 4:

Malfunction Probable cause Additional Checks Remedy

Spool leaking oil Spool seals defective Replace spool seals (see § 7.2)

Check the rubber boot condition

Oil leakage at pressure

relief valves and plugs

Seals defective Remove pressure relief valve or plug

and replace seals (see § 7.1)

Oil leakage between

elements

Seals between elements defective Remove working sections and

replace seals (see § 8)

Control block assembly tie rods

not enough tight

Check tightening torque Tight to 18 ± 10% N.m.

CAUTION

REMOVE CONTROL BLOCK

FROM ITS FIXATION POINTS

Oil leaking from hydraulic

operator housing

Seal between housing and body

defective

Replace seal (see § 7.7)

R5 manual operation boot

damaged

Replace boot (cf. § 7.6)

RE 64122-S/06.2011 | Type SM 12 Bosch Rexroth AG 7/30

Troubleshooting

Fundamental rules4

General information concerning control block4.1

connection

When removing the block, all openings must be plugged immediately to

prevent any contamination of the hydraulic system.

When replacing the block, remove the plastic plugs from the openings and

lines just before making the connections.

Do not tighten connectors to a torque greater than that specified in the

assembly instructions.

Check the hydraulic installation’s oil quality and filtration capacity during all

servicing/maintenance operations.

The use of Teflon tape, hemp and joint filler is prohibited.

Hydraulic lines and connections must not be under any strain whatsoever.

Removal / installation of the SM 125

control block

General recommendations5.1

NOTICE

Property damages risk

BEFORE REMOVING THE SM 12 CONTROL BLOCK FROMf

THE MACHINE, THE BLOCK AND ITS SURROUNDINGS MUST

BE THOROUGHLY CLEANED (DO NOT DIRECT THE JET OF A

PRESSURE WASHING UNIT DIRECTLY AT THE UNIT).

NO IMPURITIES MUST ENTER THE HYDRAULIC SYSTEM.f

PLASTIC PLUGS ARE TO BE FITTED ON LINES AND ORIFICES

IMMEDIATELY FOLLOWING THEIR REMOVAL.

DANGER

Wear protective clothing and use suitable equipment to preventf

accidents, particularly concerning the hydraulic fluid.

Use the lifting eyes and suitable handling equipment.f

Set all actuators connected to the machine in neutral position (on thef

ground, at lower limit ...) to avoid accidents which could result from

uncontrolled movements of the equipment when the hydraulic system

is disconnected.

With the machine off, release the pressure remaining in the systemf

by manipulating all of the distribution spools. This is performed by

moving the handle in all directions.

8/30 Bosch Rexroth AG Type SM 12 | RE 64122-S/06.2011

Fundamental rules

Removal of the SM 12 control block5.2

Install a vacuum pump on the tank to limit oil leakage whenf

connections are removed.

After disconnecting the lines from the block, immediately fit the sealingf

plugs. Make sure to collect any possible oil leakage in a suitable

receptacle.

Unscrew the mounting screws and remove the control block.f

Installation of the SM 12 control block5.3

Contact faces must be perfectly clean.f

Check the evenness of support area on the machine (Tolerance:f

0.5 mm).

Check the condition of line connector seals.f

Clean the block if it has been in storage for a long period of time.f

Correctly place and secure the control block onto the machine with thef

mounting screws.

Connect the lines to the block as per the connecting diagram andf

tighten to the torque specification (refer to the table in the Data sheet).

Ensure that hoses are not twisted or rub.f

Once correctly installed, the unit can be placed into operation.

Starting, maximal pressure set up5.4

Decalibrate the primary pressure relief valve (17 mm open end spannerf

on counternut) before starting the machine,

Maintain one of the control block spool valve in action before the linkedf

hydraulic receiver is at the end of stroke.

On the spool valve, the value of the secondary valve pressure must be

greater than that of the primary pressure relief valve to adjust.

Adjust the maximum pressure measured in M using the primaryf

pressure relief valve (6 mm socket wrench).

Tighten the counternut of the adjusting screw to the torque:f

20 ± 10% N.m.

RE 64122-S/06.2011 | Type SM 12 Bosch Rexroth AG 9/30

Removal / installation of the SM 12 control block

Inlet and outlet elements repair6

procedure

6.1 Primary pressure relief valve replacement

On the inlet element, unscrew the primary pressure relief valve (24 mm

open end spanner).

Reassembly:

install the primary pressure relief valve on the inlet element, torque:1.

45 ± 10% N.m.

set the primary pressure relief valve to the specified value (see § 5.4),2.

fit a new appropriate locking cover.3.





 

The control block does not need to be removed from the machine to

perform this operation.

DANGER

Oil pressure

Machine off:

place all of the machine’s actuators connected to the control block inf

neutral position,

release stored pressure by operating all the spools.f

NOTICE

Environment damages risk

Install a vacuum pump on the tank to limit oil leakage during thisf

operation.

Collect possible leaks with a suitable receptacle.f

10/30 Bosch Rexroth AG Type SM 12 | RE 64122-S/06.2011

Inlet and outlet elements repair procedure

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