Operating instructions for hydraulic systems
Contents
1. Copyright reserved 2 4 2 5 Page 15 37 Operating instructions for hydraulic systems AB E 01 01 02 2003 02 24 Basic safety guidelines A Warning a Are the Hazard and safety guidelines on the machine Operating instructions describing how to react during operation so that accidents and health problems are prevented These are to be created by the operator company that have e g to take into account the accident prevention regulations Operating instructions describing how to correctly and safely use the hydraulic system for the intended purpose b Mineral oil based hydraulic oils are hazardous to water and are inflammable It can only be used if the relevant safety data sheet from the manufacturer is present and that all of the measures stipulated therein have be implemented c The hydraulic system can only be used when it is in a technically perfect condition d The intended use performance data and application conditions must not be changed e Ke Protective measures components may not be rendered inoperable e g limit switches valves and other control elements must not be bypassed f If for maintenance purposes protective measures have to be bypassed then safety measures must be carried out beforehand to ensure that a hazardous situation can not occur The main machine operating instructions are to be taken into account g The actuation of component adjustment systems or changes to programma2. Copyright reserved Page 8 37 AB E 01 01 02 2003 02 24 Operating instructions for hydraulic systems 1 3 3 1 3 4 1 3 5 1 3 5 1 Monitoring the filter For the type see circuit parts list Table 1 Back pressure or differential pressure clogging indicator Without clogging indicator Optical clogging indicator EE Permanent indicator 1 or pressure gauge Optical electrical clogging indicator Lamp Or pin Pannen indicator H electrical signal Signal suppression 2 Optical electrical clogging indicator and electrical Lamp or pin Permanent indicator 1 signal suppression until the oil electrical signal Signal suppression 3 temperature is 30 C Lamp or pin electrical signal with 2 switching points at 75 100 of the back pressure or differential pressure 1 If the permissible back differential pressure at the filter element is exceeded then this results in an optical signal With certain types of filter the red pin on the clogging indicator has to be pressed in daily check function The indicator has to be at its operating temperature If during this check the pin jumps back out straight away then at the latest by the end of the shift the filter element must be changed During the cold start phase due to the fact that higher oil viscosity higher pressure a filter clogged signal usually occurs The electrical signal should be suppressed until an average operating temperature gt 30
3. 12 Others 5 2 5 6 Fault effect F Pump on or off load switching too frequent Table 11 Force The operating pressure should be maintained without accumulators 11 Drive cylinder motor when the pump is switched off The compression volumes e g the volume within the drive and pipes hoses is in relation to the system leakage too low For systems with accumulators The oil demands from the actuator and or leakage is too high The oil volume is not or only partially available 12 Others Isolator valve to the accumulator is closed Bladder membrane defective Gas pre charge operating and set pressures e g pressure switches do not meet the requirements 5 2 5 7 Fault effect G Switching shocks when valves are switched Table 12 4 Pressure lines SeeG9 A4 SeeG9 A5 6 Pressure valves Opens too fast e g with electrical unloading increase the switching time by Pressure valves means of orifices 8 Isolator valves Opens too fast Increase the switching time by means of orifices ee Optimise the switching time influence between the delay E 9 1 and the severity of Directional valves ee the switching shocks See fault source l entrapped air in the oil 1 Compression energy the product of the compression volume x the pressure is dissipated too quickly 2 The kinetic energy weight x velocity is too high see G 9 1 11 Drive cylinder motor 1 The system is not fully bled 12 Oth
4. C has been reached During the cold start phase the electrical signal is suppressed until an operating temperature of 30 C has been reached The electrical signal is transmitted at two switching points i e 75 and 100 of the back differential pressure During the cold start phase due to the fact that higher oil viscosity higher pressure a filter clogged signal usually occurs The electrical signal should be suppressed until an average operating temperature gt 30 C has been reached 5 We recommend that a clogging indicator is fitted Optical electrical clogging indicator with a 2 point signal Permanent indicator 1 Signal suppression 4 2 lt 3 4 Protecting against unpermissible operating pressures Safety valves must not be altered by the user of the system The set value must be 10 or at least 20 bar above the permissible system operating pressure for details see circuit Information regarding safety measures The performance capabilities of technical safety measures are split into 5 categories according to EN 954 B 1 2 3 4 The categories describe the performance capabilities of the control in relation to their fault resistance and their reaction in the case of a fault due to the layout arrangement of the components and or their reliability Unless otherwise agreed category B applies If higher safety requirements are demanded then categories 1 to 4 are to be applied and agre
5. Removal of impurities The removal of locally accumulated heat 4 3 1 4 Hydraulic oil characteristics The characteristics of hydraulic oils diminishes chemical changes as it ages The following factors accelerate the ageing process High temperatures as a rule of thumb at oil temperature above 70 C the speed at which the oil ages doubles for each 10 C increase Air oxygen Water Metallic catalysts and contamination Acids and resinous residues form which can lead to valve spools sticking 4 3 1 5 Selection and maintenance of pressure fluids Due to the many tasks of the pressure fluid its selection and maintenance is of vital importance for the Operating safety Service life Economy of a hydraulic system Copyright reserved Page 23 37 Operating instructions for hydraulic systems AB E 01 01 02 2003 02 24 4 3 2 Selecting the viscosity class The most important technical characteristics of a pressure fluid is the value of its thickness viscosity The viscosity values stated within the data sheets are the governing factors Pumps and hydraulic motors in particular demand that the permissible viscosity ranges are complied with H the viscosity is too high thick fluid then this leads to cavitation a low viscosity results in increased leakage losses warming and thereby a further reduction in the viscosity Subsequently the lubrication limits will be reached The viscosity of a pressure fluid
6. relevant signals are input and ends at the output of the power control elements The electrical control must conform to the requirements of EN 60204 1 point 5 3 so that an unintended start up is prevented Category 3 system performance If a single fault occurs the safety functions are maintained Some but not all faults are recognised Asummation of unrecognised faults can lead to the loss of safety functions Category 4 Safety is primarily achieved via the control structure The considerations commence where the safety relevant signals are input and ends at the output of the power control elements The electrical control must conform to the requirements of EN 60204 1 point 5 3 so that an unintended start up is prevented Category 4 system performance If a single fault occurs the safety functions are maintained A fault is recognised early enough to prevent the loss of safety functions Operating and environmental conditions Unless other technical data is stated within the order then the following conditions apply Climate Moderate climate zones indoors the relative air humidity should be lt 70 at an ambient temperature of 22 C Ambient temperature 0 30 C For power units with surface cooled electric motors without heat exchangers with a free circulation of air lt 40 C With heat exchanger nominal power to EN 60034 1 for continuous operation 50 Hz KT 40 C and for u
7. 2003 02 24 5 2 6 2 Assembling the coupling Both coupling halves are to be so assembled that A B s A Measured from the pump mounting bracket connection flange to the base of the pump coupling half i e base of the claws B A s Measured from the electric motor connection flange to the end of the motor coupling half i e the top of the claws Motor side Di BS X S x a Pump mounting bracket length Possibly with 3 damping ring Table 15 Claw upper edge Claw lower edge 5 2 6 3 Securing the coupling half onto the shaft a Cylindrical shaft with key The coupling is secured via the fixing screw provided grub screw with cutting ring b Splined shaft The coupling half is in the form of a clamp and is therefore clamped onto the shaft with a radial force see AB E 33 22 c Conical shaft The coupling half is fixed by means of a disc and axial screw The correct tightening torque can be obtained from the pumps operating instructions e g M 6 6 2Nm M12 50 10Nm M14 70 15Nm M16 100 10Nm Copyright reserved Page 36 37 AB E 01 01 02 2003 02 24 Operating instructions for hydraulic systems 5 2 7 Assembly guidelines for vertically mounted motor pump assemblies 5 2 7 1 General safety guidelines This maintenance activity requires specialised knowledge EN 292 2 and should therefore only be carried out by trained personnel A Hazards when removing the motor pump assembly
8. a limited service life They are To be checked by a qualified person To be replaced in the required time Wipping of a pressure scales even if no safety technical line after ripping off problems are visible see 5 1 5 hoses AB E 01 02 06 AB E 23 10 AB E 33 16 Dependent on the place of application the hose may require a retainer or screen shield Commissioning using the hand overrides of control elements is not recommended Dangerous movement Valve hand overrides of drives and pressure generation due to Hand operated valves unauthorised manual operation Control relays The operator is responsible for safe movement sequences and the build up of pressure Suitable retaining measures leak free contamination due to Components and pipe work system to accept water contaminating AB E 01 02 15 leaks in the hydraulic that le outside the cil reservoir fluid that is escaping from AB E 40 40 system reservoirs pipes Let the hydraulic system cool down before commencing any maintenance work If so then it must only be carried out by qualified personnel see 2 3 personnel qualifications Water or ground 7 Hydraulic reservoirs Danger of burning due Surfaces of individual to surface components and pressure temperatures gt 80 C Times Wear protective clothing Copyright reserved Page 12 37 AB E 01 01 02 2003 02 24 Operating instructions for hydraulic systems Table 2 continued Hydraul
9. and high response valves corresponds approximately to class 9 of the standard NAS 1638 which is no longer valid ISO 4406 KL 19 16 13 Servo valves servo cylinders corresponds approximately to class 7 of the standard NAS 1638 which is no longer valid Hazard potential Water contaminating products When operating with water contaminating products there is a hazard to lakes rivers and canals etc With regard to the water protection act WHG and the regulation concerning the use of water contaminating products VAwS the following applies for Germany Hydraulic systems lie within the group of HBV systems systems for manufacture treatment and use of fluids In accordance with 819 h section 1 S 1 No 2 6 WHG section 2 the systems do not require a suitability check or type acceptance when the water contaminating material is to be found in the working process This is the case with hydraulic systems Unless otherwise stated the hydraulic systems are suitable for use with mineral oil to DIN 51524 part 2 These mineral oils are generally given the water hazard classification of 2 The water protection regulation WHG requires in 19 for systems using water contaminating materials that these are only erected installed maintained and cleaned by specialised companies As Bosch Rexroth AG Lohr am Main is a member of the Fachbetriebsgemeinschaft Maschinenbau e V FGMA and is so defined as a specialised company to 19
10. hoses are subject to natural ageing Therefore their service life is limited see 1 6 Residual risks Hoses must according to EN 982 meet all of the requirements that are specified in all of the applicable European and or International standards In hydraulic systems high dynamic loads fast internal pressure changes pressure peaks etc can occur The requirements that are stated in the hose standards can in specific applications be too low In this case hoses with strengthened fittings to AB E 23 16 are used A Strengthened hoses can only be replaced by hoses of the same specification Warning Testing Unless there are other regulations then hoses should be checked for operational safety before the first commissioning and then at least once a year by an authorised person Manufacturer s instructions with regard to storage life must be complied with The storage room should be cool up to 25 C dry and protected against sunlight O zone generating sources are to be prevented as they reduce the hose service life Copyright reserved 5 1 5 4 5 1 5 5 5 1 5 6 5 1 7 Page 27 37 Operating instructions for hydraulic systems AB E 01 01 02 2003 02 24 Storage time and service life The service life of hoses should not exceed six years including a maximum storage time of two years excerpt from DIN 20066 The service life is defined as the duration of use and any storage time from the date of manufacture Whe
11. i WHG For further information see AB E 01 02 15 and AB E 40 40 Copyright reserved Page 11 37 Operating instructions for hydraulic systems AB E 01 01 02 2003 02 24 1 4 5 2 Explosive surroundings Bosch Rexroth hydraulic systems can only be used in explosive atmospheres when they have been specifically designed for this application and that this has been explicitly documented within the product specific documentation Note The 94 9 EG directive also named ATEX 100 controls the use of components and protective systems in explosive surroundings 1 5 Unpermissible use Operating the unit with Higher operating pressures Anon specified pressure fluid and Warning Deviating operating and environmental conditions is not permissible 1 6 Hydraulic system residual risks Table 2 Hydraulic system Protective measure s Relevant e z Hazard area Sage residual risks safety guidelines standards on Immediately stop leaks AB E 20 06 pipes and hoses Escaping pressurised Hydraulic components pumps De pressurise hydraulic systems before h valves filters measurement A pressure fluid 8 commencing any maintenance work equip cylinders etc Accumulators Attention Unload the accumulator lower loads Ignition of the Ignition source with a surface escaping pressure temp gt than the flame point of fluid in the vicinity of the fluid being used ignition sources Screen shield Hoses have
12. level mark If the filling level falls below or exceeds the defined points then an electrical signal is given which is actuated by a float The switching points are identified with L1 to L see circuit The switching points are defined to meet the technical requirements e g Switching point L3 Maximum level Switching point L2 Add pressure fluid Switching point L1 System Emergency off The minimum level has been reached danger that the pump will fail due to cavitation This point lies below the minimum level on the oil level gauge Temperature limit System Emergency off with a fixed switching point The maximum permissible system temperature has been reached The fault can be found and rectified with the aid of the fault cause analysis chapter 5 2 5 8 H Pressure fluid operating temperature too high Controlling and monitoring the pressure fluid temperature if fitted Temperature switches are used to switch heat exchangers on or off heaters coolers and for monitoring and indicating the operating temperature Thermostats are defined as per the technical requirements eg Thermostat 1 Set value C for switching the cooling on The switch off point is determined by the switching hysteresis Thermostat2 Set value C for switching the heating off The switch on point is determined by the switching hysteresis Thermostat 3 For monitoring functions see circuit
13. measured in Sl units mm s changes with temperature The viscosity classifications to ISO VG are based on a reference temperature of 40 C e g ISO VG 46 relates to 46 mm s at 40 C The viscosity classes are included in the type code e g HLP 46 The hydraulic units operating conditions dependent on the pump type switching proportional servo valves demand that the following viscosity ranges are maintained Recommended range for continuous operation 20 100 mm s Briefly permissible for cold start up for pumps speeds up to 1800 U min 500 mm s Minimum permissible 12 mm s The selection of a suitable viscosity class for a Pressure fluid temperature range of 0 80 C Can be determined herewith Example for ISO VG 46 recommended for Central European climate or enclosed rooms results from the relationship between the oil temperature and the viscosity Viscosity temperature diagram Viscosity temperature diagram E Viscosity in mm m BS HHH aum HHHH H 26 PE EEE 3 40 35 30 25 20 1510 5 O 5 1015202530 40 60 60 70 80 90 100 110 120 130 140 Temperature in C The priority when selecting a viscosity grade is the permissible viscosity range At given ambient and pressure fluid temperature it is not always possible to fulfill all requirements by varying the viscosity clas In this case HV oils with viscosity index improvers can be used or an oil cooler heater may be employed Copyright
14. of the final operating temperature after the machine has been operating for a longer period of time Rectifying leakage points Check joints after the machine has been in operation for a period of time for leaks Problems during commissioning Identical hydraulic systems can have differing function or fault characteristics after being fitted into the machine due to machine specific conditions weights speeds electrical controls command values etc As an aid for systematic fault finding or localising faults the matrix for fault causes and their effects in hydraulic systems is available see 5 2 5 Copyright reserved Page 22 37 AB E 01 01 02 2003 02 24 Operating instructions for hydraulic systems 4 3 Pressure fluid 4 3 1 Requirements and tasks 4 3 1 1 Pressure fluid requirements Mineral oil based hydraulic oils That the minimum requirements of DIN 51524 part 2 are fulfilled Other fluids on requests 4 3 1 2 Safety guidelines Mineral oil based hydraulic oils Are materials that are hazardous to water Are flammable take the ignition point into account May only be used it the relevant safety data sheet is present for the pressure fluid that is intended to be used and that all of the measures stated therein have been implemented 4 3 1 3 The tasks of the pressure fluid To transmit hydraulic energy from the pump to the hydraulic cylinder motor Lubrication of moving parts Corrosion protection
15. to the cross section being too small See A10 See A4 Switching shocks due long return lines and or too high flow velocities The oil column is not pre loaded 1 Flow noises and oscillation due to incorrect valve selection unfavourable Pressure valves characteristic curve or the flow is too high 2 Valve oscillations causes other controller to oscillate 1 See A6 7 Flow valves DE 2 Flow control valve pressure compensator oscillation Suction conditions Pressure lines NAIR OND AIT BROWN AOR Gab 3 Performance limits have been exceeded flow too high Directional valves 1 See A6 2 Valve rattles defective solenoid or the voltage is too low 1 Fluid level is too low 2 The viscosity is too high temperature is too low oil with an unsuitable viscosity grade 10 Pressure fluid 3 The pressure fluid foams too much air in the fluid 1 to 3 results in dependent on the combinations suction problems pump noise flow noises switching shocks 11 Dave Wear on the running surfaces cylinder motor 1 See A6 E Isolator valves 2 Vibration caused by control pressure fluctuations with pilot operated check valves Copyright reserved Page 32 37 AB E 01 01 02 2003 02 24 Operating instructions for hydraulic systems 5 2 5 2 Fault effect B Insufficient power torque pressure at the drives Table 7 1 Defective pump see A3 2 Pump flow too low or with variable pumps the de swash pressure is set too l
16. Company standard Rexroth Operating instructions Bosch Group for hydraulic systems AB E 01 01 02 2003 02 24 Replaces Bosch Rexroth AG Department BRI TDV3 Industrial Hydraulics Created C Ewald Zum Eisengie er 1 e D 97816 Lohr am Main Examined E Wiesmann Tel 0 93 52 18 0 e Fax 0 93 52 18 29 17 Technical responsibility BRI AB PMT Copyright reserved Page 1 37 Page 2 37 AB E 01 01 02 2003 02 24 Operating instructions for hydraulic systems Product specific information Fundamental information Intended purpose scope of supply Information regarding monitoring and safety functions Monitoring functions Monitoring the change of pressure fluid level Monitoring via a level indicator Monitoring via level indicator and temperature switch i Controlling and monitoring the pressure fluid temperature if fitted Monitoring the filter Protecting against unpermissible operating pressures Information regarding safety measures Category B Category 1 Category 2 Category 3 Category 4 Copyright reserved Page 3 37 Operating instructions for hydraulic systems AB E 01 01 02 2003 02 24 Copyright reserved Page 4 37 AB E 01 01 02 2003 02 24 Operating instructions for hydraulic systems Copyright reserved Page 5 37 Operating instructions for hydraulic systems AB E 01 01 02 2003 02 24 Fault effect A Fault effect B
17. Fault effect C Fault effect D Fault effect E Fault effect F Fault effect G Fault effect H Copyright reserved Page 6 37 AB E 01 01 02 2003 02 24 Operating instructions for hydraulic systems 1 Product specific information 1 1 Fundamental information This hydraulic system has been manufactured in accordance with the directive 89 37 EC EC MCD in its latest edition and the C MCD and EN 982 this hydraulic system is a system that is not ready for use and is intended to be subsequently built into a machine These operating instructions are intended to provide information and to prevent hazards when installing the hydraulic system in the machine as well as information and guidelines for transport storage and maintenance inspection servicing repair of the hydraulic system Only by strictly observing these operating instructions is it possible to prevent accidents and material damage and ensure fault free operation of the hydraulic system Furthermore observation of these operating instructions Minimises stoppages and repair costs Increases the service life of the hydraulic system A This does not replace the operating instructions for the entire machine Warning When the hydraulic system is fitted into a machine the interaction between the entire machine and the hydraulic system causes changes to the potential hazards In particular the influence of hydraulic and electrical controls on hyd
18. Hazard The weight is not known The centre of gravity is not necessarily in the middle of the assembly Always use Suitable lifting equipment 5 2 7 2 Disassembly procedures Dismantling the motor pump assembly is carried out in two steps 1 Remove the electric motor 2 As can be seen from the above photograph two lifting eyes are to be screwed into the threaded holes in the pump mounting bracket The unit should then be slightly lifted to check to see whether the centre of gravity is satisfactory so that the unit can be dismantled without any hazard The procedure is reversed for re assembly Copyright reserved Page 37 37 Operating instructions for hydraulic systems AB E 01 01 02 2003 02 24 6 Decommissioning Attention When decommissioning and partially disassembling the hydraulic system the following has to be taken into account 1 Assembly disassembly work should only be carried out by trained and experienced personnel who have knowledge of hydraulics see 2 3 Personnel qualifications 2 Due to safety reasons no pipe work connections or components may be loosened removed when the system is pressurised Before any work commences loads are to be lowered accumulators unloaded pumps are to be switched off and secured against being restarted The general safety regulations are to be taken into account see 1 6 Residual risks and 2 4 Basic safety guidelines 6 1 Decommissionin
19. and dispose of them in a correct manner Fault causes and their effect on hydraulic systems An overview of the effects of a fault A Excessive noises B Insufficient force torque pressure at the drives C Uneven drive movements pressure and or flow oscillations D The drive does not move or is too slow none or too little flow E The drive does not stop or overruns F The pump switches on and off loads too frequently Switching shocks when valves are switched The operating pressure fluid temperature is too high I Contaminated pressure fluid Copyright reserved Page 31 37 Operating instructions for hydraulic systems AB E 01 01 02 2003 02 24 5 2 5 1 Fault effect AT Excessive noises Table 6 1 Coupling Incorrectly aligned loose defective 4 Mechanical drive 2 Pump or motor fixing loose component 3 Defective pump or motor 4 Wrong direction of rotation Unfavourable suction conditions due to Air breather clogged or too small The suction line isolator valve is not fully open Suction line is blocked too small too many bends Located 1000 m above seal level Suction line is not air tight air is being sucked in See A10 Incorrect direction of rotation or the speed is too high The suction and pressure lines exchanged Defective pump seals pump Oscillating control system See A1 A2 Pipe mounts missing or loose Incorrectly fitted e g not free of tension Flow noises due
20. asures to maintain the functionality of the fluid condition cleanliness class see 1 4 Operating and environmental conditions Maintenance and inspection General notes Personnel qualifications Maintenance and service work may only be carried out by trained and instructed personnel see 2 3 Personnel qualifications Safety See 2 4 Basic safety guidelines Scope and time intervals for maintenance and inspection The basis for the recommendations are Central European climate average loading and operating conditions and the environmental conditions that are normally to be found in metal processing companies see 5 1 8 Maintenance and inspection intervals Inspection documentation It is recommended that inspection results are documented a so that by taking into account functionality and economics it is possible to match the inspection and maintenance intervals to the actual operating conditions b so that comparisons can be made enabling the possibility of early fault recognition Copyright reserved Page 25 37 Operating instructions for hydraulic systems AB E 01 01 02 2003 02 24 A steady increase in temperature and or shorter filter element change intervals point to possible wear of pumps control lands seals and ageing of the pressure fluid and should be a trigger to check all of the affected components A sudden fast increase in temperature is a warning sign and requires that the syste
21. ating personnel They must be kept in a known and accessible place immediately by the hydraulic system and be permanently to hand Copyright reserved Page 16 37 AB E 01 01 02 2003 02 24 Operating instructions for hydraulic systems 2 6 2 7 i In Germany hydraulic systems that are operated with mineral oil DIN 51524 in general WGK 2 are within the sense of the water protection act WHG 19 g Systems for handling water hazardous substances Hydraulic systems lie within the HBV group of systems systems to manufacture handle and use fluids According to 19 h par 1 S 1 No 2 b WHG systems do not require a suitability check or a design acceptance when the water hazardous materials are used in a work process This is the case with hydraulic systems The binding obligations of the operator of a water hazarding system WHG 19 i are l nder German states specific and are regulated in the relevant VawS Conventions Table 3 This symbol indicates a threat of danger which will directly result in death or very serious injury if not avoided This symbol indicates a threat of danger which may result is death or very serious injury if not avoided The symbol indicates a possible danger which may lead to minor or serious injury or material damage Caution This symbol indicates back up information Copyright 2003 by Bosch Rexroth AG Industrial Hydraulics D 97816 Lohr am Main All rights re
22. ation of an oil sediment 1 Increase the oil compressibility which can result in jerky drive movements and Entrapped air switching shocks air bubbles in the oil 2 Increase the danger of cavitation wear on metallic surfaces locally high fluid temperatures as well as the destruction of seals when unloading The combined effects of all contamination types is increased ageing of the oil which results in a chain reaction see 4 3 1 Requirements and tasks of the pressure fluid Assembly guidelines for couplings to AB E 33 22 KD 5 2 6 1 General The following has to be taken into account when dismantling or assembling The couplings must not be removed fitted using a hammer The fitting or withdrawing is mainly carried out by hand or with a suitable withdrawal tool The coupling halves can be warmed up to simplify fitting Attention the maximum temperature to which they can be warmed is 100 C Danger of burning Distance between the coupling halves The service life of the coupling spider and thereby the coupling is dependent on the correct axial coupling half separation Dimension s for each coupling size stated on the spider can be obtained from the table Coupling halves for cylindrical shafts electric motor and pump must have at least 90 of the coupling halve length fitted onto the cylindrical shaft Copyright reserved Page 35 37 Operating instructions for hydraulic systems AB E 01 01 02
23. ble control systems must only be carried out by authorised personnel see 2 3 Personnel qualifications h In the event of an emergency fault or other irregularities Switch off the hydraulic system and secure the master switch so that it cannot be switched back on Immediately notify the responsible personnel i Uncontrolled access of non company personnel to the immediate operational area of the hydraulic system is prohibited this also applies if the hydraulic system is not operational Responsibilities and obligations of the machine manufacturer operator created by the operator owner and are to regulate the personal behaviour in the company to The operating instructions do not include the in company operating instructions that are to be prevent accident health and environmental risks The supplied equipment is exclusively intended to be built into a machine or assembled with other machines as part of a complete machine A The commissioning of the supplied equipment is therefore not permitted until it has been established that the machine into which the equipment is to be assembled complies with Warning all requirements of the relevant EC directives see 1 7 Manufacturer s declaration The operating instructions are a basis for the operating instructions of the complete machine which are to be produced by machine manufacturer These operating instructions must be read understood and all points observed by the responsible and oper
24. d electrical personnel Circuit parts list and possibly the functional diagram and other information should be available As an aid for systematic fault finding or localising faults a matrix for fault causes and their effects in hydraulic systems is available see 5 2 5 Fault rectification Faults can primarily be corrected by replacing the defective component on site Only parts stated within the parts list spare parts can be replaced with new interchangable and tested components and these must be of the same quality as the original equipment see hazard area All components through maintenance in 1 6 Residual risks Component repair is generally carried out by the manufacturer or his authorised workshop If a repair is provided for and described in the component specific operating instructions then it may be carried out by the operator provided appropriate expertise and facilities are available After rectification of the actual damage the cause and possible consequential damage must also be rectified For example if a pump fails due to wear then the system should be flushed and the oil cleaned or replaced Functional testing and acceptance Dependent on the scope of the work which is to be carried out the procedure as for commissioning is to be carried out see 4 If required documentation is to be corrected supplemented or notes added to the maintenance handbook so that in future the fault may be eliminated minimi
25. ding of the hydraulic control They are however not a component part of these operating instructions Copyright reserved 1 3 1 3 1 1 1 3 1 2 1 3 1 3 Page 7 37 Operating instructions for hydraulic systems AB E 01 01 02 2003 02 24 User information Parts list Spare parts list Circuit Operating instructions Information regarding monitoring and safety functions Monitoring functions Monitoring the change of pressure fluid level The pressure fluid level is not constant when the hydraulic system is in operation The level changes result from The differing volume requirements of plunger and differential cylinders or the loading unloading of accumulators with pressure fluid during the work cycle Leakage losses Monitoring via a level indicator Due to the above stated reasons it has to be determined by visually monitoring the fluid level over a complete machine working cycle if and how much pressure fluid has to be added During operation the pressure fluid level must not exceed the upper level mark and not fall under the lower level mark Monitoring via level indicator and temperature switch if fitted Due to the above stated reasons it has to be determined by visually monitoring the fluid level over a complete machine working cycle if and how much pressure fluid has to be added During operation the pressure fluid level must not exceed the upper level mark and not fall under the lower
26. e jerky movements and no abnormal noises can be heard Attention Run the system at a low pressure until the hydraulic system has been fully bled Monitor the fluid level in the reservoir if necessary top up Flushing the system When installing the hydraulic system into the machine addition of components pipe work systems and drives it must be ensured that the maximum permissible degree of contamination cleanliness class to ISO 4406 KL 21 18 15 for the entire system is not exceeded Systems which contain servo valves cleanliness class to ISO 4406 KL 19 16 13 must be flushed The servo valves are to be replaced by flushing plates or directional valves of the same nominal size The system is to be operated at its operating temperatures and minimum pressure until the required cleanliness class to ISO 4406 is reached see 1 4 4 The cleanliness class is measured by using a particle counter The filter elements are to be changed as required Final valve settings and running in of the machine in accordance with the details stated in the circuit diagram or the machines operating instructions The switching processes acceleration delays pressure increases etc of valves with switching time adjustment ramps are to be optimised taking the dynamic relationships into account Adjusting and optimising proportional valves see General operating instructions The product specific operating instructions are to be observed Monitoring
27. e reservoir s lifting lugs Carefully lift and take care to ensure that the centre of gravity in correct stable see Loading regulations transport devices means of attachment AB E 02 70 01 Copyright reserved Page 18 37 AB E 01 01 02 2003 02 24 Operating instructions for hydraulic systems 3 2 3 2 1 3 2 2 3 2 3 Storage Excerpt from AB E 01 02 11 Hydraulic components and hydraulic units guidelines for interior conservation Factory corrosion protection Bosch Rexroth hydraulic systems are tested as standard with mineral oil HLP 68 DIN 51524 part 2 After testing the remaining oil film provides the internal conservation For longer storage times as an option MZ 45 corrosion protection oil can be used Increased internal corrosion protection is achieved by filling the internal chambers remain full of protective oil Carrying out the internal corrosion protection Referring to the values stated in table 4 preservation is achieved by testing or filling of the units or components Testing means a short running period using the protective medium The medium is then drained from the reservoir or component All pipe connections are then plugged If table 4 states that the conservation is achieved by filling the protective medium is used to test the unit or component The protective medium remains in the component or unit The pipe connections are plugged using fittings or blank flanges Reservoirs do not
28. ed with the customer also see the BIA Report 6 97 Category B Safety is achieved by the selection and reliability of the valves The electrical control must conform to the requirements of EN 60204 1 so that unexpected start up or not complying with a stop command due to a fault in the electrical control is prevented Category B system performance The occurrence of a fault can lead to the loss of safety functions Copyright reserved 1 3 5 2 1 3 5 3 1 3 5 4 1 3 5 5 1 4 1 4 1 1 4 2 Page 9 37 Operating instructions for hydraulic systems AB E 01 01 02 2003 02 24 Category 1 The requirements of category B must be fulfilled Well tried components and well tried safety principles must be applied Category 1 system performance The occurrence of a fault can lead to the loss of safety functions however the possibility of this occurring must be less than category B Category 2 The requirements of category B must be fulfilled and well tried safety principles must be applied The safety functions must be in suitable time periods checked by the machine control Category 2 system performance The occurrence of a fault can lead to the loss of safety functions between checks The loss of a safety function is recognised by the check Category 3 Safety is primarily achieved via the control structure The considerations commence where the safety
29. ent of machines Signature Le fabricant d clare que les composants sous ensembles livr s ont t fabriqu s conform ment aux normes sp cifications harmonis es utilis es La mise en service de ces composants sous ensembles est Interdite jusqu ce qu il ait t constat que la machine dans laquelle ces composants sous ensembles doivent tre int gr s est conforme aux stipulations de la directive europ enne Norme harmonis e utilis e EN 292 1 11 1991 S curit des machines terminologie de base m thodologie EN 292 2 06 1995 S curit des machines principes techniques et sp cifications EN 982 09 1996 Prescriptions de s curit d installations et composants fluidiques Hydraulique EN 983 09 1996 Prescriptions de s curit d installations et composants fluidiques Pneumatique EN 60 204 1 06 1993 S curit des machines quipement lectrique des machines RDEF 00 025 10 01 Page 14 37 AB E 01 01 02 2003 02 24 Operating instructions for hydraulic systems 2 General information 2 1 Area of validity These operating instructions are only valid for hydraulic systems manufactured by Bosch Rexroth AG industrial hydraulics business unit 2 2 Liability Any material defect or liability claim against Bosch Rexroth AG will be invalid in the case of damages caused by use other than for the agreed purpose or unauthorised actions that are not provided for in these operating instruct
30. ers 2 With accumulator systems when the accumulator energy is switched to a low pressure potential see G 9 1 Copyright reserved Page 34 37 AB E 01 01 02 2003 02 24 Operating instructions for hydraulic systems 5 2 5 8 Fault effect H Pressure fluid temperature too high Table 13 than the machine s energy requirements e g during Increased efficiency loses due to changed conditions They primarily result from faults caused by fault reaction B insufficient force Due to inadequate heat dissipation Not enough fluid in the reservoir The ambient temperature is too high Insufficient heat dissipation due to encapsulation With an oil water cooler the cooling water is not available or is insufficient inlet 12 Others y E pressure is too low or there is sedimentation in the cooler With oil air coolers the air flow is disrupted e g by the cooling covers being blocked The cooler control and adjustment elements should be checked to ensure that they are set to the correct values and that they are functional Pressure relief valves that are set too low or isolator valves that are not correctly closed on accumulator or safety blocks 5 2 5 9 Fault effect l Contaminated pressure fluid 5 2 6 Table 14 1 Coarse particles result in the sudden failure of components Solid particle contamination 2 Fine particles cause wear internal leakage control inaccuracy jamming of valves and the form
31. g storage and re commissioning Dependent on the storage conditions and storage time the appropriate anti corrosion measures are to be carried out see 3 2 Storage When re commissioning the commissioning guidelines are to be taken into account see 4 Commissioning 6 2 Decommissioning and disposal The individual materials are to be disposed taking the environmental requirements into account Particular care has to be taken with components that contain pressure fluid residues The pressure fluid safety data sheet guidelines are to be observed when carrying out any disposal activities Copyright reserved
32. ging the filter element see Maintenance 5 2 4 Attention The safety guidelines and the qualification requirements for maintenance 5 2 1 are to be observed Air breathers permit filtered air to be exchanged in the oil reservoir when the oil level fluctuates The correct function is to be checked dependant upon environmental conditions and if necessary replaced Accumulators Accumulators are pressure vessels and the local place of use safety regulations apply see Product specific operating instructions In addition to the prescribed checks the gas pressure also has to be monitored Measuring checking the gas pre charge pressure takes place by the means of a test charging kit see Product specific operating instructions Before dismantling the accumulator the oil side must be de pressurised Attention Only use nitrogen as the pre charge gas nitrogen to class 4 0 reinst N2 99 99 Vol as carelessness and incorrect procedures can lead to serious accidents No welding brazing or any mechanical work in any form or manner is permitted on the accumulator vessel See Product specific operating instructions for accumulators Hoses A Particular care must be taken when working on systems which contain accumulators Warning Hazards The incorrect use or selection of hoses can lead to fatal accidents personal injury and material damage Storage and service life Even when hoses have been correctly stored and applied
33. have to remain filled it is sufficient to fill the built on components e g pumps filters valves etc Notes on reservoir internal paint finish Reservoirs intended for use with a HLP pressure fluid are protected against corrosion by means of an inner coating zinc dust coating to AB E 01 03 05 RAL 7000 Table 4 Storage time in months Packing Protective Storage condition suitable for medium Storage in dry constant temperature rooms Storage in the open Sea freight protected against damage and water ingress Non sea freight Test with protective medium A Mineral oil ME ill with protective medium B Corrosion prevention oil If the storage period is longer than as stated in table 4 the components especially the hydraulic pumps have to be dismantled and cleaned in a suitable cleaning fluid to remove any protective medium residues the seals also have to be changed Notes on external protection The exterior is protected using coating methods corrosion protection as stated in AB E 01 03 05 For storage up to six months in dry constant temperature rooms It is sufficient to used the under coat Epoxy to AB E 01 03 05 If the storage period exceeds six months the relevant top coat should be applied see AB E 01 03 05 Copyright reserved 3 2 4 4 1 4 2 4 2 1 4 2 1 1 4 2 1 2 Page 19 37 Operating instructions for hydraulic systems AB E 01 01 02 2003 02 24 Guidelines for packing hydraulic c
34. he documentation provided with the accumulator s is to be carefully filed so that they are available for subsequent inspections by a specialist Copyright reserved 4 2 4 Page 21 37 Operating instructions for hydraulic systems AB E 01 01 02 2003 02 24 Accumulators are to be pre charged to the values stated on the circuit diagram Filling and testing takes place via a test filling assembly for this see Product specific operating instructions Attention Only use nitrogen as the filling gas nitrogen class 4 0 reinst Nz 99 99 Vol The operator is responsible in ensuring that the checks before commissioning and the subsequent repeat inspections tests are carried out Piping systems Are to be checked to ensure that they are in a safe operation condition by a responsible person Filling the pump housing for pumps with a drain connection the housing has to be filled with pressure fluid also see Product specific operating instructions Commissioning Open isolator valves in the suction line if fitted Slowly start the drive motors Electric motors in inching mode combustion engines in the idle mode Ensure direction of rotation is correct Bleed the system in the actuator lines at the highest possible point Actuate directional valves and extend and retract the actuators several times Slowly increase the load Complete bleeding has been carried out when there is no foam in the reservoir actuators do not mak
35. ic system Haapt area Protective measure s Relevant residual risks safety guidelines standards Noise De couple the hydraulic system an Classification level Anti noise hood Sound insulation AB E 43 01 gt 85 dB A at the gt 90 dB A cover AB E 01 02 05 place of work Provide appropriate ear protection Do not use the hydraulic system and pipe work as steps Hydraulic system in general Remove any traces of hydraulic oil from steps platforms walkways The general safety regulations must be complied with Particular care has to be taken with components installed in the reservoir as Parts falling during the weight and centre of gravity can not assembly disassembly of the always be directly recognised hydraulic system or individual see 5 2 7 vertically mounted motor components pump assemblies The general safety regulations must be taken into account Only components stated within the parts list may be exchanged by new identical tested components of original equipment All components during quality maintenance Components may only be dismantled for repair purposes as described within the component specific operating instructions Via appropriate maintenance it is to be ensured that it is not possible to come Electrical shock Electrical equipment into contact with live components due to isolation breaks caused by early aging or damage due to improper use Basic hazards The required protective measures
36. inen Hersteller Manufacturer Fabricant Bosch Rexroth AG Industrial Hydraulics Postfach D 97813 Lohr am Main Bauteil Baugruppe Component Sub assembly Composant Sous groupes Seriennummer Auftrags Nr Serial number Order Nbr Numero de serie Commande No Baujahr Date of construction Date de fabrication Stellung im Betrieb Position Position 222220000 Datum Unterschrift Date Signature Date Copyright reserved im Sinne der EG Maschinen Richtlinie 98 37 EG Anhang II Abschnitt B as defined by EC machinery directive 98 37 EC Annexe Il Section B au sens de la directive machines de la CEE 98 37 CEE Annexe Il Section B The manufacturer declares that the components sub assemblies delivered have been manufactured in accordance with the stated harmonized standards specifications The components sub assemblies must not be operated until the machine into which these components sub assemblies are to be incorporated has been declared in conformity with the provisions of the directive Applied harmonised standards EN 292 1 11 1991 Safety of machines EN 292 2 06 1995 Basic concepts general principles for design EN 982 09 1996 Safety requirements on fluid power installations and components Hydraulics EN 983 09 1996 Safety requirements on fluid power installations and components Pneumatics EN 60 204 1 06 1993 Safety of machinery electrical equipm
37. ions For details of material defect liability please refer to the contract documents 2 3 Personnel qualification Hydraulic technical knowledge means that personnel must Be capable of reading and fully understand hydraulic circuits In particular fully understand the interrelationship of the built in safety systems and Have knowledge regarding the function and build up of hydraulic components A qualified person is one who due to his technical training and experience has sufficient knowledge that he Can evaluate the work transferred to him Can recognise possible hazards Can instigate measures to eliminate hazards And has the required repair and assembly knowledge 2 3 1 Personnel for maintenance and inspection chapter 5 1 The following requirements have to be fulfilled Experienced personnel Hydraulic technical knowledge is required A Filter and oil changes belong to the maintenance activities Care 2 3 2 Personnel for commissioning chapter 4 maintenance chapter 5 2 and de commissioning chapter 6 The following requirements have to be fulfilled Experienced personnel Hydraulic technical knowledge is required EN 50110 1 VDE 0105 1 operation of electrical installations applies for any work that is to be carried out on the electrical system A Incorrectly carried out work can cause injury as well as present a safety hazard in the operation of the system including a danger to life Danger
38. l water coolers The cleaning intervals are dependent on the water quality the temperature and the water flow Cleaning is also dependent on the cooler type Set values Pressure valves flow valves and pump controls as well as signal elements e g pressure switches limit switches temperature controllers etc are all set during the first commissioning Checks should be carried out to ensure that these values have not changed Adjustments of valves for setting operating pressure are critical e g variable displacement pump pressure controllers With incorrect settings i e if the difference between the operating pressure and safety valve pressure is too small see 1 3 4 then the safety valve opens during normal operation which increases losses and causes a large increase in the pressure fluid temperature Copyright reserved Page 28 37 AB E 01 01 02 2003 02 24 Operating instructions for hydraulic systems 5 1 8 Maintenance and inspection intervals Table 5 Commissioning Continuous Kou Words 1st week operation y Pressure fluid Oil level OOo D J D KS 14 nn Ds fe ke Condition oil sample visual 1000 h een Wetec ol Without an analysis replace after p 4000 h hours Analysis change 4000 h If the analyse is ok then remove oil sedimentation to 4 1 2 Monitoring clogging indicators D DP Check the air breather 500h Dependent on the ambient 5 1 3 2 conditions Accumulators Check the gas pres
39. lves Entrapped air in the pressure fluid see I Drive 1 Hydraulic motor speed below minimum limit 11 cylinder motor 2 Stick Slip Effect jerky movement with cylinder the lower the stick friction the lower the cylinder speed can be 12 Others 1 Insufficient load holding on the return side of the drive 2 The system has not been fully bled 5 2 5 4 Fault effect D The drive does not move or is too slow none or insufficient flow _9 Directional valves Drive cylinder motor SECH The start conditions have not been met Electrical control lines plugs 12 Others disconnected signal elements e g pressure switches are incorrectly set or defective or limit switches are not being Copyright reserved Page 33 37 Operating instructions for hydraulic systems AB E 01 01 02 2003 02 24 5 2 5 5 Fault effect E The drive does not stop or follows on Table 10 1 Do not close or are too slow due to back pressures Isolator valves b f 2 The valve seat is contaminated or defective 1 Switching time adjustment is too slow 2 The drive creeps due to the internal leakage of the valve design constrictions ine Internal leakage e g due to worn out cylinder seals 1 The system has not been adequately bled 2 The electrical signal processing from the contact switch to the adjustment element is defective or too slow 3 The valve spool jams e g due to contamination Directional valves
40. m be checked immediately A further aspect is the simplified processing of possible guarantee claims 5 1 2 Pressure fluid 5 1 2 1 Pressure fluid temperature A maximum oil reservoir temperature of 55 C is recommended for mineral oil as an increase in the operating temperature results in an accelerated ageing of the oil and a reduction in the service life of seals and hoses 5 1 2 2 Pressure fluid condition The ageing and contamination of the pressure fluid is dependent on a multitude of operating conditions such as temperature operating pressure filtration increases of contamination from the environment via the breather systems and movement seals between moving parts air humidity etc A visual check can only give a rough estimation the pressure fluid becoming opaque looking darker than at the time of filling sediment in the reservoir A laboratory check is recommended Corrective action is dependant on the results Ageing and or sedimentation Fluid is to be changed Contamination the cleanliness class is not being maintained Filtration via a separate filtration unit To remove sedimentation and large volumes of water it is recommended that approx 90 of the reservoir volume is removed via an external filtration unit and cleaned The rest is to be removed complete with the contamination and water and to be subsequently disposed of 5 1 2 3 Changing the pressure fluid For oil that is not subject to laboratory m
41. n the hose is manufactured the hose itself stock length should not be older than four years Details for procurement of spare parts regarding dimensions requirements testing and identification are contained in DIN 20066 Hoses Inspection criteria excerpt from DIN 20066 Functionality in respect to the recommendations stated within 5 1 8 Maintenance and inspection intervals is to be checked Replacing hoses Hoses are to be replaced when during the inspection the following criteria are determined 1 Damage to the external layer down to the wire textile braiding e g rubbing points cuts or tears 2 Enbrittlement of the outside layer rips in the hose material 3 Deformation of the hoses natural form in the de pressurised and pressurised condition also see DIN 20066 Leakage points Damage or deformation of the hose fitting taking the sealing function into consideration small surface damage is no reason to change the hose Evidence that the hose is coming out of the fitting Function and strength reducing corrosion of the fitting The installation requirements of the hose have not been observed see DIN 20066 The storage and in service life has been exceeded oa E oO ON OD If the user has no details regarding the storage and in service life then the standard values are recommended Coolers Oil air coolers are dependent on the ambient conditions to be regularly cleaned Oi
42. omponents and units If packing is opened for inspection purposes then it is to be carefully resealed With packing suitable for sea freight the desicannt material also has to be renewed For further information regarding internal conservation see AB E 01 02 11 Commissioning General notes Attention EC MCD EC Machinery Directive annex IB states that commissioning cannot take place until it has been determined that the machine into which this machine hydraulic system is to be built into conforms to all of the relevant EC regulations see 1 7 Manufacturers declaration and 2 5 Responsibilities and obligations of the machine manufacturer operator Combining components can result in further other hazards occurring It is therefore a requirement that the guidelines stated within the complete machines operating instructions are taken into account This of particular importance for mechanical hazards EN 292 1 section 4 2 that could occur due to machine movements initiated by the hydraulic system and drives cylinder motor Safety See 2 4 Basic safety guidelines Personnel qualifications Commissioning may only be carried out by trained and instructed personnel with specialised hydraulic knowledge see 2 3 Personnel qualifications Cleanliness During all kinds of work great emphasis is to be placed on cleanliness as contamination can lead to faults and can influence the correct function of the componen
43. onitoring an oil change is necessary after successful first commissioning and each time approx 4000 operating hours have been reached A prerequisite is however that the maximum oil reservoir temperature of 55 C has not been exceeded and that regular filter monitoring and filter element changes have taken place Via the appropriate oil maintenance and monitoring of the pressure fluid the oil change intervals can be greatly increased If the fluid volume falls below the marked minimum level faults can occur see Fault effects 5 2 5 A10 H12 the pressure fluid level is therefore to be checked and if necessary oil is to be added Take care to ensure that when filling the same type and make of oil is used 5 1 3 Filter monitoring 5 1 3 1 Filters with a clogging indicator Filters with clogging indicators permanently measure the degree of contamination The contamination retention capacity of the filter is fully utilised see 1 3 3 Filtration monitoring Attention is to be paid when filter elements rarely or never have to be replaced Clogging indicators does not show filter element change required If the clogging indicator is functional then the filter element is defective or the bypass valve if fitted does not close correctly e g due to entrapped particle Copyright reserved Page 26 37 AB E 01 01 02 2003 02 24 Operating instructions for hydraulic systems 5 1 3 2 5 1 4 5 1 5 1 5 1 5 2 5 1 5 3 Chan
44. or those for the user relevant rises results from the rise analysis of the entire machine Warning Copyright reserved Page 13 37 Operating instructions for hydraulic systems AB E 01 01 02 2003 02 24 1 7 Herstellererklarung nach RDEF 00025 10 01 Mobile Hydraulics Service Automation Linear Motion and Assembly Technologies Electric Drives and Controls Industrial Hydraulics RDEF 00 025 10 01 Ersetzt Replaces Remplace 11 00 Rexroth Bosch Group Pneumatics EG Herstellererkl rung EC Declaration by the manufacturer Declaration CEE du fabricant Der Hersteller erkl rt dass die gelieferten Bau eile Baugruppen in bereinstimmung mit den angewendeten harmonisierten Normen Spe zifikationen hergestellt worden sind Die Inbetriebnahme dieser Bauteile Baugrup pen ist solange untersagt bis festgestellt wur de dass die Maschine in die diese Bauteile Baugruppen eingebaut werden sollen den Be stimmungen der EG Richtlinie entspricht Angewendete harmonisierte Norm EN 292 1 11 1991 Sicherheit von Maschinen EN 292 2 06 1995 Grundbegriffe allgemeine Gestaltungs eits tze EN 982 09 1996 Sicherheitstechnische Anforderungen an fluid chnische Anlagen und Bauteile Hydraulik N 983 09 1996 icherheitstechnische Anforderungen an fluid tech ische Anlagen und Bauteile Pneumatik N 60 204 1 06 1993 icherheit von Maschinen Elektrische Ausr stung von asch
45. ow see B 12 2 3 The controller is defective 1 The operating pressure is set too low see B 12 2 2 The valve seat is contaminated damaged or worn 3 The safety valves are set too close to the operating pressure relief valve d gt 20 bar so that flow can pass to tank Incorrect settings see B 12 2 8 Isolator valves See B 12 2 ER Incorrect switched position e g zero pressure circulation the valve does not Directional valves f d switch or the spool jams see B 12 2 1 The viscosity is too low gt leakage is too high 2 The viscosity is too high gt flow resistance is too high Drive 1 Internal leakage e g worn cylinder seals 11 cylinder motor 2 Friction is too high in the cylinder e g due to side loading at the piston rod or seal y elements 12 Others 1 Check the display instruments 2 The sum of the flow working resistance and or leakage is too high 5 2 5 3 Fault effect C Uneven drive movements Table 8 6 Pressure valves Pressure fluid Fluctuating flows with variable displacement pumps caused by 1 Defective pump controller 2 Unsuitable pilot control valve 3 Influences from the system acting io the controller 4 See B 3 2 6 Pressure valves 1 Changes to the flow rates at the throttle valves due to pressure changes 7 Flow valves 2 Fluctuations at the pressure compensator when the natural frequency of the drive is low Isolator valves See A 8 2 8 _9 Directional va
46. raulic drives which cause mechanical movements This necessitates a hazard analysis and operating instructions for the entire machine Definitions EN 1070 Hydraulic fluid technology Transmission control and distribution of energy and signals by utilising a pressurised fluidic medium System Components that are interconnected such that they can transmit and control fluidic energies Components An individual unit e g valve filter cylinder motor which comprises of one or more components and is a functional part of a hydraulic system Drive A component that converts the energy from the pressure medium into mechanical energy e g motor cylinder Piping system Any combination of connections couplings or pipe connections hoses or pipes that permit the pressure medium to flow between the components Max operating pressure The highest pressure at which the system or part of the system may be operated under constant conditions 1 2 Intended purpose scope of supply The hydraulic system is designed for the generation control and regulation of oil flows for hydraulic drives in machines The product specific documentation scope of supply performance data and functions is detailed within the order see order technical pre amble or quotation check list parts list circuit general assembly drawing as well as the test and acceptance certificates If hydraulic drives are shown within the hydraulic circuit this is only to aid understan
47. reserved Page 24 37 AB E 01 01 02 2003 02 24 Operating instructions for hydraulic systems 4 3 3 4 3 3 1 4 3 3 2 5 1 5 1 1 5 1 1 1 5 1 1 2 5 1 1 3 5 1 1 4 Oil type selection HLP DIN 51524 part 2 Mineral oil based hydraulic fluids with additives for increased corrosion protection ageing resistance and increased wear protection HV multi grade hydraulic oil Hydraulic oils with a particularly low viscosity temperature relationship The other characteristics are as HLP oils Maintenance As defined by DIN 31051 encompasses all measures required to maintain and restore as well as to determine and assess the actual condition of technical systems These measures are divided into three categories Maintenance Measures to maintain the required condition Inspection Measures to determine and assess the actual condition Corrective maintenance Measures to restore the required condition In this way the functionality of the hydraulic system can be ensured in the most economic manner Bosch Rexroth systems are so designed that they have high functionality operational safety service life They only require minimum maintenance This is however necessary to guarantee the functionality of the system From experience 70 of all faults and damage to hydraulic systems is indirectly caused by the pressure fluid Therefore the primary inspection and maintenance work is in checking and carrying out me
48. s and hose fittings partially lie above the values stated in DIN EN ISO 8434 1 Only components from manufacturers that guarantee these higher pressures are to be used Warning The pipes are to be cleaned of dirt slag and chips before installation Welded pipes in particular must be internally clean and flushed Rags must not be used for cleaning purposes The installation instructions of the fitting manufacturer are to be observed Fittings with a soft seal at the interface between the body of the fitting and the component into which it is to be fitted are recommended pipe thread to ISO 1179 2 metric threads to ISO 9974 2 Sealing materials such as hemp and putty are not permissible as they cause contamination and can therefore cause functional faults Bosch Rexroth recommends the Walform pipe forming system to AB E 20 06 Hoses must comply with all of the associated European and or international standards see 5 1 5 Hoses Connection ratings are to be checked before electrical installation of the drive and controls Connect cooling water if required Filling the system When filling the system cleanliness is most important Clean the filling screw and the plug on transport and storage containers before opening them Check the oil reservoir for contamination and clean if necessary Fill the oil reservoir with the specified or a suitable pressure fluid The correct pressure fluid in particular the viscosity is a deciding factor for
49. se up to 1000 m above sea level 20 50 C For control units Copyright reserved Page 10 37 AB E 01 01 02 2003 02 24 Operating instructions for hydraulic systems 1 4 3 1 4 4 1 4 5 1 4 5 1 Protection A minimum of IP 55 with fitted and secured electrical connections Attention With vertical mounted electrical motors that do not have a protective cover means are to be provided so that water and dust cannot enter directly Pressure fluid Mineral oil based hydraulic oil to DIN 51524 part 2 other mediums on request Temperature Recommended for continuous operation 25 55 C permissible min max 0 80 C Viscosity Recommended for continuous operation 20 100 mm s max permissible 12 500 mm s see 4 3 2 pressure fluid viscosity class selection Contamination The permissible degree of contamination undissolved foreign bodies in the pressure fluid is dependent on the most contamination sensitive component within the system The stated cleanliness class is the maximum permissible value which should not be exceeded taking consideration of Operational safety clogging of gaps orifices as well as sticking spools and the service life wear reduction see 4 3 1 Pressure fluid demands and tasks see filter concept AB 01 02 35 Required cleanliness classes to ISO 4406 KL 21 18 15 External gear pumps piston and vane pumps directional pressure flow and check valves proportional
50. sed through appropriate maintenance Copyright reserved Page 30 37 AB E 01 01 02 2003 02 24 Operating instructions for hydraulic systems 5 2 3 5 2 4 5 2 4 1 5 2 4 2 5 2 5 Removing fitting components The guidelines stated within the component specific operating instructions that are provided with the replacement component are to be observed General guidelines to prevent control spools jamming hydraulic components have to be fitted free of tension Mounting surfaces must therefore be flat The fixing screws are to be evenly tightened to the prescribed tightening torque When working on systems that contain accumulators particular care and attention is required as improper actions lead to serious accidents No welding brazing or any mechanic work in any form or manner is permitted on the accumulator vessel The guideline stated within the accumulator operating instructions must be complied with Changing the filter element Attention The safety guidelines and qualification requirements for maintenance works stated 5 2 1 are to be observed Changing the element If the clogging indicator signals that the element is clogged then it should at the latest by the end of the shift be exchanged Care should be taken when replacing the element Exchanging or cleaning the filter elements Fibre elements must be replaced and must not be cleaned Used filter elements contain oil Let them drain throughly
51. served No part of this publication may be reproduced or stored processed duplicated or circulated using electronic systems in any form or by means without the prior written authorisation of Bosch Rexroth AG Industrial Hydraulics In the event of contravention of the above provisions the contravening party is obliged to pay compensation Copyright reserved 3 1 3 1 2 Page 17 37 Operating instructions for hydraulic systems AB E 01 01 02 2003 02 24 Transport and storage Transport Hydraulic systems can be dependent on the size and local conditions transported by means of a fork lift truck or lifting equipment A During transport the appropriate safety regulations are to be complied with Attention Only transport hydraulic systems without being filled with oil Bosch Rexroth hydraulic systems are delivered unfilled It is possible that oil residue from testing may be present in the product deviations see 3 2 1 Increased internal corrosion protection by filling Transport with a forklift truck Built on equipment components pipe work etc must not come into contact with the forklift truck Place the forks under the reservoir and Carefully lift and take care to ensure that the centre of gravity in correct stable Transport with lifting equipment Built on equipment components pipe work etc must not come into contact with the lifting equipment Suitable lifting equipment is to be attached to th
52. sure and 1 to 2 Repeat checks The regulations for the place of 514 operation apply Measurement visual touch acoustic check Operating pressure at the Ww pressure gauge External leakage Formation of drops of oil Be Air inlets of electric motors Contamination oil coolers Damage and secure fixing of 500 h Including wiring and electrical all components connections 1000h a Noises vibration W Running and flow noises 5 2 5 A switching shocks equipment Operating hours time scales D Daily W Weekly or after 40 operating hours 500 h Quarterly or after 500 operating hours 1000 h Half yearly or after 1000 operating hours 2000 h Yearly or after 2000 operating hours B As required If irregularities are found during the checks then the check intervals are to be shortened If the inspection results are documented and no negative points are found during the checks then the time periods can be extended This in particular applies to the oil analysis During the start up phase and long term operation with appropriate care and attention and the documenting of maintenance and inspection results in a maintenance handbook it is possible to carry out preventative maintenance Attention Negative trends in the test parameters e g pressure fluid temperature frequency of filter element replacement or noises indicate changes By using the fault matrix it is possible to localise the problem Copyright reser
53. trouble free operation of the system see 1 4 Operating and environmental conditions as well as 4 3 Pressure fluid Check the pressure fluid to ensure that there has been no ingress of water Do not remove filter sieves at the filling point or elements from filters during the filling process The base level of contamination of the pressure fluid which is to be filled into the reservoir must not exceed the maximum permissible cleanliness class see Flushing the system Experience has shown that new pressure fluids often lie above these values In such cases the pressure fluid is to be filled via a special filtration unit Recommendation To ensure that the cleanliness class is maintained filling should be carried out via filtration unit Monitor the maximum minimum fluid levels take into account the volumes contained within the interconnecting pipe work and actuators Before commissioning Valve settings Set the operating pressure valves Attention Not the safety valves and flow control valves to their lowest settable values and directional valves in the neutral position see 1 3 4 Safety against non permissible pressures The command values for proportional valves should also be reduced Accumulators If accumulators are fitted in the hydraulic system then the local regulations are to be observed before commissioning and during operation Product specific operating instructions are provided for each accumulator T
54. ts Before loosening fittings and components the immediate outside area has to be cleaned all openings are to be closed by means of protective caps so that contamination cannot enter the system Rags are not to be used for cleaning purposes Painting If hydraulic systems are to be repainted then care is to be taken to ensure that elastic materials seals hoses anti vibration mount etc labels indicators scales of measuring and control equipment running surfaces of cylinders and valve mounting surfaces as well as connections are covered protected Commissioning of functionally tested hydraulic units Building in or on Visual check for transport damage and contamination Long storage times can lead to the seals becoming brittle and that the anti corrosion oil becomes resinous see 3 2 2 Carrying out internal conservation Installation and fixing of units and sub assemblies Care has to be taken to ensure that there is sufficient space available for access operation and maintenance as well as the orientation and mounting of components and systems so that stability and operational reliability is ensured Copyright reserved Page 20 37 AB E 01 01 02 2003 02 24 Operating instructions for hydraulic systems 4 2 1 3 Connecting the hydraulic drive 4 2 2 4 2 3 The interconnecting pipes are to be dimensioned in accordance with the performance data stated within the circuit The required nominal pressures for fitting
55. ved 5 2 5 2 1 5 2 1 1 5 2 1 2 5 2 1 3 5 2 2 5 2 2 1 5 2 2 2 5 2 2 3 Page 29 37 Operating instructions for hydraulic systems AB E 01 01 02 2003 02 24 Repairs General guidelines Personnel qualifications Repair work must only be carried out by trained and instructed personnel who have specialised hydraulic knowledge see 2 3 Personnel qualifications Safety Due to safety reasons no pipe joints connections and components are to be loosened as long as the system is pressurised Lower all loads unload accumulators switch off pumps and secure them from being switched back on The general safety regulations are to be observed see points 1 6 Residual risks and 2 4 Basic safety guidelines Cleanliness During all work particular care is to be taken with regard to cleanliness Before loosening any fitting or components the immediate area has to be cleaned All openings are to be plugged with protective caps so that contamination cannot enter the system Do not use rags for cleaning Maintenance tasks Fault finding Determining damage or preventive maintenance Determining and localising the potential fault source s To successfully carry out fault finding within a hydraulic system knowledge regarding the design and operation of the individual components is a pre requisite Hydraulics combined with electrics electronics naturally complicate fault finding and necessitate the co operation of hydraulic an
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