Basic Hyd Components - REXROTH

RE 09960-B/04.
08
“Basic Hydraulic Components Kit”
Training System
Operation Manual
Operation Manual Basic Hydraulic Components Kit | RE 09960 Bosch Rexroth AG 3/36
Notes
Table of Contents
1 About this Manual.......................................................................................... 4
Related Documentation ................................................................................... 4
2 Principal Safety Instructions........................................................................... 5
Intended Use ................................................................................................... 5
Non-Intended Use ........................................................................................... 5
Qualification of Staff......................................................................................... 5
Warning Notices in this Manual ....................................................................... 7
You have to Observe the Following ................................................................. 7
Obligations of the Operator............................................................................ 10
Safety Devices............................................................................................... 10
Training Stations............................................................................................ 11
3 Scope of Delivery ........................................................................................ 12
4 Product Description ..................................................................................... 13
Specification .................................................................................................. 13
Device Description......................................................................................... 14
Operating and Display Elements ................................................................... 15
Drive module ................................................................................................. 15
Identification of the Product ........................................................................... 17
5 Transport and Storage ................................................................................. 18
6 Assembly..................................................................................................... 19
Mounting the Frame ...................................................................................... 20
Assembly of Hydraulic Components .............................................................. 21
7 Commissioning ............................................................................................ 24
Initial Commissioning..................................................................................... 24
8 Operation .................................................................................................... 26
9 Maintenance and Servicing.......................................................................... 27
Cleaning and Maintenance ............................................................................ 27
Maintenance Schedule .................................................................................. 28
Maintenance .................................................................................................. 29
10 Decommissioning ........................................................................................ 31
11 Disassembly and Replacement.................................................................... 31
12 Disposal ...................................................................................................... 31
Environmental Protection............................................................................... 31
13 Fault Finding and Troubleshooting............................................................... 32
14 Extension and Transformation ..................................................................... 32
15 Technical Data............................................................................................. 33
16 Index ........................................................................................................... 33
4/36 Bosch Rexroth AG Operation Manual Basic Hydraulic Components Kit | RE 09960
Notes
1 About this Manual

This manual contains important information for the safe and appropriate transport,
installation, commissioning, operation, maintenance, disassembly, and
independent troubleshooting of simple malfunctions of the basic hydraulic
components kit.
X Please read this manual thoroughly, particularly the chapter on “Principal
Safety Instructions” on page Fehler! Textmarke nicht definiert., before working
with the basic hydraulic components kit.
Related Documentation
Please also observe the following manuals:
Data sheet RE 51142 “Clamping and Drive Module, type UPE2”.
Data sheet RE 07008 “General Product Information for Hydraulic Products”.
Please also observe the generally valid legal and other relevant provisions of the
European and/or national legislation as well as the provisions on the prevention of
accidents and on environmental protection valid in your country.
The data specifed 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 rememebered that our products
are subject to a natural process of
wear and aging.
© This document, as well as the

data, 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.
Subjet to revision.
Printed in Germany.
RE 09960-B/04.08
Mat. - Nr. R961004689

Notes
2 Principal Safety Instructions

The basic hydraulic components kit was manufactured according to the state of
the art. Nevertheless, there is a risk of personal injury and damage to property if
you do not comply with the following principal safety instructions and the warning
notices indicated before the instructions given in this manual.
X Read this manual carefully and completely, before working with the basic
hydraulic components kit.
X Keep the manual at hand for future reference by any user.
X Hand over the basic hydraulic components kit to third parties only together
with this manual.
Intended Use
The basic hydraulic components kit is a product complying with the Machinery
Directive 98/37/EC (entire machine).
X Observe the specification limits indicated in the technical data.
The basic hydraulic components kit must only be used in order to convey
hydraulic skills and knowledge in the framework of commercial technical
education and further education.
For the development of control circuits and simulations, only devices and device
kits approved for the basic hydraulic components kit must be used.
The basic hydraulic components kit is a technical working appliance and not
intended for any private use.
The intended use is also based upon the provision that you have completely read
and understood this manual, particularly chapter 2 “Principal Safety Instructions”.
Non-Intended Use
The basic hydraulic components kit must never be used with actuators and
components other than those provided in the framework of the basic hydraulic
components kit.
The drive module must not be used for continuous duty. After an operation of
15 minutes at most, it must be switched off and not be used for 30 minutes.
Non-intended use is any use of the basic hydraulic components kit other than the
use described in chapter “Intended use”.
The connection of several pressurized circuits is forbidden.
It is also prohibited to use the training system, both during the technical exercises
and out of lessons, for amateurish or unprofessional purposes.
Qualification of Staff
Training Lessons
Trainees and apprentices may work on the basic hydraulic components only
under direct supervision and in accordance with the instructions of the trainer or
qualified staff.
Trainer The trainer for the training system must be a skilled and qualified expert having
experience with electric, hydraulic and mechanical systems, as well as in the
mechatronics field.
The trainer must
Notes
give clear instructions, when trainees or participants in training courses are to

install control circuits on the “Basic Hydraulic Components Kit” training system.
check the installation and functional consequences of the control circuits,
before they are switched on, in order to ensure a safe operation.
answer any questions in a clear and easy-to-understand way.
Qualified staff Qualified staff can also be deployed for the monitoring of trainees during
exercises on the “Basic Hydraulic Component Kit” training system.
This includes qualified persons who were instructed and informed about:
assigned tasks,
possible risks in case of inappropriate use,
safety devices and protective measures.
Transport, Installation, Assembly and Commissioning

Any installation, connection, maintenance, or repair works on the “Basic Hydraulic
Components Kit” training system must only be carried out by authorized and
skilled experts or by any person having sufficient qualification or authorization.
People entrusted with works to be carried out on the “Basic Hydraulic Component
Kit” training system must be able to understand the instructions given in this
documentation as well as to also carry out any missing instructions on the basis
of their own professional qualification.
Troubleshooting, Maintenance and Repair

Maintenance and repair works as well as fault finding and troubleshooting
measures require special knowledge and must only be carried out by qualified
experts!
Works on electrical equipment must only be carried out by a qualified electrician
or by any other instructed person under the direction and supervision of a
qualified electrician according to electrical regulations.
Qualified electrician A qualified electrician is any person who, due to their professional training, their
skills and their experience as well as their knowledge of the relevant provisions,
can assess the works assigned to them, recognize possible dangers and take
suitable safety measures.
Works on hydraulic components must only be carried The
out data
by skilled
specifedstaff
abovewith
only
special knowledge and experiences in the hydraulic field!
Hydraulic expert Special knowledge in the hydraulic field means that the staff must be able to read
and completely understand hydraulic diagrams, particularly completely
understand the interplay of the integrated safety devices, and have knowledge
about the functionality and structure of hydraulic components.
wear and aging.

Subjet to revision.
Printed in Germany.
RE 09960-B/04.08
Mat. - Nr. R961004689

Notes
Warning Notices in this Manual

In this manual, warning notices are given before an instruction, where there is a
risk of personal injury or damage to property. The measures described for the
prevention of risks have to be complied with.
Warning notices are structured as follows:
SIGNAL WORD! Type of danger!
Consequences
X Prevention measure
Warning sign (warning triangle): draws attention to the danger

Signal word: indicates the severity of the danger
Type of danger: indicates the type or source of the danger
Consequences: describes the consequences in case of non-compliance
Prevention measure: indicates how the danger can be avoided
The signal words have the following meaning:

Table 1: Meaning of signal words
Signal word Application
DANGER! marks an immediately threatening great danger which will surely

cause severe injuries or even death if the danger is not prevented.
WARNING! marks a possible danger which might cause severe injuries or even
death if the danger is not prevented.
CAUTION! points out to a possibly dangerous situation which could cause

moderate or minor personal injuries or damage to material if it is not
prevented.
If this information is not observed, this may lead to deteriorations in

the operating sequence.
You have to Observe the Following
General Notices
Observe the provisions on accident prevention and environmental protection
valid in the country of the user and at the workplace.
Only use Rexroth products when they are in technically perfect condition.
X Check the product for evident faults, such as cracks in the housing or missing
lead seals, screws, caps or seals.
Never modify or reconstruct the basic hydraulic components kit.
Only use the product within the specifications indicated in the technical data.
Notes
Persons who install, operate, disassemble, or maintain Rexroth products must

not be under the influence of alcohol, other drugs or medications that could
affect their ability to react.
Make sure that all the safety devices belonging to the product are available,
properly installed and fully functional. You must not modify the position of safety
devices, avoid them or make them ineffective.
If it is necessary, e.g. for commissioning or maintenance works, that you switch
off safety devices, you have to take measures guaranteeing that no dangerous
situations may arise for persons or property. Always consult the superior
operation manual of the machine or system in such case.
Never remove or damage lead seals attached by Bosch Rexroth.
The warranty only applies to the supplied configuration.
In case of incorrect installation, non-intended use and/or improper handling, the
warranty expires.
Never load the product mechanically in an inadmissible way. Never use the
product as a handle or step. Do not place any objects on the product.
Never switch on the system with uncoupled hoses.
Immediately replace defective couplings. Faults occur on the O-ring seals.
Do not close used Minimess connections with protecting caps. Contaminations
may lead to coupling leakage.
Never try to close coupling connections using force; always relieve the pressure
control valve. The connection can then be closed without any difficulties.
Never depressurize the hydraulic system by opening it (screwed connections).
During transport
Please note that the grid, the drive module and the hydraulic components must be
transported separately.
During assembly
Always depressurize and de-energize the relevant part of the system prior to
installation and/or prior to connecting or pulling a plug.
Prior to commissioning, make sure that all seals and caps of the plug
connections are built in correctly and undamaged, in order to avoid that fluids or
foreign bodies can penetrate into the product. The data specifed above only
During assembly, make sure everything is clean in order to prevent dirt from
penetrating into the hydraulic tubes and thus leadingcondition
to wear and malfunctions
or suitability for a certain
of the product. application can be derived from
Space requirement In order to be able to teach and learn on the training system how
given does not processes work,
release the user
the following space requirements are to be provided for the
from the“Basic Hydraulic
obligation of own
Components Kit” training system: judgment and verification. It must
wear and aging.

Subjet to revision.
Printed in Germany.
RE 09960-B/04.08
Mat. - Nr. R961004689

Notes
Fig. 1: Space requirement for the hydraulic basics components kit
Installation surface The table or surface, where the “Basic Hydraulic Components Kit” training
system is to be installed, must meet the following requirements:
The load capacity of the table (the installation surface) must amount to at least
75 kg.
The installation surface must be at least 150 cm long and at least 75 cm large.
The installation surface must be plane.
In order to guarantee an ergonomically favorable position for the operation of the

training system, the table height has to comply with the following instructions:
Work station (sitting): table height of 70-75 cm
Work station (standing): table height of 90 cm
During operation
Trainees and apprentices must only work on the training system under
supervision of trainers and skilled staff.
Restrict the access to the direct operating area of the system to persons
authorized by the operator. This is also valid, when the system is at standstill.
In case of an emergency, an error or other irregularities, switch off the system
and secure it against restarting.
During cleaning
Close all openings with the help of appropriate safety devices in order to
prevent the cleaning agent from penetrating into the system.
Never use solvents or aggressive cleaning agents. Clean the product with a
slightly humid non-fiber cloth. Use only water and, if need be, a mild cleaning
agent for this.
Do not use pressure washers to clean the system.
Notes
During maintenance and servicing

Carry out the maintenance works prescribed at the intervals stipulated in the
operation manual.
Make sure that the hose lines, connections and components are not loosened
as long as the system is under pressure and voltage. Secure the system
against restarting.
During disposal
Dispose of the product in accordance with the provisions valid in your country.
Dispose of the hydraulic fluid in accordance with the provisions valid in your
country.
Dispose of any hydraulic fluid residues according to the respectively valid safety
data sheets for hydraulic fluids.
Obligations of the Operator

The operator must make sure that the requirements for the installation and
assembly of the basic hydraulic components kit are met and
- ensure a safe installation of the training system by the staff and/or by persons
authorized by the operator.
- instruct their employees and/or employees of third companies about possible
risks on the site of installation.
- make sure that accident prevention regulations, safety instructions of the
professional associations as well as further in-house, local stipulations are
complied with.
The operator must provide sufficient lighting in the installation area of the
training system.
The operator of the “Basic Hydraulic Components Kit” training system must
instruct their staff at regular intervals regarding the following subjects:
- observation and compliance with the operating manual as well as legal
provisions
- intended use of the basic hydraulic components kit
- compliance with instructions of the works protection force and the operating
instructions of the operator
- behavior in an emergency serve to describe the product. No
Bosch Rexroth offers additional training courses incondi
special technical fields. An
tion or suitability for a certain
overview of the course contents is given in the internet under
http://www.boschrexroth.de/didactic. our information. The information
Safety Devices be rememebered that our products
In order to protect the operating staff, the training are subje
system ct to a natural
is equipped withprocess
the of
wear and aging.
following safety devices:
© This
hydraulic pressure limitation of the hydraulic unit with the document,
help of the as well as the
pressure
control valve data, specifications and other
protective sheathing of the cylinder exclusive property of Bosch
Hydraulic pressure limitation The training system must only be operated up to a maximum hydraulic operating
pressure of 50 bars. The pressure is limited to 50 barspartie
by means
s withoutofits a pressure
consent.
control valve. It is not possible to set a higher pressure on the pressure control
valve. Subjet to revision.
Printed in Germany.
Protective sheathing of the cylinder The stroke area of the cylinder is equipped with a fixed protective cap made of
transparent polymethyl methacrylate. RE 09960-B/04.08
Mat. - Nr. R961004689

Notes
Personal protective equipment

The operator must provide personal protective equipment (such as e.g. gloves,
safety boots, protective glasses, overalls etc.).
Training Stations
Subject to the use of the basic hydraulic components kit, the following training
stations are provided:
Table 2: Training stations on the basic hydraulic components kit

Work step Number of persons
Configuration 2
Operation 2
Notes
3 Scope of Delivery
The following is included in the scope of delivery:
operation manual for the basic hydraulic components kit
frame including grid 1,000x500x30
- pre-assembled: frame parts connected via two joints
- 2 cross members
Fig. 2: Scope of delivery of the frame
hydraulic components - party pre-assembled

wear and aging.

Fig. 3: Scope of delivery of hydraulic components data, specifications and other
1 Cylinder with measuring ports, 5 pressure-reducing valve
exclusive property of with
Boschhose
throttle valve and hose lines lines Rexroth AG. It may not be
2 Drive module with operating unit 6 hose linereproduced or given to third
3 Pressure gauge to be hung up on 7 2 screw-in pressure gauges
the grid Subjet to revision.
Printed in Germany.
4 Directional control valve with
throttle valve and hose lines RE 09960-B/04.08
Mat. - Nr. R961004689

Notes
4 Product Description
Specification
The basic hydraulic components kit is a components pack for beginners. It allows
conveying the following contents in the framework of industrial education and
further education:
identification of components
commissioning
how does pressure develop?
directional control valve, direction of travel of the cylinder
load pressure
setting the velocity, inlet throttle
change of pressure difference via the system pressure
change of pressure difference via the load pressure
pressure transmission, outlet throttle
pressure reduction, force-distance curve
Notes
Device Description
The basic hydraulic components kit comprises the following components:
Fig. 4: Individual components of the basic hydraulic components kit
1 Drive module 5 200 cm cylinder with throttle valve

2 Electric control unit with main 6 Pressure gauge
switch 7 Frame with grid
3 Manual directional control valve 8 Pressure gauge
with throttle valve The data specifed above only
4 Pressure-reducing valve
Pressure gauges The pressure gauges display the pressure in bars. application can be derived from
Frame with grid On the frame with grid, the individual components of theour basic hydraulic
information. The information
components kit are fixed. given does not release the user
Drive module The drive module serves to feed hydraulic fluid into thejudgment
hydraulic circuit.
and verification. It must
Electric control unit with main switch The drive module is switched on and off, respectively,be byrememebered
means of the that main
our products
switch. are subject to a natural process of
wear and aging.
Manual directional control valve The 4-port directional control valve with 3 outputs releases different groups of
lines. It is operated manually and reset by means of spring
© This force.
document, as well as the
Pressure-reducing valve With the help of the pressure-reducing valve, the pressure on working port A is
set.
Throttle valves The throttle valves serve to set the volumetric flow in the inletAG.
Rexroth lines of not
It may thebecylinder.
200 cm cylinder reproduced
Tension-rod type cylinder with one port each on the piston or given
and the rodtoside.
third For
reasons of protection, the cylinder is equipped with a protective sheathing.
Subjet to revision.
Printed in Germany.
RE 09960-B/04.08
Mat. - Nr. R961004689

Notes
Operating and Display Elements
Drive module
Fig. 5: Operating and display elements of the drive module
1 Oil filler cap 2 Level indicator with integrated

temperature control
Level indicator The optical level indicator fulfills the following functions:
“MIN” and “MAX” display for oil level and
visual control of the oil state
Temperature control The temperature control integrated in the level indicator serves to visually check
the oil temperature.
The indicating range of the operating temperature goes from +20 ｰC to a
maximum of +80 ｰC.
Notes
Hydraulic components
Fig. 6: Operating and display elements for hydraulic components
1 Pressure gauge 4 Pressure gauge

2 Main switch 5 Adjusting screws for throttle valves
3 Handle-operated lever for
directional control valve
Pressure gauges The pressure gauges display the pressure in bars.

Main switch The drive module is switched on and off, respectively, by means of the main
switch on the control unit. statements concerning a certain
Handle-operated lever for directional The handle-operated lever on the directional control valve releases
condition different
or suitability for a certain
control valve groups of lines. application can be derived from
Adjusting screws for throttle valves The adjusting screws serve to manually relieve the throttle valves.
wear and aging.

Subjet to revision.
Printed in Germany.
RE 09960-B/04.08
Mat. - Nr. R961004689

Notes
Identification of the Product

The name plate of the drive module for the “Basic Hydraulic Components Kit”
training system is attached to the top side of the drive module.
Fig. 7: Name plate of drive module

Notes
5 Transport and Storage

For the transport and storage of the kit, you must comply with the ambient
conditions indicated in the technical data (see “Technical Data” on page 33).
Please note that the grid, the drive module and the hydraulic components must be
transported separately.
The drive module must always be transported and stored vertically - i.e. with the
handle pointing to the top.

wear and aging.

Subjet to revision.
Printed in Germany.
RE 09960-B/04.08
Mat. - Nr. R961004689

Notes
6 Assembly
CAUTION!
Risk of personal injury and damage to property!
Any irregularities, deviations, defaults, or vices may lead to personal injury or
damage to products.
X Examine the cause and repair the default.
X Replace the defective component.
X Do not put the basic hydraulic component kit into operation or switch off the
training system immediately.
Preparations for installation An impeccable installation is based upon the fact that:
all required components are within reach and operational,
required auxiliary means, such as lifting gears, ladders and stepladders,
barriers are provided.
Before the final installation, the following items have to be checked:

Are the clearance required for the basic hydraulic components kit and the
safety distances to other fixed installations complied with (for corresponding
instructions, see page 9)?
Is the installation surface plane?
Does the installation surface have the required load capacity?
Is the installation surface sufficiently dimensioned?
Is an electrical connection available?
Are the light conditions at the site of installation sufficient?
Unpacking Dispose of the packaging in accordance with the provisions applicable in your
country.
Installation conditions For the installation, you must comply with the ambient conditions indicated in the
technical data (see “Technical Data” on page 33).
Required tools 5 mm Allen key
Notes
Mounting the Frame
Fig. 8: Arrange pre-assembled frame parts vertically
X For the assembly of the frame, arrange the frames already connected via
joints in a vertical manner.

wear and aging.
Fig. 9: Cross member © This document, as well as the

1 Sliding blocks 2 Screws exclusive property of Bosch
1. Remove the covering caps from the frame's ends. parties without its consent.
2. Loosen the screws on both sides on the delivered cross members, until the
Subjet to revision.
sliding blocks can be slightly pulled out. The screws, however, should not be
Printed in Germany.
removed completely.
RE 09960-B/04.08
3. Now, push the sliding blocks on both sides into the frame’s profile.
Mat. - Nr. R961004689
Notes
4. Align the cross members at the height of the bottom cross member of the
frame.
5. Tighten the loose screws on the cross members again.
6. Tighten the two screws on the upper joint.
7. Put the frame’s covering caps on the free frame's ends.
X Turn the frame by 180°.
X Repeat steps 1 to 6 on the other side of the frame.
X Put the frame on the installation surface.
The frame is now completely mounted.
Assembly of Hydraulic Components
CAUTION!
Risk of personal injury or damage to property!
The installation of the product requires basic hydraulic knowledge.
X The product must solely be assembled by qualified personnel (see
“Qualification of Staff” on page Fehler! Textmarke nicht definiert.).
All hydraulic components - with the exception of the drive module and the screw-
in pressure gauges - are hung up on the grid. The mounting unit is provided on
the back side of the respective component.
Mounting on the grid
Fig. 10: Example of holder
X For this, push at first the longer part of the mounting unit through the grid.
X Now, lift the mounting unit in order to also push the lower part of the mounting
unit behind the grid.
X Guide the component down, until it is safely mounted in the grid.
Notes
Fig. 11: Arrangement of hydraulic components
1 Drive module 5 200 cm cylinder with throttle valve

2 Electric control unit with main 6 Pressure gauge on the piston side
switch of the cylinder
3 Manual directional control valve 7 Pressure gauge on the piston side
with throttle valve of the cylinder
4 Pressure-reducing valve 8 Pressure gauge to be hung up on
the grid
X Put the frame on the work surface. condition or suitability for a certain
wear and aging.
Fig. 12: Holder of drive module
X Fix the drive module by means of the holder screwed to the bottom right to the
frame. Fix the two sliding blocks of the holder in the frame's profile.
X Hang up the electric control unit at the right bottomreproduced
of the grid.
or given to third
X Hang up the manual directional control valve with throttlewithout
parties valve,its left
consent.
to the
control unit, on the grid. Subjet to revision.
X Hang up the pressure-reducing valve, left to the directional control valve, on
Printed in Germany.
the grid. RE 09960-B/04.08
Mat. - Nr. R961004689

Notes
X Hang up the cylinder, above the directional control valve and pressure-
reducing valve, on the grid.
X Screw the pressure gauges to the measuring ports on the cylinder
X Hang up the pressure gauge, above the operating unit, on the grid.
The hydraulic components are now in the correct position.

Notes
7 Commissioning
Initial Commissioning
Checking the hydraulic feed Before the hydraulic unit can be switched on, the oil tank is to be filled.
The basic hydraulic components kit is partially pre-assembled and only delivered,
after tests have been carried out in the factory. During the transport, however,
defaults or damage can occur on the training system.
Before the hydraulic unit can be switched on, the oil tank is to be filled.
Before the commissioning, always check

the oil level,
the minimum pressure setting,
the electrical connection,
the hose lines for damage,
the hose couplings for tight fit,
whether all components are undamaged,
whether all attachment parts are correctly attached.
Filling the oil tank Inappropriate hydraulic fluids can lead to malfunctions and damage to the
hydraulic installation.
Do not use hydraulic fluid that is older than 1 year or that was stored outside.
Aging products or condensate are possible.
Do not mix different hydraulic fluids. Even if they are of the same type, different
hydraulic fluids have a different age and can - if mixed - lead to a deterioration
of the hydraulic fluid.
Provide the specified hydraulic fluid in a sufficient quantity (see chapter Technical
Data).
Provide the specified hydraulic fluid in a sufficient quantity (see chapter Technical
Data).
Requirements to be met for filling the oil tank: The data specifed above only
The hydraulic unit is switched off and the power plugstaistements
not connected.
concerning a certain
The hydraulic installation must be depressurized. condition or suitability for a certain
Provide appropriate cleaning cloths. application can be derived from
How the hydraulic unit is filled: from the obligation of own
X Clean the environment of the filler. judgment and verification. It must
X Loosen the filler and breather cap and lay them aside.
X Push the filter funnel into the oil filler. wear and aging.

CAUTION!
Risk of injury! information set forth in it, are the
Slip hazard due to leaking hydraulic oil. exclusive property of Bosch
X Immediately bind/dispose of leaking hydraulic fluid.reproduced or given to third
X Provide binding material before the filling or change of soil.
partie without its consent.
Subjet to revision.
Printed in Germany.
RE 09960-B/04.08
Mat. - Nr. R961004689

Notes
X Fill up hydraulic oil up to the “MAX” marking visible in the oil-level glass.
X Wait for about 15 minutes, until the hydraulic fluid settled down in the tank.
This is also valid, if you only refill partial quantities.
X Close the tank filler with the filler and breather cap.
X Remove any leaking hydraulic oil by means of the cleaning cloths.
X Always dispose of contaminated cleaning cloths according to the rules.
The oil tank is now refilled.
X In order to confirm the actual oil level of the hydraulic unit, the hydraulic fluid
must circulate in the system by means of the pump for about 20 minutes.
During this, the oil is filtered through the optional line filter. After the time
elapsed, the oil level is to be checked again and hydraulic oil is to be refilled, if
necessary.
Switching on the power supply X Connect the power plug to the socket (230 V).
X Switch the main switch provided on the operating module from “0” to “1”.
X Check the circuit after the first switch-on for leakages.
Notes
8 Operation
If, during operation or inspection, any irregularities, deviations, defaults, or wear
are noticed, you must in any case:
immediately switch off the training system.
examine the cause and remedy the default.
replace the defective component.
no longer put into operation the training system, if applicable.
All safety devices must be operational and complete.
The unit must only be switched on, after the hose lines P and T were connected
to the unit. Otherwise, there is a risk of quick heating of the unit and thus of
damage to the pump.
The unit was developed for the short-term duty cycle S3 only. After a duty time of
15 minutes at most, plan a resting period of about 30 minutes.
After each exercise, the unit must be switched off.
Switching on
X Prior to every switch-on, check the hydraulic fluid level.
X Before switching on the unit, check the hose and hose connections.
X Switch the main switch provided on the control unit from “0” to “1”.
Pressure relief
Before and after each exercise, the unit must be depressurized. There are three
possibilities to do this:
Depressurization on the pressure X Depressurize the adjusting spindle by turning it completely to the left.
control valve
The connection P to T is depressurized.
Depressurization on the directional X Pressure relief A to T:

control valve Operate the directional control valve manually in direction A.
X Pressure relief B to T: statements concerning a certain
Operate the directional control valve manually in direction B.suitability for a certain
condition or
Depressurization on the pressure- application can be derived from
X Completely depressurize the pressure-reducing valve.
reducing valve our information. The information
The connection A to T is depressurized.
wear and aging.

Subjet to revision.
Printed in Germany.
RE 09960-B/04.08
Mat. - Nr. R961004689

Notes
9 Maintenance and Servicing

Report any errors you detect to your superior in order for them to be repaired as
quickly as possible. Note that small errors may turn into great errors, if they are
not repaired in time.
Clean plastic components only with a slightly humid cloth!
Use only water and, if need be, a soft cleaning agent without chemical additives.
Never use solvents or aggressive cleaning agents!
Before using the cleaning agent, consult the operating instructions and the DIN
material safety data sheet for its scope of application and possible risks.
Never blow off dust from the training system with the help of compressed air,
since this could damage sensors and valves of the function modules.
If you have to remove oil, use appropriate binding materials and cleaning cloths!
Protect the training system from dust and humidity so as to make sure that it does
not contaminate and that you can use it for a long period of time.
Cleaning and Maintenance

When? Where? What? Remarks
Remove any parts lying around.

Complete training Clean the environment of the training
system system. Immediately remove any fluid from the floor,
bind it with an oil-binding agent and dispose
Clean and keep free work surfaces.
of it.
Handles
Daily /
Operating elements Before the beginning and after the end of the
before each
Display and visual Clean thoroughly. work, make sure the work surfaces and
use
installations, sight devices and device kits are clean!
glasses
Hydraulic components of Clean contaminated parts.

It is thus easier for you to detect and observe
the system and hose Immediately wipe up leaking oil with a leakages.
couplings cloth.
Keep clean all lines, hoses and screwed

connections. If the exterior (abrasive points, cuts, breaks,
Hydraulic lines and
embrittlements) is damaged, immediately
hydraulic hoses Check them for any leakage or externally
replace the hydraulic hoses.
visible damage!
Hose couplings Check the free movement. Replace them immediately.
Weekly Check all lines, hoses and screwed Check for leakages and visible damage.
Hydraulic unit connections for leakages or externally
Immediately have repaired any damage
visible damage!
Check electrical connection cables and

Complete training Have repaired any damage immediately by
lines for visible damage (abrasive points,
system the competent qualified electrician!
breaks, cuts).
Visual examination, check for damage and Tighten any loose screws etc. Immediately
Connecting elements
tight fit. have repaired any damage!
Notes
Maintenance Schedule
When? Where? What? Remarks
Oil tank Check the level: In case of low level:

above MIN? refill hydraulic fluid up to the MAX marking.
below MAX?
Fittings Check for externally visible damage! Have them replaced immediately in case of
Breaks on pressure gauges? damage!
Inform Bosch Rexroth customer service.
Hydraulic unit Running smoothness of motor and pump: Inform Bosch Rexroth customer service in
Noises? Vibrations? case of irregularities.
Daily / Hydraulic lines, hydraulic Check all lines, hoses and screwed Hydraulic hoses must be immediately
hoses connections for leakages or externally replaced, if:
before each
visible damage! the exterior is damaged (abrasive points,
use
cuts, breaks, embrittlements).
they are deformed in the pressurized or
depressurized state, if the hydraulic hose
lines do not have their natural forms.
Leakages.
Hydraulic hoses Check the compliance with replacement Exchange / Replacement 6 years after date
delays. of manufacture at the latest.
Hydraulic fluid Check the compliance with replacement Exchange / Replacement, see
periods. manufacturer's specification.
Pressurized circuit Switch the line filter to the circuit and filter applicationare
Any oil contaminations canremoved
be derived/ from
filtered
Once every the circulating oil for 15 minutes. out. our information. The information
10 operating given does not release the user
hours from the obligation of own
wear and aging.

Subjet to revision.
Printed in Germany.
RE 09960-B/04.08
Mat. - Nr. R961004689

Notes
Hydraulic wiring diagram with line filter

for oil cleaning
Maintenance
Imperfect maintenance leads to faults and, as the case may be, to failure and
high servicing costs.
If, during operation or inspection, any irregularities, deviations, defaults or wear
are noticed, you must in any case:
immediately switch off the training system.
examine the cause and remedy the default.
replace the defective component.
no longer put into operation the training system, if applicable.
Notes
WARNING!
Risk of injury!
Hydraulic oil squirting under high pressure can lead to very severe injuries!
X Carry out any repair works only, when the basic hydraulic components kit is at
standstill.
X Before opening the unit, depressurize it.
X Despite the pressure relief, open the unit with the utmost care.
X Works on the hydraulic installation must only be carried out by a hydraulic
expert.
CAUTION!
Risk of injury!
Slip hazard due to leaking hydraulic oil.
X Immediately bind/dispose of leaking hydraulic fluid.
X Provide binding material before the filling or change of oil.
DANGER!
Risk of injury!
Death or serious bodily injury due to dangerous electrical voltage!
X Works on the electronic installation must only be carried out by a qualified
electrician.
Replacement of parts Only use original equipment parts.

In case of replacement part orders, always indicate the device type and material
number, the year of manufacture and the part designation.
Please consult the Bosch Rexroth customer service.
The “Address and Contact Data” are given on the verso of this operation manual.
After the repair for wear and tear was carried out and before the unit can be put
into operation again, a qualified expert has to check:
whether the work(s) was/were carried out according to the rules.
if the training system is operational without any restrictions.
wear and aging.

Subjet to revision.
Printed in Germany.
RE 09960-B/04.08
Mat. - Nr. R961004689

Notes
10 Decommissioning
Decommissioning 5 mm Allen key
CAUTION!
Risk of injury!
Slip hazard due to leaking hydraulic oil.
X Immediately bind/dispose of leaking hydraulic fluid.
X Provide binding material before the filling or change of oil.
Carrying out the decommissioning X Pull the power plug out of the socket.
X Loosen the coupling connections.
X Unscrew the pressure gauges from the measuring ports on the cylinder.
X Remove the hydraulic components from the grid.
11 Disassembly and Replacement

See decommissioning.
12 Disposal
Environmental Protection
Store leaked and used resources as well as auxiliary agents according to the
rules and dispose of them in accordance with the legal provisions.
In case of doubt, consult the respective material manufacturer or supplier for
information about how the material is to be stored and disposed of.
Notes
13 Fault Finding and Troubleshooting

When practicing the exercises, strictly comply with the instructions given! Faults
can almost always be explained by non-compliance with instructions.
Table 3: List of faults
Fault Cause Remedy
Drive module not connected Plug in the power plug

Unit does not run up
to the power supply
Couplings cannot be Pressure was not relieved Depressurize the system

connected or only
connected with
difficulties
Wrong group of lines chosen Operate the handle-operated

on the directional control lever
valve
Cylinder does not Throttle valve closed Open the throttle valve
extend / retract
Drive module not switched Operate the main switch
on provided on the operating
module.
Pressure too low
Pump loud No oil Refill oil
14 Extension and Transformation

Optional accessories for the basic hydraulic components kit:
line filter
teachware
load unit The data specifed above only
wear and aging.

Subjet to revision.
Printed in Germany.
RE 09960-B/04.08
Mat. - Nr. R961004689

Notes
15 Technical Data
Weight and dimensions Table 4: Weight and dimensions

Designation Unit Value
Total weight kg approx. 30
Length mm 1300
Width mm 375
Height mm 475
Ambient conditions Table 5: Ambient conditions

Min. storage temperature °C +5
Max. storage temperature °C +50
Condition of the installation surface Plane
Relative air humidity % 25-70
1000 above
Max installation height m
sea level
Hydraulic system Table 6: Technical data of the hydraulic system

Max. operating pressure bar 250
Tank volume l 2,4
Oil type (DIN 51524) HLP68
Cleanliness (ISO 4406) Class 20/18/15
Volumetric flow l/min 2
Mains connection Table 7: Technical data of mains connection

Mains/Operating voltage V 230
Frequency Hz 50
Rated power kW 1,1
Elecrical protection class Class IP44
16 Index
No index is available for the present document.
Notes

wear and aging.

Subjet to revision.
Printed in Germany.
RE 09960-B/04.08
Mat. - Nr. R961004689

Notes
Bosch Rexroth AG
Training & Didactic
Maria-Theresien-Str. 23
D-97816 Lohr am Main, Germany
Phone +49 (0) 93 52 / 18-10 41
Fax +49 (0) 93 52 / 18-10 40
trainingsystems.brs@boschrexroth.de
www.boschrexroth.com

wear and aging.

Subjet to revision.
Printed in Germany.
RE 09960-B/04.08
Mat. - Nr. R961004689

Basic Hyd Components - REXROTH

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1 About this Manual

The data specifed above only

© This document, as well as the

Mat. - Nr. R961004689

2 Principal Safety Instructions

 give clear instructions, when trainees or participants in training courses are to

Transport, Installation, Assembly and Commissioning

Troubleshooting, Maintenance and Repair

© This document, as well as the

Mat. - Nr. R961004689

Warning Notices in this Manual

 Warning sign (warning triangle): draws attention to the danger

The signal words have the following meaning:

Signal word Application

DANGER! marks an immediately threatening great danger which will surely

CAUTION! points out to a possibly dangerous situation which could cause

If this information is not observed, this may lead to deteriorations in

You have to Observe the Following

 Persons who install, operate, disassemble, or maintain Rexroth products must

© This document, as well as the

Mat. - Nr. R961004689

Fig. 1: Space requirement for the hydraulic basics components kit

In order to guarantee an ergonomically favorable position for the operation of the

During maintenance and servicing

Obligations of the Operator

Mat. - Nr. R961004689

Personal protective equipment

Table 2: Training stations on the basic hydraulic components kit

Fig. 2: Scope of delivery of the frame

 hydraulic components - party pre-assembled

The data specifed above only

© This document, as well as the

Mat. - Nr. R961004689

Fig. 4: Individual components of the basic hydraulic components kit

1 Drive module 5 200 cm cylinder with throttle valve

Mat. - Nr. R961004689

Operating and Display Elements

Fig. 5: Operating and display elements of the drive module

1 Oil filler cap 2 Level indicator with integrated

Fig. 6: Operating and display elements for hydraulic components

1 Pressure gauge 4 Pressure gauge

Pressure gauges The pressure gauges display the pressure in bars.

© This document, as well as the

Mat. - Nr. R961004689

Identification of the Product

Fig. 7: Name plate of drive module

5 Transport and Storage

The data specifed above only

© This document, as well as the

Mat. - Nr. R961004689

Before the final installation, the following items have to be checked:

Mounting the Frame

Fig. 8: Arrange pre-assembled frame parts vertically

The data specifed above only

Fig. 9: Cross member © This document, as well as the

The frame is now completely mounted.

Assembly of Hydraulic Components

Mounting on the grid

Fig. 10: Example of holder

Fig. 11: Arrangement of hydraulic components

1 Drive module 5 200 cm cylinder with throttle valve

Mat. - Nr. R961004689

give clear instructions, when trainees or participants in training courses are to

Warning sign (warning triangle): draws attention to the danger

Persons who install, operate, disassemble, or maintain Rexroth products must

hydraulic components - party pre-assembled