Industrial Hydraulics Manual

Electric Drives Linear Motion and
and Controls Hydraulics Assembly Technologies Pneumatics Service
Project Manual RE 00845/04.07
Industrial Hydraulics
Trainer‘s manual
Foreword Bosch Rexroth AG I RE 00845/04.07
Foreword
In July 2004 the Federal Minister for Economics and Labor passed the new regulations for
vocational training in industrial metalworking professions.
Basic training for the entire field of professions, the structure and objectives of vocational train-
ing are set out in paragraph § 3. Skills and knowledge (qualifications) are to be imparted with
reference to practical needs. To be capable of carrying out qualified work, the trainees are to
be trained in particular in independent planning, execution and checking as well as acting in
the overall operative context.
Specialist Profession-specific specialist qualifications, e.g. the manufacture, assembly and disassembly of
qualification assemblies and systems are to imparted in conjunction with core qualifications, e.g. planning
Core qualification and organizing of the related work and the evaluation of work results.
The training contents for the profession-specific specialist qualification include, among others,
business processes and quality assurance systems in the relevant field of activity.
Project Manual The present Project Manual Industrial Hydraulics is intended as accompanying and exercise
book to help trainers and technical instructors to impart knowledge through project work.
BIBB In line with the exercises compiled by the Bundesinstitut for berufliche Bildung in Berlin BIBB
(Federal Institute for Vocational Training in Berlin BIBB) project tasks are described, which are
oriented towards the restructured industrial metalworking and electrical engineering profes-
sions.
Practice-oriented With all practice-oriented project tasks core and specialist qualifications are imparted in an
project tasks integrated form involving independent planning, execution and checks.
The training course was structured in a way that the project manager/trainer explains the project
order first and also supports the trainees during their project work.
In the course of the further project tasks, the information and assistance provided by the proj-
ect manager is reduced. In this way the trainees learn to actively proceed in line with project
management requirements.
Foreword Bosch Rexroth AG I RE 00845/04.07
Notes
Introduction Bosch Rexroth AG I RE 00845/04.07
Restructuring of industrial metalworking and electrical professions

The increasing importance of process-oriented working procedures, the growing complexity
and networking of new technologies as well as comprehensive, customer-oriented services
have resulted in the necessity to restructure industrial metalworking professions, which was
laid down in regulations in 1987.
1987 2004
3,5 3,5
Profession-specific
Subject Subject specialized training
Training period (years)

3 area-specific area-specific
3
over 21 months, including
specialized specialized specialized task in the
training training company’s field of
2 2 activities
Profession-specific specialized training
Integrated training
Interdisciplinary specialized training
1 1 Common
core qualification
Basic training 21 months
0 0
Restructuring of industrial metalworking professions (source: DIHK 06/2004)
Qualification requirements
The requirements for core qualification are met by solving tasks set in the form of project
steps, which involve informing, planning, decision-making, executing, checking and assess-
ing. Mastering and internalizing the multitude of qualifications finally results in the professional
competence to act.
Field of
activities
ns
1st step 2nd step

io
at
Analysis of qualification Synthesis of

c
ifi
requirements qualification contents

al
qu
ns
ist
→ Training pattern → Time frame

tio
l
ia
(technical structure) (time structure)

ca
ec
ifi
Sp
al
- Core qualifications In the sense of fields of

qu
- Specialist qualifications + work/activities within the

re
context of profession-
Co
Fields of activities
specific business
processes
Time frame - method (source: DIHT 06/2004)

Imparting knowledge through project work

The present Project Manual Industrial Hydraulics is intended for imparting the required spe-
cialist knowledge in the field of hydraulic control technology in practice-oriented applications.
Through the logically structured project work the trainee:
Training contents • is to understand the physical laws and technical interrelationships (area, pressure, force,
work and power),
• is to become able to explain the function, structure, practical operating principle and pos-
sible applications of hydraulic equipment,
• is to become able to read and understand symbols and circuit diagrams,
• is to get to know basic controls of hydraulics and assemble units according to prepared
circuit diagrams,
• is to be made familiar with types, properties, requirements and application of hydraulic
fluids.
Framework The project tasks and project work described in the Project Manual Industrial Hydraulics pro-
curriculum vide trainers and trainees with information and instruments that will help them comply with the
demands made on the transfer of specialist know-how in the field of hydraulics.
The sub-objectives listed below, which are taken from the framework curriculum for vocational
training of industrial mechanics, are matched with the regulations for vocational training in
industrial metalworking professions dated 09.07.2004 (BGBl. I. S. 1502). The sub-objectives
listed refer to training objectives given for hydraulic control technology.
Industrial mechanics
• plan and organize work sequences, check and assess work results,
• verify mechanical and physical variables,
• assemble and disassemble machines, equipment, fixtures and systems,
• commission systems and plants, including open and closed-loop control equipment, and
instruct customers,
• carry out maintenance work and ensure the operability of technical systems,
• prepare technical documentation,
• apply standards and regulations for safeguarding the process and product quality and
contribute to continuing improvements in the work sequences in the company.
Fields of activities Industrial mechanics are mainly assigned to professional activities in the field of production,
assembly, maintenance and automation of technical systems. The fields of activities mentioned
before are dealt with in individual training sections. Within the fields of activities, the training
sections of the individual training years are based on each other.
Training sections In training section-oriented lessons the solutions required for project handling are not imparted
like in conventional lessons. The solution of the task set is worked out alternately in systematic,
technical and situation- or case-related training. In the course of the project work it should
be envisaged that the trainee can handle the projects on his/her own and under his/her own
responsibility and, whenever possible, in a team.
This brings the training contents closer to the trainee's real world of experience, which enables
and simplifies imparting the professional competence to act in the lessons.
To solve a more complex project task, it may be required to impart the basic principles for this
project in systematic technical training.
Training section 6, which is geared to hydraulic control technology, is described below.

(Training framework curriculum § 10 section 1 No. 10/Control technology)
Training Installing and commissioning 2nd year of training

section 6: control systems Recommended time: 60 hours
The trainees are to install and commission control systems. They determine the control
components to be used and the functional sequence for controls on the basis of circuit
diagrams and other documentation for various component technologies. For this, they use
manufacturers's documents.
The trainees plan and realize the set-up of the control. They commission the control system
observing rules for safety at work. They develop strategies for troubleshooting and optimiza-
tion of the control systems and apply them.
They document and present their results utilizing suitable user programs.
Contents:
• Technology diagram
• Hydraulic power part
• Supply unit
• Sensors
• Flow of material, energy, information
• Electrical circuit diagrams
• Pressure fluids
• Pressures, forces, velocity, flow
• Operating modes
• Plant safety
The starting point of didactic-methodical structuring of the training situation in the individual
training sections is to be the business and work process in the vocational field of activities. This
is reflected in the formulation of objectives in the individual training sections. The objectives of
the training sections are the decisive factors for the structuring of the lessons and represent
the minimum scope together with supplementary contents.
Training schedule The technical contents of the individual training sections are formulated generally and are not
listed in a differentiated way. The individual contents of the training sections are coordinated
with the training curriculum for in-company training.
According to § 7 of the regulations for vocational training in industrial metalworking professions
deviations from the training curriculum are permitted in terms of technical contents and time
schedule, in particular, where practical requirements necessitate this deviation.
The project tasks described in the Project Manual Hydraulics are structured so that the trainee
achieves the training objectives described in the project definition in 6 project steps:
• Informing,
• Planning,
• Deciding,
• Executing,
• Checking,
• Evaluating.
Specialist The objectives described are geared to the development of competence to act. The trainee will
competence develop his or her competence to act from the capability and willingness to solve tasks and
problems and evaluate results in a target-oriented manner, skillfully, methodically and indepen-
dently on the basis of technical knowledge and skills.
Professional The projects described in the project definition are oriented towards practical needs and are
competence to act characterized by a high level of conformity with customer orders from industry and trade. Cus-
tomer orders represent complete activities and develop and promote the trainee's professional
competence.
As mentioned before, the trainee is to work off the project task or the project order in 6
steps.
1. Informing
Based on the project definition, the trainee is to get a clear idea of the finished solution, including
any required details. This is achieved through a systematic analysis of the project documenta-
tion and, if required, by asking questions.
Possible questions: • What is to be done?
• Have I understood the task completely?
• Which hydraulic component/system is to be dealt with?
2. Planning
Planning means the theoretical preparation and anticipation of the concrete execution. In detail,
planning requires competence to handle the project order and to organize the project handling
steps.
Possible questions: • How to proceed?
• What knowledge is required?
• Which aids are available?
• Are there comparable applications in my company?
3. Decision-making
After the planning stage, the trainee determines the aids to be used, e.g. which data sheets are
required for coping with the project task. He/she decides on the sequence and the interrela-
tionships of the individual project steps. Moreover, a decision should be made as to whether it
would be easier to solve the project task in a team.
Possible questions: • Which hydraulic components will be used?
• How can you know that technical data sheets are up to date?
• Have I utilized all available sources of information?
• Are the prescribed safety instructions at hand?
4. Executing:
The order is to be executed according to the work instructions given in the chapter "order execu-
tion", taking all safety notes into account. After a thorough preparatory phase, the trainee is to
carry out the project order largely on his/her own. After the solution was worked out in writing,
it should be verified or questioned, whether the right attempt at a solution was selected.
Depending on the project order, the possibilities of execution may be limited. This is valid, for
example, in the case of costly work in the field of information technology.
Possible questions: • Have I chosen the correct sequence?
5. Checking:
The trainee must check intermediate results as early as during the execution stage, and finally
the result of the customer requirement. In some cases, the result can be compared with the
manufacturer's documents. In the case of measuring exercises, it must be checked, whether the
measured results are realistic. The documentation should also be finally corrected, improved
and completed. This also includes the preparation of a final report. After completion, the trainer
makes a final check.
Possible questions: • Was the control properly installed?

• Has the project objective been complied with?
• Is the customer satisfied with the project result?
• Which documentation is required?
• Is the result completely documented in the correct order?
6. Evaluating:
In the final evaluation phase, an external or self-evaluation is to be carried out on the basis of
a comparison of project order documents, the installed control and results of measurements
and checks.
Faults, if any, and their causes must be analyzed and possibilities discussed as to how faults
can be avoided in the future.
The trainee must learn to assess his/her strengths and weaknesses and develop objective quality
standards for his/her acting, which ultimately leads to personal competence. The evaluation can
be finalized in a technical discussion, possibly also in a discussion with the customer.
General notes:
For didactic reasons, we refer exclusively to trainees and trainers in the present manual. We
expressly point out that these terms include all persons involved in the basic and advanced
training: Instructors, teachers, project managers, etc., whether male or female.
Procedural In this manual, we do not give notes on procedural knowledge (explanatory knowledge). It is
knowledge the knowledge of how to achieve a certain result with which measures, procedures or pro-
cesses - in this case, how the learning target can be reached.
The present manual must be understood as a tool for providing the required core and special-
ist qualification that must be imparted in an integrated form through independent planning,
executing and checking according to the regulations for vocational training in industrial met-
alworking professions.
Pictogram The pictograms, which are used as recurrent symbols, are to transfer important information
as quickly as possible in the form of a simplified graphical representation and independently
of languages.
Project designation with short description of the industrial application

The knowledge of basic principles of hydraulic control technology is to be imparted with rela-
tion to practice.
The trainer can impart the basic knowledge of hydraulics in 21 individual projects. Together
with the customer requirements the detailed project definitions are finally intended to make the
function and possible applications of individual system components clear to the trainee during
processing of the order.
No. Project designation Industrial application (example)

01 Hydraulic power unit Pressure oil supply to a hydraulic cylinder by a hydraulic
power unit. Rating of a simple power unit on the basis of
parameters specified by the customer.
02 Hydraulic pump, charac- Typical features of a pressure-compensated vane pump.
teristic curve Understanding the control behavior with the help of a
characteristic curve.
03 Single-rod cylinder, Safety aspects when using a single-rod cylinder and a
pressure intensification meter-out throttle, e.g. for an advance movement.
04 Single-rod cylinder, Different traversing speeds when extending and retract-
flow ing a single-rod cylinder. Application of different types of
hydraulic cylinders.
05 Hydraulic motor Powering a hoist with the help of a hydraulic motor for lift-
ing and lowering of a load.
06 4/3 directional valve Controlling the direction of a single-rod cylinder by means
of a 4/3 directional valve. It should be possible to position
the cylinder at any position.
Properties of different directional valve spool shapes and
symbols.
07 Check valve Protection of a vertical cylinder with suspended load in
a welding in a welding fixture by means of a check valve.
When a tool change takes place, lowering of the load at
adjustable lowering speed by means of a shut-off valve.
08 Check valve, Protection of a vertical cylinder with suspended load by
pilot operated means of a pilot operated check valve. Opening the check
valve by means of a 4/2 directional valve, adjustable lower-
ing speed.
09 Throttle valve, Powering a conveyor belt by means of a hydraulic motor
adjustable with adjustable output speeds for both directions.
10 Throttle check valve Traversing a tool carriage at different speeds.
11 Flow control valve Rotary drive (hydraulic motor) with constant speed.
12 Pressure relief valve, Preparation of a characteristic curve for the pressure/flow
direct operated relationship.
Possible use of direct operated pressure relief valves.
13 Pressure relief valve, Electrical pre-selection of various pressures (series, paral-
controls lel circuit) on punching equipment.
14 Pressure reducing valve Swiveling a clamped workpiece by means of a hydraulic
motor.
15 Pressure switch Hydraulic pressing of two workpieces with monitoring by a
pressure switch.
16 Pressure switch, Working out the hysteresis of a mechanical pressure

hysteresis switch.
17 Hydraulic accumulator Moving the tool from the working range of the machine tool
using the oil volume stored in the hydraulic accumulator.
18 Regenerative circuit Increasing the velocity by using the oil returning from the
single-rod cylinder for extending.
19 Rapid speed/creep speed Rapid speed/creep speed control for lifting a pallet onto a
control conveyor belt at load-independent, adjustable creep speed
and with fastest return stroke possible.
20 Valve by-pass control Lifting and lowering of a load by a single-rod cylinder,
which is controlled by a 4/3 directional valve with blocked
central position. Sparing of the hydraulic pump and energy
savings through by-pass circuit.
21 Commissioning, Observing regulations, safety rules and generally rec-
inspection, maintenance, ognized technical rules when handling production and
... hydraulic systems in everyday work.
Comparison of project exercises of Bosch Rexroth AG/BIBB

The comparison below refers to the BIBB training course Hydraulics, recommended and pub-
lished by the Bundesinstitut für Berufsbildung (BIBB).
Project
Project designation Project content BIBB
no.
Component selection for hydraulic
01 Hydraulic power unit A1
power unit
Hydraulic variable displacement
02 Pump characteristic curve A2
pump
Safety aspects with regard to pres-
03 Single-rod cylinder/pressure B 1.1
sure intensification
04 Single-rod cylinder/flow Traversing speeds B 1.2
05 Hydraulic motor Lifting platform drive B2
Control of direction, single-rod

06 4/3 directional valve B3
cylinder
Protection of a hydraulic cylinder,
07 Check valve C1
negative load
Check valve, flow possible from
08 Check valve, pilot operated C1
both sides
09 Throttle valve, adjustable Conveyor belt drive D1
10 Throttle check valve Traversing an advance slide D3
11 Flow control valve Tool drive D2
12 Pressure relief valve Characteristic curve E 1.2
Pressure relief valve controls Pressure pre-selection on punch-

13 E1
ing equipment
14 Pressure reducing valve Tool advance E3
Workpiece pressing with monitor-

15 Pressure switch E4
ing
16 Pressure switch hysteresis Characteristic curve E4
Storing energy in view of a hydrau-

17 Hydraulic accumulator F1
lic pump failure
Increasing the velocity by using the
18 Regenerative circuit G1
returning oil flow
19 Rapid speed/creep speed control Production line, lifting of a pallet G2
20 Valve circulation control Lifting and lowering of a load G3
Commissioning, troubleshooting,
21 Commissioning H1
maintenance
Component matrix
The matrix below provides an overview of the components, which are required for the individual project exercises.
Project 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21
Component designation
ZY 1.3
1 1 1 1 1 1 1 1 1 1
Double-acting cylinders
ZY 1.Load
1 1 1
Double-acting cylinders with load
DM 2.N
1 1 1 1 1
Hydraulic motor
DW 3E
1 1 1 1 1 1 1
4/2 directional valve C
DW 4E
1 1
4/3 directional valve G
DW 10E
1 1
4/3 directional valve J
DW 13E
1 1 1 1 1 1 1 1 1 1
4/3 directional valve E
DS 2.1
1 1
Check valve
DS 1.1
1 1 1
Check valve, pilot operated
DZ 2.1
1 1
Shut-off valve
DD 1.1
1 1 2 1 2 2 2 2 2 1 2 2 1 1 1 1 1 1
Pressure relief valve
DD 2
1
Pressure reducing valve
DF 1.2
1 1 1 1 1 1 1 1
Throttle valve
DZ 2.2
1 1
Throttle check valve
DF 3
1 1 1 1
Flow control valve
DD 6.E
1 1
Pressure switch
DZ 3.2
1
Hydraulic accumulator
DE 2
2
Limit switch
DZ 4.1
2 1 1 1 3 3 2 1 2 1 2 3 1 1 1 2 2
Distributor plate
DZ 1.4
1 3 3 4 3 3 3 4 3 4 1 3 3 3 1 2 3 3 3 4
Pressure gauge/minimess connection
DZ 25.1
1 4 3 3 3 4 3 4 1 3 3 3 1 1 3 3 3 4
Hydraulic hose/minimess connection
Note on the utilization of the matrix:

• The table shows the number of hydraulic components required for each exercise.
• Optionally, the following is required additionally:
– 1 stopwatch for projects 02, 04 and 05
– 1 flowmeter DZ 30.N for projects 04 and 06
– 1 tachometer in project 05 and
– 1 Multihandy (electronic measuring transducer) 5050 for acquiring the values of the
flowmeter (measuring turbine) and the tachometer.
Introduction 10 Bosch Rexroth AG I RE 00845/04.07
Overview of components
Symbol Component designation Type designation
Double-acting cylinder
ZY 1.3
with single-sided piston rod
ZY 1.Load
with single-sided piston rod with load
Fixed displacement motor with external

DM 2.N t
leakage line and two directions of rotation
4/2 directional valve with solenoid actua-

DW 3E
tion, spring return
4/3 directional valve with direct actuation

by two solenoids, spring centering of the
DW 4E
central position and central position P - T,
A, B
DW 10E
central position and central position P, A
-B-T
DW 13E
central position and central position P, T,
A, B
Check valve with spring, flow possible in

only one direction, rest position closed, DS 2.1
cracking pressure 1 bar
Pilot operated check valve, with spring, pi-

DS 1.1
lot pressure enables flow in both directions
Shut-off valve, actuated by turning DZ 2.1
Direct operated pressure relief valve, the

cracking pressure can be adjusted by DD 1.1
means of a spring
3-way pressure reducing valve DD 2
Pressure switch, electromechanical,

DD 6E
adjustable
Throttle valve, adjustable DF 1.2
Throttle check valve, adjustable,

DZ 2.2
free flow in one direction
2-way flow control valve, adjustable, for one

direction of flow, largely independent of vis-
DF 3
cosity and pressure differential, adjustable,
with by-pass check valve
Accumulator safety block

DZ 3.2
for diaphragm-type accumulator
Pressure gauge with hose

and quick release coupling DZ 1.4
without check valve
Hose with quick release coupling with

DZ 25.1
check valve
Hose VSK 1
Distributor plate with four ports DZ 4.1
Flow-meter DZ 30
Tachometer
1)
red
black
Limit switch, inductive DE 2.2
blue
1)
Stopwatch
1)
No symbol according to DIN ISO 1219
Safety aspects
Safety and the economic use of resources are essential demands that are placed on modern
plant and machinery and serve to protect people. These two requirements have in common
that they have to be taken into account as early as possible, that is, at the product concept
stage. Only in this way can optimized and low-priced solutions be found. Safe machines with
low consumption demonstrate that the manufacturer masters his processes; they are a quality
feature.
In order that hazards to plant and machinery can be recognized, safety regulations, product
information brochures and operating instructions must be observed. Corresponding notes on
the handling of electrohydraulic components and systems of Bosch Rexroth can be found in:
• General product information on hydraulic products
RE 07008/02.05
• Operating instructions for hydraulic systems
AB 01-01.02
• Hydraulic cylinders of tie rod/mill-type design (operating instructions)
RE 07100-B/10.04
• Operating instructions DS4 – 1X
RE 00225-B/05.05
The safety notes and product information in the above documentation are exclusively valid for
Bosch Rexroth hydraulic products.
Only when operating instructions, safety notes and product information are observed can the
trouble-free operation of Rexroth products be ensured.
The present Project Manual Industrial Hydraulics includes warning notes, which precede in-
structions for activities that involve a risk of personal injury or damage to property. The described
precautions for averting risks must be taken.
Conventions
This symbol refers to imminent danger that, if not avoided, can lead to sever-
est injuries or death.
Warning
This symbol refers to a potential risk, which can lead to light or serious injuries
or damage to property.
Caution
This symbol refers to supplementary information.
Note:
The electrohydraulic components and systems described in this Project Manual are technical
equipment, which is not intended for private use.
The use for the intended purpose also includes that the safety regulations, product information
and operating instructions described in the following are read and understood.
Qualification of Installation, commissioning and operation, disassembly, upkeep and maintenance require fun-
personnel damental knowledge of mechanics and electrohydraulics as well as the knowledge of related
technical terms. In order to ensure operational safety, these activities may only be carried out by
a corresponding specialist or by an instructed person under the supervision of a specialist.
A specialist is, who, due to his/her professional training, his/her knowledge and experience and
the knowledge of relevant regulations, can asses the duties assigned to him/her, recognize po-
tential risks and take suitable precautions. A specialist must observe relevant technical rules.
Consequently, this means that the trainer must point out potential risks to the trainees and
provide information on how to avert such risks.
Work carried out improperly on electrohydraulic components and systems

involves the risk of injury and represents a safety risk during operation of
Warning the system, including danger to life!
Liability In the case of damage resulting from improper use and unauthorized interventions, which are
not provided in the Project Manual Industrial Hydraulics, any liability claims for defects or other
liability claims vis-à-vis Bosch Rexroth AG become void.
If Projects 01 to 21 described in the Project Manual Industrial Hydraulics are carried out on
training stands and with electrohydraulic components that were not delivered by Rexroth, that
is, products of competitors' make, any defect or liability claims vis-à-vis Bosch Rexroth AG shall
be void as well.
When using competitors' products, observe the safety notes of the manufac-
turer and make sure that the components and systems comply with currently
valid EU Directives.
For this reason, commissioning is prohibited until it was established that the
electrohydraulic components and systems to be used meet the stipulations
Warning of all relevant EU Directives.
Note:
The required safety regulations, product information documents* and operating instructions
must be handed over or be accessible to the trainee in their latest issue.
In the Project Manual Industrial Hydraulics we do not refer in detail to the correct handling of
hydraulic fluids in the project exercises 01 to 21. The corresponding information can be found
in the safety data sheet.
The correct handling of hydraulic fluids and possible risks as well as measures for averting
risks are described in a separate topic "Hydraulic fluids" in the following.
* Rexroth product information sheets are valid exclusively for hydraulic products, which are
operated with hydraulic fluids based on mineral oil, unless the use of other hydraulic fluids
is expressly permitted in the operating instructions.
Basic principles of hydraulics Bosch Rexroth AG I RE 00845/04.07
Basic principles of hydraulics

Introduction Hydraulics, derived from the Greek word hydro = water, refers, in a scientific sense, to the sci-
ence of still and moving fluids (hydrostatics and hydrodynamics).
If we speak of hydraulics in mechanical, vehicle and aircraft engineering, we understand by this
the practical application of this discipline of physics in the fields of power transmission and
open and closed-loop control technology.
Comparison of System technologies such as hydraulics, pneumatics, electrics/electronics and mechanics

systems compete with each other as means for the transmission of power; on the other hand, they
complement each other and are also combined.
The decision in favor of a certain system, or a combination, requires detailed knowledge of the
features and also of the pros and cons.
Hydraulics Pneumatics Electrics Mechanics
Source of energy El. motor El. motor Mains El. motor

(drive)
Combustion engine Combustion engine Battery Combustion engine
Pressure vessel Weight
Tension force by
spring
Energy transmis- Pipes and hoses Pipes and hoses Electric cables Mechanical parts:
sion elements Levers, shafts, etc.
Magnetic field
Energy carriers Fluids Air Electrons Rigid and elastic
bodies
Force density High Relatively low Low High
(power density)
High pressures Low pressures cf. power/weight Volume and assign-
ratio of el. motor to ment of required
Large forces hydraulic motor 1:10 installation space is
often less favorable
Small installation than with hydraulics
space requirement
Smooth control Excellent via pres- Good via pressure Good to excellent Poor
(accelerating, sure and flow and flow
decelerating) Electrical open and
closed-loop control
Motion types of Linear and rotary Linear and rotary Mainly rotary move- Linear and rotary
drives movements can eas- movements can eas- ments movements
ily be achieved with ily be achieved with
hydraulic cylinders pneumatic cylinders
and hydraulic motors and pneumatic mo-
tors
Comparison of system technologies

System planning The specific advantages of hydraulic technology over other technologies such as pneumatics,
electrics and mechanics, can only be utilized to the full extent, if the system planner knows the
typical features offered by hydraulic control technology.
Features of hy- • Transmission of large forces within a minimum of space;
draulic systems • High energy density
• Storing of energy is possible
• Stepless changes in motion variables such as velocities, forces and moments
• Good monitorability of occurring forces
• Swift reversing operation due to small masses (low moments of inertia) of the drive ele-
ments
• High switching dynamics
• Good transmission ratio
• Simple conversion of rotary movements into linear movements or vice versa
• Constructive flexibility in the arrangement of components
• Physical separation of input and output through pipes and hoses
• Possibility of automating all types of movements and auxiliary movements by means of pilot
control valves and electronic command transmission
• Usability of standard components and assemblies
• Simple overload protection
• Low wear, since hydraulic components are lubricated by the operating medium
• Long service life
• Possibility of energy recovery
• Pressure and flow losses (fluidic friction) in line systems and control elements
• Dependence of viscosity of the hydraulic fluid on temperature and pressure
• Leakage problems; therefore risk of accidents and risk of fire
• Compressibility of the hydraulic fluid
Energy conversion Hydraulic systems convert mechanical energy into hydraulic energy, transport it in this form in
an open or closed-loop controlled way and then re-convert it into mechanical energy.
For the conversion of energy, hydraulic pumps are used on the primary side, and hydraulic
cylinders and hydraulic motors on the secondary side.
Hydraulic energy and hence the transmitted power can be influenced in pressure and flow by
hydraulic pumps, and in its magnitude and direction of action by open and closed-loop control
valves.
The hydraulic fluid that is directed via pipes, hoses and bores in control blocks or manifolds
assumes, among others, the energy transport.
For storing and maintaining the hydraulic fluid, additional equipment such as reservoirs, filters,
coolers, heaters, measuring and testing instruments are required.
Drive Hydraulic system Drive
Energy conver- Open, closed- Energy conver-

sion loop control sion
Electric motor, Hydraulic open Hydraulic cyl-

Working element
combustion engine, Hydraulic pump and closed-loop inder, hydraulic
to be actuated
manual drive control valves motor
Electric energy,
thermal energy, Hydraulic energy Mechanical energy
mechanical energy
Energy conversion in a hydraulic system
As illustrated in the schematic above, an oil-hydraulic system firstly converts mechanical energy
into hydraulic energy, transports it in an open or closed-loop controlled way, and then converts
it into mechanical work. The components used in hydraulics can be classified according to
their function.
The figure below schematically shows the components of a simple hydraulic system.
Hydraulic cylinder
Throttle
check valve
Directional valve
Pressure relief
Check valve valve
Return line filter
Hydraulic pump
Section circuit diagram of a hydraulic system

Instead of sectional drawings, standardized symbols according to DIN ISO 1219 part 1 are
used in hydraulic circuit diagrams. More detailed information is provided in the next chapter
"Symbols".
Symbol circuit diagram of a hydraulic circuit

Symbols according to DIN ISO 1219-1

In fluid power systems, energy is transported within a circuit by a pressurized medium (liquid
or gaseous) and open or closed-loop controlled.
Graphical symbols help to identify the function in circuit diagrams of fluid power technology.
They can also be attached to the components themselves for this purpose.
DIN ISO 1219-1 The symbols included in standard DIN ISO 1219 should preferably be used, but their use does
in no way rule out the use of symbols commonly applied in other technical areas for identifying
pipes and hoses.
The followings lists are not complete, but must be regarded as working aid for the preparation
or completion of project-related circuit diagrams.
The graphical symbols used in the manual comply with DIN ISO 1219 - fluid power technology;
graphical symbols and circuit diagrams; part 1: Graphical symbols.
DIN ISO 1219-2 The basic rules for the preparation of hydraulic circuit diagrams are determined in part 2 of
standard DIN ISO 1219. Circuit diagrams are a tool to simplify the planning and description of
a hydraulic system in order to prevent - through a standardized representation - uncertainties
and faults at the planning stage, during production, installation, and servicing.
Basic symbols
Supply line, return flow line, frames for com-
ponents and symbols
Internal and external pilot line, leakage line,

flushing line, venting line
The crossing of two lines without connec-

tion point indicates that there is no connec-
tion
The connection of two lines is represented

by means of a connection point.
Hose
Function unit for valves having a maximum

of four service ports
Frame for energy conversion unit

(pump, compressor, motor)
Adjustability of a pump/motor
Direction of action of the hydraulic force

Overview of
symbols Directional valves Pressure control valves Flow control valves
Check valve Pressure relief valve Throttle valve/orifice
Directional poppet valve Pressure reducing valve Two-way flow control valve
Directional spool valve Sequencing valve
Overview of symbols according to DIN ISO 1219, part 1 (excerpt)

Hydraulic circuit In the field of hydraulics, we differentiate between three circuit systems:
systems
• Open circuit,
• closed circuit,
• semi-closed circuit.
Open circuit In an open circuit, the hydraulic pumps usually aspires hydraulic fluid through the suction pipe,
which is installed below fluid level. The hydraulic fluid is directed by directional valves to the
actuator and fed back to the storage reservoir; this means, there is no connection between the
suction pipe of the hydraulic pump and the hydraulic fluid returning from the actuator.
Typical features of the open circuit:

• The hydraulic pump aspires oil directly from the hydraulic tank,
• the hydraulic fluid flows via control elements to the actuator,
• the hydraulic fluid flows from the actuator back to the hydraulic tank,
• simple structure,
• better cooling,
• contamination can settle in the hydraulic tank,
• large amount of fluid,
• large hydraulic tank required,
• large space requirement,
• unfavorable volumetric efficiency
Input speed
Schematic n = constant
diagram
Lifting speed
v = constant
Flow
qV = constant
The open circuit is employed, for example, in machine tools, handling systems, press controls,
winch drives, and gears for mobile applications. The actuators can be hydraulic cylinders and
hydraulic motors.
Closed circuit In a closed circuit, the hydraulic fluid returning from the actuator is directly re-fed to the hydraulic
pump. The high-pressure side of the system is protected by a pressure relief valve. The pressure
is unloaded to the low-pressure side, that is, the hydraulic fluid remains in the circuit.
The design-inherent permanent, internal leakage of the hydraulic pump and the hydraulic mo-
tor is compensated for by a separate auxiliary pump, which is flange-mounted to the hydraulic
pump in most of the cases.
Typical features of the closed circuit are:

• The hydraulic fluid is fed by the pump to the actuator,
• the hydraulic fluid flows from the actuator directly back to the pump,
• compact design,
• silent, smooth running,
• good controllability,
• good volumetric efficiency,
• complicated structure,
• greater stressing of the oil,
• sensitive to contamination
Schematic Flow
diagram Auxiliary pump for qV = variable
leakage compensation
Output speed
n = variable
Cooler
The closed circuit is used almost exclusively in mobile applications, e.g. for powering a wheel
loader travel drive. The hydraulic pumps and hydraulic motors used are in most of the cases
axial piston units.
Basic principles of hydraulics 10 Bosch Rexroth AG I RE 00845/04.07
Semi-closed circuit The semi-closed circuit is a combination of the open and the closed circuit and is used, if the
volume must be balanced by means of anti-cavitation valves, for example, when a single-rod
cylinder is employed in a mobile machine.
drive and control The schematic illustration "drive and control / driving - controlling - and moving" on the next
page shows the task set to a hydraulic cylinder or hydraulic motor as machine element.
• The travel speed of the actuator is realized by the hydraulic pump flow.
• The direction, start and stop are controlled by directional valves.
• The required force can be varied by adjustable pressure control valves.
• The specified travel speed of the actuator can be influenced by means of a flow control
valve.
• Optimized system technology includes monitoring elements such as pressure switches and
pressure gauges. Hydraulic accumulators can be provided for realizing faster movements.
Heat exchangers optimize the oil quality and hence the availability of the system.
drive and control *

driving, controlling and moving
* Rexroth-specific statement
Driving machines Hydraulic cylinders and motors

and systems as machine elements
Pumps
Driving and controlling
Flow +
hydraulic cylinders and motors
storage tank
Hydraulic fluids
Directional seat valves

Direction + position
Start – direction – stop Spool, poppet and
are to be controlled
isolator valves
The required force Pressure control valves

Pressure
is to be adjustable limit – reduce – switch
The required velocity Flow control valves

Velocity
is to be adjustable Throttles – orifices
Power units & accessories

System technology optimized – accumulators – pressure
to suit the specific application switches – pressure gauges
– heat exchangers
Demands made on hydraulic cylinders / motors as drive elements
Physical basic principles

Pascal's law Pressure (p) in the vessel results from force (F), which acts on the piston. This means that a
greater force (load) generates a higher pressure, whereas with decreasing force (load), the
pressure falls.
The second relationship lies in the size of the area (A), onto which the force acts.
The smaller the area, the higher the pressure; and, of course, vice versa, the greater the area,
the smaller the pressure.
Consequently, the pressure is dependent on the amount of the effective force (F) and the size
of the area (A) onto which this force acts.
Pascal's law: F
p=
A
or: F
A=
p
F = pA
Force = pressure • area
p A
Pascal is the SI unit of pressure. It was named after Blaise Pascal.

1 kg
1 Pa = 2
= 1 N/m2
m • s
The force in Newton per surface area of one square meter, where:
1 bar = 100,000 Pascal (105 Pa)
1 bar = 10 N/cm2
In pressure calculations, the unit Dekapascal (daPa) is often used, where one Dekapascal
corresponds to 0.1 mbar.
100 Pa = 10 daPa = 1 haPa = 1 mbar
100,000 Pa = 0.1 MPa = 1 bar = 1,000 mbar
1.000.000 Pa = 1 MPa = 10 bar = 1 N/m2
Force transmis- In a closed system with two cylinders of different size, only one pressure (p) can prevail. If both
sion cylinders are to be held in balance and the areas (A1 - A2) have different sizes, the loads (F)
acting on the areas must consequently be different.
F1
Cylinder 1 means: p=
A1
F2
Cylinder 2 means: p=
A2
F1 F2
If p is identical in both cylinders, this means: =
A1 A2
A2
Rearranged by force: F1  = F2
A1
A2
is the area ratio of the cylinders and is identified by letter ϕ.
A1
Consequently: F1 • ϕ = F2
A2
Example: Solution: F1  = F2
Area A1 = 50 cm2 A1
Area A2 = 750 cm2
Weight force F1 = 1.000 daN 750 cm2
1.000 daN  = 15.000 daN
Weight force F2 = ? 50 cm2
A2 750
or with ϕ = = = 15
A1 50
F1 • ϕ = F2
1.000 daN  15 = 15.000 daN
This means that cylinder 1 with a force of 1,000 daN, which corresponds to a mass of 1,000 kg,
can hold cylinder 2 with a load of 15,000 kg or 15 t.
F1 F2
A1 A2
Pressure intensifi- The extending speed of a piston is to be adjustable by means of a meter-out throttle.
cation
Which risk arises, when the throttle is completely closed, e.g. due to dirt?
Example:
pK = 100 bar
ϕ = 2 : 1
AK
ϕ=
AR
Solution:
pK  ϕ = pR
2
100 bar  = 200 bar
1
pR = 200 bar
Conclusion:
Meter-out throttling involves the risk of pressure intensification!
AK ASt AR
pK pR
Flow The flow is the amount of fluid (nominal volume) that moves in a hydraulic systems within a
certain time.
In conjunction with pumps, we also speak of displacement.
The unit commonly used in industrial hydraulics is l/min.
If in the schematic diagram below the lever of the pump is shifted to the right, the piston dis-
places fluid into the system. If there is no counterforce (counterpressure), almost no pressure
will consequently build up in the pump. The fluid is fed to the system at zero pressure.
Only when the displacement is opposed by a resistance (directional valve, throttle, cylinder
piston or similar elements), can a counterforce be generated. The pump continues to displace
fluid and compresses the fluid. Pressure builds up, which depends on the resistance not gen-
erated by the pump.
The pump only displaces fluid into the system.
qV in l/min
s
t in s in mm
A in cm2
qV in l/min
V As
qV = =
t t
qV = A  v  6 in l/min
A in cm2
s
v = = Velocity in m/s
t
s in mm
A in cm2
v in m/s
In technical data sheets, the size of the pump is given in cm3/revolution. The following formula
is applied for determining the power:
Vg  n
qV = in l/min
1.000
Vg = displacement in cm3/rev
n = speed of the pump shaft in min-1
(rule of thumb without consideration of the volumetric efficiency).

Flow law The identical volumes flow through a pipe with different cross-sections within the same time.
This means that the flow velocity of the fluid must increase at the narrow point.
Flow q is fluid volume V divided by time t V

qV =
t
Fluid volume V is the product from area A times distance s V=A•s
As
If A • s is subsituted for V, q is then given by qV =
t
s
Distance s divided by time t provides velocity v v=
t
Flow q hence equals the product from the cross-sectional area of pipe A multiplied by the
velocity of the fluid v qv = A • v.
Flow
Flow q in L/min is the same at any point in a pipe. If the pipe has two cross-sections A1 and A2,
corresponding velocities must occur at the two cross-sections.
q1 = q2
q1 = A1 • v1
q2 = A2 • v2
This results in the following continuity equation A1 • v1 = A2 • v2

A
v 2 = v1 1 > v1
A2
Hydraulic fluids
General In a hydraulic system, the fluid assumes the task of force transmission. This means that certain
demands must be placed on the fluid.
The fluid should:

– be incompressible for the transmission of forces
– dissipate heat that is generated
– not change its viscosity at different temperatures
– carry away abrasion from hydraulic components
– be easy to filter
– be neutral against metal guides, seals and paints
– feature good lubrication properties
– be resistant to aging
– not be detrimental to health
– be easy to dispose of after use
Environmentally friendly
Neutral against seals, plastics, paint
Corrosion protection
Good lubrication properties
Good dirt transportation capacity
Temperature stability
Neutral against bearings,

good shear stability
Resistant to aging Not detrimental to health
No tendency towards
foaming
Good air separation
capacity
Demands made on hydraulic fluids

Requirements of None of the fluids offered on the market today can meet all of the requirements listed on the
the market previous page. Even in view of ongoing discussions about environmental compatibility of hy-
draulic fluids and in spite of all concerns, mineral oil is still the most common hydraulic fluid
used in hydraulic systems.
Selection criteria Being an important design element and machine element, the hydraulic fluid must be taken
into account at the planning stage, and during engineering and commissioning of hydraulic
systems.
The hydraulic fluid to be used is selected according to the prevailing operating conditions such as:
• Operating temperature range
• Concept of the hydraulic system
• Hydraulic pump type
• Working pressure and environmental requirements
• Operating time and availability
• Economic and ecological factors
Viscosity Viscosity is the most important criterion for the selection of the hydraulic fluid. Viscosity data
indicate whether a pressure medium is light or viscous at a certain temperature and hence
whether friction between the fluid layers is smaller or greater.
The viscosity is measured in the SI unit mm2/sec. It changes as temperature changes. In a
diagram with a double logarithmic scale for the viscosity axis, the representation in the change
in viscosity in dependence upon temperature T shows a straight line.
Manufacturer's For determining the application limits of a hydraulic system and consequently for the selection
data of the hydraulic fluid, it is important to take minimum and maximum viscosity values into account
that are given by the manufacturer in his documentation for the hydraulic components used.
The component manufacturer Rexroth, for example, indicates the data for the selection of the
hydraulic fluid in the technical data sheet of the component - RE data sheet - in the section
Technical data, hydraulic. Here, you can find details about the hydraulic fluid, hydraulic fluid
temperature and viscosity range.
Classification of
hydraulic oils
Hydraulic oils Hydro-kinetic application
DIN 51 502 ISO 6743/4
ATF HA
HN
Hydrostatic application Mobile hydraulics: UTTO, STOU
Hydraulic oils based on Flame-retardant hydraulic Fast bio-degradable Hydraulic oils compatible
mineral oils oils hydraulic oils with foodstuffs
7. Lux. report,
ISO 6743/4, ISO/CD VDMA sheet 24568, ISO FDA, USDA and NSF
DIN 51 502, ISO 6743/4
12922, DIN 51 502, 6743/4 and ISO 15380 classification
Factory Mutual - USA
DIN 51 ISO/DIS Containing Water- Water-

Water-free HSF H1 NSF H2
524 11158 water insoluble soluble
HL HH HFAE HFDR HETG HEPG Basis white Basis white

HLP HL HFAS HFDU HEES oil oil
HLPD HM HFB HEPR
HVLP HR HFC Basis PAO Basis PAO
HVLPD HV
HS Basis
HG mineral oil
Source: Specialist magazine 0 + P

Classification of
hydraulic fluids
based on mineral
oil
Code letter according to DIN 51 502 and ISO 6743/4

Class L: Lubricants, industrial oils and related products; Class H: Hydraulic systems
Code letter Code letter Composition Field of application

(symbol) DIN (symbol) ISO-L Typical properties Operating temperature
Hydraulic systems without specific

Mineral oils without active addi- requirements (only in rare applica-
-- HH
tives (base oils) tions today)
-10 to 90 °C
Mineral oils with active additives Hydrostatic drives with high ther-
to increase the resistance to mal stress, good water separation
HL HL
aging and to improve corrosion capacity
protection -10 to 90 °C
Hydrostatic drives with high ther-

Mineral oils of type HL with active mal stress, which require additives
HLP HM additives to improve wear protec- for the reduction of wear, good
tion in the mixed friction area water separation capacity
-20 to 90 °C
Extended operating temperature

Mineral oils of type HL with active
range when compared with HL
-- HR additives to improve viscosity /
oils
temperature characteristics
-35 to 120 °C
Mineral oils of type HM with active Among others, hydrostatic drives

HVLP HV additives to improve viscosity / in mobile hydraulics
temperature characteristics -35 to 120 °C
Special applications in hydrostatic

Synthetic fluids without specific
-- HS systems
flame-retardant properties
-35 to 120 °C
Hydrostatic systems with plain

Mineral oils of type HM with ac-
bearings at intermittent, low ve-
(HLPD) HG tive additives to improve stick-slip
locities
characteristics
-30 to 120 °C
Hydrostatic drives with high ther-

Mineral oils of type HM with
mal stress, which require EP/AW
detergent / dispersive (DD) addi-
HLPD -- additives; DD additives hold con-
tives; DD additives reduce friction
taminations in balance, e.g. in ma-
values
chine tools and mobile systems.

Classification of
flame-retardant
hydraulic fluids
and water-free,
fast bio-degrad-
able hydraulic
fluids
Code letter according to Composition Field of application

7th Luxemb. report, Typical properties Operating temperatures
DIN 51 502 and (Notes)
DIN EN ISO 6743/4: April 2002
Flame-retardant, water-containing hydraulic fluids
Oil-in-water emulsions, mineral oil / Power hydraulics of about 300 bar, for
HFA-E synth. esters example in shield tunneling in the field
Concentrate share < 20 % of mining
Mineral oil-free watery solutions of Hydrostatic drives - working pressures
HFA-S chemicals < 160 bar
Concentrate share < 20 % 5 to < 55 °C
Water-in-oil emulsion For example in British mining
HFB
Share of mineral oil 60 % 5 to 60 °C
Hydrostatic drives, industrial and mining
Watery polymeric solution
HFC hydraulics
Water share > 35 %
-20 to 60 °C
Water-free, synthetic, flame-retardant hydraulic fluids
Lubrication and control of steam tur-
Synthetic fluids based on phosphate bines, industrial hydraulics
HFD-R esters, -20 to 150 °C
water-free in hydrostatic systems often
10 to 70 °C
Synthetic fluids of other composition
Hydrostatic drives, industrial hydraulics
HFD-U (mostly carboxylic acid, polyesters)
-35 to 90 °C
water-free
Code letter according to Composition Field of application

VDMA 24568 and ISO 15380 Typical properties Operating temperatures
(Notes)
Water-free, fast bio-degradable hydraulic fluids
Hydrostatic drives,
Polyalkylene glycol
HEPG e.g. ship lock hydraulics
Water-soluble
-30 to < 90 °C
Hydrostatic drives,
Triglycerides (vegetable oils)
HETG mobile hydraulics
Not water-soluble
-20 to 70 °C
Hydrostatic drives,
Synthetic esters
HEES mobile and industrial hydraulics
Not water-soluble
-35 to 90 °C
Hydrostatic drives,
Polyalpha olefins (synth. hydrocarbons)
HEPR mobile and industrial hydraulics
Not water-soluble
-35 to < 80 °C
Viscosity/ 10.000
temperature
Viscosity mm2/s
diagram
1.000
* Max. permitted
100 * Permitted briefly for

cold start (cavitation)
Recommended range for

continuous operation
36
* Min. permitted
(lubrication problems)
20
Ideal operating point
Reference point for all data
12
10
9
8
IS
7
O SO
VG V
6
10
IS
0
O
G
IS
5
V G
68
O
46
VG VG
IS
3
O
4
2
2 2
IS
O
3,0
VG
15
-40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 120 140
Temperature °C
Reference temperature for ISO viscosity classes
Viscosity/temperature diagram with application limits for hydraulic systems
Viscosity Viscosity is the reference for internal friction of the fluid.

It is the resistance that material particles put up to the force during mutual shifting.
Comparison of
different SAE classes ISO - VG SAE classes
viscosity classes (DIN 51519)
100 68
30
49
68
20, 20 W 36
46
25
10 W 32
5W 22 16
(15)
9
10
Additives No hydraulic fluid can meet all requirements. Thanks to additives, certain properties of the
hydraulic fluid can be optimized to suit the requirements of specific applications.
For example:
• for improving:
– corrosion protection
– pressure resistance
– resistance to aging
– viscosity/temperature behavior
• for reducing:
– the pour-point
– foaming
– wear
Practical notes
Effects of air Air can be present in hydraulic oils in the following forms: as dissolved air (invisible), as surface
in the oil foam (visible), and as undissolved, dispersed air (visible). While dissolved air and minor surface
foam hardly show any adverse effects, dispersed air can cause severe problems. Since the oil
contains very small air bubbles, which are finely dispersed and can rise to the surface only very
slowly, the following troubles can occur:
• Uneven or jerky movements of hydraulic spools, vibration in the system due to increased
compressibility, changed actuating times of servo-valves
• Pump noise
• Damage to pumps, lines and seals caused by cavitation
• Accelerated aging of the oil
• Micro-diesel effect, a form of thermal cracking due to high temperatures in compressed air
bubbles
Environmental Hydraulic systems are closed systems. When hydraulic systems are used properly, hydraulic fluid
aspects does therefore not get into the environment. Care must be taken that power units are leak-free
and maintenance/repairs are carried out in due time. Especially hydraulic hoses and hose con-
nections must be intensively observed and inspected. Oil changes must be made properly and
thoroughly; waste oil must be disposed of in accordance with all relevant legal stipulations.
Safety aspects Hydraulic fluids based on mineral oil are water-endangering and inflam-
mable. Pressure fluids may only be used, if the corresponding safety data
Danger
sheet of the manufacturer is at hand and all precautions prescribed therein
are observed.
If leakage on the hydraulic product can lead to the contamination of water
and soil, the hydraulic product must be placed in a suitable oil drip tray.
Filters Causes of contamination

One of the preconditions for the trouble-free operation of a hydraulic system is filtration of the
hydraulic fluid and the ambient air connected to the tank.
The contamination to be removed by means of filters enters the hydraulic system from the sur-
roundings via the filling connection or past the seals.
This type of contamination is termed external contamination or contamination that enters the
system from outside.
The contamination ingression rate to be expected depends exclusively on the contamination of
the surroundings and the design of systems and components.
Moving parts in the hydraulic system such as pumps, spools and valves also generate particles
(abrasion). This type of contamination is termed internal contamination.
Especially during commissioning of the system, there is a risk that the individual components
are damaged or destroyed by solid particles that were transported into the system already
during assembly.
The majority of malfunctions in hydraulic systems are caused by strongly contaminated hydraulic
fluids. Fresh pressure fluid, with which the hydraulic fluid is to be filled, is often contaminated
to an impermissibly high level.
– Contamination during the production of components

(component contamination)
Due to the often highly complicated internal contours of housings and internal parts of com-
ponents, the latter cannot in every case be sufficiently cleaned. When the hydraulic system
is flushed, the contaminants get into the hydraulic fluid.
Components are often preserved for intermediate storage. The preservatives bind dirt and
dust. This dirt also gets into the hydraulic fluid when the system is commissioned.
Typical contaminants are:
Chips, sand, dust, fibres, paint flakes, water or preservatives.
– Contamination during the assembly of systems

(assembly contamination)
When individual parts are joined, e.g. installation of fittings, solid particles may be pro-
duced.
Typical contaminants are:
Seal material, scales, welding beads, rubber parts from hoses, residues of pickling and
flushing fluids, cutting and grinding dust.
– Contamination during operation of the hydraulic systems

(production contamination)
Abrasion in components results in the formation of particles. Particles smaller than 15 µm
are particularly wear-promoting.
Aging residues in hydraulic fluids, which are in most of the cases caused by high operating
temperatures, change the tribological properties of the hydraulic fluid.
Critical tolerances
for hydraulic
components Gear pump
J1 from 0.5 to 5 μm
Vane pump
J2 from 5 to 20 μm
J3 from 30 to 40 μm
Piston pump
J1 from 5 to 40 μm
J4 from 1 to 25 μm
Valve
J1 from 5 to 25 μm
Servo-valve
Causes and
sources of
contamination
1 External contamination
2 Installation + repair
3 Fresh oil
4 Abrasion in the pump
5 Abrasion of seals
Arrangement of The task of filters is directly related to their arrangement in the system.
filters in the open Filters perform certain tasks depending on their location in the system.
circuit
Main flow filtration

Control
1
8
10 6 Off-line filtration
3
2
5 9
1 Built-on return flow filter

2 Filling filter
3 Breather filter
4 Suction filter
5 Hydraulic pump
6 Cooler
7 Hydraulic pump
8 High-pressure filter
9 Off-line filter
10 Underpressure switch
Filter types Return flow filter

These filters are located at the end of the return flow line and are designed mostly as filters for
tank mounting. This means that the hydraulic fluid coming from the system is filtered before
being fed back to the tank. Thus, the major part of dirt particles, which entered the system or
are produced in the system, are filtered out of the hydraulic fluid.
The maximum flow must be taken into account for the selection of the filter size.
Advantages
– Low cost
– Ease of maintenance
– Can be fitted with clogging indicator
– Provides fine filtration
– No pump cavitation
Disadvantages
– A by-pass valve is required
– Lets dirt particles through the open by-pass valve in the case of pressure peaks and cold
start conditions
The filter shown below is mounted to the tank cover using a mounting flange. The housing with
the filter connection protrudes directly into the tank. A great advantage of this filter design is
good accessibility and consequently maintenance-friendliness.
The filter element can be quickly and easily taken out by removing the cover.
An important feature is that a strainer encloses the filter element. When the filter element is taken
out, the strainer is pulled out as well, thus preventing dirt already settled from flowing into the
hydraulic tank. The filters are generally provided with a connection for a clogging indicator.
In-line filter (pressure filter)

This filter type ensures that the function of downstream hydraulic components is maintained.
For this reason, these filters must be installed as closely as possible to the components to be
protected.
The following aspects are decisive for the use of pressure filters:
– Components are particularly susceptible to dirt (e.g. servo-valves or high-response valves)
or decisive for the operation of a system.
– Components are particularly expensive (e.g. large cylinders, servo-valves, hydraulic motors)
and of extreme importance for the safety of a machine.
– Downtime costs of a system are extraordinarily high.
Pressure filters should generally be fitted with a clogging indicator.
Upstream of particularly critical components, only pressure filters without by-pass valve should
be used. This type of filter must be provided with a filter element that withstands also higher
pressure differential loads without any damage.
The filter housings must withstand the max. system pressure.
The filter basically consists of a filter head with a screw-in filter housing and a filter element.
The standard variant is designed without by-pass valve and without pressure unloading screw.
A connection for a clogging indicator is generally provided.
Advantages
– Can be installed directly upstream of sensitive components
– No pump cavitation
Disadvantages
– Element must be provided for a high differential pressure
Filler and breather

filter
Symbol for filler and breather filter without (on the left-hand Filler and breather filter with and without filling filter
side) and with by-pass valve (on the right-hand side)
Filler and breather filter with filling strainer
In the past minor importance had been attached to these filters in hydraulic systems. However,
according to latest findings, they are one of the most important elements for the filtration of
hydraulic fluids in hydraulic systems. A significant part of contaminants gets into hydraulic
systems through unsuitable venting equipment. Design measures such as pressurization of oil
tanks are often uneconomical when compared with the highly efficient breather filters offered
on the market today.
Depending on the required cleanliness class, breather filters are equipped with replaceable
elements of different filtration ratings. The filters should be fitted with a connection for clogging
indicators (2).
Filler and breather filters basically consist of an air filter (1) for filtering the air flowing into the
tank and a filling strainer (3) for retaining coarse particles when the system is filled with fluid.
The air filters are available with different filtration ratings so that CETOP standard RP 70 can
be complied with, which prescribes the same filtration rating for system filters and air filters.
The requirements for this filter type are laid down in DIN 24557.
Filtration media For the filtration methods described, various filter media or a combination of filter media are
used.
a) Surface filtration
With surface filters, the particles are separated directly at the surface of the filter media.
Particles that get into the filter medium due to their small diameter can pass through the filter
without any hindrance. However, the filter resistance increases as the surface is clogged.
The filter cake built up on the surface can result in a reduction in the filtration rating.
For surface filtration, diaphragm filters of filter materials made of wire mesh, metal edges or
Dutch weave are used.
b) Deep filtration
The fluid to be filtered penetrates the filter structure. The particles to be removed are also
retained in the deeper layers of the filter. As more and more particles are retained by the
filter, the flow resistance increases so that the filter element has to be replaced. For these
filters, filter media are used, which are made of
– impregnated cellulose materials (organic filter material),
– glass fiber material (inorganic filter material),
– sintered metal meshpacks,
– porous, sintered metal.
Particle size and

Finest particle Fine particle Coarse particle
filtration rating
contamination contamination contamination
Finest particles (3 to 5 µm) Fine particles (5 to 20 µm) Coarse particles > 20 µm
cause an impairment of cause cratering mainly in often cause a sudden total
function and reduction in the narrow fits. failure due to clogging and
performance due to: blocking effects or direct
The consequences are:
destruction.
– the erosive effect of finest
– Increase in clearance due
particles (often erosion on Typical:
to abrasion (increased
control lands)
internal leakage) – Blocking of nozzles
– fine sedimentation in nar-
– Temporary failure (brief – Jamming or seizing of
row gaps (through edge
seizing effect on sliding spools
filtration effect - risk of
spool valves or leakage on
clogging) – Material breakouts due to
valve seats)
effect of large forces
– Changes of the operating
– Total failure due to severe
medium (oil aging) as a re-
abrasion
sult of chemical reactions
on the particle surface
Finest filtration Fine filtration Coarse filtration
Effective separation of finest- Partial separation of fine Separation of mainly coarse

dispersed particles particle contamination and particles (bX → 100)
(b3 to 5 → 100) complete separation of
X = µm particle size, which
coarse-grain contamination
High differential pressure- can cause a sudden failure
(b5 to 20 → 100)
stable finest filters safeguard on the component to be
the function Fine filters reliably control protected.
the acceptable degree of
– They minimize the forma- Coarse filters protect the
contamination of the system
tion and further develop- system against coarse
ment of erosion – They protect components particle contamination
optimally against contami-
– They prevent clogging of They reduce the risk of a
nation
narrow gaps sudden failure or total loss.
– They reduce cratering
– They provide protection
against aging of oil – They prevent sudden
failures of components
– They prevent system
malfunction
Classification The solid particle content in the hydraulic fluid is determined with the help of classification
systems for the systems (standardized cleanliness classes).
degree of con-
tamination of the The most common standards today are NAS 1638 (National Aerospace Standard) and DIN
hydraulic fluid ISO 4406.
Classification according to NAS 1638

14 cleanliness classes are available for the classification of the hydraulic fluid. For each class,
a certain number of particles (in 100 ml) is specified for each of the 5 sizes.
Particle size in µm
Contamina-
tion class
5 - 15 15 - 25 25 - 50 50 - 100 > 100
00 125 22 4 1 0
0 250 44 8 2 0
1 500 89 16 3 1
2 1000 178 32 6 1
3 2000 356 63 11 2
4 4000 712 126 22 4
5 8000 1425 253 45 8
6 16000 2850 506 90 16
7 32000 5700 1012 180 32
8 64000 11400 2025 360 64
9 128000 22800 4050 720 128
10 256000 45600 8100 1440 256
11 512000 91200 16200 2880 512
12 1024000 182400 32400 5760 1024
Contamination classes to NAS 1638

Maximum number of dirt particles in 100 ml hydraulic fluid
Classification Number of particles per milliliter Scale number

according to
ISO DIS 4406 more than up to and including
Assignment of 2500000 > 28
scale numbers
1300000 2500000 28
640000 1300000 27
320000 640000 26
160000 320000 25
80000 160000 24
40000 80000 23
20000 40000 22
10000 20000 21
5000 10000 20
2500 5000 19
1300 2500 18
640 1300 17
320 640 16
160 320 15
80 160 14
40 80 13
20 40 12
10 20 11
5 10 10
2.5 5 9
1.3 2.5 8
0.64 1.3 7
0.32 0.64 6
0.16 0.32 5
0.08 0.16 4
0.04 0.08 3
0.02 0.04 2
0.01 0.02 1
0.00 0.01 0
Filter clogging Inside the clogging indicators, each change in pressure is recorded as change in travel by means
indicators of metering pistons or diaphragms. A piston with attached magnet is moved against the force
of a spring inside the clogging indicator. On visual clogging indicators, a unipolar magnet is
mounted in the indicator head. The closer the poles come to each other, the greater becomes
the repulsive force between the magnets, until finally the red indictor button pops out.
With the electrical variant, a switching contact picks up.
For a permanent indication of the element contamination electronic clogging indicators were
developed. Through the use of these indicators, maintenance intervals become foreseeable.
With these fully electronic clogging indicators, the differential pressure building up as a result
of contamination of the element is converted contact-free into an analog electrical output
signal with the help of a sensor. A pressure peak suppression and cold start suppression are
additionally integrated.
Differential pressure clogging indicators
Backpressure clogging indicators

Safety notes Bosch Rexroth AG I RE 00845/04.07
Fundamental safety notes

In order that potential risks for plant and machinery can be recognized, safety regulations,
product documentation and operating instructions must be observed.
The trainer must make the required documents available to the trainee. When competitors' prod-
ucts are used, the safety notes of the relevant manufacturer are applicable, and it must be ensured
that the components and systems comply with currently valid, relevant EU Directives.
For this reason, commissioning is prohibited until it was established that the
electrohydraulic components and systems to be used meet the stipulations
Warning of all relevant EU Directives.
Fundamental, ge-
neral safety notes
Warning
Observe
• danger signs and safety notes on the machine
• instructions, which prescribe the behavior during operation in order to prevent accidents
and health damage and must be prepared by the operator/employer on the basis of, for
example, regulations for the prevention of accidents,
• operating instructions, which ensure the proper use of the hydraulic system in accordance
with its intended purpose.
The operating instructions are intended for information purposes and for the
prevention of risks when hydraulic components are being installed in a system
- in this case mounting of electrohydraulic components on the training stand
-, and include information and notes on transport, storage and maintenance
(inspection, servicing, corrective maintenance) of the hydraulic system.
Only when the operating instructions are strictly observed can accidents
and damage to property be avoided and the trouble-free operation of the
hydraulic system be ensured.
Moreover, observing the operating instructions helps to:
• reduce downtimes and repair costs
• prolong the service life of the hydraulic system.
Hydraulic oil based on mineral oil is water-endangering and inflammable. It may only be used
when the corresponding safety data sheet is available and all precautions prescribed therein
were taken.
The hydraulic system may only be operated when in technically perfect condition.
The use for the intended purpose, performance data and operating conditions must not be
changed.
Protective equipment / components must not be rendered inoperable, e.g. by bridging limit
switches, valves or other control components.
If protective equipment must be bridged to allow servicing work to be carried out, precau-
tions must be taken to ensure that no dangerous situation can arise. The higher-order machine
operating instructions must be observed.
Safety notes Bosch Rexroth AG I RE 00845/04.07
Adjustment features on components may exclusively be operated or changes to program-

mable control systems made by authorized personnel within the framework of the intended use
of the hydraulic system.
In the case of an emergency, fault or other irregularities:

• hydraulic systems must be switched off and the main circuit breaker be secured against
restarting,
• the danger zone must be fenced off in order that nobody can enter the danger zone unknow-
ingly or in an uncontrolled manner,
• immediately inform the responsible specialist personnel.
Uncontrolled access by external persons to the direct operating area of the hydraulic system
is prohibited (even in case that the hydraulic system is at rest).
Note:
These are the fundamental safety regulations that must be observed for every project task.
Project 01:
Hydraulic power unit Bosch Rexroth AG I RE 00845/04.07
Project 01: Hydraulic power unit

01
Project/trainer information
Hydraulics as technology can be assigned to drive technology. The task of drive engineering
is to provide a drive for a machine or system that ensures optimum performance of the tech-
nological function. This is equally valid for the engine of a passenger car as for the drive of the
projects described in this project manual such as the drive of:
• feed equipment for the vertical transport of workpieces,
• rope winches for lifting loads,
• lifting gear for the horizontal transport of loads,
• conveyor belts for transporting loads,
• feed carriages for tool transport,
• punching equipment for punching perforated metal sheets,
• rotary drives for relocating workpieces, and
• pressing equipment for workpiece pressing.
The drive power is made available by an electric motor or combustion engine. The output
torque of the motor or engine is converted by a convertor into a rotary or linear movement as
required by the machine. This task is assumed by a transmission - in this case, the hydraulic
component such as a hydraulic cylinder or a hydraulic motor. The power is transmitted by the
hydraulic fluid.
The basic components of a hydraulic system are:

• Fluid flow generator/pump,
• fluid flow consumers/hydraulic cylinders and motors,
• open and closed-loop control equipment/valves,
• accessories.
The components of a hydraulic system listed above can be designed as individual components
or, to form a compact assembly, combined in a hydraulic power unit (without consumers). The
valves such as directional, pressure and flow control valves are in most of the cases installed
separately into a machine.
A simple hydraulic power unit consists of:

• Hydraulic pump with drive motor,
• reservoir for storing the fluid,
• instruments for monitoring the fluid level, temperature and pressure,
• equipment for fluid care such as filters, coolers and heaters,
• valves for pressure relief functions and, if required,
• hydraulic accumulators as energy accumulators.
In the following Project 01 you can impart knowledge of the general structure of a hydraulic
power unit.
In the project order, the trainee sets up the required components on the basis of the given
requirements. In this project task, he or she is to understand the following:
• A hydraulic system consists of a fluid flow generator and a fluid flow consumer (actuator),
open and closed-loop control devices and accessories.
• In a hydraulic power unit, hydraulic components are grouped to form a compact assembly.
Project 01:
01
• The required drive elements and the accessories such as control and monitoring devices as
well as maintenance equipment can be mounted on top or to the hydraulic fluid reservoir.
• The size of the power unit, e.g. the capacity of the reservoir, depends on the given conditions
and customer requirements.
In this project task, the trainee is to set up a power unit on the basis of the conditions listed
below and draw a sketch of a schematic diagram:
• Hydraulic pump in the form of a pilot operated, variable vane pump with a displacement of
qV = 20 l/min;
• electric motor for a maximum system pressure of p = 80 bar,
• reservoir according to the displacement (3 - 5 times qV),
• carrier components,
• hydraulic filter with visual, mechanical clogging indicator,
• filler and breather filter,
• level monitor and
• drain valve for changing the hydraulic fluid.
A hydraulic accumulator is not provided.
Notes on the detailed technical information about hydraulic power units:

• The Hydraulic Trainer Volume 1/Bosch Rexroth AG
Basic principles and components, chapter 17
Planning and design of hydraulic systems
• Technical data sheet RE 51098
Modular standard power units
Variable vane pump, pilot operated
Project 01:
01
Project definition
In a hydraulic system for driving lifting equipment for heavy loads, a hydraulic power unit with
a variable displacement pump powered by an electric motor and associated accessories is to
be used.
The customer wishes to get information about the structure of a hydraulic power unit with pilot
operated vane pump. In the list of the hydraulic power unit components he requests the provi-
sion of short information about the selected components, including a schematic diagram of the
hydraulic system and a parts list.
Fig. 01.1 Practical example: Hydraulic power unit with hydraulic pump/el. motor and
accessories
Project tasks
• Independent understanding of the task and its putting into practice using hydraulic control
technology
• Planning and organizing the customer requirement (core qualification)
• Analyzing the technical data sheet for a standard power unit with pilot operated vane pump
(technical qualification)
• Handling of hydraulic components in line with functional needs
Project 01:
01
Project steps
• Informing: Accepting and understanding the order, among others, through discussions
with the customer.
• Planning: Planning and organizing the execution of the customer order; among oth-
ers, through the selection of power unit construction parts from a technical
data sheet (RE 91098 / modular standard power units).
• Deciding: Hydraulic design and dimensioning of the power unit.
• Executing:: Preparation of a schematic circuit diagram and selection of the required

drive elements and accessories with short description.
• Checking: Are all customer requirements met?
• Evaluating: Are there further possibilities of meeting the customer requirement or simpler
ways of project execution? Have unforeseeable problems occurred?
Notes
Project 01:
01
Hydraulic schematic diagram
Item 9.0 Item 10.0
Measuring glass
Item 6.0
Item 2.0
Item 4.0 Item 7.0
Item 8.0
Item 3.0
Item 1.0 Item 5.0
Fig. 01.2 Hydraulic schematic diagram: Drive power unit

Project 01:
01
Component selection with parts list
Item Qty Component designation Type designation Symbol
1.0 1 Reservoir with cover 100 L/steel
Variable displacement pump,

2.0 1 PV7-1X/16-30...
pilot operated
3.0 1 Level control FSK
4 KW/1450 rev/
4.0 1 Electric motor
min.
5.0 1 Shut-off valve, operated by turning
Check valve with spring, flow

6.0 1 enabled in only one direction; S6-1X/...
closed at rest position
Filter with by-pass valve and

7.0 1 RF 060...
pressure measuring device
8.0 1 Tank breather filter
Connection block with 1/4" coupler

9.0 1
plug
10.0 1 Measuring glass
Table 01.1 Parts list for hydraulic circuit diagram Fig. 01.2
Notes for the trainer:

Items 9.0 and 10.0 listed in the parts list are accessory components for a training system and
are not part of a hydraulic power unit in real industrial applications.
Project 01:
01
Safety notes
To ensure the operability of plant and machinery, and consequently to allow

the recognition of potential risks, safety regulations must be observed before
and during the execution of the order. Relevant sources of regulations are
given in the introduction of the present manual.
If work on electrohydraulic components is carried out improperly, risks of
injury and a safety risk can arise during operation of the system, including
danger to life.
Warning
Before starting work on the training stand, make sure that electrical ON/OFF
switches on the hydraulic power unit are pressed in, that is, that the system
is switched off. Check on the system pressure gauge that the system is
Caution
depressurized.
Hydraulic systems can store pressure energy at rest. This can cause injury
when the system is opened.
Notes
Project 01:
01
Execution of the order
Dimensioning of a hydraulic power unit requires fundamental knowledge of hydraulic control

technology. This also includes knowledge of the design of hydraulic systems inclusive of the
drive power unit. The listing on the next page shows influencing factors that have to be taken
into account when rating a hydraulic power unit.
In the project order, only simple rules for the rating of power units can be applied. For this,
formulas from physical basic principles can be applied (see Fig. 01.3). Any power losses are
not considered.
Piston area AP Annulus area AA

Force
Force = pressure • area Force F pA
Energy converter F =
10
e.g. cylinder v F = force in N
Pressure differential ∆p
p = pressure in bar
A = area in mm2
Velocity
s
v=
t
m
Flow control valve v = velocity in
s
Change in velocity s = travel in m
t = time in s
Directional valve Displacement/flow

Start, direction, stop Vg  n  ηvol
qV =
1000
l
qV = flow in
min cm3
Vg = geometric displacement in
rev
n = Speed of the pump shaft in rev
min
η = volumetric efficiency in %
Pressure control Motor power

valve p  qV
Force / pressure PM =
600  ηtotal ,P
limitation
PM = power in kW
p = pressure in bar
Energy converter l
qV = flow in
e.g. fixed displace- min
ηtotal,P = overall efficiency in %
ment pump
Fig. 01.3 Physical basic principles with formulas

Project 01:
01
Factors that have an influence on the rating of a power unit
• Environment, surroundings - climate

• Pipe length to the consumer
• Place of installation: integrated - separate
• Duty cycle
• Expected drive power
• Volume fluctuation
• Ambient temperatures
– Heat dissipated by the reservoir
– Cooling (air, water)
– Heating
• Noise - transmitted by pipes and air ducts
• Acoustic insulation
– Hoses
– Compensators
– Anti-vibration mounts
– Low flow velocity
– Pump selection
– Encapsulation
– Hydraulic accumulator
– Silencers
etc.
• Assembly - disassembly - maintenance
Factors that have an influence on the rating of a return flow filter
• Field of application, environment

• Susceptibility of components (the component with the most stringent requirement determines
the filter rating for the entire system!)
• The required cleanliness class and filter rating must be adhered to. Both must be speci-
fied by the component manufacturer. State of art with regard to minimum requirements is,
for example, NAS class 9 and a minimum retention rate of ß10 ≥ 100; ISO 4406 (c) class
20/18/15.
• A reliable calculation of cleanliness is impossible, because the ingress of dirt in relation to
the ß value cannot be determined.
• Arrangement of filters
• Type, viscosity and operating temperature of the fluid
• Operating pressure
• The flow rate determines the selection of the filter size
• Permissible Dp across the clean element (Bosch Rexroth selection series: Rated Dp for a
pressure filter - 1 bar, return line filter = 0.4 bar)
• By-pass valve - determined by the filter series, not provided for pressure filters
• Clogging indicator - a MUST in modern hydraulic systems - visual and/or electrical
• The tank breather filter must have the same filter rating as the fluid filters.
Project 01:
Hydraulic power unit 10 Bosch Rexroth AG I RE 00845/04.07
01
Hydraulic pump:
The following must be known for rating the hydraulic pump:
qV = ? l/min., i.e. which volume is the pump to provide within which time.
Since manufacturers usually indicate only the sizes in technical data sheets (how much is
displaced during one revolution of the pump?), the speed of the drive/electric motor must be
known. In industrial applications, motors of approx. 1,500 rev/min. are employed. For converting
the displacement into power per unit of displacement the following formula can be applied:
Vg  n
qV = in l/min
1.000
Because no manufacturer will be able to offer a hydraulic pump with exactly the requested
power, the next larger size is usually selected.
Electric motor:
For rating the electric motor, the possible maximum system pressure must be known apart from
the displacement of the hydraulic pump in l/min.
Calculation formula for the selection of the hydraulic motor:

p • qV
P= in kW
600
p in bar
qV in l/min
Also here, the next larger frame size of the manufacturer's electric motor is selected. Typical
frame sizes are, e.g. 3 kW, 4 kW, 5.5 kW, 7.5 kW, etc.
The selection of the required carrier components such as coupling, pump mounting bracket
and damping elements will not be considered here and are not part of the order execution.
Hydraulic fluid reservoir:
Hydraulic fluid reservoirs are selected on the basis of practical experience such as:
Reservoir size = displacement of the hydraulic pump • 5
Whenever possible, standard reservoirs of standardized sizes should be used. The topic of
cooling is not dealt with in this simple engineering task. The provision of a drain valve is always
recommended for changing the hydraulic fluid.
Accessories:
In this project task, required accessories for a hydraulic fluid reservoir are a return flow filter, a
filler/breather filter and a level control device. For the selection, please refer to technical data
sheets of the manufacturers.
When selecting the return flow filter, the actual flow required for operating a single-rod cylinder
must in any case be taken into account, i.e. how much oil returns from the hydraulic cylinder to
the filter (see Project 04).
The factors that have an influence on the selection of a return flow filter are listed on the previ-
ous page.
Project 01:
01
As additional aid for rating a hydraulic power unit we recommend the use of a hydraulic slide
rule.
For the simplified rating of a return flow filter, see technical data sheet RE 50081.
Detailed notes on the engineering and design of hydraulic systems can be found in The Hydraulic
Trainer Volume 3/Bosch Rexroth AG.
General note:
In contrast to the following project tasks, this order execution does not involve any practical
work on the training system.
A component arrangement drawing and a general layout of the training system are therefore
not provided.
Evaluating the work results in relation to the customer requirement
• A hydraulic system consists of a fluid flow generator and a fluid flow consumer, valves and
accessories.
• A hydraulic power unit accommodates the hydraulic components to form a compact unit.
• The required drive elements and reservoir accessories such as control and monitoring and
maintenance devices can be mounted to or on top of the reservoir.
• The size and design of the hydraulic power unit depends on the given conditions and the
requirements of the customer.
Project 01:
Notes
01
Project 01:
01
Project schedule: Project 01 Q. Public, John
………………………………………………………………………………………
Last name, first name
Hydraulic power unit

……………………………………………………………………………………………………………
Customer requirement: Project handler

……………………………………………………………………………………………………………
– Hydraulic circuit diagram

……………………………………………………………………………………………………………
– Parts list Informing

……………………………………………………………………………………………………………
Project designation from the project definition.
– Information about components
……………………………………………………………………………………………………………
– System rating/calculation
……………………………………………………………………………………………………………
Understand the circuit diagram

……………………………………………………………………………………………………………
Identifiy components
……………………………………………………………………………………………………………
Supplement parts lists

……………………………………………………………………………………………………………
Rate components Planning

……………………………………………………………………………………………………………
Planning steps of the project objective and
Evaluate the result
…………………………………………………………………………………………………………… the proceeding.
……………………………………………………………………………………………………………
Sources of information
DIN ISO 1219

……………………………………………………………………………………………………………
The Hydraulic Trainer Volume 1

……………………………………………………………………………………………………………
Project manager
……………………………………………………………………………………………………………
Data sheets
……………………………………………………………………………………………………………
Internet
……………………………………………………………………………………………………………
Hydraulics supplier
……………………………………………………………………………………………………………
Select components from data sheets

……………………………………………………………………………………………………………
Make calculations
……………………………………………………………………………………………………………
……………………………………………………………………………………………………………
Deciding on
……………………………………………………………………………………………………………
Decision-making and selecting components;
…………………………………………………………………………………………………………… complementing the circuit
diagram and parts list.
……………………………………………………………………………………………………………
(Overleaf)
Project 01:
01
Summarize the information obtained
……………………………………………………………………………………………………………
……………………………………………………………………………………………………………
……………………………………………………………………………………………………………
Execution
……………………………………………………………………………………………………………
Execution of the order Set-up of the electrohy-
…………………………………………………………………………………………………………… draulic control and acqui-
sition of required data.
……………………………………………………………………………………………………………
Special points?
Pump data sheet RE 10515 is very complex

……………………………………………………………………………………………………………
……………………………………………………………………………………………………………
……………………………………………………………………………………………………………
……………………………………………………………………………………………………………
……………………………………………………………………………………………………………
……………………………………………………………………………………………………………
Comparison of summary with customer requirements

……………………………………………………………………………………………………………
……………………………………………………………………………………………………………
……………………………………………………………………………………………………………
Checking
……………………………………………………………………………………………………………
Quality check Are all customer require-
…………………………………………………………………………………………………………… ments met?
……………………………………………………………………………………………………………
Evaluating
Optimize project steps
(If required, add

supplementary sheet)
Assign individual project steps to team members → faster results

………………………………………………………………………………………………………………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………………………………………………………………………………………………………………
Project 01 ……………………………………………………………………………………………………………………………………………………………
Note of completion by confirmation of the project manager/place, date, signature
Project 02:
Hydraulic variable displacement pump Bosch Rexroth AG I RE 00845/04.07
Project 02: Hydraulic pump/characteristic curve of variable displacement pump

In a hydraulic system, fluid flow generators/hydraulic pumps convert the mechanical energy
02
of a drive motor (torque, speed) into hydraulic power (flow, pressure).
The hydraulic pump usually aspires the hydraulic fluid from a storage tank (suction side) and
displaces it to the pump outlet (pressure side). In terms of construction, hydraulic pumps can
be differentiated as follows:
Gear, internal gear, screw, vane,

radial piston and axial piston pumps.
Hydraulic pumps are displacer pumps, the displacement of which can be either fixed or variable.
Hydraulic pumps that feature an adjustable displacement are called variable displacement pumps.
The displacement/flow is adjusted by means of mechanical or electronic control systems.
In the following Project 02 you can impart knowledge of the interrelationship between the
hydraulic variable displacement pump, the displacement and pressure build-up through resist-
ances in the hydraulic system.
In the project order, the trainee is made familiar with the characteristic curves of a pilot operated
variable displacement vane pump and the direct relationship between the displacement and the
system pressure. This project task is to help the trainee to understand the following:
• With hydraulic variable displacement pumps, the flow is almost reduced to zero when the
system pressure has been reached.
• Due to the design of a variable displacement pump, internal leakage oil occurs, which is
refed to the reservoir through an external leakage oil line.
• The leakage oil flow increases as the resistance rises, which opposes the displacement in
the pressure line of the pump
• The drained leakage oil flow is the power loss of the hydraulic pump.
With the help of the control set up on the training system, the trainee can recognize that when
the system pressure increases as resistance at the pressure port of the hydraulic pump, the
total displacement reduces. The resistance is realized by means of a hand lever valve, with the
system pressure being steplessly variable via a pressure relief valve operated in parallel.
Notes on the detailed technical information about hydraulic variable displacement

pumps:
Variable vane pump, pilot operated
Project 02:
Project definition
In a hydraulic power unit, the hydraulic energy is to be provided by a variable, pilot operated
02
vane pump. The power that can be generated by the hydraulic pump is to be measured in an
experiment set-up.
The customer wishes detailed information about the pros and cons of this vane pump, including
a flow characteristic curve, from which the relationship between increasing system pressure
and losses of the vane pump can be seen.
Fig. 02.1 Practical example: Vane pump/function elements
Project tasks
technology
• Analyzing the technical data sheet for a pilot operated vane pump (technical qualifica-
tion)
Project 02:
Project steps
02
with the customer.
• Planning: Planning and organizing the execution of the customer order; among
others, through the selection of components from a technical data sheet
(RE 10515 vane pump, pilot operated).
• Deciding: Preparation of a circuit diagram sketch and selection of components.
• Executing:: Working out the set-up of a hydraulic control on the training system, docu-
menting the characteristic curve required by the customer and providing
explanations with regard to the characteristic curves and power losses.
Notes
Project 02:
Hydraulic circuit diagram

02
Item 1.1
Item 1.2
Item 0.1
Measuring
glass
Item 1.0
Power unit limit
Fig. 02.2 Hydraulic circuit diagram: Test set-up

Project 02:

02
Direct operated pressure relief

1.0 1 valve; the cracking pressure can be DD 1.1
adjusted by means of a spring
1.1 1 Throttle valve, adjustable DF 1.2
1.2 1 Shut-off valve, operated by turning DZ 2.1
Pressure gauge with hose and

0.1 1 quick-release coupling, without DZ 1.4
check valve
Hydraulic hose with

1 DZ 25.1
minimess connection
Hose with quick-release coupling,

VSK 1
with check valve
1 Stopwatch
Notes for the trainer:

The pilot operated, variable vane pump is not included as individual component in parts list
table 02.1. It is an integral part of the hydraulic power unit from Project 01.
Project 02:
Component arrangement
02
Measuring glass
Connection block
D Note:
In the case of connection
elements marked with “D”, the
components can be connected
directly with each other.
Fig. 02.3 Recommended component arrangement with component designation for parts list table 02.1 and hydraulic circuit diagram Fig. 02.2
Note:
The designations of components in the parts list and the component arrangement are Rexroth-
specific designations. Also the grid layout is Rexroth-specific and adapated for use on the
training system.
Notes
Project 02:
Safety notes

02
injury and a safety risk can arise operation of the system, including danger
to life.
Warning
Caution depressurized.
Set-up of the control as described in the following:

1. Mount the components required according to Table 02.1 on the training system in a clearly
arranged manner according the prepared circuit diagram.
Connect the hydraulic control according to hydraulic circuit diagram Fig. 02.2 by means
of hoses.
For connections, to which pressure gauges with minimess hose DZ 1.4 are to be connected,
use hydraulic hoses DZ25. Hand-tighten the pressure gauge measuring lines hand tight at
the relevant minimess connection of the hydraulic hose.
The proper and tight fit of hose connections of components can be easily checked by
slightly turning the hoses.
Make sure that pipes or hoses are connected to all connections - in this case
also to minimess lines, or that the connections are plugged by means of plug
screws or protective caps. Leakage oil may drip through open connections
Warning
and cause a slipping risk.
Before commissioning the hydraulic control, i.e. before switching the hydrau-
lic pump on, check, whether all pressure control valves are set to minimum
Caution pressure (spring unloaded) and all throttle valves are open.
An electrical control is not required for this experiment set-up.
Completely close throttle valve item 1.1. To this end, turn the adjustment element clockwise
to the mechanical limit stop. Close shut-off valve item 1.2.
2. Switch the hydraulic pump on and check and the set up control for any leakage.
3. Adjust the system pressure on pressure relief valve item 1.0 to 50 bar plus one turn.
4. Check the set pressure on the variable displacement pump of the drive power unit (zero
stroke pressure 50 bar).
Project 02:
Flow measurement
5. Open shut-off valve item 1.2. 02
6. Open throttle valve item 1.1 until a pressure of 15 bar is present at measuring point M1.
7. Flow measurement by means of the measuring glass; to this end, close shut-off valve item
1.2, close the measuring glass, open shut-off valve item 1.2 for 10 s.
Record the filling quantity and enter the measured value in Table 02.2.
8. Take flow measurements as described in points 6. to 7. at pressure values of 30 bar,
40 bar, 45 bar and 50 bar and enter the recorded measured values in Table 02.2.
After completion of practical work, switch the hydraulic pump on the training
system off! Turn pressure relief valve item 1.0 back to minimum pressure.
Caution Open throttle valve item 1.1 completely. No pressure gauge may indicate a
pressure!
9. Calculate the measured oil flow/time and enter it as flow in qV = l/min in Table 02.2.
Enter the individual values as points in Diagram 02.3 and connect the individual points with
a line to create a curve.
The resulting curve is the typical characteristic curve of the pilot operated, variable vane
pump.
Measured values
Pressure p bar 15 30 40 45 50
Time t s 10 10 10 10 10
Volume V l 1.32 1.25 1.20 1.10 0
Flow qV l/min 7.92 7.50 7.20 6.60 0
Table 02.2 Evaluation of the measured oil volumes
The values were measured at an oil temperature of approx. 20 °C.

The values measured by trainees can deviate by 10 %.
Project 02:
02
Flow qV in l/min
Operating pressure p in bar

Diagram 02.1 Characteristic curve of the hydraulic pump
Evaluating the work result with regard to the customer requirement
• On hydraulic variable displacement pumps, the displacement is reduced to almost 0 l/min

when the maximum pressure set on the hydraulic pump is reached.
• Internal leakage oil in the variable displacement pump must be fed back to the reservoir via
an external leakage line.
• The amount of leakage oil in the variable displacement pump increases as the resistance/
pressure at the pressure port of the hydraulic pump rises.
• The amount of leakage oil corresponds to the power loss of the pump.
Project 02:
Hydraulic variable displacement pump 10 Bosch Rexroth AG I RE 00845/04.07
Notes
02
Project 03:
Single-rod cylinder / pressure intensification Bosch Rexroth AG I RE 00845/04.07
Project 03: Single-rod cylinder/pressure intensification

If in a hydraulic system the hydraulic force, which is converted into mechanical energy, is to be
transmitted to an actuator in the form of a linear (straight) movement, a hydraulic cylinder is
used. We distinguish hydraulic cylinders by their design principles: 03
Plunger, single-rod and double-rod cylinders.
The hydraulic cylinder as output element forms the link between the hydraulic circuit and the
working element/tool in a technological system. Lifting, lowering, locking and transporting loads
are typical applications of hydraulic cylinders.
Neglecting friction, the possible maximum cylinder force F in kN depends on the possible
maximum system pressure p and the effective piston area A of the hydraulic cylinder, i.e.
F = p • A in dN m2
p in bar; A in cm
The piston velocity v in m/s of the hydraulic cylinder is determined by the pump flow supplied.
Flow control valves are used to change, i.e. reduce, the piston velocity. When throttling, for
example, the piston extension velocity, important physical laws must be taken into account.
In the following Project 03 knowledge can be imparted with regard to the use of single-rod
cylinders as machine elements.
In the project order, the trainee is to work out the physical basic principles of pressure inten-
sification with single-rod cylinders. On the basis of this project task, he/she is to understand
the following:
• The hydraulic cylinder performs a straight movement and transmits the supplied piston pres-
sure in the form of force.
• Double-acting hydraulic cylinders with different piston areas are pressure intensifiers.
• Due to adhesive friction in the hydraulic cylinder the pressure actually transmitted via the
piston area or through the differences in areas is reduced.
• Forces and velocities can be kept constant over the entire stroke.
Biased on the control set up on the training system the trainee is to learn that the use of a meter-
out throttle on the piston rod side involves a risk of pressure intensification. When the hydraulic
pump is switched on, the piston of the single-rod cylinder extends. The extension velocity can
be varied by means of a throttle valve. Retracting of the single-rod cylinder is accomplished
with the help of a 4/2 directional valve.
Notes on detailed technical information about hydraulic cylinders:

Basic principles and components, Chapter 7
Hydraulic cylinders of tie rod design
Project 03:
Project definition
A workpiece is to be shifted by a horizontally installed single-rod cylinder to the working range

of a simple fixture when the hydraulic pump is switched on. To this end, the extension velocity
of the cylinder must be adjustable. Retracting is to be achieved by means of a 4/2 directional
valve.
03
The customer installed a throttle valve on the piston rod side and, while adjusting the extension
velocity, recognizes that the pressure upstream of the throttle becomes higher than the set
system pressure. Apart from the technical documentation he wishes to get an explanation of
the pressure intensification of the single-rod cylinder.
Fig. 03.1 Practical example: Hydraulic cylinder of tie rod design
Project tasks
• Independent understanding and execution of the task set through application of hydraulic
control technology
• Analyzing the technical data sheet of a hydraulic cylinder (specialist qualification)
Project 03:
Project steps
with the customer.
03
ers, through the selection of hydraulic components from the data sheet
collection (RE 17039 Hydraulic cylinders, tie rod design).
• Deciding: Preparation of a schematic diagram sketch and selection of components.
• Executing: Set-up of the hydraulic control on the training system. Working out and
documenting the system parameters required by the customer and expla-
nations with regard to pressure intensification on the basis of a calculation
example.
Notes
Project 03:
Item 1.0 03
Item 0.2 Item 0.3
Item 1.3
Item 1.1
Measuring
Item 0.1 glass
Item 1.2
Power unit limit
Fig. 03.2 Hydraulic circuit diagram: Feeding cylinder

Project 03:
Electrical circuit diagram
03
Control 4/2 directional valve
Retraction
-Single-rod cylinder-
Note:
The single-rod cylinder
extends automatically
when the hydraulic pump is
switched on.
Fig. 03.3 Wiring diagram re hydraulic circuit diagram Fig. 03.2

Project 03:
03
1.0 1 ZY 1.3
4/2 directional valve with solenoid

1.1 1 DW 3 E
actuation, spring return

1.2 1 valve, the cracking pressure can be DD 1.1
1 Distributor plate with four ports DZ 4.1

0.1 - 0.3 3 and quick release coupling DZ 1.4
without check valve
Hose with quick release coupling

3 DZ 25.1
with check valve
Hose VSK 1
Project 03:
03
Measuring glass
Connection block
D Note:
Fig. 03.4 Recommended component arrangement with component designations for parts list Table 03.1 and hydraulic circuit diagram Fig. 03.2
Note:
specific designations. Also the grid arrangement is Rexroth-specific and adapted for use on
the training system.
Notes
Project 03:
Safety notes

03
Warning
danger to life.
Before starting work on the training stand, check that the electrical ON/
OFF switch on the hydraulic power unit is pressed in, i.e. that the system is
Caution switched off. Use the system pressure gauges to check that the system is
depressurized.
Hydraulic systems can store pressure energy when at rest. It can cause injury
Set up the control as described below:

1. Mount the components required according to Table 03.1 in a clearly arranged form on the
training system according to the prepared circuit diagram.
Connect the hydraulic control according to hydraulic circuit diagram Fig. 03.2 by means of
hoses.
For connections, to which pressure gauges with minimess line DZ 1.4 are to be connected,
use hydraulic hoses DZ 25. Hand-tighten the pressure gauge measuring lines at the relevant
minimess connection of the hydraulic hose.
The correct and proper fit of the component connections with hoses can be checked
by slightly turning the hoses.
Warning
Wire the electrical control according to wiring diagram Fig. 03.3.
2. Switch the hydraulic pump on and inspect the set up control for leakage. No pressure gauge
may indicate a pressure.
3. Check the pressure set on the variable displacement pump of the drive power unit (if
required, correct to 50 bar).
4. Set the system pressure on pressure relief valve Item 1.2 to 50 bar plus one turn; operate
push-button S2 to prevent the piston of hydraulic cylinder Item 1.0 from extending.
5. Through operation of push-button S1 the control voltage of solenoid Y1 of the 4/2 directional
valves Item 1.1 drops, and the piston of the hydraulic cylinder extends due to the pump flow
supplied directly to the piston side.
Project 03:
6. Switch the hydraulic pump off and wait until the system is depressurized. Close throttle
valve Item 1.3. To this end, turn in the adjustment element counter-clockwise to the limit
stop.
7. Switch the hydraulic pump on. The piston of the hydraulic cylinder cannot extend, because
the counterforce on the piston rod side is greater than the force on the piston side, since
the throttle valve is closed. Pressure gauge M3 indicates the value of pressure intensifica-
03
tion. Note the measured values and enter them in Table 03.2.
After having completed practical work on the training system switch the
hydraulic pump off! Turn pressure relief valve Item 1.2 back to minimum
Caution
pressure. No pressure gauge may indicate a pressure!
Measured values
Hydraulic Measuring point M1 M2 piston side M3 piston rod side

cylinder System pressure p in bar p in bar p in bar
Extending/
48 48 82
Y1 not operated
Table 03.2 Pressure intensification values measured

The values measured by the trainees can deviate by 10 %.
Additional task in conjunction with the customer requirement:
Calculation of the pressure intensification on the basis of given hydraulic cylinder values.
Hydraulic cylinder of tie rod design: Type CD T3...25/18...200
Bore: 25 mm Apiston = 4,91 cm2

Piston rod diameter: 18 mm Arod = 2,54 cm2
37 cm2
Aannulus = 2,3
4,91 cm2
= 2,07 : 1
2,54 cm2
If the meter-out throttle is completely closed,

then:
FK = FR
pK  AK = pR  AR
2,07
pR =  50 bar = 103,5 bar
1,00
Project 03:
Single-rod cylinder / pressure intensification 10 Bosch Rexroth AG I RE 00845/04.07
Evaluating the work results with regard to the customer requirement
• Hydraulic cylinders perform linear movements and transmit the piston pressure in the form
of force.
• Double-acting hydraulic cylinders with different areas are called single-rod cylinders. 03
• Single-rod cylinders are pressure intensifiers.
• Velocities can be kept constant over the entire stroke.
Project 04:
Single-rod cylinder/flow Bosch Rexroth AG I RE 00845/04.07
Project 04: Single-rod cylinder/flow

If a hydraulic cylinder in a hydraulic system is not only to transmit the force, but also work in the
form of piston velocity, double-acting hydraulic cylinders are used such as:
single-rod and double-rod cylinders.
Due to the different areas, single-rod cylinders feature different piston velocities, even if the
pump flow provided remains unchanged. Here, the load force generated by the moved workpiece
often has an influence on the piston velocity (see Project 09 - 10). Due to the area ratio of the
04
piston side to the piston rod side, different flows occur during extending and retracting of the
cylinder. To prevent high flow velocities in the connected hoses and pipes, the latter must be
selected taking into account the given flow supplied by the hydraulic pump and the area ratio
of the single-rod cylinder.
AK AR AK
=ϕ
AR
Area ratio of the single-rod cylinder
40 10 e.g. qV = 20 l/min
Values in l/min ϕ = 2 : 1
20 20
The following Project 04 is intended to impart knowledge of the use of single-rod cylinders as
machine element, in particular with reference to the piston velocities and flows.
In this project order, the trainees are to be made familiar the velocity behavior during the exten-
sion and retraction of the cylinder piston of single-rod cylinders. Through this project task, they
are to understand the following:
• The piston velocity of a double-acting cylinder - single-rod cylinder - depends on the cylinder
size and the supplied flow.
• The different piston areas result in different flow velocities, which have an influence on the
selection of connection elements, the line system and power unit accessories such as filtra-
tion and cooling systems.
• In the case of double-rod cylinders, the forces transmitted and the piston velocities are
identical in both directions of action of the piston.
On the basis of the control set up on the training system the trainees are to recognize that the
cylinder piston retracts and extends at different velocities. When the hydraulic pump is switched
on, the piston of the single-rod cylinder extends. Controlled by a 4/2 directional valve, the pis-
ton of the hydraulic cylinder retracts. The extension and retraction velocity can be changed by
means of a throttle valve on the piston rod side.
Notes on detailed technical information about hydraulic cylinders:

Hydraulic cylinders, tie rod design
Project 04:
Project definition
Like in Project 03 a workpiece is to be moved to the working range of a simple fixture by a

horizontally installed single-rod cylinder when the hydraulic pump is switched on. To this end,
the extension velocity of the cylinder must be adjustable. The return is to be accomplished with
the help of a 4/2 directional valve.
The customer observes that with an open throttle valve the piston velocities during extending
and retracting of the cylinder are different. Apart from the technical documentation, he wishes
04
to obtain an explanation with regard to the different piston velocities of the single-rod cylinder.
He also requests details about the filling volume of the hydraulic cylinder used.
Fig. 04.1 Practical example: Schematic illustration of flow velocities in the single-rod cylinder
Project tasks
technology
• Analyzing the technical data sheet of a hydraulic cylinder (specialist qualification)
Project 04:
Project steps
with the customer.
• Planning: Planning and organizing the execution of the customer order; among others,
through the selection of hydraulic components from the data sheet collection
(RE 17039 Hydraulic cylinders of tie rod design). 04
• Executing: Set-up of the hydraulic control on the training system. Prepration and docu-
mentation of the information and explanations with regard to the single-rod
cylinder as demanded by the customer.
Notes
Project 04:
Item 1.0
04
Item 0.2 Item 0.3
Item 1.1
Item 0.1 Measuring

glass
Item 1.3 Item 1.2
Power unit limit
Fig. 04.2 Hydraulic circuit diagram: Feed cylinder

Project 04:
04
Retraction
Note:
The single-rod cylinder
extends automatically
when the hydraulic pump
is switched on.
Fig. 04.3 Wiring diagram re hydraulic circuit diagram Fig. 04.2

Project 04:
Double-acting cylinder with single-

1.0 1 ZY 1.3
sided piston rod
04
1.1 1 DW 3 E


without check valve

3 DZ 25.1
with check valve
Hose VSK 1
1 Stopwatch
1 Flowmeter DZ 30
Project 04:
��
��
��
��
04
Measuring glass
��
��
�
�
��
Note:
The component arrangement
shows the optional variant with
�� electronic flow measurement
�
Connection block
��
��
�
D Note:
� � In the case of connection
��
�

�� directly with each other.
�
Note:
Notes
Project 04:
Safety notes

injury and a safety risk can arise during operation of the system, including 04
danger to life.
Warning
Before starting work on the training system, check that the electrical ON/
OFF switch on the hydraulic power unit is pressed in, i.e. that the system
Caution
depressurized.

of hoses.
Warning
3. Check the pressure set on the variable displacement pump of the drive power unit (if
4. Set the system pressure on pressure relief valve Item 1.2 to 50 bar plus one turn; operate
push-button S2 to prevent the piston of hydraulic cylinder Item 1.0 from extending.
5. Due to the operation of push-button S2 the control voltage of solenoid Y1 of the 4/2 di-
rectional valve Item 1.1 drops and the piston of the hydraulic cylinders extends due to the
pump flow fed directly to the piston side.
6. The extension velocity of hydraulic cylinder piston Item 1.0 is to be adjusted to 5 s by
means of throttle valve Item 1.3 while directional valve Item 1.1 is not operated.
Project 04:
7. Measure the pressures at measuring points M1, M2, M3 during extending, retracting and
at the relevant end position of the cylinder and enter the values in Table 04.2.
Establish the time required for extending and retracting by means of a stopwatch and enter
the values also in Table 04.2.
Caution
hydraulic pump off! Turn all pressure valves of the electrohydraulic control
back to minimum pressure. Completely open throttle valves, if installed. No
04
pressure gauge may indicate a pressure!
Measured values
Hydraulic Position M1 M2 M3 t v V
cylinder 4/2 directional p in bar p in bar p in bar in s in m/s in l
Piston position valve
Extending b 49 0 0 5 0.051 -
Extended b 50 49 0 - - 0.098
Retracting a 49 0 6 3.2 0.073 -
Retracted a 50 0 49 - - 0.058
Table 04.2 Values of velocity/flow measurement

Additional task in conjunction with the customer requirement:
Calculation of the filling volume of the single-rod cylinder used for the execution of the order
(enter calculated values in Table 04.2).
Hydraulic cylinder of tie rod design Type: CD T3...25/16...200
Bore: 25 mm Apiston = 4.91 cm2

Piston rod diameter: 16 mm Arod = 2.01 cm2
Aannulus = 2.90 cm2
Piston stroke: 200 mm = 20 cm
Fill: V = A • s A in cm2
s in mm
V in l
Piston volume: V = 4.91 cm2 • 20 cm = 98.2 cm3 = 0.098 l

V = 2.90 cm2 • 20 cm = 58.0 cm3 = 0.058 l
Project 04:
Single-rod cylinder/flow 10 Bosch Rexroth AG I RE 00845/04.07
• The extension and retraction velocity of a single-rod cylinder piston depends on the supplied
hydraulic pump flow and the cylinder areas.
• With double-rod cylinders with identical piston rods on both sides, the piston velocities are
identical in both directions.
04
Project 05:
Hydraulic motor Bosch Rexroth AG I RE 00845/04.07
Project 05: Hydraulic motor

If the hydraulic force is to be transmitted via a rotary movement to an actuator in a hydraulic sys-
tem, a hydraulic motor is used. Hydraulic motors are distinguished by their design principle:
Gear, gear wheel/planetary gear, vane,

radial piston and axial piston motors.
In functional terms, a hydraulic motor is the inversion of a hydraulic pump. Hydraulic pumps
convert the mechanical energy, which is fed to the pump via a drive shaft, into hydraulic energy.
Hydraulic motors convert hydraulic energy into mechanical energy. 05
In principle, a hydraulic motor is a hydraulic pump, which works in the opposite direction and
with which both directions of rotation are possible. If you connect a hydraulic pump directly to a
hydraulic motor in a closed circuit you get a hydrostatic gearbox, which is steplessly adjustable
by means of appropriate control systems.
The following Project 05: Hydraulic motor is intended to gain knowledge of the operating
principle and the use of hydraulic motors.
In the project order, the trainee is to get familiar with the operating features of a hydraulic motor.
Through this project task, he/she is to understand the following:
• Hydraulic motors convert hydraulic energy into torque and speed.
• The direction of rotation or the direction of flow of hydraulic motors can be controlled by
means of a directional valve.
• The speed of the hydraulic motors is determined by the flow provided and by the swept
volume of the hydraulic motors.
• The torque of hydraulic motors is determined by the differential pressure between the inlet
and the outlet and by the swept volume.
By the control to be set up on the training system, the trainee can recognize the operating
principle of a hydraulic motor. 4/3 directional valves can be used to implement clockwise and
counter-clockwise running of the hydraulic motor. The speed of the hydraulic motor can be
changed by means of a meter-in throttle. For a positioned standstill of the hydraulic motor the
return line (T) of the 4/3 directional valve is pre-loaded by means of a pressure relief valve.
Notes on detailed technical information about hydraulic motors:

Fixed displacement axial piston motor
Project 05:
Project definition
Heavy loads are to be lifted and lowered by means of a rope winch. The velocity of the rope
winch is to be adjustable. For space reasons, the use of a hydraulic cylinder is impossible, i.e.
the rope winch must be powered by a hydraulic motor. Also an electrical solution is not desir-
able due to changing loads.
In order that the customer can understand the hydraulic solution proposed, he requires technical
documentation such as a hydraulic circuit diagram with parts list and the required measured
data such as an evaluation of the differential pressure across the hydraulic motor at different
flows. 05
Fig. 05.1 Practical example: Winch for lifting heavy loads
Project tasks
technology
• Analyzing the technical data sheet of a hydraulic motor (specialist qualification)
Project 05:
Project steps
with the customer.
through the selection of hydraulic components from the data sheet collection
(RE 91001 Axial piston motor).

05
documenting the system parameters required by the customer.
Notes
Project 05:
Item 0.2 Item 0.3
Item 1.0
05
Item 1.1
Item 0.4
Item 1.4
Item 1.3
Item 0.1 Measuring

Item 1.2 glass
Power unit limit
Fig. 05.2 Hydraulic circuit diagram: Lifting platform control

Project 05:
05
Stop
Rotation Rotation
-Hydraulic motor-
Fig. 05.3 Wiring diagram for hydraulic circuit diagram Fig. 05.2
Project 05:
Fixed displacement motor with

1.0 1 external leakage line and two DM 8
directions of rotation
4/3 directional valve with direct

actuation by two solenoids, spring
05
1.1 1 DW 13 E
centering of the central position
and central position P, T, A, B

1.2/1.4 2 valve; the cracking pressure can be DD 1.1

without check valve

4 DZ 25.1
with check valve
Hose VSK 1
1 Stopwatch
1 Tachometer
1 Flowmeter DZ 30
Project 05:
05
Measuring glass
Connection block
D Note:
Note:
Notes
Project 05:
Component arrangement/optional
Note:
electronic flow measurement
05
Measuring glass
Connection block
D Note:
Note:
Notes
Project 05:
Safety notes

danger to life.
05
Warning
switched off. Use the system pressure gauges to check that the system is

of hoses.
Make sure that all ports - in this case also minimess lines - pipes and hoses
are connected or that the ports are blocked with plug screws or protective
caps. Leakage oil can drop through open ports on the floor and cause a risk
Warning
of slipping.
Caution
pressure (spring unloaded) and all throttle valves are open.
3. Check the set pressure on the variable displacement pump of the drive power unit (if
4. Set the system pressure on pressure relief valve Item 1.2 to 50 bar plus one turn.
Completely open throttle valve Item 1.3.
Project 05:
Hydraulic motor 10 Bosch Rexroth AG I RE 00845/04.07
In the next working step the hydraulic motor rotates. Take care that clothes,
hair, etc. cannot get caught by the motor plate.
Caution
5. By actuating push-button S4 solenoid Y1b of 4/3 directional valve Item 1.1 is energized.
Hydraulic motor Item 1.0 rotates clockwise.
While the hydraulic motor is rotating, adjust preload pressure M4 to 20 bar by means of
pressure relief valve Item 1.4.
6. Close throttle valve Item 1.3, then open it by � turn (the first value given in Table 05.2).
7. By actuating push-button S2 solenoid Y1a of 4/3 directional valves Item 1.1 is energized. 05
The hydraulic motor rotates counter-clockwise.
Use the measuring glass and a stopwatch or optionally an electronic flow measuring system
to acquire the flow qV in l/min and enter the values in Table 05.2. Also measure pressures
M1, M2, M3, M4 and enter them in Table 05.2.
8. Continue to set throttle valve Item 1.3 to the values given in Table 05.2 and enter the mea-
surement result in Table 05.2.
Measure all specified values for the clockwise direction of rotation.
Caution pressure, completely open throttle valve Item 1.3. No pressure gauge may
indicate a pressure!
Measured values
Adjustment of speed of rotation M1 M2 M3 M2 - M3 M4 qV n

Throttle valve Item 1.3 p in bar p in bar p in bar Dp in bar p in bar in l/min in min-1
Throttle closed 50 0 0 0 0 0 0
� turn opened 49 20 17.5 2.5 15 2 264 *
½ turn opened 48 22 19 3 16 2.6 335 *
1 turn opened 48 25 21 4 17.5 3.7 435 *
1 ½ turn opened 48 30 25 5 18 4.7 540 *
2 turns opened 48 31 25 6 19 5.1 595 *
More than 2 ½ turns opened 48 34 27 7 19 5.7 655 *
Table 05.2 Measured values from the work order for counter-clockwise direction of rotation of the motor
* The values in column 8 were established by means of a speed sensor.

Project 05:
Additional tasks:
Calculation of the output power at maximum speed using the formulas below.
∆ p • qV P = output power in kW
P= in kW p = pressure in bar
600
qV = swept volume in l/min
V = content of the measuring glass in l
V t = measuring time in s
qV = • 60
t n = drive speed in min-1
n=
qV • ηvol
• 1000
hvol = volumetric efficiency of the motor
Vg = geometric swept volume (displacement) of the 05
motor in cm3/rev
Vg
hvol = 0.8
Vg = 4.93 cm3/rev - DM2
• Hydraulic motors convert hydraulic energiy into torque and speed.

• The direction of rotation of hydraulic motors can be controlled by means of a directional
valve.
• The speed of hydraulic motors is determined by the supplied hydraulic pump flow and by
the swept volume of the hydraulic motors.
• The torque of hydraulic motors is determined by the differential pressure and the swept
volume.
Project 05:
Notes
05
Project 06:
4/3 directional valve Bosch Rexroth AG I RE 00845/04.07
Project 06: 4/3 directional valve

If the travel, direction, start, and stop of a hydraulic cylinder is to be controlled in a hydraulic
system, a directional valve must be used. Directional valves are differentiated as follows:
Directional spool valves, direct operated, pilot operated and directional poppet valves.
Directional valves are elements that assume the task of opening, closing or changing the flow
paths in hydraulic systems.
The spool of a directional valve is installed with a certain clearance. This clearance causes a
continuous leakage oil flow. This leakage, which is not externally visible, results in a flow loss
that increases as the pressure rises. When a directional valve is used for controlling a hydraulic
cylinder, pressure/force losses occur on the hydraulic cylinder when the fluid flows through
the valve. 06
Possible applications and the operating characteristics of the directional valve are determined
by, among others, the selection of the valve spool. The valve spool also determines the form
of the symbol.
The following Project 06: 4/3 directional valve is intended to gain knowledge of the operating
principle and the possible applications of direct operated directional valves.
In the project order the trainee is to work out and document the following:
• The spool shape determines the symbol, and all directional spool valves feature internal
leakage for design reasons caused by the clearance of the spool in the valve housing.
• With a valve being in the blocked position:
– a connected single-rod cylinder can extend due to internal leakage of the valve while the
valve is in its rest position and the pump is running.
– the total flow of a fixed displacement pump flows via the pressure relief valve to the tank
when the set system pressure is reached while the pump is running and the valve is in its
rest position, i.e. high power losses incur and the oil heats up.
– the working pressure utilized last slowly decreases via the clearance of the spool when
the hydraulic pump is switched off and the valve is in its rest position.
• With a valve being in the circulation position:
– when the valve is in its rest position and the pump is switched on the total pump flow
flows almost at zero pressure to the tank; the backpressure and hence the power loss
is determined by the pressure differential across the valve;
– energy is saved while the pump is running and the valve is in its rest position. This feature
cannot be installed in controls, where the system pressure is required by further actua-
tors.
With the help of the control set up on the training system the trainee gets familiar with the pos-
sible application of a 4/3 directional valve. A hydraulic cylinder is to be controlled alternately by
a 4/3 directional valve with different spool shapes (blocked and circulation position). The trainee
can recognize the special features of different symbols by measuring the different pressure dif-
ferentials across the 4/3 directional valve. Internal leakage can be recognized by the horizontal
arrangement of the single-rod cylinder, on which no external forces act.
Notes on detailed technical information about direct operated directional valves:

4/3, 4/2 and 3/2 directional valves with wet pin solenoids
Project 06:
Project definition
A single-rod cylinder is to shift and position tools horizontally in a fixture. When in the rest posi-
tion the hydraulic cylinder must not move, and the fixed displacement pump is to be spared
and thus energy saved.
The customer wants to be informed about the pros and cons of the various spool shapes, in
particular blocked and circulation position. In order that the customer can understand your
proposed solution, he requires technical documentation such as the hydraulic circuit diagram
with parts list, and the required measured data for the spool shapes/symbols.
06
Fig. 06.1 Practical example: Section of a 4/3 directional valve
Project tasks
technology
• Analyzing the technical data sheet of a directional valve (specialist qualification)
Project 06:
Project steps
with the customer.
collection (RE 23178/4/3 directional valve).
documenting the system parameters as required by the customer. 06
Notes
Project 06:
Hydraulic circuit diagram/task 1
Item 1.0
Item 0.2 Item 0.3
06
Item 1.1
Item 0.1 Measuring

glass
Item 1.3
Power unit limit
Fig. 06.2 Hydraulic circuit diagram: Tool carriage control 1

Project 06:
Electrical circuit diagram/task 1
Circulation
06
Extension Retraction
Project 06:
Hydraulic circuit diagram/task 2
Item 1.0
Item 0.2 Item 0.3
06
Item 1.2
Item 0.1 Measuring

glass
Item 1.3
Power unit limit
Fig. 06.4 Hydraulic circuit diagram: Tool carriage control 2

Project 06:
Electrical circuit diagram/task 2
Stop
06
Retraction Extension
Project 06:
1.0 1 ZY 1.3

1.1 1 DW 4E
06
and central position P - T, A, B

1.2 1 DW 13E


without check valve

3 DZ 25
with check valve
Hose VSK 1
1 Flowmeter DZ 30.N
Table 06.1 Parts list for hydraulic circuit diagrams Fig. 06.2 and 06.04
Project 06:
Component arrangement/task 1
Note:
Measuring glass
06
Connection block
D Note:
Note:
Notes
Project 06:
4/3 directional valve 10 Bosch Rexroth AG I RE 00845/04.07
Component arrangement/task 2
Note:
Measuring glass
06
Connection block
D Note:
Note:
Notes
Project 06:
Safety notes

danger to life.
Warning
Caution
depressurized. 06
Task 1 Set-up of the controls as described below:

of hoses.
Warning
of slipping.
3. Set the system pressure on pressure relief valve Item 1.3 to 30 bar,
and: By actuating push-button S4 solenoid Y1b of 4/3 directional valve Item 1.1 is ener-
gized. The pump flow is fed against the piston rod side of hydraulic cylinder Item 1.0
and the system pressure can be set to 30 bar.
4. By actuating push-button S2 solenoid Y1a of 4/3 directional valve Item 1.1 is energized.
The piston of the hydraulic cylinder extends.
Project 06:
Measurements for task 1:

5. Measure the specified values in the end positions of the hydraulic cylinder and in the rest
position (central position) of the 4/3 directional valve as listed in Table 06.2 and enter the
values in Table 06.2.
Caution pressure. No pressure gauge may indicate a pressure!
Task 2 6. Modify the hydraulic control according to hydraulic circuit diagram 06.4. Proceed as de-
scribed in task one, steps 1 and 2.
Check the electrical control for correct wiring.
06
8. Set the system pressure on pressure relief valve Item 1.3 to 30 bar.
9. By actuating push-button S4 solenoid Y1b of 4/3 directional valve Item 1.2 is ener-
gized. The piston of hydraulic cylinder Item 1.1 extends.
By actuating push-button S2 the piston of the hydraulic cylinder retracts.
In contrast to task 1, positions "a“ and "b“ of the 4/3 directional valve are exchanged due
to the spool shape/symbol.
Measurements for task 2:
10. Measure the specified values in the end positions of the hydraulic cylinder and in the rest
position (central position) of the 4/3 directional valve as listed in Table 06.3 and enter the
values in Table 06.3.
Caution
pressure. No pressure gauge may indicate a pressure.
Measured values for task 1
Hydraulic cylinder Directional valve M1 M2 M3 qV

Position position p in bar p in bar p in bar in l/min
Piston extended a 30 30 0 7.66
Piston retracted b 30 0 30 7.66
Rest position of piston 0 8 5 8 0
Table 06.2 4/3 directional valve with circulation position

Project 06:
Measured values for task 2
Hydraulic cylinder Directional valve M1 M2 M3 qV

Position position p in bar p in bar p in bar in l/min
Piston extended b 30 30 0 7.66
Piston retracted a 30 0 30 7.66
Piston at rest position 0 30 7 9 7.66
Table 06.3 4/3 directional valve with blocked position
06
• With a 4/3 directional valve with circulation position the total flow of the hydraulic pump is
fed back to the tank almost at zero pressure when the directional valve is in its rest/central
position. The pressure differential, and hence the power loss, is determined by the spool
shape of the directional valve and by line resistances in the return line.
• With a 4/3 directional valve with circulation position, energy is saved due to the pressureless
circulation in der central position, but this valve can not be used, if further actuators are to
be controlled by an additional directional valve.
• With a 4/3 directional valve with blocked position, the total flow of a fixed displacement
hydraulic pump is fed via the pressure relief valve to the tank in the rest/central position of
the directional valve when the system pressure is reached. The hydraulic fluid heats up and
a high power loss incurs.
• With a 4/3 directional valve with blocked position a connected single-rod cylinder can
extend due to internal leakage oil while the directional valve is in its rest position and the
fixed displacment pump is running.
The working pressure utilized last slowly decreases via the clearance between spool/
housing.
Project 06:
Notes
06
Project 07:
Check valve Bosch Rexroth AG I RE 00845/04.07
Project 07: Check valve

If the flow in hydraulic system is to be blocked in one direction, a check valve is required.
Check valves are available as seat valves, with ball or poppet as closing element. They are
subdivided as follows:
Check valves, pilot operated check valves.
Through the installation of a check valve it is possible to prevent, for example, the load pressure
from driving a hydraulic pump reversely when the electric motor is switched off. Also pressure
peaks, e.g. upstream of filters or coolers, can be reduced by means of a check valve installed
in a by-pass.
However, the use of a check valve also results in additional resistance in the system so that a
greater power must be installed.
The following Project 07 can be used to impart knowledge of the operating principle and the
use of a check valve.
07
In the course of the project order the trainee is to understand the operating principle of a check
valve installed in a by-pass. Through this project tasks he/she is to recognize the following:
• Fluid can only flow through a check valve in one direction.
• A check valve results in additional hydraulic resistance in the system.
• Pressure peaks can be reduced with the help of a check valve installed in a by-pass.
• When loads are secured by a check valve on the piston rod side, there is a risk of pressure
intensification.
On the basis of the control set up on the training system the trainee is to understand the oper-
ating principle of a check valve. A hydraulic cylinder under load, which is secured by a check
valve, can be lowered by operating a shut-off valve. The cylinder velocity can be adjusted by
means of a throttle.
To provide protection against pressure intensification a pressure relief valve is to be installed
on the piston rod side.
Notes on detailed technical information about the check valve:

Check valve
Project 07:
Project definition
In a fixture, a load suspended on a vertical cylinder is to be held by means of a check valve.

Lowering of the load should be possible with a shut-off valve. The piston rod side is to be pro-
tected by means of a pressure relief valve. (The lowering movement via the electrical control is
not an integral part of the order). The velocity is to be adjustable.
In order that the customer can understand your proposed solution, he requires technical docu-
mentation.
In addition, he wants to know whether particular problems could arise, if a check valve is installed
on the piston rod side.
07
Fig. 07.1 Practical example: Check valve
Project tasks
technology
• Analyzing the technical data sheet of a check valve (specialist qualification)
Project 07:
Project steps
with the customer.
collection (RE 20375 Check valve).
documenting the system parameters requred by the customer.

07
Notes
Project 07:
Item 1.0
Item 0.3
Item 1.6
Item 0.2
Item 1.5
07
Item 1.3 Item 1.4
Item 1.1
Item 0.1 Measuring

glass
Item 1.2
Power unit limit
Fig. 07.2 Hydraulic circuit diagram: Control of a vertical cylinder with suspended load
Project 07:
07
(Emergency stop)
Stop
Retraction
* Solenoid Y1.b
is not energized
Fig. 07.3 Wiring diagram re hydraulic circuit diagram 07.2

Project 07:
1.0 1 with single-sided piston rod with ZY 1.Last
load

1.1 1 DW 10E
and central position P, A - B - T 07
1.2/1.5 2 valve, the cracking pressure can be DD 1.1

possible in only one direction, rest
1.3 1 DS 2.1
position closed, cracking pressure
1 bar
1.4 1 Shut-off valve, actuated by turning DZ 2.1

without check valve

3 DZ 25
with check valve
Hose VSK 1
Project 07:
Measuring glass
07
Connection block
D Note:
Fig. 07.4 Recommended component arrangement with component designation for parts list Table 07.1 and hydraulic circuit diagram Fig. 07.2
Note:
Project 07:
Safety notes

danger to life.
Warning
when the system is opened. 07

of hoses.
Warning
of slipping.
Caution
Observe the installation direction of check valve Item 1.3.

Warning
3. Set the system pressure on pressure relief valve Item 1.2 to 50 bar plus one turn (in
pressure line M1).
Project 07:
4. By actuating push-button S2 solenoid Y1a of 4/3 directional valve Item 1.1 is energized,
i.e. the cylinder retracts. Opening of shut-off valve Item 1.4 causes the cylinder to extend.
5. Safety valve setting against pressure intensification on the piston rod side:
Starting position of the cylinder: B.D.C. (bottom dead center, cylinder extended).
Close shut-off valve Item 1.4. Set pressure relief valve Item 1.5 on the piston rod side to
maximum pressure (spring tensioned - 1 turn).
Move the cylinder to the U.D.C. by operating push-button S2. Move directional valve Item
1.1 by manual operation to position Y1b while opening pressure relief valve Item 1.5 on
the piston rod side until pressure gauge M3 indicates a pressure of 80 bar (safety setting
against pressure intensification on the piston rod side).
Check the set value by extending the cylinder again.
6. Check lowering of the load in the de-energized condition by opening shut-off valve Item 1.4.

The lowering velocity can be adjusted by means of throttle valve Item 1.6.
The pressure that builds up when the cylinder supports on the counterforce of pressure
07
relief valve Item 1.5 on the piston rod side is called load holding pressure. To determine
the load holding pressure, the cylinder must be at the U.D.C. While the shut-off valve is
closed, slowly open the pressure relief valve until the cylinder starts to lower. M3 indicates
the load holding pressure. On the basis of the load holding pressure and the dimensions of
the hydraulic cylinder the weight of the load can be calculated.
Note:
To prevent pressure intensification, a safety valve (pressure relief valve) is used in practi-
cal applications, e.g. in a welding fixture. The upward stroke is accomplished via a check
valve installed in parallel.
hydraulic pump off! Set the throttle valve and the pressure relief valves to
minimum pressure. For the disassembly, the load must be lowered. No pres-
Caution
sure gauge may indicate a pressure!
• Fluid can flow through a check valve only in one direction.

• Load securing by means of a check valve on the piston rod side involves the risk of pressure
intensification.
• The installation of a check valve results in the build-up of additional resistance in the direc-
tion of flow.
• A check valve can be used as safety valve, e.g. to provide protection against pressure
peaks.
Project 07:
Check valve 10 Bosch Rexroth AG I RE 00845/04.07
Notes
07
Project 08:
Check valve, pilot operated Bosch Rexroth AG I RE 00845/04.07
Project 08: Check valve, pilot operated

In contrast to simple check valves, pilot operated check valves can also be opened in the direc-
tion opposite to the direction of flow (direction of closure).
Pilot operated check valves can be installed for isolating pressurized working circuits (hydraulic
isolation of a hydraulic cylinder) or for providing protection against lowering of a load in the
event of a line rupture.
In the following Project 08 you can impart knowledge of the operating principle and the use of
a pilot operated check valve.
In the project order, the trainee has to make himself/herself familiar with the operating principle
of a pilot operated check valve, when it is opened by an additional hydraulic control signal. With
the help of a practice-oriented experiment set-up on the training system he/she is to undertand
the following:
• Fluid can only flow through a hydraulically pilot operated check valve in the checking direc-
tion, if it is opened by means of a hydraulic control signal.
• The check valve can only be closed when the pilot line is depressurized.
08
• The check valve can only close properly, if the fluid can freely flow from the closing element
to the reservoir.
• To prevent decompression shocks when the check valve opens, components are used that
feature a pre-opening function of the main poppet.
With the help of a control set up on the training system for a lifting apparatus, the trainee can
see the operating principle of a pilot operated check vave. A hydraulic cylinder under load
(vertical cylinder with suspended load) is secured by a pilot operated check valve. This pilot
operated check valve is opened by means of a 4/2 directional valve. The lowering speed can
be adjusted with a throttle. A pressure relief valve on the piston rod side provides a pressure
relief function for pressure intensifications.
Notes on the detailed technical information about the direct operated pressure relief
valve:
• The Hydraulic Trainer Volume 1, Bosch Rexroth AG
Check valve
Project 08:
Project definition
A cylinder in a rig (gripper) is to be protected against lowering by a pilot operated check valve. The
hydraulic control from Project 07 is to be modified according to the customer requirements.
In order that the customer can understand your proposed solution, he requires the modified
technical documentation.
As the lowering speed should also be adjustable here, the customer wants to know, at which
position the throttle valve can be installed. Moreover, he wants to know at which pilot pressure
the pilot operated check valve opens.
08
Fig. 08.1 Practical example: Hydraulically pilot operated check valves in a rig (gripper)
Project tasks
technology
• Analyzing the technical data sheet for a pilot operated check valve (technical qualifica-
tion)
Project 08:
Project steps
with the customer.
collection (RE 21460 / pilot operated check valve).

08
Notes
Project 08:
Item 1.0
Item 0.3
Item 1.6
Item 1.4 Item 1.5

Item 0.2
Item 1.3
08
Item 1.1
Measuring
Item 0.1 glass
Item 1.2
Power unit limit
Fig. 08.2 Hydraulic circuit diagram: Check valve, hydraulically pilot operated
Project 08:
Stop
08
Control 4/3 directional valve - 4/2 directional valve
Retraction Extension Unlocking

Note:
Extension = Y1.b + Y2
Fig. 08.3 Wiring diagram for hydraulic circuit diagram 08.2

Project 08:
Double-acting cylinder with piston

1.0 1 ZY 1.Last
rod with load on one side

1.1 1 DW 10E
centring of the central position and
central position P, A - B - T
1.2/1.5 2
valve; the cracking pressure can be DD 1.1
08

1.3 1 DW 3E
operation, spring return
Pilot operated check valve, with

1.4 1 spring, flow possible in both DS 1.1
directions due to pilot pressure
Distributor plate with four

3 DZ 4.1
connections

0.1 - 0.3 3 quick-release coupling, without DZ 1.4
check valve

3 DZ 25
with check valve
Hose VSK 1
Project 08:
Measuring glass
08
Connection block
D Note:
Note:
training system.
Project 08:
Safety notes

injury and a safety risk can arise operation of the system, including danger
to life.
Warning
Caution
depressurized.
08
Set-up of the control as described in the following:

1. Mount the components required according to Table 08.1 on the training system in a clearly
arranged manner according the prepared circuit diagram.
of hoses.
For connections, to which pressure gauges with minimess hose DZ 1.4 are to be connected,
use hydraulic hoses DZ25. Hand-tighten the pressure gauge measuring lines hand tight at
Warning
2. Switch the hydraulic pump on and check the set up control for leakage. No pressure gauge
3. Adjust the system pressure on pressure relief valve item 1.2 to 50 bar plus one turn.
4. The operation of pushbutton S2 causes the energization of solenoid Y1a of 4/3 directional
valve item 1.1, i.e. the cylinder retracts. Turn item 1.5 in until the cylinder starts to move.
Project 08:
Only operate S3; turn in pressure relief valve completely, then turn pressure
relief valve out until 80 bar is applied at M3. The cylinder is to come to a
Caution standstill.
5. The actuation of pushbutton S3 causes 4/3 directional valve item 1.1 to be operated, i.e.
pressure is supplied to the the piston side of the hydraulic cylinder. The piston cannot ex-
tend.
Measure the pressures in M1, M2 and M3 and enter the values in Table 08.2.
6. Only when pushbutton S4 is operated additionally is port X of pilot operated check valve
item 1.4 controlled via 4/2 directional valve item 1.3 and the check valve opens. Fluid can
now flow at zero pressure from the piston rod side via 4/3 directional valve item 1.1 to the
reservoir.
Measure the pressures at M1, M2 and M3 during operation and enter the values in Table
08.2.
While the throttle is open and the piston is lowering, the movement of the
piston may be very jerky. The piston can advance due to the load on the ver-
Caution
tical cylinder. This causes underpressure in the piston chamber and hence 08
an absence of pilot pressure at port X of the pilot operated check valve, i.e.
the valve closes abruptly. When pressure is built up again on the piston side,
port X on the check valve is again supplied with pilot pressure. The check
valve opens abruptly.
7. Set the lowering speed of the cylinder to a lowering time of approx. 5 s on throttle valve
item 1.6.
Before converting the circuit for the further execution of the order, switch
the hydraulic pump off!
Caution
Notes
Project 08:
Check valve, pilot operated 10 Bosch Rexroth AG I RE 00845/04.07
Measured values
M1 M2 M3
Measuring point
p in bar p in bar p in bar
Lower cylinder via the pressure relief valve 45 45 70
Lower cylinder via the check valve 20 10 15
Table 08.2 Lowering pressures

08
After having completed the practical work on the training system, switch the
hydraulic pump off! Set the throttle valve and the pressure relief valves to mini-
Caution mum pressure. No pressure gauge may indicate a pressure!
• Fluid can only flow through a hydraulically pilot operated check valve in the checking direc-
tion, if it was opened by means of a hydraulic control signal.
• The pilot operated check valve can only close, when the pilot line is depressurized.
• The pilot operated check valve can only close properly, when the fluid can freely flow away
from the closing element.
• To prevent decompression shocks during opening of the check valve, components with a
pre-opening feature of the main poppet are used (development of theoretical knowledge).
Project 09:
Throttle valve, adjustable Bosch Rexroth AG I RE 00845/04.07
Project 09: Throttle valve, adjustable

In hydraulic systems the piston velocity of a hydraulic cylinder or the revving speed of a hydraulic
motor should often be adjustable. The flow provided by the hydraulic pump can be controlled
with the help of flow control valves. Flow control valves are classified in:
Throttle - fine throttle/orifice and flow control valve.
In the following Project 09 knowledge is to be imparted with regard to the operating principle
and the use of throttle valves. The task of a throttle valves is to offer a flow resistance by chang-
ing the flow cross-section. As a result of the pressure drop, Dp across the throttling point, the
flow and consequently the speed of the actuator changes.
In the project order the trainee is to work out and document the characteristic curve of a throttle.
By changing the throttle settings, he/she is to understand that:
• the differential pressure Dp rises while the flow increases and the throttling cross-section
remains constant,
• the differntial pressure Dp rises in proportion to the reduction in the throttling cross-section
while the flow remains constant,
• the flow is independent of the pressure level when the pressure differential Dp is con-
stant.
09
The control set up on the training system allows the trainee to measure various differential pres-
sures across the throttle valve at certain flows. A load can be simulated by installing a pressure
relief valve in the return line of the 4/3 directional valve.
Notes on detailed technical information about the throttle valve:

Throttle valve type MG
Project 09:
Project definition
In the plant of the customer, a conveyor belt, on which unchanged loads are transported, is
powered by a hydraulic motor. The drive speed of the hydraulic motor is to be adjustable in
both directions of travel.
In order that the customer can understand the proposed solution, he requires technical docu-
mentation.
As an option, he wants to know whether the drive speed changes when loads of different
weights are transported.
09
Fig. 09.1 Practical example: Conveyor belt for transporting printed-circuit boards
Project tasks
technology
• Analyzing the technical data sheet of a throttle valve (specialist qualification)
Project 09:
Project steps
with the customer.
collection (RE 27219 Throttle check valve).
documenting the system parameters requred by the customer.
ways of project execution?
09
Notes
Project 09:
Item 0.2 Item 0.3
Item 1.3 Item 1.0
Item 1.5
Item 1.1 Optional
Item 1.4 09
Load pressure
Item 0.1 Measuring

glass
Item 1.2
Power unit limit
Fig. 09.2 Hydraulic circuit diagram: Throttle valve, adjustable

Project 09:
Stop
09
Rotation Rotation
-Hydraulic motor-
Project 09:

1.0 1 external leakage line and two DM 2.N

1.1 1 DW 13E

1.3 1 Throttle valve, adjustable DF 1.2 09

without check valve

3 DZ 25
with check valve
Hose VSK 1
1 Stopwatch
1 Flowmeter DFF 1
Project 09:
Measuring glass
Connection block
D Note:
09
Fig. 09.4 Recommended component arrangement with component designation for parts list 09.1 and hydraulic circuit diagram Fig. 09.2
Note:
Notes
Project 09:
Safety notes

danger to life.
Warning
Caution
depressurized.
Execution of the order 09

hoses.
Warning
4. By actuating push-button S1 solenoid Y1b of 4/3 directional valve Item 1.1 is energized,
the hydraulic motor Item 1.0 rotates.
Throttling process 1:
5. Close throttle valve Item 1.3. Then open the throttle valve by � turn of the adjustment knob.
Marking with a point for the precise adjustment (1st position).
Project 09:
While directional valve Y1b is operated, the load pressure can be adjusted to 20 bar on
pressure relief valve Item 1.4, which is installed in the return line of the 4/3 directional valve,
and the pressure value read off from pressure gauge M3.
6. The flow measurement can be taken with the help of a measuring glass in liters/time or
optionally using flowmeter Item 1.5. Measure the pressure differential ∆p across throttle
valve Item 1.3 using pressure gauges M2 and M3 and enter the values in Table 09.2.
7. While the throttle position remains unchanged (1st position) increase the load pressure
to 25 bar, 30 bar, 35 bar, 40 bar and 42 bar.
8. Throttle valve Item 1.3, � turn opened (2nd position).
Follow the instructions in points 6 to 8 and enter the values in Table 09.2.
9. Throttle valve Item 1.3, 1� turns opened (3rd position).
Follow the instructions in points 6 and 7 and enter the measurement result in Table 09.2.
After having completed practical work on the training system, switch the
hydraulic pump off! Open the throttle valve and set the pressure relief valves
Caution
to minimum pressure. No pressure gauge may indicate a pressure!
09
10. Optional: Carry the measured values over in a Diagram 09.1.
Measured values
M3
20 25 30 35 40 50
p in bar
Throttle M2
46 46 47 47 47 48
Item 1.3 p in bar
1st M2 - M3
26 21 17 12 7 2
position ∆p in bar
q
1.98 1.74 1.47 1.20 0.87 0
in l/min
M3
20 25 30 35 40 50
p in bar
Throttle M2
44 45 45 46 47 48
Item 1.3 p in bar
2nd M2 - M3
24 20 15 11 7 2
q
3.64 3.22 2.77 2.26 1.71 0
in l/min
M3
20 25 30 35 40 50
p in bar
Throttle M2
39 41 43 44 45 48
Item 1.3 p in bar
3rd M2 - M3
19 16 13 9 5 2
q
6.40 5.82 5.09 4.20 3.18 0
in l/min
Table 09.2 Measurement results from execution of the order
Project 09:
Throttle valve, adjustable 10 Bosch Rexroth AG I RE 00845/04.07

1st position 2nd position 3rd position
30
Differential pressure ∆p in bar
25
20
15
10
5
09
0
0 1 2 3 4 5 6 7
Flow qV in l/min
Diagram 09.1 Diagram with measured values
• The customer requirement can be met by means of a throttle valve.

• As the flow increases the differential pressure ∆p rises when the throttling cross-section
remains constant.
• At a constant flow the differential pressure becomes greater, the smaller the throttling cross-
section is.
• At a constant differential pressure, the flow is independent of the pressure level.
• As an optional extra, the customer wishes to implement a velocity adjustment feature for
various weights. Since the throttle operates in dependence upon loads, the velocity of the
conveyor belt becomes smaller as the load increases (greater weight).
Project 10:
Throttle check valve Bosch Rexroth AG I RE 00845/04.07
Project 10: Throttle check valve

If a given velocity is to be adjustable, a throttle valve can be used. If the traversing speed is to
be adjustable in only one direction, a throttle check valve is used.
Like a throttle valve a throttle check valve is a variable throttle with the disadvantages dealt with
in Project 09 such as temperature and dependence on the differential pressure.
In the following Project 10 knowledge of the operating principle and the use of a throttle check
valve can be imparted. The task of a throttle check valve is to throttle a given flow in only one
direction of rotation. The actuator to be controlled moves with flow throttling in one direction
and almost unthrottled in the opposite direction.
If the throttle is used, for example, on a single-rod cylinder, meter-in or meter-out throttling can
be provided.
In the project order, the trainee is to get familiar with the typical characteristics of a meter-in or
meter-out throttle. By installing the throttle valve differently, he/she is to understand that:
• a throttle check valve is a combination of a throttle and a check valve
• with a throttle check valve the piston velocity of a single-rod cylinder can be adjusted in only
one direction,
• in the case of meter-out throttling the single-rod cylinder is hydraulically isolated, but pres-
sure intensification can occur on the piston rod side,
• the use of a meter-in throttle can result in jerky movements of the single-rod cylinder (slip
stick). 10
On the basis of the control set up on the training system for powering a horizontally installed
single-rod cylinder, the trainee can recognize the pros and cons of meter-in and meter-out throt-
tling by taking measurements on the piston and on the piston rod side.
Notes on detailed technical information about the throttle check valve:

• Technical data sheet RE 27219/throttle check valve, type MK
Technical data sheet RE 27506/double throttle check valve, type Z2FS
Project 10:
Project definition
In a machining station (bending of a roll seam) the hydraulic advance velocity is to be adjust-
able.
The return stroke is to be performed at maximum velocity.
As in Project 09, the customer requires technical documentation in order to be able to under-
stand the proposed solution. In addition, measurements of meter-in and meter-out throttling
are required.
10
Fig. 10.1 Practical example: Tool advance for roll seam bending
Project tasks
• Independent understanding and solving of the task set by applying hydraulic control tech-
nology
• Analyzing the technical data sheet of a throttle check valve (specialist qualification)
Project 10:
Project steps
with the customer.
• Planning: Planning and organizing the customer order with the help of, among others,
the technical data sheets RE 27219 and RE 27506.
10
Notes
Project 10:
Hydraulic circuit diagram 1
Item 1.0
Item 0.2 Item 0.3
Item 1.3
Item 1.1
10
Measuring
Item 0.1 glass
Item 1.2
Power unit limit
Fig. 10.2 Hydraulic circuit diagram: Meter-in throttle - extending a single-rod cylinder
Project 10:
Item 1.0
Item 0.2 Item 0.3
Item 1.3
Item 1.1
10
Measuring
Item 0.1 glass
Item 1.2
Power unit limit
Fig. 10.3 Hydraulic circuit diagram: Meter-out throttle - extending a single-rod cylinder
Project 10:
Item 1.0
Item 0.2 Item 0.3
Item 1.3
Item 1.1
10
Measuring
Item 0.1 glass
Item 1.2
Power unit limit
Fig. 10.4 Hydraulic circuit diagram: Meter-in throttle - retracting a single-rod cylinder
Project 10:
Item 1.0
Item 0.2 Item 0.3
Item 1.3
Item 1.1
10
Measuring
Item 0.1 glass
Item 1.2
Power unit limit
Fig. 10.5 Hydraulic circuit diagram: Meter-out throttle - retracting a single-rod cylinder
Project 10:
Stop
10
Fig. 10.6 Wiring diagram for hydraulic schematic diagrams Fig. 10.2 to 10.5
Project 10:
1.0 1 ZY 1.3

1.1 1 DW 13E


1.3 1 DF 2.2
10

without check valve

3 DZ 25
with check valve
Hose VSK 1
Table 10.1 Parts list for hydraulic circuit diagrams 10.2 to 10.5
Project 10:
Throttle check valve 10 Bosch Rexroth AG I RE 00845/04.07
Component arrangement 1
Measuring glass
Connection block
D Note:
10
Fig. 10.7 Recommended component arrangement with component designation for parts list Table 10.1 and hydraulic circuit diagram 10.2
Note:
Notes
Project 10:
Measuring glass
Connection block
D Note:
10
Note:
Notes
Project 10:
Measuring glass
Connection block
D Note:
10
Note:
Notes
Project 10:
Measuring glass
��
Connection block
D Note:
10
Fig. 10.10 Recommended component arrangement with component designation for parts list Table 10.1 and hydraulic circuit diagram 10.5
Note:
Notes
Project 10:
Safety notes

danger to life.
Warning
Caution
depressurized.
Set up the controls as described in the following: 10

hoses.
Warning
of slipping.
Task 1 Meter-in throttle: Piston side → extending

4. Adjust throttle check valve Item 1.3 so that the piston of the single-rod cylinder extends
within 5 s; to this end operate push-button S2. Enter the pressure values (during extending)
on piston side M2 and on piston rod side M3 in Table 10.2.
Project 10:
Before making any conversion for further order processing, switch the hy-
draulic pump off! No pressure gauge may indicate a pressure!
Caution
Task 2 Meter-out throttle: Piston rod side → extending

5. Convert the hydraulic control according to Hydraulic circuit diagram Fig. 10.3, observing
the safety notes given under point 1. Repeat working steps 2 and 3.
6. Adjust throttle check valve Item 1.3 so that the piston of the single-rod cylinder extends
within 5 s. To this end actuate push-button S2. Enter the pressure values (during extending)
on piston side M2 and on piston rod side M3 in Table 10.2.
Caution
Task 3 Meter-out throttle: Piston rod side ← retracting

the safety notes given under point 1. Repeat working steps 2 to 4.
8. Adjust throttle check valve Item 1.3 so that the piston of the single-rod cylinder retracts
within 5 s. To this end first operate push-button S2 for extending and then for the adjust-
ment of the throttle operate push-button S4 for retracting. Enter the pressure values (during
retracting) on piston side M2 and on piston rod side M3 in Table 10.2. 10
Caution
Task 4 Meter-out throttle: Piston side ← retracting

the safety notes given under point 1. Repeat working steps 2 and 3.
10. Adjust throttle check valve Item 1.3 so that the piston of the single-rod cylinder retracts
within 5 s. To this end first operate push-button S2 for extending and then for the adjust-
ment of the throttle operate push-button S4 for retracting. Enter the pressure values (during
retracting) on piston side M2 and on piston rod side M3 in the table of measured values.
hydraulic pump off! No pressure gauge may indicate a pressure! Open the
Caution throttle check valve.
Project 10:
Measured values
M2 M3
Measuring points →
p in bar p in bar
Meter-in throttle, piston side
2 3
→ extending
Meter-out throttle, piston rod side
50 77
→ extending
Meter-in throttle, piston rod side
2 4
← retracting
Meter-out throttle, piston side
27 50
← retracting
Table 10.2 Measurement results from the execution of the order
The measurement results were obtained at an oil temperature of approx. 20 °C.

10
Safety note from accident prevention regulations:
If there is a riks of pressure intensification on the piston rod side, protection
Warning must be provided in the form of an additional pressure relief valve.
Setting: 10 % above system pressure; the system operator must secure the
setting against unauthorized changes by providing a lead seal.
• The customer requirement can be met by means of a throttle check valve, i.e. the traversing
speed of the advance carriage is adjustable in one direction.
• A throttle check valve is a combination of devices comprising a throttle valve and a check
valve.
• The advance cylinder can be hydraulically isolated during extended, but on the piston rod
side there is a risk of pressure intensification. Depending on the area ratio of the single-rod
cylinder the intensified pressure can reach, e.g. 2 : 1, which is the double system pres-
sure.
• To provide protection against pressure intensification a pressure relief valve can be in-
stalled.
• The flow through a throttle check valve depends on the differential pressure ∆p.
Project 11:
Flow control valve Bosch Rexroth AG I RE 00845/04.07
Project 11: Flow control valve

If the velocity of a hydraulic cylinder or the speed of a hydraulic motor is to be kept constant
independently of pressure fluctuations, a flow control valve is used, e.g. in conjunction with a
hydraulic cylinder, which is to lift and lower different loads, but is to move at the same travers-
ing velocity.
A flow control valve comprises a control loop and consists of an adjustable orifice and an up-
stream or downstream pressure compensator. Due to a continuous comparison of the pressures
upstream and downstream of the adjustable orifice, the set flow is kept constant.
In the following Project 11 you can impart knowledge of the operating principle and use of flow
control valves. The task of the flow control valve used is to maintain the speed of a hydraulic
motor constant despite varying loads.
In the project order, the trainee has to work out and record the characteristic curves of a 2-way
flow control valve. By making various adjustments to the flow control valve and changing the
loads on the hydraulic motor, he/she is to recognize that:
• the flow remains constant at varying load pressures,
• at varying inlet pressures, the flow remains constant,
• a flow control valve features a closed hydraulic control loop,
• flow qV eff. drops below a minimum pressure differential.
With the help of the control set up on the training system for driving a hydraulic motor, the trainee
can recognize the different flow rates under changing loads. The load can be simulated with the
help of a pressure relief valve installed in the return line of the 4/3 directional valve. 11
Notes on the detailed technical information about the flow control valve:
• Technical data sheet RE 28163/2-way flow control valve
Project 11:
Project definition
In a machining station, a hydraulic rotary drive is to swivel a drum from the horizontal to the
vertical position after a welding process. The movement is to be performed by a hydraulic mo-
tor. Despite varying loads, the motor speed must remain constant.
Applying the knowledge that was gained in Project 09, a load-independent throttle valve is to
be used in the velocity control.
In order that the customer can understand the solution, he requires, apart from the technical
documentation for the use of different workpiece weights, a flow/pressure differential curve for
varying loads and falling system pressures.
11
Fig. 11.1 Practical example: Rotary drive for workpiece relocation
Project tasks
technology
• Analyzing the technical data sheet for a flow control valve (technical qualification)
Project 11:
Project steps
with the customer.
by dealing intensively with data sheet RE 28163.
• Deciding: Using the sketches of the circuit diagrams from Project 10: Throttle check
valve, selection of the relevant sketch with selection of the hydraulic com-
ponents.
• Executing: Set-up of the hydraulic control on the training system and preparation and
documentation of the system parameters requested by the customer.
Notes 11
Project 11:
Item 0.2 Item 0.3
Item 1.3 Item 1.0
Item 1.1
Item 0.4
Item 1.4
Load pressure
11
Measuring
Item 0.1 glass
Item 1.2
Power unit limit
Fig. 11.2 Hydraulic circuit diagram: Load-independent speed control of a tool spindle
Project 11:
Stop
11
Rotation Rotation
-Hydraulic motor-
Project 11:

1.0 1 external leakage line and two direc- DM 2.N
tions of rotation
4/3 directional valve direct oper-

ated by two solenoids, spring
1.1 1 DW 13E
central position P, T, A, B

2-way flow control valve, adjust-

able, for one direction of flow,
1.3 1 largely independent of viscosity DF 3
and pressure diferential, adjustable,
11

0.1 - 0.4 4 quick-release coupling, without DZ 1.4
check valve

4 DZ 25.1
with check valve
Hose VSK 1
1 Stopwatch
Table 11.1 Parts list for hydraulic circuit diagram 11.2

Project 11:
Measuring glass
Connection block
D Note:
11
Fig. 11.4 Recommended component arrangement with component designations to parts list Table 11.1 and hydraulic circuit diagram Fig. 11.2
Note:
training system.
Notes
Project 11:
Safety notes

danger to life.
Warning Before starting work on the training stand, make sure that electrical ON/OFF
Set up the controls as described below:

1. Hang the components required according to Table 11.1 in a clearly arranged manner into

the training system according to the prepared circuit diagram.
11
hoses.
use hydraulic hoses DZ 25.1. Hand-tighten the pressure gauge measuring lines hand tight
at the relevant minimess connection of the hydraulic hose.
Warning
Caution
Task 1 Determining the flow/pressure differential curve with rising load pressure
3. Set the system pressure on pressure relief valve item 1.2 to 45 bar.
4. Turn flow control valve item 1.3 to scale position 2.
5. Operate pushbutton S4; the hydraulic motor rotates clockwise; adjust the load pressure on
pressure relief valve item 1.5 in the return flow line to 10 bar (pressure gauge M4). Enter
the pressure values M2 (upstream of DF 3) and M3 (downstream of DF 3) in measurement
table 11.2. Calculate the pressure differential Dp (M2 - M3) and enter it in the measure-
ment table.
Project 11:
Flow measurement by means of the measuring glass as a function of time or optionally

using flowmeter DZ 30.
6. Stepwise increase (in 5 bar increments) the load pressure on the hydraulic motor by means
of pressure relief valve item 1.5 in the return flow line to 40 bar and enter the pressure
values M2, M3, the Dp and flow qV in Table 11.1.
8. Repeat order steps 5 to 6 and enter the measured values in Table 11.2.
Measured values
Measuring point M2 M3 Pressure differential Flow

p in bar p in bar Dp in bar qV in l/min
Scale Scale Load Scale Scale Scale Scale
position 2 position 4 pressure position 2 osition 4 position 2 position 4
42 40 10 32 30 0.47 1.92
42 40 15 27 25 0.47 1.92
42 40 20 22 20 0.46 1.90
42 40 25 17 15 0.46 1.90
42 40 30 12 10 0.45 1.86
42 40 35 7 5 0.31 1.30 11
42 42 40 2 2 0 0
Table 11.2 Values measured during the execution of the order, increasing load pressure

Scale position 2 Scale position 4
2,5
2
Flow qV in l/min
1,5
0,5
0
0 5 10 15 20 25 30 35 40
Pressure differential Dp in bar
Diagram 11.1 Flow/pressure differential curve, increasing load pressure
Project 11:
Flow control valve 10 Bosch Rexroth AG I RE 00845/04.07
Task 2 Determining the flow/pressure differential curve at varying system pressure

9. Set pressure relief valve item 1.5 in the return flow line (load pressure) to minimum (spring
unloaded).
10. Set the system pressure on pressure relief valve item 1.2 to 40 bar.
12. Operate pushbutton S4; the hydraulic motor rotates clockwise. Enter pressure values M1
(upstream of DW 13E) and M3 (downstream of DF3) in Table 11.3. Calculate the pressure
differential Dp (M1 - M3) and enter the value in the measurement table.
Flow measurement by means of the measuring glass or optionally by means of flowmeter
DZ 30. Enter flow qV in Table 11.3.
13. Stepwise reduce (in 5 bar increments) the system pressure by means of pressure relief
valve item 1.2 down to the minimum pressure of 10 bar.
After completion of the practical work on the training system, switch the hy-
draulic pump off! Set the throttle valve and pressure relief valves to minimum
Caution pressure. No pressure gauge may indicate a pressure!
Measured values
11
Measuring point M1 Measuring point M3 Pressure differential Flow
p in bar p in bar Dp in bar qV in l/min
40 5 35 0.5
35 5 30 0.5
30 5 35 0.5
25 5 20 0.5
20 5 15 0.5
15 5 10 0.5
10 5 5 0.4
Table 11.3 Falling system pressure
The results above were measured at an oil temperature of approx. 20 °C.

Project 11:
0,6
0,5
0,4
Flow qV in l/min
0,3
0,2
0,1
0 10 15 20 25 30 35 40
Pressure differential ∆p in bar
Diagram 11.2 Flow/pressure differential curves, system pressure falling
11
• At a varying load pressure, flow qV remains largely constant.

• At varying inlet/system pressure, flow qV remains largely constant.
• In terms of construction, the flow control valve consists of an adjustable orifice and a pres-
sure compensator, which creates a constant ∆p across the orifice; the flow control valve
features a closed hydraulic control loop.
• Below a minimum pressure differential (manufacturer-specific) flow qV drops.
Project 11:
Notes
11
Project 12:
Pressure relief valve, direct operated Bosch Rexroth AG I RE 00845/04.07
Project 12: Pressure relief valve, direct operated

If the operating pressure/system pressure is to be limited to an adjustable maximum value in a

hydraulic system, a pressure relief valve is used. We differentiate pressure relief valve by:
Pressure relief valves, direct operated and pilot operated.
The limitation of the system pressure protects system components such as pipes and hoses,
connections, control blocks, pump housings, etc. against destruction. Pressure relief valves are
also used to provide protection against, e.g. pressure peaks. In the special machinery construc-
tion sector, e.g. in presses, pressure relief valves are also used as load holding valves.
To be able to assess the characteristics of a direct operated pressure relief valve, the charac-
teristic curves of the pressure/flow relation must be known.
In the following Project 12 knowledge of the operating principle, use and adjustment options
of direct operated pressure relief valves is to be gained. Pressure relief valves are used to limit
the system pressure of a hydraulic control.
In the project order, the trainee is to get to know the characteristic curves of a direct oper-
ated pressure relief valve. By making various settings on the pressure relief valve, he/she is to
recognize that:
• the characteristic curve of a pressure relief valve shows the dependence of pressure p on
flow qV;
• despite an open pressure relief valve a resistance (line and valve resistance) can be ob-
served;
• in the case of a parallel connection of throttle and pressure relief valves the flow is di-
vided;
• pressure relief valves can be used, for example, as overload protection. 12
On the basis of the set up control the trainee can work out the characteristic curves of a pres-
sure relief valve by changing the system pressure and the resistance installed in parallel. The
resistance is provided by an adjustable throttle valve.
Notes on detailed technical information about the direct operated pressure relief valve:
• Technical data sheet RE 25402/Pressure relief valve, direct operated
Project 12:
Project definition
On a lifting platform, the system pressure is to be reduced due to the use of lower weights.
The new setting is to save energy.
The customer requires work instructions in order that he can adjust the pressure without re-
quiring expert help. Moreover, he is interested in the pressure/flow relationship characteristic
curves of pressure relief valves.
12
Fig. 12.1 Practical example: Pressure relief valves
Project tasks
technology
• Analyzing the technical data sheet of a pressure relief valve (specialist qualification)
Project 12:
Project steps
with the customer.
• Planning: Planning and organizing the customer order, among others, by dealing
intensively with technical data sheets RE 25402.
Notes
12
Project 12:
Item 1.1
Item 1.5
Item 0.1
Measuring
glass
Item 1.0
Power unit limit 12
Fig. 12.2 Hydraulic circuit diagram: Determination of technical data of a pressure relief valve, direct operated
Project 12:


0.1 1 and quick release coupling DZ 1.4
without check valve

1 DZ 25
with check valve
Hose VSK 1
12
1 Stopwatch
1 Flowmeter DZ 30
Project 12:
Measuring glass
Connection block
D Note:
Note: 12
Notes
Project 12:
Safety notes

danger to life.
Warning

1. Mount the components required according to the parts list in a clearly arranged form on the
of hoses. 12
Warning
Caution
An electrical control is not required for this experiment set-up.
Relationship between flow and pressure relief valve
3. Close throttle valve Item 1.1, set the system pressure to 30 bar on pressure relief valve
Item 1.0. Measure the flow through the measuring glass as a function of time or optionally
using flowmeter Item 1.2 (DZ 30).
Enter the values in Table 12.2.
Project 12:
4. Open throttle valve Item 1.1 in individual steps (5 bar increments). The pressure is shown
on pressure gauge M1. Enter the M1 measurement results and flow qV in Table 11.2.
5. Carry over the measurement results from Table 12.2 to Diagram 12.1.
throttle check valve.
Caution
Measured values
Flow
System pressure M1 qV in l/min
Throttle valve
p in bar through pressure relief
valve
Closed 30 7.6
25 4.3
20 1.8
15 0 12
Open 10 0
Table 12.2 Measured values: Pressure relief valve - pressure/flow

Project 12:
35
30
System pressure M1 p in bar
25
20
15
10
0
0 1 2 3 4 5 6 7 8
Flow qV across the pressure relief valve in l/min
Diagram 12.1 Pressure/flow characteristic curves, falling system pressure

12
• The characteristic curve of the pressure relief valve shows the dependence of pressure p
on flow qV.
• When the throttle valve is open or the pressure relief valve is open, a resistance can be
measured, which can be traced back to line resistances and the valve resistance.
• Due to the interaction of the throttle valve and the pressure relief valve the flow is divided.
• Pressure relief valves are mainly used as overload protection for limiting the maximum pres-
sure.
Project 12:
Pressure relief valve, direct operated 10 Bosch Rexroth AG I RE 00845/04.07
Notes
12
Project 13:
Pressure relief valve control Bosch Rexroth AG I RE 00845/04.07
Project 13: Pressure relief valve control

If three different pressures are to be realized in a hydraulic circuit, pressure relief valves
connected in series or in parallel

can be used for this purpose.
The following Project 13 can be used to acquire knowledge of the practical use and adjustment
options of direct operated pressure relief valves.
In the project order, the trainee has to develop and record the adjustment options of parallel
and series circuits with the help of experiment set-ups on the training system. As preparation
to the practical experiment, the trainee has to become familiar with the theoretical principles
of the circuits.
By controlling the pressure relief valves in different ways by means of a 4/3 directional valve,
he/she is to recognize that:
• Pressure relief valves can be used for pre-selecting various system and pilot pressures via
pressure stage circuits,
• in the case of pressure relief valves controlled in parallel, the lowest set pressure becomes
effective,
• in the case of pressure relief valves controlled in series, the pressures add up.
With the help of the controls set up on the training system, the trainee is to understand the
typical features of the controls by operating pressure relief valves connected in parallel and in
series. With the help of a 4/3 directional valve he/she can control pressure relief valves option-
ally connected in parallel or in series.
Notes on the detailed technical information about the direct operated pressure relief
valve:
13
• Technical data sheet RE 25402/Pressure relief valve, direct operated
Project 13:
Project definition
On a punching rig, three, electrically controllable pressures are to be callable for different tools
and different working sequences.
The customer wishes solution proposals for the simple realization of a pressure control and
requires technical documentation with the necessary system parameters.
13
Fig. 13.1 Practical example: Punching equipment
Project tasks
technology
• Analyzing the technical data sheet for a pressure relief valve (technical qualification)
Project 13:
Project steps
with the customer.
• Planning: Planning and organizing the execution of the customer order, among others,
by dealing intensively with data sheet RE 25402.

Notes
13
Project 13:
Hydraulic circuit dagram 1
Item 0.3
Item 1.2
Item 0.2
Item 1.1
Item 1.0
Measuring
Item 0.1 glass
13
System
Power unit limit
Fig. 13.2 Hydraulic circuit diagram: 3-stage pressure circuit

Project 13:
Item 0.3
Item 1.2
Item 0.2
Item 1.1
Item 1.0
Measuring
Item 0.1 glass
13
System
Power unit limit
Fig. 13.3 Hydraulic circuit diagram: Parallel pressure circuit

Project 13:
Item 0.2 Item 0.3
Item 1.1 Item 1.2
Item 1.0
Measuring
Item 0.1 glass
System
Power unit limit

13
Fig. 13.4 Hydraulic circuit diagram: Series pressure circuit

Project 13:
Circulation
13
Solenoid “a” Solenoid “b”
Fig. 13.5 Wiring diagram for hydraulic circuit diagrams Fig. 13.2 and 13.4
Project 13:

operated by two solenoids, spring
1.0 1 DW 4E
central position P - T, A, B

Distributor plate with four

2 DZ 4.1
connections

0.1 - 0.3 3 quick-release coupling without DZ 1.4
check valve
Hose with quick-action coupling,

3 DZ 25
with check valve
Hose VSK 1
Table 13.1 Parts list for hydraulic circuit diagrams Fig. 13.2 to 13.4
13
Project 13:
Measuring glass
Connection block
D Note:
Fig. 13.6 Recommended component arrangement with component desgnations for parts list Table 13.1 and hydraulic circuit diagram Fig. 13.2
Note:
training system. 13
Notes
Project 13:
Pressure relief valve control 10 Bosch Rexroth AG I RE 00845/04.07
Measuring glass
Connection block
D Note:
Note:
training system. 13
Notes
Project 13:
Measuring glass
Connection block
D Note:
Note:
training system. 13
Notes
Project 13:
Safety notes

danger to life.
Warning Before starting work on the training stand, make sure that electrical ON/OFF

1. Hang the components required according to the parts list in a clearly arranged manner into
the training system according to the prepared circuit diagram.
of hoses.
For the connections, to which the pressure gauges with minimess line DZ 1.4 are to be
connected, use hydraulic hoses DZ 25. Hand-tighten the pressure gauge line hand tight to 13
also to minimess lines or that the connections are plugged by means of plug
Warning
Wire the electrical control according to wiring diagram 13.5.
Check the pressure set on the control pump of the drive power unit and, if required, cor-
rect it to 50 bar.
Task 1 3-stage pressure circuit

2. Switch the hydraulic pump and check the set up control for leakage. No pressure gauge
3. Operate directional valve item 1.0 by actuating pushbutton S4. Set the system pressure
on pressure relief valve item 1.1 at port B to 15 bar (pressure gauge M2).
Project 13:
4. Operate directional valve item 1.0 by actuating pushbutton S2. Set the system pressure
on pressure relief valve item 1.2 at port A to 20 bar (pressure gauge M3).
Enter the measured values (pressure gauge M1, M2, M3) in Table 13.2.
Before converting the circuit for the further execution of the order, switch the
hydraulic pump off! No pressure gauge may indicate a pressure!
Caution
Task 2 Parallel circuit

5. Connect the hydraulic control according to circuit diagram Fig. 13.3 by means of hoses.
Do not change the pressures set on pressure relief valves item 1.1 and item 1.2!
6. Operate directional valve item 1.0 by actuating pushbutton S2.
Enter the measured values (pressure gauges M1 and M2) in Table 13.3.
Before converting the circuit for the further execution of the order, switch the
hydraulic pump off! No pressure gauge may indicate a pressure!
Caution
Task 3 Series circuit

7. Connect the hydraulic control according to circuit diagram Fig. 13.4 by means of hoses.
Do not change the pressures set on pressure relief valves item 1.1 and item 1.2!
8. Operate directional valve item 1.0 by actuating pushbutton S2.
Enter the measured values (pressure gauges M1, M2, M3) in Table 13.4.
After completion of the practical work on the training system, switch the
hydraulic pump off! No pressure may indicate a pressure! Open the throttle
Caution
check valve.
13
Notes
Project 13:
Measured values
Spool position Measuring point M1 Measuring point M2 Measuring point M3

DW 4E p in bar p in bar p in bar
0 8 0 0
a 23 0 20
b 18 15 0
Table 13.2 3-stage pressure circuit
Spool position Measuring point M1 Measuring point M2

DW 4E p in bar p in bar
0 8 0
a 18 15
Table 13.3 Parallel pressure circuit
Spool position Measuring point M1 Measuring point M2 Measuring point M3

DW 4E p in bar p in bar p in bar
0 8 0 0
a 38 35 20
Table 13.4 Series pressure circuit

13
• In a 3-stage pressure circuit, direct operated pressure relief valves can be controlled via a
directional valve and consequently three different, pre-selected system pressures can be
realized.
• In the case of pressure relief valves connected in parallel, the lowest pressure set is effec-
tive.
• In the case of pressure relief valves connected in series, the set pressures add up.
Project 14:
Pressure reducing valve Bosch Rexroth AG I RE 00845/04.07
Project 14: Pressure reducing valve

If a secondary actuator in a hydraulic control is to be controlled at a lower pressure indepen-

dently of the system pressure, a pressure reducing valve is used.
In contrast to the pressure relief valve, which limits the input pressure, the pressure reducing
valve influences the output pressure (actuator pressure). The pressure that can be set on a
pressure reducing valve is always lower than the system pressure.
The following Project 14 is intended to impart knowledge of the operating principle and the
use of a pressure reducing valve. The task of a pressure reducing valve is to keep the output
pressure constant and lower than the input pressure.
In the project order the trainee is to get familiar with the typical characteristics of a pressure
reducing valve with the help of a practice-oriented experiment set up on the training system.
This project task is to help him/her understand that:
• with the help of a pressure reducing valve a secondary actuator can be controlled at a pres-
sure which is lower than the system pressure,
• excess pressure in port A is discharged via port T of the pressure reducing valve to the
tank,
• a pressure reducing valve without by-pass check valve operates as pressure relief valve
when controlled via port A.
The control set up on the training system (two actuators are controlled simultaneously at dif-
ferent pressures via a 4/3 directional valve) is to make the characteristics of a 3-way pressure
reducing valve clear to the trainee.
Notes on detailed technical information about the pressure reducing valve:

Pressure reducing valve, direct operated
14
Project 14:
Project definition
In Project 11 a workpiece is to be swiveled by a hydraulic motor in a machining station. In a

further step of the project the same workpiece is to be clamped at reduced pressure. In order
that the hydraulic motor only starts to rotate after clamping is completed, it is to be hydrauli-
cally pre-loaded.
The customer wishes a solution with which the control can easily be realized and requires the
associated technical documentation with the necessary system parameters. In addition, he
needs information about the setting options and wants to know, why a by-pass check valve is
required.
14
Fig. 14.1 Practical example: Swiveling/clamping unit
Project tasks
technology
• Analyzing the technical data sheet of a pressure reducing valve (specialist qualification)
Project 14:
Project steps
with the customer.
• Planning: Planning and organizing of the customer order by, among others, dealing
intensively with technical data sheet RE 26564.
• Executing: Set-up of the hydraulic control on the training system. Preparation and
documentation of the measured data.
Notes
14
Project 14:
Item 2.0 Item 0.1

Rotate Clamp
Item 0.3
Item 0.2 Item 1.3
Item 2.1
Item 1.4
Item 1.1
Measuring
Item 0.1 glass
Item 1.2
14
Power unit limit
Fig. 14.2 Hydraulic circuit diagram: Machine tool control

Project 14:
Stop
14
Clockwise rotation
-Hydraulic motor-
Project 14:
1.0 1 ZY 1.3

2.0 1 exteral leakage oil lines and two DM 2.N

1.1 1 DW 13E

1.3 1 3-way pressure reducing valve DD 2

1.4 1 DS 2.1
1 bar

14

without check valve

3 DZ 25
with check valve
Hose VSK 1
Project 14:
Measuring glass
Connection block
D Note:
Note:
14
Notes
Project 14:
Safety notes

danger to life.
Warning
Set up the controls as described in the following:

of hoses.
Observe installation direction of check valve Item 1.4! 14
Warning
For the connections, to which pressure gauges with minimess line DZ 1.4 are to be con-
nected, use hydraulic hoses DZ 25. Hand-tighten the pressure gauge measuring lines at
Warning
of slipping.
Caution
Project 14:
Task 1 Control with by-pass check valve

Set the system pressure on pressure relief valve Item 1.2 to 50 bar plus one turn.
3. Actuate push-button S4 to operate directional valve Item 1.1. Hydraulic motor Item 2.0
rotates clockwise; set pressure relief valve Item 2.1 on the hydraulic motor (port B) to a
load pressure of 40 bar (pressure gauge M2).
4. Set the clamping pressure to 20 bar on pressure reducing valve Item 1.3.
Enter the values measured during extending and retracting of the advance cylinder piston
(pressure gauge M1, M2, M3) in Table 14.2.
Also enter the pressures in the extended and retracted condition.
Caution
Task 2 Control without by-pass check valve

5. Modify the hydraulic control. To this end remove by-pass check valve Item 1.4 and the two
connection hoses.
Do not change the load pressure on hydraulic motor Item 2.0 and the pressure on clamp-
ing cylinder Item 1.0.
6. Actuate push-button S4 to operate directional valve Item 1.0. The hydraulic motor rotates
against the load pressure of 40 bar, and the clamping cylinder clamps at a pressure of
20 bar.
7. Enter the values measured during extending and retracting of the clamping cylinder piston
(pressure gauge M1, M2, M3) in Table 14.2.
Also enter the pressures in the extended and retracted condition.
Note:
When the clamping piston retracts after operation of push-button S2 the cylinder moves against
a clamping pressure of 20 bar provided via port A of the pressure reducing valve.
In this case, the pressure reducing valve assumes a pressure relief function. 14
Caution hydraulic pump off! No pressure gauge may indicate a pressure! Open the
Project 14:
Pressure reducing valve 10 Bosch Rexroth AG I RE 00845/04.07
Measured values
With by-pass check valve Without by-pass check valve

DS 2.1 DS 2.1
Measuring point
→ M1 M2 M3 M1 M2 M3
p in bar p in bar p in bar p in bar p in bar p in bar
Clamping cylinder
20 15 3 20 15 3
extending →
Clamping cylinder
45 40 20 45 40 20
extended →
Clamping cylinder
45 15 20 48 0 26
retracting ←
Clamping cylinder
50 0 0 50 0 0
retracted ←
Table 14.2 Values measured on the pressure reducing valve

• A pressure reducing valve can supply a secondary actuator with a lower pressure than the
14
system pressure.
• The system pressure must always be higher than the secondary pressure.
• When the pressure rises in port A of the pressure reducing valve (e.g. pressure peaks/
changes in the load by the secondary actuator), the pressure increase is reduced to the
tank via port T of the pressure reducing valve.
• When controlled via channel A, a pressure reducing valve operates as pressure relief
valve.
• When controlled from T to P the pressure relief valve on the hydraulic motor operates as
check valve.
Project 15:
Pressure switch Bosch Rexroth AG I RE 00845/04.07
Project 15: Pressure switch

If a control signal is to be switched in dependence upon a pressure, pressure switches are

used. These are subdivided into:
Bourdon tube, piston-type and electronic pressure switches.
Bourdon tube and piston type pressure switches are hydro-electrical switches. Electronic
pressure switches are a combination of a pressure transducer, an indicator and a threshold
switch.
The switching elements integrated in a piston-type pressure switch make or break an electrical
circuit.
In the following Project 15 knowledge can be imparted with regard to the operating principle
and use of a piston-type pressure switch. Pressure switches assume switching and monitoring
functions in a hydraulic control.
In the project order the trainee is to get familiar with the typical characteristics and the setting
options of a piston-type pressure switch with the help of a practice-oriented experiment set-up
on the training system. The following knowledge is to be gained with this project task:
• Piston-type pressure switches issue an electrical control signal.
• The hydraulic pressure is used to switch an electrical signal via a micro-switch.
• In the case of a piston-type pressure switch the pressure must exceed or fall below the set
value in order that a switching process in initiated.
Based on the control set up on the training system the trainee is to understand the possible
applications of a piston-type pressure switch. A cylinder is to be controlled by means of a 4/2
directional valve, and the pressure on the piston side controlled by a piston-type pressure switch.
When the set pressure is reached, the return stroke is to be initiated.
Notes on detailed technical information about the piston-type pressure switch:

Hydro-electrical pressure switch
15
Project 15:
Project definition
Two hydraulic workpieces are to be pressed together in a fixture by means of a hydraulic cylin-
der. After the pressing pressure was reached, the hydraulic cylinder is to retract automatically.
The pressing velocity is to be adjustable.
The customer wishes to obtain a proposed solution for an automatic, hydraulic pressing pro-
cess. In the event of a fault of pressure monitoring, it should be possible to release the pressing
fixture electrically. The customer also wants to know the settable minimum pressing pressure.
For his technical documentation, the customer requires a circuit diagram with parts list and
functional description.
15
Fig. 15.1 Practical example: International pressure indications on pressure switches for system monitoring
Project tasks
technology
• Analyzing the technical data sheet of a piston-type pressure switch (specialist qualification)
Project 15:
Project steps
with the customer.
• Planning: Planning and organizing of the customer order by, among others, dealing
intensively with technical data sheet RE 50060.
• Executing: Set-up of the hydraulic control on the training system. Working out the set-
ting options of the pressure switch at different, given system pressures.
Notes
15
Project 15:
Item 1.0
Item 0.2
Item 1.3
Item 1.4
Item 0.3
Item 1.1
Item 0.1 Measuring

glass
Item 1.2
Power unit limit

15
Fig. 15.2 Hydraulic circuit diagram: Pressure switch

Project 15:
15
Extension
Note:
Retracting of the single-rod cylinder
can additionally be controlled
by means of push-button S1.
Fig. 15.3 Wiring diagram for hdraulic circuit diagram Fig. 15.2
Project 15:
1.0 1 ZY 1.3

1.1 1 DW 3E

Pressure switch, electromechani-

1.3 1 DD 6E.1
cal, adjustable

1.4 1 DZ 2.2

without check valve
15
hose with quick release coupling
3 DZ 25
with check valve
Hose VSK 1
Project 15:
��
��
��
��
��
Measuring glass
��
�
��
��
��
��
�
Connection block
��
��
�
D Note:
� � In the case of connection
��
�

�� directly with each other.
�
Note:
Notes
15
Project 15:
Safety notes

Warning
danger to life.
Caution switched off. Use the system pressure gauges to check that the system is
depressurized.

of hoses.
Observe direction of installation of the throttle check valve!

Danger
The correct and proper fit of the component connections with hoses can be checked 15
Warning
of slipping.
Set the system pressure to 30 bar on pressure relief valve Item 1.2.
Set piston-type pressure switch Item 1.3 to maximum by turning the setscrew completely
in using an Alllan key 10 A/F.
Project 15:
3. Check that the pressing cylinder extends and retracts correctly while the throttle check valve
is open. Actuate push-button S2 to operate directional valve Item 1.1. Adjust the extension
velocity of the pressing piston to a forward speed of 0.05 m/s by means of throttle check
valve Item 1.4. To this end, calculate the velocity as a function of the measured extension
time and the stroke length.
4. Adjust the pressing pressure on piston-type pressure switch Item 1.3 (release spring)
so that the pressing cylinder piston retracts automatically. To this end, extend the pressing
piston to the end position.
5. Set the pressures given in Table 15.2 and verify whether the cylinder retracts automati-
cally.
Enter the results in Table 15.2.
Measured values
Pressure relief valve Retracts automatically

p in bar Yes/no
20 No
28 No
30 Yes
32 Yes
40 Yes
Table 15.2 Pressure monitoring of the hydraulic cylinder

15
• Piston-type pressure switches output an electrical signal.

• The hydraulic pressure is used to switch an electrical signal by means of a micro-switch.
• In the case of a piston-type pressure switch, the pressure must exceed or fall below the set
value in order to initiate a switching process.
Project 15:
Pressure switch 10 Bosch Rexroth AG I RE 00845/04.07
Notes
15
Project 16:
Pressure switch hysteresis Bosch Rexroth AG I RE 00845/04.07
Project 16: Pressure switch/hysteresis

If pressures are to be processed as signals in a hydraulic control, pressure switches must be

used.
A pressure switch is a converter, which converts an incoming hydraulic pressure into an electrical
signal. The switching elements installed in a pressure switch close or open an electric circuit.
The switching point at increasing pressure and at falling pressure varies due to friction. The
difference in the values is called hysteresis (Greek hysteros: later).
SP
Hysteresis
rP
1
0 Hno (normally open)
1 Hnc (normally closed)
0
Diagram 16.1 Hysteresis
Adjustable hysteresis on electronic pressure switches

Hysteresis maintains the switched state of the output stable, when the system pressure fluctu-
ates around the command value. While the system pressure rises, the output switches when the
switching point (SP) is reached; when the system pressure falls again, the output only switches
when the reset point (rP) is reached. On electronic pressure switches, the hysteresis is adjust-
able: Firstly the switching point is determined, then the reset point at the desired distance.
In the following Project 16 knowledge can be imparted of the practical effects of hysteresis on
a piston-type pressure switch.
In the project order the trainee is to get familiar with the hysteresis of a piston-type pressure
switch through a practical experiment set-up on the training system. Through this project task,
the trainee is to gain the following knowledge:
• A piston-type pressure switch always has a hysteresis.
• Hysteresis is the difference of switching points at rising and falling pressure.
• Hysteresis can have different amounts, which can be attributed to the individual design. 16
• On certain pressure switches, hysteresis can be adjustable.
On the basis of the control set up on the training system, the trainee is to get to know the hys-
teresis of a piston-type pressure switch. With the help of a 24 V bulb, which serves as control
unit, and a pressure relief valve installed in a by-pass, he/she can set given values and measure
the hysteresis by way of the hydraulic pressure.
Notes on detailed technical information about the piston-type pressure switch:

Hydro-electrical pressure switch
Project 16:
Project definition
As described in Project 15 a customer uses a piston-type pressure switch in hydraulic pressing

equipment. For his technical documentation the customer requires detailed information about
the hysteresis of this piston-type pressure switch. In addition, he wants to know, whether this
is always the same, and if so, whether he can utilize this for the sequence of his control.
max.
Pressure stage 100 bar
Switching pressure differential in bar →
Scatter
min.
Lower switching pressure in bar →
Fig. 16.1 Practical example: Piston-type pressure switch
16
Project tasks
technology
• Analyzing the technical data sheet of a piston-type pressure switch (specialist qualification)
Project 16:
Project steps
with the customer.
• Planning: Planning and organizing the customer order using, among others, technical
data sheet RE 50060.
• Executing: Set-up of the hydraulic control on the training system. Working out the
hysteresis of a piston-type pressure switch at various, given system pres-
sures.
Notes
16
Project 16:
Item 1.1
Item 1.2
Item 0.1
Measuring
glass
Item 1.0
Power unit limit
16
Fig. 16.2 Hydraulic circuit diagram: Pressure switch hysteresis

Project 16:
16
Note:
The pressure switch is
supplied with voltage via
push-button S1.
Project 16:

Pressure switch, electromechani-

1.1 1 DD 6E.1
cal, adjustable

0.1 1 and quick release coupling DZ 1.4
without check valve

2 DZ 25
with check valve
Hose VSK 1
16
Project 16:
Measuring glass
Connection block
D Note:
Note:
Notes
16
Project 16:
Safety notes

danger to life.
Warning
Caution
depressurized.

of hoses.
are connected or that the ports are blocked with plug screws or protective 16
Warning
of slipping.
Caution
3. Set piston-type pressure switch Item 1.1 to 30 bar; to this end, set pressure relief valve
Item 1.0 to 30 bar. To this end, close throttle Item 1.2 and operate push-button S1.
4. Set the system pressure to 25 bar on pressure relief valve Item 1.0.
Project 16:
Slowly increase the system pressure to 30 bar while observing indicator lamp H1 on the
electrical control.
When the pressure rises to 30 bar, lamp H1 goes on.
Increase the system pressure by further 5 bar to 35 bar. During this, lamp H1 must not go
out.
5. Slowly reduce the system pressure until lamp H1 goes out. The pressure indicated by the
pressure gauge should be 27.5 bar.
This switching difference is called hysteresis.
Note:
The value given under point 5 can deviate by 1 - 2 bar.
Caution
• A piston-type pressure switch always features hysteresis.

• The pressure switch responds at increasing and falling pressure.
• On a piston-type pressure switch, hysteresis is not adjustable.
16
Project 16:
Pressure switch hysteresis 10 Bosch Rexroth AG I RE 00845/04.07
Notes
16
Project 17:
Hydraulic accumulator Bosch Rexroth AG I RE 00845/04.07
Project 17: Hydraulic accumulator

If, in a hydraulic control, a cylinder should be operable also in the event of a failure, for example
of the hydraulic pump, the energy required for this can be taken from a hydraulic accumulator.
Depending on their design, hydraulic accumulators are classified as:
Piston-type, bladder-type and diaphragm-type accumulators.
A hydraulic accumulator is a pressure vessel with a separating element, in which energy is stored.
Hydraulic accumulators are used for storing energy, for damping, for leakage oil compensation,
for holding pressures constant and for vehicle suspension.
Safety notes
(Excerpt from currently valid safety regulations - not exhaustive).
Hydraulic accumulators are pressure vessels and are subject to national

regulations valid at the place of installation. In Germany, these are the health
and safety at work regulations (BetrSichV). The rating, manufacture and test-
ing must comply with AD sheets. The installation, equipment and operation
are regulated by "Technischen Regeln Druckbehälter“ (TRB) (technical rules
for pressure vessels).
Welding, soldering or carrying out mechanical work on pressure equipment
is prohibited. Pressure equipment must not be charged with oxygen or air.
Pressure equipment (accumulators) must not be opened before the gas
Warning
and fluid sides were depressurized. Accumulators contain nitrogen (risk of
suffocation).
Accumulators may only be protected by pressure relief valves, which comply
with Directive 97/23/EC.
Caution
Pressure accumulators may only be installed, repaired and put into service
by specialist personnel trained in the field of hydraulics.
The following Project 17 is intended to impart knowledge of the possible applications of a

diaphragm-type accumulator as energy storage. You could also explain how to check the gas
pre-charge pressure.
In the project order the trainee is to understand the behavior of a hydraulic cylinder in the event
of a hydraulic pump failure and the withdrawal of energy from a diaphragm-type accumulator
in a practical experiment set-up on the training system. Through this project task, the following
knowledge is to be acquired:
• Due to the compressibility of the filled-in gas, a diaphragm-type accumulator can be used
for storing energy.
• The oil volume that can be stored in the hydraulic accumulator depends on the size of the 17
accumulator, the nitrogen pre-charge pressure and the system pressure.
• The amount of oil available for withdrawal depends on the accumulator size, the nitrogen
pre-charge pressure and the pressure difference between the minimum and maximum work-
ing pressure.
• If the system pressure falls below the nitrogen pre-charge pressure, the hydraulic accumula-
tor is completely discharged.
On the basis of the control set up on the training system the trainee is to work out the pos-
sible application of a hydraulic accumulator as energy storage. The usable oil volume can be
calculated on the basis of a hydraulic cylinder that is controlled by a 4/3 directional valve at
different system pressures.
Project 17:
Notes on detailed technical information about the hydraulic accumulator:

Accumulator safety valve
Diaphragm-type accumulator
Project definition
In a fixture, a tool is to be moved by means of a hydraulic cylinder into and out of the machining
area. In the event of a hydraulic pump failure, the tool most be extended by means of stored
energy.
Since the customer has never utilized an accumulator before, he would like to know whether he
selected the correct accumulator size, i.e. whether the usable accumulator volume is sufficient.
He uses various system pressures and therefore requires documents that describe the usable
volume. In addition, he is interested in test documents such as a table that shows the various
system pressures and the usable oil volume.
17
Fig. 17.1 Practical example: Bladder and diaphragm-type accumulators with accumulator safety block
Project 17:
Project tasks
technology
• Analyzing the technical data sheet of a hydraulic accumulator (specialist qualification)
Project steps
with the customer.
• Planning: Planning and organizing the customer order by, among others, working out
the topic of hydraulic accumulators (The Hydraulic Trainer - Basic Principles)
and the technical data sheet RE 50130/Accumulator safety block.
• Executing: Set-up of the hydraulic control on the training system and calculation of
the usable oil volume at different, given system pressures, and of the pre-
charge pressure.
17
Project 17:
Item 0.2
Item 1.0
Item 1.4
Lead-
sealed
Item 1.1
Item 0.1
Item 1.3 Measuring

glass
Item 1.2
Power unit limit
17
Fig. 17.2 Hydraulic circuit diagram: Hydraulic accumulator

Project 17:
Circulation
-Single-rod cylinder- 17
Project 17:
1.0 1 ZY 1.3

1.1 1 DW 13E


1.3 1 DS 2.1
1 bar
Accumulator safety block

1.4 1 DZ 3.2
for diaphragm-type accumulator
0.1 - 0.2 2
and quick release coupling DZ 1.4 17
without check valve
hose with quick release coupling

1 DZ 25
with check valve
Hose VSK 1
Project 17:
Measuring glass
Connection block
D Note:
Note:
Notes
17
Project 17:
Safety notes

Warning danger to life.
Caution
depressurized.

of hoses.
Observe direction of installation of check valve Item 1.3. Hand lever (P) on
the accumulator safety valve open, rotary knob (T) of the discharge valve
Warning closed.

Make sure that all ports - in this case also minimess lines - pipes and hoses 17
Warning caps. Leakage oil can drop through open ports on the floor and cause a risk
of slipping.
Project 17:
Task 1 Check the nitrogen pre-charge pressure:

3. Set the system pressure to 40 bar on pressure relief valve Item 1.2. The system pressure
can also be read off from pressure gauge M2. Close the shut-off valve (hand lever P) of ac-
cumulator safety valve Item 1.4. The system pressure is now isolated in the accumulator.
Switch the hydraulic pump off. Carefully open the discharge valve (rotary knob T) on the
accumulator safety valve until the pressure shown on M2 slowly falls. The pressure slowly
decompresses down to the gas charging pressure and then rapidly falls to 0 bar. The pres-
sure value at which the pressure starts to fall quickly is the nitrogen charging pressure.
Task 2 Usable accumulator oil volume:
4. Switch the hydraulic pump on again. Open the hand lever (P) on the accumulator safety
block, close the discharge valve by means of the rotary knob (T).
Set the system pressure on pressure relief valve Item 1.2 to 10 bar. Extend and retract
cylinder Item 1.0 by operating push-buttons S4 and S2 and provide markings on the base
plate at the end positions (the stroke should be 200 mm). Retract cylinder Item 1.0 to the
basic position.
5. Switch the hydraulic pump off.
Extend and retract cylinder Item 1.0 by operating push-buttons S4 and S2 until the piston
does no longer move. The required oil volume is now taken from the hydraulic accumulator.
Note the number of strokes (extending and retracting), including the residual stroke during
extending and retracting, and enter the values in Table 17.2.
6. Switch the hydraulic pump on and set the system pressure on pressure relief valve Item 1.2 to
15 bar.
Repeat the experiment set-up as described under point 5 and enter the measurement re-
sults in Table 17.2. Repeat the experiment with the accumulator charging pressures given
in Table 17.2.
hydraulic pump off! No pressure gauge may indicate a pressure! Unload the
Caution hydraulic accumulator via the accumulator safety valve (rotary knob T).
Evaluating
Calculation of the useful volume of the accumulator
On the basis of the total number of strokes of the hydraulic cylinder the useful volume of the
hydraulic accumulator can be calculated according to the following formula. 17
( a • s + x ) + (d )
d K2 • π
V =
4 K
2
- d St2 •
π
4
(
• e • s • z ) dm3 
 
V = useful volume of the hydraulic accumulator

dK = bore of the hydraulic cylinder (25 mm)
dSt = piston rod diameter of the hydraulic cylinder (16 mm)
S = stroke length of the hydraulic cylinder (200 mm)
a = number of complete extending strokes
e = number of complete retracting strokes
x = residual stroke of the extending hydraulic cylinder
z = residual stroke of the retracting hydraulic cylinder
Project 17:
Hydraulic accumulator 10 Bosch Rexroth AG I RE 00845/04.07
Cylinder comes to a halt while extending
Cylinder comes to a halt while retracting

z=s-y
Fig. 17.6 Residual stroke of the hydraulic cylinder
After having calculated the useful volume, prepare a characteristic curve (Diagram 17.1)
Measured values Hydraulic accumulator pre-charge pressue p0 = 10 bar

Hydraulic No. of complete strokes Residual stroke in mm Useful
accumulator volume
Extending a Retracting e Retracting x Extending z
charging pressure V in dm3
M2 p in bar
10 0 0 0 0 0
15 1 1 195 0 0.25
20 2 2 95 0 0.36
25 3 3 0 50 0.42
30 3 3 10 0 0.47
35 3 3 100 0 0.52
40 3 3 160 0 0.55
45 4 3 0 0 0.57
Table 17.2 Useful volume of hydraulic accumulator 17

Project 17:
0,6
0,5
Useful volume V in l
0,4
0,3
0,2
0,1
0
0 10 20 30 40 50
Charging pressure M2 p in bar
Diagram 17.1 re Table 17.2
• Due to the compressibility of the filled in gas, diaphragm-type accumulators can be used as
energy storage.
• The oil volume stored in the hydraulic accumulator depends on the accumulator size, the
nitrogen pre-charge pressure and the system pressure.
• The effective useful volume of the hydraulic accumulator depends on the accumulator size,
the nitrogen pre-charge pressure and the pressure difference between minimum and maxi-
mum working pressure.
• If the system pressure falls below the nitrogen pre-charge pressure, the hydraulic accumula-
tor is completely unloaded.
• The hydraulic accumulator is charged when the system pressure is higher than the nitrogen
pre-charge pressure. 17
Project 17:
Notes
17
Project 18:
Regenerative circuit Bosch Rexroth AG I RE 00845/04.07
Project 18: Regenerative circuit

If in a hydraulic control the extension velocity of a hydraulic cylinder (area ratio 2 : 1) is to be

doubled, a regenerative circuit (recovery of the returning oil) can be employed. In a regenerative
circuit, the extending piston is pre-loaded. The working pressure is permanently applied to both
areas (piston and annulus piston area) of the hydraulic cylinder when the piston is extending.
The advantages of this control are the smaller pump displacement and the approximately identi-
cal extension and retraction velocity of the hydraulic cylinder. A disadvantages is the force loss
during extending, because the force of the piston rod side counteracts the piston side.
In the following Project 18 knowledge can be imparted of how to increase the velocity without
enlarging the pump displacement.
In the project order the trainee is to work out the behavior of a hydraulic cylinder, when the oil
volume of the piston rod side is directly fed to the piston side during extending. On the basis
of a practical experiment set-up on the training system, the trainee is to gain the following
knowledge:
• For a single-rod cylinder the area ratio can be calculated on the basis of the piston area and
the annulus piston area.
• In the case of a regenerative circuit, the volume of the piston rod side is directly fed to the
piston side.
• With a regenerative circuit, the required pump displacement can be reduced.
With the help of the control set up on the training system the trainee is to get familiar with the
typical behavior of a regenerative circuit. The hydraulic cylinder is controlled by a 4/2 directional
valve. During extending, the oil volume of the piston rod side is directly fed to the piston side.
The piston velocity is to be adjustable by means of a flow control valve.
Notes on detailed technical information about the regenerative circuit:

• Technical data sheet RE 48005/RE 48015
Velocity controls for on/off directional valves
18
Project 18:
Project definition
On a machine tool the velocity of a feed cylinder is to be increased and thus the cycle time of
the system shortened without changing the pump flow. The advance velocity (extending time
of the hydraulic cylinder) is to be adjustable independently of the load.
In order that the customer can understand the circuit structure of the control, he requires the
associated documentation such as the hydraulic circuit diagram with parts list. He also requires
a table of the travel times of the hydraulic cylinder with different flow control settings.
Moreover, the customer wants to know which effect the increase in the cycle time has on the
advance force.
Fig. 18.1 Practical example: Control block with hydraulic components such as directional, pressure and flow control
valve
18
Project tasks
technology
• Analyzing the technical data sheet for velocity controls (specialist qualification)
Project 18:
Project steps
with the customer.
• Planning: Planning and organizing the customer order by, among others, working out
the technical data sheets relating to velocity controls.
• Executing: Set-up of the hydraulic control on the training system. Preparation of a table
of travel times and velocities and a comparison of pros and cons.
Notes
18
Project 18:
Item 1.0
Item 0.2 Item 0.3
Item 1.1
Item 1.2
Item 0.1 Measuring

glass
Item 1.3
Power unit limit
18
Fig. 18.2 Hydraulic circuit diagram: Regenerative circuit

Project 18:
Extension
18
Project 18:
1.0 1 ZY 1

1.1 1 valve, the cracking pressure can be DW 3E
2-way flow control valve, adjusta-

ble, for one direction of flow, lar-
1.2 1 gely independent of viscosity and DF 3
pressure differential, adjustable,


without check valve

3 DZ 25
with check valve
Hose VSK 1
18
Project 18:
Measuring glass
Connection block
D Note:
Note:
Notes
18
Project 18:
Safety notes

Caution is switched off. Check on the system pressure gauge that the system is
depressurized.

1. Mount the components required according to parts list Table 18.1 in a clearly arranged form
on the training system according to the prepared circuit diagram.
of hoses.
use hydraulic hoses DZ 25.1. Hand-tighten the pressure gauge measuring lines at the rel-
evant minimess connection of the hydraulic hose.
Warning
2. Switch the hydraulic pump on and inspect the set up control for leakage. No pressure gauge 18
3. Set flow control valve Item 1.2 to scale position 1.0.
Extend hydraulic cylinder Item 1.0 by operating push-button S1. Measure the extension time;
enter the extension time and pressures M3 and M2 at the end position of hydraulic cylinder
Item 1.0 in Table 18.2.
Project 18:
Operate push-button S1, which causes the piston of hydraulic cylinder Item 1.0 to retract again;
enter the retraction time of the piston and pressures M3 and M2 at the end position of
hydraulic cylinder Item 1.0 in Table 18.2.
4. Set flow control valve Item 1.2 successively to scale positions 1.2, 1.4, 1.6, 1.8 and 2.0
and enter the individual measuring results in Table 18.2 as described under point 3.
5. Enter the calculated traversing velocities of the feed cylinder as characteristic curve in
Diagram 18.1.
After having completed practical work on the training system, switch the
Caution
Scale position Cylinder piston M2 M3 Travel Velocity

Flow control p in bar p in bar time v in mm/s
valve t in s
Extended 50 50 19 10.5
1.0
Retracted 0 50 28 7.1
Extended 50 50 16.5 12.1
1.2
Retracted 0 50 20.7 9.7
Extended 50 50 11.6 17.2
1.4
Retracted 0 50 14.7 13.6
Extended 50 50 8.6 23.3
1.6
Retracted 0 50 10.5 19.0
Extended 50 50 6.8 29.4
1.8
Retracted 0 50 8.4 23.8
Extended 50 50 5.3 37.7
2.0
Retracted 0 50 6.5 30.8
Table 18.2 Measured values of regenerative circuit

6. Calculation of the area ratio of single rod cylinder ZY1 used in the regenerative circuit.
Required dimensions of the hydraulic cylinder:

Piston diameter D = 2.5 cm
Piston rod diameter d = 1.6 cm
Solution: 18
D2 • π
A1 = = 4,9 cm2
4
A2 =
( )
D2 - d 2 • π
= 2,9 cm2
4
4, 9 cm2 : 2,9 cm2 = 1,689
Area ratio A1 : A2 = 1.69 : 1

Project 18:
Regenerative circuit 10 Bosch Rexroth AG I RE 00845/04.07
Cylinder in Cylinder out
3,5
3
Velocity v in cm/s
2,5
1,5
0,5
0
0 0,5 1 1,5 2 2,5
Position of flow control valve DF3
Diagram 18.1 re Table 18.2
As mentioned in the introduction, a disadvantage of the regenerative circuit is that piston force
FK counteracts annulus piston force FR, i.e. the remaining useful force is the force of piston rod
area FST.
For information, please find below notes on pressures and flows for a single-rod cylinder con-
trolled in a regenerative circuit, including the required calculation formula.
Single-rod cylinder
A special type of circuit for a single-rod cylinder is the regenerative circuit.

In this circuit, the cylinder is extended when the directional valve takes the spool position …
and the oil displaced from the piston rod chamber is fed together with the pump displacement
to the piston chamber.
Note:
When neglecting the pressure drop in the lines and the directional valve, the pressure is
identical on both sides of the cylinder.
The cylinder force during extending consequently becomes

Fext = p  AK – p  AR Fext = p  ASt 18
= p  (AK – AR )
and the piston velocity with pump displacement qP
AK AR ASt
qP qP
Vext = =
AK – AR ASt
because the pump flow must only fill the space that corresponds to the piston rod area.
Project 18:
For retracting of the cylinder with spool position … of the directional valve, the force is calcu-
lated as follows:
Fretr = pB  AR – pA  AK
the retraction velocity

q
Vretr = P
AR
Thus, it becomes obvious that with an area ratio of
AK
ϕ= =2
AR
the extension and retraction velocities become identical.
qP qP qP
Vext = = = = Vretr
AK – AR 2  AR – AR AR
The following is valid:
Vext qP  AR AR
= =
Vretr (AK – AR )  qP AK – AR
where
AK
ϕ= → AK = ϕ  AR
AR
consequently
Vext AR AR 1
= = =
Vretr ϕ  AR – AR AR  (ϕ – 1) ϕ –1
Vext 1
=
Vretr ϕ –1
18
Project 18:
AK AR ASt
F1 (out)
F2 (back)
pA
∆pmin
qB
qA
qtotal = qB + qP
qA
qP
• The area ratio of a single-rod cylinder can be calculated on the basis of the piston area and
the annulus piston area.
18
• In a regenerative circuit, the volume displaced on the piston rod side while the piston is
extending is fed to the piston side.
• In a regenerative circuit, the required pump displacement can be reduced.
Project 19:
Rapid speed / creep speed control Bosch Rexroth AG I RE 00845/04.07
Project 19: Rapid speed/creep speed control

A rapid speed/creep speed control can be used in a hydraulic circuit to control the advance
velocity of a hydraulic cylinder independently of the load.
In the following Project 19 you can impart knowledge of a velocity control. Here, a flow control
valve is cut in and out on the piston rod side of the extending hydraulic cylinder. With this veloc-
ity control, pressure intensification occurs on the piston rod side.
In the project order the trainee is to work out the behavior of a hydraulic cylinder when a flow
control valve is activated by means of a directional valve while the cylinder is extending. On the
basis of a practice-oriented experiment set-up on the training system the trainee is to gain the
following knowledge:
• With a rapid speed advance control the hydraulic cylinder extends at maximum velocity
without any throttling.
• The extension velocity can be varied independently of the load by means of an electrical
limit switch by cutting in a flow control valve.
• The return stroke of the hydraulic cylinder is performed at maximum velocity.
• Pressure intensification occurs when a flow control valve is activated on the piston rod
side.
On basis of the control set up on the training system the trainee is to understand the typical
behavior of a single-rod cylinder in such a rapid speed advance control. A 4/2 directional valve
is used to control a hydraulic cylinder. With an additional 4/2 directional valve the oil volume
of the piston rod side is fed via a flow control valve to the tank. The return stroke is performed
at the maximum velocity possible.
Notes on detailed technical information on the rapid speed advance circuit:

Velocity controls for on/off directional valves
19
Project 19:
Project definition
At the end of a production line, workpieces are to be lifted from a conveyor belt and put down
on a pallet. The lifting movement is to be performed using a hydraulic cylinder. To achieve
shorter cycle times, fast motion sequences are required. Due to changing workpiece weights,
the residual stroke is to be performed independently of loads at strongly reduced velocity.
The return stroke is to be performed as fast as possible.
For his documentation, the customer wishes to obtain a travel/time diagram in addition to a
hydraulic circuit diagram and a parts list.
Fig. 19.1 Practical example: Production line
Project tasks
19
technology
• Analyzing the technical data sheet of velocity controls (specialist qualification)
Project 19:
Project steps
with the customer.
• Planning: Planning and organizing the customer order, by, among others, examining
the technical data sheet for velocity controls.
• Executing: Set-up of the hydraulic control on the training system and preparation of a
travel/time diagram.
Notes
19
Project 19:
Item 0.2
Item 1.0
Item 0.3
Item 1.4
Item 1.2
Item 1.1
Item 0.1 Measuring

glass
Item 1.3
Power unit limit
19
Fig. 19.2 Hydraulic circuit diagram: Rapid speed advance circuit

Project 19:
red red
black black
blue blue
Extension Rapid speed

-Hydraulic cylinder-
Note on sensor B1/B2

19
Blue – red – black = plug colors
Project 19:
1.0 1 ZY 1.3

1.1 - 1.2 2 DW 3E

2-flow control valve, adjustable, for

one direction of flow, largely inde-
1.4 1 pendent of viscostiy and pressure DF 3
differential, with by-pass check
valve

without check valve

3 DZ 25
with check valve
Hose VSK 1
red
black
B1/B2 2 Limit switch, inductive DE 2
blue
Table 19.1 Parts list for hydraulic circuit diagram Fig. 19.2 19
Project 19:
Measuring glass
Connection block
D Note:
Note:
Notes
19
Project 19:
Safety notes

Warning
danger to life.
Caution
depressurized.

of hoses.
Warning
of slipping.
Position limit switches B1 and B2 so that the change-over takes place in the middle of the
total stroke.
19
Project 19:
3. Set flow control valve Item 1.4 to scale positio. 1.0.

Extend hydraulic cylinder Item 1.0 by actuating push-button S2. 4/2 directional valve Item
1.2 is operated by limit switch B1 and the flow is fed to the tank via flow control valve Item
1.4. When limit switch B2 is reached, 4/2 directional valves Items 1.1 and 1.2 are switched
again to the rest position and the cylinder retracts. Enter the retraction time of the piston
and the pressures M3 and M2 in Table 19.2. Enter the extension time over the entire stroke
and pressures M2 and M3 (during operation at reduced velocity) in Table 19.2.
Release push-button S2. This causes the piston of hydraulic cylinder Item 1.0 to retract
again. Enter the retraction time of the piston and pressures M3 and M2 in Table 19.2.
4. Set flow control valve Item 1.4 to scale position 1.5 and enter the measuring results in
Table 19.2 as described under point 3.
pump off! No pressure gauge may indicate a pressure! Open the throttle
Caution check valve.
Measured values
Flow control valve

Hydraulic cylinder scale position
1.0 1.5
M3 p bar 7 6
Rapid speed M2 p bar 9 9
Time t s <1 <1
M3 p bar 50 50
Advance M2 p bar 80 80
Time t s 23 12
M3 p bar 19 19
Return stroke M2 p bar 38 38
Time t s <1 <1
Table 19.2 Measured values from the project order
The values were measured at an oil temperature of approx. 20 °C. 19

Project 19:
Rapid speed / creep speed control 10 Bosch Rexroth AG I RE 00845/04.07
For information, please find below the graphical representation of the piston velocity of the
single-rod cylinder.
Table 19.3 shows a function sequence chart commonly used in practice.
Travel
t
Rapid speed Advance Return stroke Time
Diagram 19.1 Travel/time diagram
Item 1.1 Item 1.2

→
→ 1 0
Rapid speed lifting
→
1 1
Advance lifting
←
← 0 0
Lowering
Table 19.3 Function chart Legend: 0 not operated
1 operated
• With a rapid speed advance circuit, the piston of a hydraulic cylinder extends with maximum
pump flow without throttling. 19
• With the help of an electrical limit switch, the extension velocity can be adjusted - controlled
by a directional valve - independently of the load by means of a flow control valve.
• The return stroke of the piston is performed with the maximum pump flow.
• When the flow is throttled at the piston rod side, pressure intensification occurs during
extending.
Project 20:
Valve circulation control Bosch Rexroth AG I RE 00845/04.07
Project 20: Valve circulation control

A circulation control for a fixed displacement pump can be used to prevent the hydraulic fluid
from excessive overheating. Overheating would not only lead to premature wear of the hydrau-
lic fluid, but can also result in lubrication problems. If the hydraulic pump displaces hydraulic
fluid via the pressure relief valve while the hydraulic cylinder is at a standstill, more energy is
consumed.
In the following Project 20 you can impart knowledge of a valve circulation control.
In the project order the trainee is to work out the possibility of directing the pump flow via a
circulation valve. In a practice-oriented experiment set-up on the training system, the following
knowledge is to be gained through the project task:
• When the pump flow circulates, only a small pressure builds up in the hydraulic pump.
• The circulation control reduces wear of the hydraulic pump.
• Circulation helps to save electric power.
• When the hydraulic fluid circulates, the fluid is not excessively heated and its service life
extended.
Based on the control set up on the training system the trainee is to implement a circuit for
circulating the pump displacement. A hydraulic cylinder is to be controlled by means of a 4/3
directional valve with circulation position. When no hydraulic energy is required, the directional
valve is brought to the central position, i.e. to the circulation position.
In a further control circuit, the hydraulic cylinder is to be controlled by means of a 4/3 directional
valve with blocked central position. However, in this case, the system pressure can only build
up, if the flow previously discharged via a 4/2 directional valve is directed to the 4/3 directional
valve.
Notes on detailed technical information about the pump control:

Basic principles and components
Fixed displacement pump/external gear pump
20
Project 20:
Project definition
For the assembly of heavy hydraulic control blocks, a scissors lift it used for lifting and lowering
pallets. In order that the hydraulic cylinder can be stopped at any position, a 4/3 directional
valve with blocked central position is used. To spare the hydraulic pump, a solution is to be
provided, with which the pump flow is directed at zero pressure to the tank when the hydraulic
cylinder is not operated.
The customer wishes to obtain several solution proposals and for his documentation, apart from
the hydraulic circuit diagram and the parts list, a comparison of the proposed solutions.
Fig. 20.1 Practical example: Scissors lift
Project tasks
technology
• Analyzing the technical data sheet of fixed displacement pump (specialist qualification)
20
Project 20:
Project steps
with the customer.
• Planning: Planning and organizing the customer order, among others, through dealing
with the technical data sheet for the 4/3 directional valve, RE 23178, and
in particular with the section of symbols.
• Executing: Set-up of the hydraulic control on the training system. Acquisition of mea-
sured values and preparation of a comparison table.
Notes
20
Project 20:
Item 1.0
Item 0.2 Item 0.3
Item 1.1
Item 0.1 Measuring

glass
Item 1.4
Power unit limit
20
Fig. 20.2 Hydraulic circuit diagram: Pressureless circulation using a 4/3 directional valve
Project 20:
Circulation
Extension Retraction
20
Fig. 20.3 Wiring diagram for hdraulic circuit diagram Fig. 20.2
Project 20:
Item 1.0
Item 0.2 Item 0.3
Item 1.1
Item 1.3
Item 0.1 Measuring

glass
Item 1.4
Power unit limit
20
Fig. 20.4 Hydraulic circuit diagram: Pressureless circulation using an additional 4/2 directional valve
Project 20:
Circulation
Retraction Extension Circulation
20
Project 20:
1.0 1 ZY 1.3

1.1 1 DW 4E
and central position P - T, A, B

1.2 1 DW 13E

1.3 1 DW 3E


without check valve

3 DZ 25
with check valve
Hose VSK 1
Table 20.1 Parts list for hydraulic circuit diagram Fig. 20.2 and 20.4
20
Project 20:
Measuring glass
Connection block
D Note:
Note:
Notes
20
Project 20:
Valve circulation control 10 Bosch Rexroth AG I RE 00845/04.07
Measuring glass
Connection block
D Note:
Note:
Notes
20
Project 20:
Safety notes

depressurized.

of hoses.
Warning
of slipping.
To make clear that in the central position the total amount of fluid flows through 4/3 direc-
tional valve Item 1.1, port T of directional valve Item 1.1 can be connected to the measuring
glass (option).
may indicate a pressure. 20
The system pressure can only be adjusted while the cylinder is at its end position.
Project 20:
Task 1 Flow in central position

4. Hydraulic cylinder Item 1.0 can be traversed with the help of push-buttons S2 and S4 as
described in the project task.
Note pressure M1 in the relevant end position of hydraulic cylinder Item 1.0 while directional
valve Item 1.1 is in its central position.
Caution
Task 2 Circulation
of hoses.
of slipping.
Caution
To provide more clarity that the entire flow is fed directly to the tank via 4/2 directional valve
Item 1.3 when directional valves Item 1.2 and Item 1.3 are not operated, port T of directional
valve Item 1.3 can be connected directly to the measuring glass (option).
The system pressure can only be adjusted while the cylinder is at its end position.
7. Hydraulic cylinder Item 1.0 can be controlled via directional valve Item 1.2 using push-but-
tons S2 and S4. To this end, directional valve Item 1.3 must be operated before by means
of push-button S3.
Measure and note pressure M1 in the relevant end position of hydraulic cylinder Item 1.0
(S2, S4 operated) while directional valve Item 1.3 is not operated.
pump off! No pressure gauge may indicate a pressure! Open the throttle
Caution
check valve.
20
Project 20:
Measured values
Task 1 Task 2
M1 p in bar
p in bar p in bar
Circulation 0 8 0 8
a 50 a 50
Cylinder end position
b 50 b 50
Table 20.2 Actual pressure values with different valve settings

• When the pump displacement is circulated, only a small pressure builds up in the hydraulic
pump.
• The circulation circuit reduces wear of the hydraulic pump.
• Circulation saves electric power.
• Due to the circulation circuit, hydraulic fluid does not heat up excessively, and the service
life of the fluid is extended.
20
Project 20:
Notes
20
Project 21:
Commissioning, troubleshooting, maintenance Bosch Rexroth AG I RE 00845/04.07
Project 21: Commissioning, inspection, maintenance, troubleshooting, repair

A long service life and functional reliability of hydraulic systems and their components depend
on proper handling. The observation of system-specific installation and operating notes of
the supplier guarantee trouble-free operation. Important information can also be found in the
technical data sheets for components, power units, and their accessories.
Not only for the engineering, but also for everyday handling of modern hydraulic systems,
regulations and safety rules must be observed.
The main task of responsible persons (fitters, but also operators) is to keep systems in opera-
tion. A precondition for meeting this requirement cost-efficiently is profound knowledge. The
persons involved must be able to read and interpret not only hydraulic circuit diagrams, but also
electrical circuit diagrams. Troubleshooting in modern controls requires the skillful handling of
measuring and diagnosis devices such as pressure gauges, multi-meters, flowmeters, etc.
Repair and servicing staff must consider the entire system in examinations. Here, condition
monitoring and the determination of machine operating schedules form the basis for active
maintenance.
According to DIN 31051 maintenance includes the sum of all measures for maintaining and
restoring technical systems.
Repairs are measures for restoring the desired condition of a system.
Commissioning is the provision of an operable system.
Maintenance includes measures for maintaining the desired condition of a system.
Inspection is an assessment of the actual condition of a system.
Repairs, commissioning, maintenance, and inspections may only be carried out by trained
and instructed personnel having a specific knowledge of hydraulics.
A specialist is, who, due to his/her technical training and experience, has
sufficient knowledge and is sufficiently familiar with relevant regulations
that he/she:
• can assess the work assigned to him/her,
• can recognize possible hazards,
• can take the necessary measures to eliminate risks,
• has the required knowledge with regard to repairs and assembly.
Environmental protection also plays an important role, especially for maintenance person-
nel. For example, oil-soaked cloths and paper must be properly disposed of.
In the project order the trainee is to work out commissioning of a hydraulic control and the
procedure for component adjustments. On the basis of a practice-oriented experiment set-up,
the following knowledge is to be gained in the course of the project task:
• For commissioning, system-related machine documents such as circuit diagrams, parts list,
function charts, system parameters and operating instructions are required.
• Contamination is by far the most common cause of faults in hydraulic systems.
• Improper mounting can significantly reduce the service life of hydraulic components and
leads to costly downtimes. 21
Project 21:
• An indispensable tool for targeted fault analyses is the understanding of the function and
operating principle of all hydraulic components in the system.
• Target-oriented communication simplifies the analysis of faults.
• Preventive maintenance and inspection reduce failures of systems and prolong the service
life of components.
On the basis of the complex control set up on the training stand, the trainee is to work out commis-
sioning of an electrohydraulic control and the order of adjusting the individual components.
Controlled by a 4/3 directional valve, a hydraulic cylinder is to lift a load. The lifting time is to be
adjusted by means of a throttle and take approx. 5 s. A hydraulic motor (set to 1.5 l/min), which
is to rotate independently of the load by using a flow control valve, is hydraulically pre-loaded
by a 4/2 directional valve connected in parallel. Controlled by an electrical push-button, first
the cylinder is to lift the load, and then the hydraulic motor is to rotate uniformly.
Notes on detailed technical information about the project order:

Basic principles and components
• Technical data sheets for all hydraulic components listed such as directional, pressure,
and flow control valves
• Technical data sheet RE 07100-B
Hydraulic cylinders/operating instructions (exemplarily for notes on: commissioning, inspec-
tion, maintenance, repair)
• General product information on hydraulic products
Technical data sheet RE 07008
21
Project 21:
Project definition
On a machine tool, a workpiece is to be machined by a tool, which is powered by a hydraulic

motor. Before being machined, the workpiece is to be lifted by a lifting cylinder to the machin-
ing position.
The customer wishes to obtain the required machine documents such as hydraulic and electri-
cal circuit diagrams with parts lists, system parameters and commissioning instructions such
as the order of adjustment of hydraulic components for documentation purposes. To be able to
advise the electrician, which solenoids are to be switched for the individual process sequences,
he requires a simple diagram showing the function sequence.
In addition, he wishes to obtain notes on preventive maintenance and inspection.
A flow chart is to provide information about assumed faults (hydraulic motor does not rotate).
Fig. 21.1 Practical example: Machine tool control (not project-related)

Principle structure of a complex machine tool with components covering all technologies
Project tasks
technology
• Analyzing the required technical documents (specialist qualification)
21
Project 21:
Project steps
with the customer.
• Planning: Planning and organizing the customer order, among others, by dealing
intensively with technical data sheets.
• Executing: Set-up of the hydraulic control on the training system. Acquisition of mea-
sured values and preparation of the technical documentation requested by
the customer.
Notes
21
Project 21:
Notes
21
Project 21:
Item 1.0
Item 0.4
Item 2.0
Item 0.2 Item 0.3

Item 2.2
Item 2.3
Set to
1.5 l/min
Set to
Item 1.3 text = 5 sec
Item 1.1 Item 2.1
Item 0.1 Measuring

glass
Item 1.2
Power unit limit
Fig. 21.2 Hydraulic circuit diagram: Machine tool control 21

Project 21:
Stop
Extension Retraction Rotation

Lifting Lowering
-Single-rod cylinder- -Hydraulic motor-
Fig. 21.3 Wiring diagram for the machine control 21

Project 21:
Double-acting cylinder with single-

1.0 1
sided piston rod with load

1.1 1 DW 13E


2.0 3 external leakage oil line and two DM 8N

2.1 1 DW 3E
2-way flow control valve, adjusta-

ble, for one direction of flow, lar-
2.2 3 gely independent of viscosity and DF 3
pressure differential, adjustable,

without check valve

4 DZ 25.1
with check valve
hose VSK 1
21
Project 21:
Measuring glass
Connection block
D Note:
Note:
21
Project 21:
Commissioning, troubleshooting, maintenance 10 Bosch Rexroth AG I RE 00845/04.07
Safety notes

depressurized.

of hoses.
of slipping.
21
Project 21:
Commissioning: Lifting cylinder

3. Activate 4/3 directional valve Item 1.1 by means of electrical push-buttons S2 (extending/lift-
ing) and S4 (retracting/lowering) to traverse hydraulic cylinder Item 1.0. The lifting velocity
of approx. 5 s is set on throttle valve Item 1.3.
Measure pressure M1, M2 and M3 during operation of the lifting cylinder and enter the
values in system parameter sheet Table 21.2.
Commissioning: Hydraulic motor
4. Upon the activation of 4/2 directional valve Item 2.1 by means of electrical push-button S3
hydraulic motor Item 2.0 rotates clockwise.
While the hydraulic motor is rotating, adjust flow control valve Item 2.2 so that a flow of
approx. 1.5 l/min can be measured by means of the measuring glass. After having adjusted
the speed of the hydraulic motor while the latter was rotating, set pressure relief valve Item
2.3 to a hydraulic pre-load pressure of 20 bar.
Acquire pressures M1 and M4 while the hydraulic motor is rotating and enter the values in
system parameter sheet Table 21.2.
For system-inherent reasons, the motor only rotates clockwise!
Measured values
Actuator Function Measuring point Value in bar
M1 48
Lifting cylinder Lifting M2 0
M3 5
M1 48
Lifting cylinder Lowering M2 47
M3 30
M1 48
Hydraulic motor Rotating
M4 20
Table 21.2 System parameters of machine tool control

21
Project 21:
For a simple representation of the function sequence of an electrohydraulic control, function

charts as shown below are used in practice.
Travel/increment or travel/time diagrams can be used additionally for representing movements
of more complex controls.
Valve solenoid Y1.a Y1.b Y2
Lifting 1 0 0
Lifting cylinder Lowering 0 1 0
Holding 0 0 0
Rotating 0 0 1
Hydraulic
motor
Stop 0 0 0
Table 21.3 Function sequence/machine tool control Legend: 1 Valve spool energized
0 Valve spool not energized
21
Project 21:
Machine tool control

Example of fault: Hydraulic motor/machining motor does not rotate
Process • The machine operator loads the workpieces at a defined position.

sequence • The machine operator closes the door to the working range of the machine tool, with a check
made by sensors to guarantee compliance with safety regulations.
• After the workpiece position was checked, the operator actuates push-button S2 to lift the
workpiece by means of lifting cylinder Item 1.0 to the machining position (on sight). Lifting
time text in 5 s.
• Machining of the workpiece is accomplished with hydraulic motor Item 2.0 (rotating clock-
wise). To this end, the machine operator actuates push-button S3 (on sight).
Constant, load-independent rotating of the hydraulic motor by means of flow control valve
Item 2.2 which is set to qV = 1.5 l/min and pre-loading valve Item 2.3 set to 20 bar.
• After completion of the machining process, the machine operator stops the hydraulic motor
by actuating push-button S5 and then moves the workpiece to the basic position for the
hydraulic cylinder by operating push-button S4.
• Chips produced during machining are transported from the operating range of the machine
tool by a chip conveyor.
Sequence chart Workpiece correctly no

→→→ Check loading
for trouble- put down?
shooting ↓
yes →→→ Are faults/fault messages present such as: filter, oil level, temperature?
↓
System pressure no Is the pump run- no
→→→ →→→ Check motor
available? ning?
↓
yes
↓
↓ Pump pressure no Check pump con-
yes →→→
↓ available? troller
no Check and, if
Lifting cylinder Item →→→ required, correct
1.0 at end position?
position
↓
yes
↓
Valve Y2 no Is the valve spool yes Check by activating
activated →→→ jammed? →→→ emergency stop
↓
yes
↓
Flow control valve no

→→→ Check settings
Item 2.2 open?
Note:
↓
yes Possibly mechanical fault of the
↓
hydraulic motor?
↑
↑
Load pressure too

high?
yes
→→→
Check DB valve
Item 2.3/20 bar 21
Project 21:
Questions
Question 1:
Name the systematic working steps during commissioning and for adjusting the electrohydraulic
control.
• Check the electrical control for function
• Check the set-up of the hydraulic control
• Set the pressure relief valves to minimum pressure/spring unloaded
• Adjust flow control valves to adequate flow
• Switch the hydraulic pump on/Leakages?/Direction of motor rotation OK?/No excessive pressures
in the system?
• Set the system pressure to 50 bar plus one turn/DB valve Item 1.2
• Check the LIFTING/LOWERING function of the lifting cylinder/push-buttons S4 - S2
• Adjust the lifting time to 5 s/throttle Item 1.3
• Measure the operating pressures and enter them in the system parameter table
• Check the rotating function of the hydraulic motor.
• Adjust the rotary speed/close flow control valve/measure the flow by means of the measur-
ing glass/1.5 l/min.
• Set the pre-loading valve/DB valve Item 2.2 to 20 bar.
• Enter the machining pressure of the hydraulic motor in the system parameter table
Question 2:
Which 6 machine documents are indispensable for electrohydraulic systems?
• Hydraulic circuit diagram/with parts list
• Wiring diagram
• Function chart
• Operating instructions
• Machine key data/system parameters
• Measurement report of initial commissioning
Question 3:
Why should a hydraulic system be flushed prior to initial commissioning?
• The flushing process removes dirt particles from the individual components such as pipes. It
must be ensured that the permissible maximum cleanliness class to ISO 4406 KL. 21/18/15
is not exceeded for the entire system.
Question 4:
How should the hydraulic fluid be disposed of?
• The fluids must be disposed off in accordance with environmental regulations, i.e. the
contaminated fluid must be made available to approved recycling companies in suitable
containers for disposal. The notes on waste disposal given in the safety data sheet of the
hydraulic fluid must be observed.
Question 5:
Into which areas is maintenance subdivided?
• DIN 31051 classifies maintenance in the following areas:
Maintenance - Inspection - Repair
Question 6:
Which work (measures) must be carried out during an inspection?
• Check of set operating values
• Visual inspection of the complete system for external leakage, wear, damage, ...
• Check of hydraulic fluid for fluid level and appearance
21
Project 21:
Question 7:
Which work (measures) are to be carried out during maintenance?
• Changing the filter inserts
• Checking or changing the hydraulic fluid
• Cleaning the inside of the tank, if required
• Replacing hydraulic hoses at given intervals
Question 8:
Which of the following faults are causes for malfunction that can be traced back to improper
installation and which faults occur on running systems?
• Incorrect directional valve installed
• Electric motor incorrectly connected
• Contaminated hydraulic fluid
• Hydraulic hose improperly connected
• Wear of hydraulic seals
• Filter clogged
• Cable break at the connection of the solenoid
• Pressure switch does not switch
• Hydraulic component does not operate due to a broken spring
• Throttle bore clogged on the pilot part
Improper installation during initial commissioning:

• Incorrect directional valve installed
• Electric motor incorrectly connected
• Hydraulic hose improperly connected
• Pressure switch not set to the correct value
Faults on running systems:

• Contaminated hydraulic fluid
• Wear of seals
• Filter clogged
• Solenoid cable break
• Limit switch does not switch, loose
• Spring broken in hydraulic element, does not work
• Throttle bore clogged
Question 9:
Name a systematic order for the localization and elimination of faults.
• Recognizing faults on the system and their effect
• Analyzing the cause of fault
• Planning of how to eliminate the fault
• Proper elimination of the fault
• Re-commissioning the system
• Documenting the fault and its elimination
21
Project 21:
• For correct commissioning, system-related machine documents are required such as circuit
diagrams, parts list, function charts, system parameters and operating instructions.
• Contamination is the most common cause of faults in hydraulic systems.
• Improper installation can shorten the service life of hydraulic components.
• Preventive maintenance and repair reduce system failures and prolong the service life of
components.
• An important precondition for target-oriented troubleshooting is the knowledge of the func-
tion and the operating principle of all hydraulic components.
21
Project 21:
Notes
21
General product information on RE 07008/02.05 1/32
hydraulic products
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2/32 Bosch Rexroth AG Hydraulics General product information RE 07008
Contents Page
1 Important basic information 4
1.1 Conventions used in this product information 4
1.2 What you need to know about this product information 4
1.3 The contents of this product information 4
2 Scope of delivery and responsibilities 5

2.1 Scope of delivery and responsibilities of Bosch Rexroth 5
2.2 Responsibilities of the plant operator 5
2.3 Liability, guarantee, warranty 6
2.4 Copyright 6
3 Important basic safety instructions 7

3.1 What to do in an emergency 7
3.2 Safety labelling on the hydraulic product 7
3.3 Proper use 7
3.4 Requirements for personnel, duty of care 8
3.5 General ancillary dangers and protective measures
when operating hydraulic products 9
4 Technical data and ambient conditions 11

4.1 Information about pressure fluids 11
4.2 Ambient conditions 11
5 What you need to know about pressure fluids 13

5.1 How to handle pressure fluids safely 13
5.2 Functions and effectiveness 13
5.3 Viscosity 13
5.4 Leakage fluid 14
5.5 Topping up/refilling 14
6 Construction and mode of operation of a hydraulic system 15

6.1 Definitions of terms 15
6.2 Schematic 15
6.3 Safety concept 15
7 Moving hydraulic units/components 16
8 Storage and longer standstills 16

8.1 Hydraulic systems - subsequent bringing into use after storage 16
8.2 Seals, hoses and hose lines 17
RE 07008 General product information Hydraulics Bosch Rexroth AG 3/32
Contents Page
9 Assembly and bringing into first use 18
9.1 Safety advice for assembly and bringing into first use 18
9.2 Before bringing into first use 18
9.3 Bringing into first use, subsequent bringing into use 19
10 Operation 22
11 Trouble-shooting 22
11.1 What to do in the event of a fault 22
11.2 The basic approach to trouble-shooting 22
11.3 Trouble-shooting tables 23
12 Maintenance 24
12.2 Safety during maintenance tasks 24
12.3 Inspection and servicing 25
12.4 Service and storage lives of hose lines 28
12.5 Topping up the pressure fluid 29
12.6 Servicing pressure accumulators 29
12.7 Repair 29
13 General information about hydraulic pressure accumulators 30

13.1 General 30
13.2 Safety devices relating to hydraulic pressure accumulators 30
14 Hydraulic systems 31
14.1 Effects of leaks in the hydraulic system on the machine 31
1 Important basic information Observing the product information and Operating Instructions
Ø reduces downtimes and maintenance costs
Ø increases the service life of your hydraulic products.
1.1 Conventions used in this product
information
The Operating Instructions must be directly accessible to one
Cross-references are printed in italics. of the personnel at the hydraulic product and kept readily avail-
able at all times in a place known to the personnel.
The Operating Instructions must be read and understood and
all its provisions observed by those responsible and by the
DANGER operative personnel. We recommend that a record is made in
writing of the employees’ familiarisation with all the relevant
This symbol indicates a threat of danger which will result parts.
directly in death or very serious injury if not avoided.
The cross-references to directives, standards and regulations
contained in this product information refer to the versions cur-
rent at the time of writing of this product information, which can
WARNING be obtained from the title page of this product information.
This symbol indicates a threat of danger which may result

in death or very serious injury if not avoided. 1.3 The contents of this product information
In addition to this document, product information for Rexroth

hydraulic products normally includes Operating Instructions
CAUTION consisting of three parts:
This symbol indicates possible danger which may lead to Ø Part I, the general Operating Instructions for the relevant
minor or serious injury and/or to material damage. class of products
Ø Part II, the Technical Datasheet
IMPORTANT Ø Part III, the Product- and Application-specific Operating

Instructions.
This symbol indicates additional information.
If you do not have all three parts, please request the missing
1.2 What you need to know about this part from Bosch Rexroth. Only if all the information contained
product information in all parts of the three-part Operating Instructions is observed
can safe operation of Rexroth hydraulic products be ensured.
This product information applies to the following types of Specific cross-references are used to draw your attention to
hydraulic products: information that you can find in the Operating Instructions.
Ø Hydraulic components The Operating Instructions contain detailed information about
Ø Hydraulic power units the product, including
Ø Hydraulic systems. Ø Information about the scope of delivery

Ø Safety instructions
This product information applies exclusively to hydraulic prod- Ø Technical data and operating limits
ucts that are operated with mineral-oil-based pressure fluids, if
the Operating Instructions do not expressly permit the use of Ø Information about bringing into (first) use and maintenance
other pressure fluids. Ø Information about the mode of operation
IMPORTANT Ø Layouts, drawings
As this product information for Rexroth hydraulic products Ø Parts lists if appropriate
applies in a general sense, some of the content may not neces- Ø Information about replacement parts and accessories.
sarily apply to the hydraulic product you have purchased.
However, only by strictly observing this product information
and the Operating Instructions can accidents be prevented
and problem-free operation of your Rexroth hydraulic product
be guaranteed.
2 Scope of delivery and responsibilities Installation of Rexroth hydraulic products in a machine or sys-
tem may increase this value, and if so, the manufacturer of the
machine/system must document this.
2.1 Scope of delivery and responsibilities of At or above 85 dB(A), the plant operator must make suitable
Bosch Rexroth hearing protection available to the personnel.
Rexroth hydraulic products fulfil all safety requirements applica- 2.2.2 Special points concerning the installation of
ble to fluid power systems and their components.
certain products
IMPORTANT A Rexroth hydraulic product is intended above all for installa-
For the scope of delivery and the responsibilities of tion in machines, systems and power units as a part machine
Bosch Rexroth with respect to the product, please refer to the or a component for installation into another machine or system
Product-specific Operating Instructions. and is not a complete machine in the sense of the EU directive.
In addition to the Machinery Directive, still further directives
may apply, such as the Pressure Equipment Directive or the
Explosion Protection Directive.
2.2 Responsibilities of the plant operator A wide range of dangers can arise from the combined actions
of the hydraulic product and the machine or system in which
the hydraulic product is installed. Therefore you must always
CAUTION make sure that the hydraulic product is also suitable without
restriction for the proposed application at the installation loca-
If Rexroth hydraulic products are positioned in the vicinity tion. The interfaces with the overall machine and the operat-
of sources of ignition or strong radiators of heat, protec- ing conditions are also of the greatest importance. We recom-
tion must be put in place that would prevent any escaping mend that the results of the hazard analysis (risk assessment)
pressure fluid from igniting and the hose lines from aging of the overall machine are taken into account in the design of
prematurely. the hydraulic product.
Mineral-oil-based pressure fluid is hazardous to water and The functioning of the hydraulic product is also influenced by
flammable. It may only be used if the relevant safety data- the machine or system in which it is installed.
sheet from the manufacturer is available and all the mea- For this reason, you must also always observe the Operating
sures stipulated therein have been implemented. Instructions of the overall system in which your hydraulic prod-
If there is a risk of fluid leaking from the hydraulic product is installed. It is most important for you to also consider the
uct and contaminating water or the ground, the hydraulic possible use of the hydraulic product in a potentially explosive
product in question must be placed in a suitable collect- atmosphere (see 94/9/EC).
ing trough. In connection with this, the applicable statutory
regulations must be observed. IMPORTANT
You must also observe the EU directives for the use of work Bosch Rexroth points out that, at the time of their first intro-
equipment (Directive 89/391/EC) and the associated individ- duction on to the market, hydraulic products comply with the
ual directives, especially Directive 1999/92/EC for the protection requirements of all relevant EU directives and/or their imple-
from the danger arising from potentially explosive atmospheres mentation into national legislation in Germany. If the scope of
and their implementations in national legislation. The legisla- delivery is intended to be installed in a machine or system, then
tion contains minimum requirements with respect to the making the Machinery Directive applies as appropriate – including the
available by the employer of work equipment and for the use then currently applicable amendments – in that the scope of
of work equipment by employees at work, including the regu- delivery does not necessarily comply with the requirements
lations for operating equipment requiring supervision and the of the Machinery Directive because the scope of delivery is
obligation to produce explosion protection documentation. This intended for installation in a machine or because the scope of
involves, for example, dividing areas endangered by potentially delivery is intended for combination with other machines into a
explosive atmospheres into zones and specifying suitable work machine or a hydraulic system.
equipment and procedures for these areas. The bringing into use of the scope of delivery shall there-
fore not be permitted until the machine or system in which the
scope of delivery is to be installed or of which it represents a
2.2.1 Noise protection
component complies with the requirements of all relevant EU
directives.
The A-weighted equivalent continuous sound power level of
Rexroth hydraulic products can be obtained from the relevant Details of further responsibilities can be found in
Operating Instructions. If no values are documented then it can 3 Important basic safety instructions and in the Operating
be taken that the value is less than 70 dB(A). Instructions.
2.3 Liability, guarantee, warranty
Bosch Rexroth shall not be liable for damages that result from
non-compliance with or disregard of these and other parts of
the Operating Instructions.
Unauthorised tampering shall render the warranty null and void.
Bosch Rexroth shall only be liable if the scope of delivery was
shown to be defective. Bosch Rexroth shall not be liable if a
deficiency occurs that involves parts having been replaced by
the customer with equivalent but not identical parts as speci-
fied by the manufacturer.
Please refer to our general terms of supply or your contract for
details of the guarantee and manufacturer’s warranty.
2.4 Copyright
This product information may only be reproduced – electroni-

cally or mechanically, in whole or in part – with the express writ-
ten permission of Bosch Rexroth. It may likewise not be distrib-
uted, amended, transmitted, translated into another language
or employed or copied for other purposes or by other parties
without such consent.
3 Important basic safety instructions IMPORTANT

The hydraulic product shall be operated exclusively with pres-
sure fluids complying with DIN 51524. Where other pressure
3.1 What to do in an emergency fluids are permitted, for example brake fluids for brake valves,
this is specially mentioned in the Operating Instructions.
In the event of an emergency, fault or other abnormal occur-
For details on proper use see 4 Technical data and ambient
rences:
conditions.
1. Switch off the hydraulic system.
The following information can be found in the Operating
2. Secure the main switch against being unintentionally Instructions:
switched on again.
Ø the proper use, specific to the hydraulic product
3. Secure the danger area so that no one can enter the dan-
Ø where applicable, the safety category in accordance with
ger area unknowingly or uncontrolled.
EN 954-1
4. Notify the relevant specialist personnel immediately.
Ø non-permitted and improper use.
5. In the event of fire, observe the provisions of the safety
datasheets issued by the manufacturer of the pressure
fluid and the fire precautions specifically applicable to
your place of work, which must be documented in the 3.3.1 Proper use, requirements before operation
plant operator’s operating manual.
Ø Rexroth hydraulic products may only be operated if they
are in perfect technical condition.
WARNING • In the event of disturbances in the power supply and/

or damage to the electrical equipment, switch off
immediately and secure the main switch against being
Fighting fires with materials other than those permitted switched on again without authorisation.
can lead to explosions and/or more rapid spread of the
fire! • Report and rectify all faults and damage indicated by
Danger to life from smoke inhalation! the system or discovered by other means.
Ø The connections, operating conditions and performance
data specified in the Operating Instructions must be
observed and never changed.
3.2 Safety labelling on the hydraulic product Ø Rexroth hydraulic products shall not be converted or
otherwise modified without prior consultation with
IMPORTANT Bosch Rexroth.
Ø The meanings of the safety labelling on the Rexroth prod- Ø The plant operator shall not modify the program code of
uct are explained in the Operating Instructions. programmable control systems.
Ø For a diagram of the nameplate and an explanation of the Ø Dependencies and time factors shall not be modified with-
information on it please refer to the Operating Instructions. out prior consultation.
Ø The safety devices fitted by Rexroth must be present,
properly installed and in full working order – except when
this is impractical during setting up or maintenance work.
3.3 Proper use They shall not be relocated, bypassed or rendered ineffec-
tive.
Rexroth hydraulic products are designed and constructed for
the provision, transmission, control or regulation of energy and Ø Safety components such as limit switches, valves and
signals using the flow of oil. other control components shall not be rendered inopera-
tive.
Unless otherwise agreed, the Rexroth hydraulic product satis-
fies at least safety category B in accordance with EN 954-1. Ø Tamperproof lead seals installed by the manufacturer shall
not be removed or damaged except when this is neces-
If the hazard analysis/risk assessment of the overall machine sary in the course of maintenance tasks defined in the
in which the Rexroth hydraulic product is to be installed indi- Operating Instructions.
cates that a safety category higher than category B in accor-
dance with EN 954-1 is required for the Rexroth hydraulic Ø The specified maintenance tasks in the Operating Instruc-
product, then a correspondingly higher rated hydraulic product tions shall be carried out at the intervals stated in the
can be supplied and installed only after special agreement with Operating Instructions.
Bosch Rexroth.
Ø Uncontrolled access by persons unfamiliar with the sys- Servicing personnel (who carry out filter and oil changes, for
tem to the immediate operating zone of Rexroth hydraulic example) shall fulfil the following requirements:
products is prohibited (even if the product in question has
Ø They have been instructed in the relevant activity.
been shut down).
Ø Specialist knowledge of hydraulics is not required to carry
Ø Rexroth hydraulic products must never be assembled,
out servicing work.
operated or maintained by persons under the influence of
alcohol, drugs or other medication which affect one’s abil-
ity to react. Repair personnel shall fulfil the following requirements:
Ø The personnel must be hydraulics experts, who have been
instructed and meet the definition given above,
3.4 Requirements for personnel, Ø Repair personnel must be familiar with the function of the
duty of care hydraulic system as a whole, from subsystems to their
interaction with the function of the entire machine.
Ø Repair personnel must be able to read hydraulic circuit
3.4.1 Qualifications of specialist personnel diagrams, interpret individual functions from their symbols
and understand function diagrams.
A specialist person is someone who, using his specialist train-
ing, knowledge and experience as well as familiarity with the Ø Repair personnel must possess knowledge of the function
relevant conditions, can and construction of hydraulic elements.
Ø safely carry out the tasks allocated to him and correctly

assess the scope and implications of his work
3.4.3 Requirements for electrical maintenance
Ø recognise possible dangers
personnel
Ø undertake the necessary measures to eliminate possible
accidents. All work on electrical equipment shall only be carried out by
an authorised, qualified electrician, or by instructed persons
under the guidance and supervision of a qualified electrician, in
accordance with the rules applicable to electrotechnical prod-
3.4.2 Requirements for hydraulics maintenance ucts.
personnel
In accordance with DIN 31051, maintenance comprises the

individual activities of inspection, servicing and repair. All
3.4.4 Minimum age
personnel involved in maintenance shall be familiar with and
observe all parts of the Operating Instructions and this product
Persons under the age of 18 who are currently receiving
information.
instruction or training or are working under supervision may not
Inspection personnel shall fulfil the following requirements: work on Rexroth hydraulic products.
Ø They have been instructed in the relevant activity. This does not apply to young persons of 16 or over if
Ø Specialist knowledge of hydraulics is not required for Ø working on Rexroth hydraulic products is necessary in
purely inspection activities but the personnel must be order for them to accomplish a training objective
aware of the particular dangers associated with hydraulic
Ø their protection is guaranteed by the supervision of an
products.
experienced, competent person
Ø they are allowed to use only tools, work implements and
protective gear that preclude the risk of injury.
3.4.5 Training 3.5.1 Dangers from pressure fluid
The plant operator using Bosch Rexroth hydraulic products

shall train his personnel regularly in the following subjects: CAUTION
Ø Observation and use of the Operating Instructions and
legal requirements Handling pressure fluid without protection is hazardous to
health.
Ø Proper operation of the Rexroth hydraulic product
Please observe the manufacturer’s safety instructions and the
Ø Observation of the instructions of safety officers and the safety datasheets for the pressure fluid that you are using.
plant operator’s operating manual
Ø What to do in an emergency. DANGER
IMPORTANT Serious damage to health or death may result if pressure fluid
Bosch Rexroth can provide you with training support in special- enters the blood stream or is swallowed. If this occurs, contact
ist areas. a doctor immediately!
An overview of the training can be found on the Internet at

http://www.boschrexroth.de/didactic.
3.5.2 Malfunctions due to contamination of
pressure fluid
3.5 General ancillary dangers and Contamination of the pressure fluid can be caused by:
protective measures when operating
Ø Wear during operation of the machine/system (metallic
hydraulic products
and non-metallic abrasion)
Ø Leaks of the hydraulic product
DANGER Ø Contaminants introduced during servicing/repair
In the interests of your safety, all safety instructions shall be Ø The use of dirty (unfiltered) pressure fluid when the pres-
carefully observed, especially those in the Operating Instruc- sure fluid is changed.
tions.
In spite of the high intrinsic safety of Rexroth hydraulic prod- Contaminants lead to malfunctions, increased wear and shorter
ucts, the risk of personal injury or damage to the environment service life of the hydraulic product. This can have negative
cannot be excluded, even when the equipment is properly effects on the safety and reliability of the hydraulic product.
used. Therefore the maintenance tasks specified in the Operating
New, additional dangers may arise if the hydraulic product is Instructions shall be carried out at regular intervals and the
installed in another machine or installed with other machines utmost cleanliness is required during work on the hydraulic
in a system. This shall apply in particular to mechanical move- product.
ments generated by the hydraulic product.
Information on these additional dangers can be found in the CAUTION
overall operating manual of the supplier of the overall system in
which the hydraulic product is installed. When changing the pressure fluid, always use factory-fresh
pressure fluid and filter it before filling to remove any contami-
nants in the pressure fluid that it often contains from the pack-
aging container (drum). Flush out lines and hoses before instal-
lation.
The cleanliness class of a pressure fluid is specified in accor-
dance with ISO 4406. Detailed information can be obtained
from the relevant datasheet or the Operating Instructions.
In older datasheets, the cleanliness class is sometimes speci- 3.5.4 Product-specific ancillary dangers
fied in accordance with NAS 1638. The following table can
be used to convert this to an equivalent ISO 4406 cleanliness All product-specific ancillary dangers and precautions can be
class: found in the relevant Operating Instructions.
Comparison table for cleanliness classes
Earlier class to Current class to 3.5.5 Disposal
NAS 1638 ISO 4406 (c)
Class 7 Class 18/16/13 Ø Take metal, cable and plastic ducts to a recycling materi-
Class 9 Class 20/18/15 als collection centre.
Ø Dispose of electronic components as electronic waste.
Ø Dispose of back-up batteries as special waste.
3.5.3 Electrical dangers
Ø Cleaning agents, operating fluids and other materials:
When working on electrical systems:
• De-energise the hydraulic system before beginning any CAUTION
maintenance work.
Please observe the disposal regulations specified in
• Cordon off the working area with red-white safety chain
the appropriate Safety Datasheets.
and warning signs.
• Lock the main switch, remove the key and keep it in a safe
place until the work is completed.
• Attach a warning sign to the main switch.
• Check that there is no voltage using a two-pole voltage
detector.
• Earth and short-circuit the point where you are working.
• Cover neighbouring live parts.
• Clear your workplace to prevent contact with live parts as
a result of tripping or slipping. Wear safety footwear.
• Always use electrically insulated tools.
• Disconnect plugs at sensors and valves – even those with
low voltages – after the system has been de-energised.
DANGER
Even after disconnection of the electrical supply
(main switch OFF) the following supply systems/danger
areas can still give rise to life-threatening voltages:
Ø Electrics, electronics, hydraulics (e.g. accumulators,
rechargeable batteries)
Ø Main switch
Ø Power supply cables
Ø Points identified with an electric shock warning sign.
4 Technical data and ambient conditions 4.2 Ambient conditions
IMPORTANT
4.2.1 Use in potentially explosive atmospheres
The product-specific technical data, operating limits and ambi-
ent conditions for the operation of your Rexroth hydraulic prod-
uct can be found in the Operating Instructions. DANGER
This includes the following information:
Rexroth hydraulic products shall be used in potentially
Ø Minimum flow rate for adequate cooling explosive atmospheres only if they are designed for this
Ø Permissible maximum temperature of the coolant purpose and this is expressly stated in the Operating
Instructions.
Ø Performance data
Ø Type of control and regulation functions IMPORTANT
Ø Permissible pressures, flow rates Directive 1999/92/EC of the European Parliament and Coun-
cil dated 16 December 1999 concerning the minimum require-
Ø Connections. ments for improving the safety and health protection of work-
ers potentially at risk from explosive atmospheres governs
protection from danger from potentially explosive atmospheres.
Observe the requirements contained in the regulations for
4.1 Information about pressure fluids operating equipment requiring supervision and the obligation to
produce explosion protection documentation.
Unless otherwise indicated in the Operating Instructions, the This involves, for example, dividing areas endangered by poten-
following specification applies to the pressure fluid to be used: tially explosive atmospheres into zones and specifying suitable
Ø Mineral-oil-based pressure fluid complying with the work equipment and procedures for these areas.
requirements of DIN 51524. Observe the requirements of Directive 94/9/EC of the Euro-
Ø Operating temperature range 0 °C…+80 °C pean Parliament and Council dated 23 March 1994 on the
(in tank < 72 °C). approximation of laws of the member states concerning equip-
ment and protective systems intended for use in potentially
Any deviations from this can be found in the Operating Instruc- explosive atmospheres (ATEX Product Directive) and/or the
tions. corresponding national legislation by means of which the Direc-
tive was implemented in law in the EU member states. The
IMPORTANT directive contains requirements for the use of equipment and
protective systems in potentially explosive atmospheres.
Bosch Rexroth recommends a maximum operating tempera-
ture of 55 °C, because the rate of ageing of the pressure fluid
increases and the service life of the seals and hoses is reduced
at higher temperatures.
Ø Viscosity ranges:
see RE 07075 and RE 90220
Ø Max. permissible contamination class of the pressure fluid
in accordance with ISO 4406: see 3.5.2 Malfunctions
due to contamination of pressure fluid.
The maximum permissible cleanliness class can be found in the
Operating Instructions. The following types of pressure fluids
shall be used.
IMPORTANT
Rexroth hydraulic components are tested with test oil MZ45
manufactured by ESSO (class ISO VG 46 at 40 °C),
(Viscosity η = approx. 46 mm2/s).
4.2.2 Climatic operating conditions
Unless otherwise indicated in the Operating Instructions,

the permissible ambient temperature
Ø for control units: 0 °C…+50 °C
Ø for drive units with electric motors without heat exchang-
ers, surface-cooled by free air circulation:
0 °C…+30 °C
Ø for drive units with heat exchangers: < +40 °C.
Unless otherwise specified, Rexroth hydraulic products are

designed for use in temperate climate zones and in covered
areas (not in the open air) at relative air humidities of < 70 %
and at room temperatures of 22 °C.
IMPORTANT
For systems with oil-air heat exchangers:
Observe the information given in the circuit diagram in the
Operating Instructions.
In relation to the electronic equipment, the permissible ambient

conditions apply to installed and protected electrical connec-
tions of class IP 55.
Ø Ambient temperature +5 °C…+40 °C
assuming that the average air temperature over a 24 hour
period does not exceed +35 °C.
Ø Relative air humidity: 23…95 %, non-condensing.
Ø Altitude: up to 1000 m above national datum.
DANGER
Rexroth hydraulic products shall not be used in aeronau-
tical equipment, except where they have been specially
approved and appropriately labelled to this effect.
5 What you need to know about IMPORTANT

pressure fluids Observe the following rules of thumb:
At pressure fluid temperatures >70 °C, the rate of ageing dou-
bles for each 10 °C.
5.1 How to handle pressure fluids safely
5.3 Viscosity
DANGER
Mineral-oil-based pressure fluid is hazardous to water and
5.3.1 Viscosity grades
flammable.
It may only be used if the relevant safety datasheet from The most important characteristic of a pressure fluid is its vis-
the manufacturer is present and all the measures stipu- cosity, i.e. stickiness. Viscosity range always plays a priority
lated therein have been implemented. role in the selection of a pressure fluid.
Viscosity is measured in the SI unit [mm2/s]. Many manufactur-
ers still provide their information in centiStoke [cSt], the equiv-
alent of [mm2/s].
5.2 Functions and effectiveness The viscosity grades (VG = viscosity grade) in accordance with
ISO 3448 relate to the viscosity at 40 °C. The viscosity grade
Due to the many tasks of pressure fluid, its selection, inspec- is appended to the type designation or the commercial name of
tion and maintenance are of vital importance for: the pressure fluid.
Ø proper functioning Example: A pressure fluid with a viscosity grade of ISO VG 46
has a viscosity of 46 mm2/s at 40 °C.
Ø operating safety
The relationship between medium temperature and viscosity for
Ø service life hydraulic oil (example)
Ø and the cost effectiveness of the hydraulic product.
Medium
Viscosity
temperature
The tasks of pressure fluid: 3 °C 800 mm2/s
Ø to transmit hydraulic energy from the pump to the hydrau- 8 °C 500 mm2/s
lic cylinder/motor 25 °C 100 mm2/s
60 °C 20 mm2/s
Ø to lubricate parts moving against one another
77 °C 12 mm2/s
Ø corrosion protection
Ø to remove contaminants Too high a viscosity leads to the formation of air and vapour
bubbles as a result of low pressure (cavitation). Too low a vis-
Ø to remove locally accumulated heat. cosity leads to increased leakage losses. Increased leakage
losses cause the pressure fluid to heat up more, leading in turn
to a further reduction in viscosity. The pressure fluid then loses
its ability to lubricate.
5.2.1 Reduced function due to ageing
Valves, pumps and hydraulic motors, in particular, require exact
The effectiveness of pressure fluid diminishes as it ages compliance with the defined viscosity ranges.
(undergoes chemical changes). Acids and resinous residues
For certain ambient and operating temperatures, not all the
form, which may cause valve spools to stick.
requirements can always be covered with the available ranges
The following factors accelerate the ageing process: of the viscosity grades.
Ø high temperatures In order to comply with all the requirements, high viscosity
pressure fluids with viscosity index improvers or a pressure
Ø oxygen in the pressure fluid fluid cooler/heater may be used.
Ø air humidity
Ø water
Ø metallic catalysers
Ø operating pressure
Ø contaminants.
5.4 Leakage fluid
Clearances and play mean that some leakage fluid escapes

from all hydraulic products. Leakage fluid can be lead away
internally or externally, depending on the component. It can be
fed back into the tank or must be disposed of.
CAUTION
Make sure that the leakage fluid is fed back into the tank
in a proper manner.
Dispose of leakage fluid that is not fed back into the tank
properly, in compliance with the applicable environmental
protection regulations.
5.5 Topping up/refilling
CAUTION
When topping up/refilling your hydraulic system, make
sure that you use pressure fluid of the same sort and type
and from the same manufacturer.
If the fluid is heavily contaminated or prematurely aged,
then the system, including the tank must be cleaned and
flushed before refilling. New pressure fluid must always be
filtered in accordance with the required cleanliness class,
as it does not normally meet the required cleanliness class
in the as-supplied state.
6 Construction and mode of operation

of a hydraulic system 9

Hydraulics (fluid technology)
7
Transmission, control and distribution of energy and signals
using a pressurised fluid medium. 6
Hydraulic system 5
Arrangement of interconnected components for transferring
and controlling hydraulic energy.
4
3
Component
2
A single unit (e.g. a valve, filter, cylinder, motor) that consists
of one or more parts and which is a functional constituent of a 1
hydraulic system.
1 Tank
Oil preparation
2 Filter
Drive
3 Pump Energy conversion
A component that converts the energy of the hydraulic fluid
into mechanical energy (e.g. motor, cylinder). 4 Pressure limiting valve
5 Directional valve
Energy control
6 Check valve
6.2 Schematic 7 Throttle valve
8 Hydraulic cylinder
In a system operated with hydraulic oil, first of all mechani- Energy conversion
cal energy is converted into hydraulic energy, transported and 9 Hydraulic motor
controlled in this form, to finally be converted once more into
mechanical work.
The hydraulic elements are arranged in accordance with these 6.3 Safety concept
functions. The following diagram shows a schematic represen-
tation of the elements of a complete hydraulic system. Hydraulic products contain sensors and actuators, the interac-
tion of which is particularly important with regard to the fulfil-
To demonstrate their operating principle, standardised symbols
ment of technical safety functions.
(ISO 1219) are used instead of sectional diagrams of the vari-
ous devices. Line connections are represented by simple lines, Individual hydraulic products form part of an overall safety con-
as can be seen in the example. cept.
Applications required to perform safety functions are designed
using special hydraulic components that satisfy the require-
ments of the relevant directives, such as the Pressure Equip-
ment Directive and other standards.
The manufacturer of the overall machine or system defines and
bears responsibility for the safety category to EN 954-1 to be
fulfilled.
IMPORTANT
A more detailed description of the safety concept and the spe-
cific safety components installed can be found in the Operating
Instructions and the Operating Instructions of the supplier of
the overall system in which the hydraulic product is installed.
7 Moving hydraulic units/components IMPORTANT

The factory-applied corrosion protection is adequate provided
Hydraulic units or components may be moved by a fork-lift that
truck or a hoist, depending on their size and the local condi-
tions. Ø no condensation or leakage water can enter the system
Ø long standstills are avoided.
IMPORTANT
Contact Bosch Rexroth if you are not clear about the conse-
For details see the Operating Instructions.
quences of long standstills on the state of the hydraulic prod-
uct.
CAUTION
Always ensure hydraulic products are empty of pressure 8.1.2 Storage times in relation to the ambient
fluid for transportation. conditions
Rexroth hydraulic products are delivered empty of pressure
fluid. However, products may contain oil residues left over from Delays in bringing into use, long shipping and storage times or
the final inspection at our factory. long periods of non-use can lead to rust formation in Rexroth
hydraulic products. Additional corrosion protection measures
must be implemented to prevent this.
IMPORTANT
8 Storage and longer standstills If all the openings on the hydraulic products are not sealed so
as to be air-tight, this will reduce the storage life of the hydrau-
lic product by nine months.
8.1 Hydraulic systems - subsequent bringing After the specified storage time has expired, in any event not
longer than 24 months, the corrosion protection must be
into use after storage
checked and further conservation measures applied if neces-
sary.
Corrosion, especially oxidation, can cause metal surfaces to
lose the standard of surface finish required for the hydraulic
system to function properly.
Rust and other metallic and non-metallic particles lead to abra-
sive wear (erosion), which detrimentally affects the functioning
of the hydraulic system.
CAUTION
If a hydraulic system is to be brought into use again fol-
lowing a long standstill, it must first be flushed clean.
8.1.1 Factory-applied corrosion protection
Rexroth hydraulic products are tested in accordance with

Class III using a hydraulic oil that has additional anti-corrosive
properties. The film of oil that remains in the product after the
test provides sufficient internal corrosion protection.
This factory lubrication ensures that valves do not stick during
subsequent use of the hydraulic product, and guarantees com-
patibility with seals and the pressure fluid to be used.
8.2 Seals, hoses and hose lines
CAUTION
Seals:
Observe the requirements of ISO 2230 and/or DIN 7716
and the specific manufacturer’s data on seals.
Hoses and hose lines:
In the Federal Republic of Germany, please observe the
requirements of DIN 20066, ZH 1/74 Safety rules for
hydraulic hose lines and the specific manufacturer’s data
on hoses and hose lines.
In addition, the following conditions shall be observed:
Ø Seals, hoses and hose lines are stored in cool, dry and
dust-free conditions.
The hoses and hose lines can be enclosed in plastic foil to
ensure low-dust storage conditions. Ideal storage conditions
for hoses and hose lines are temperatures from +15 °C to
+25 °C and a relative humidity of below 65 %.
Ø Do not store elastomers below –10 °C. The ideal stor-
age conditions for seals are temperatures from +10 °C
to +20 °C and a relative humidity of between 65 % and
75 %.
Ø Store hoses and hose lines in the original packaging if
possible. Prevent the entry of air.
Ø Avoid direct sunlight and UV radiation and shield from
nearby sources of heat.
Ø Darkened storage locations are preferred.
Ø Do not use ozone-forming light sources or equipment
(e.g. fluorescent lamps, mercury-vapour lamps, copiers,
laser printers) or electrical spark-forming devices in the
vicinity of hoses and hose lines.
Ø Seals, hoses and hose lines must not come into contact
in particular with materials or vapours that could damage
them (e.g. acids, alkalis, solvents).
Ø Store seals, hoses and hose lines lying down and free
from tension. If the hoses and hose lines are coiled, take
care not to bend them to less than the smallest bending
radius specified by the manufacturer.
Maximum storage times
Ø NBR seals: 4 years
Ø FKM seals: 10 years
Ø Hoses: 4 years
Ø Hose lines: 2 years
For reasons of safety, seals, hoses/hose lines shall not be

used once these permissible storage times are reached or
exceeded. Permissible storage times could be considerably
reduced if the permissible storage conditions are not main-
tained. If you are not clear about the storage times and/or stor-
age conditions then you should not use the product.
9 Assembly and bringing into first use Bringing into (first) use shall only be done by an instructed,
authorised hydraulics expert who has the required special-
ist knowledge.
IMPORTANT
Specialist hydraulics knowledge means, among other things,
Only the permissible pressure fluids given in the Operating that the person can read and fully understand hydraulics draw-
Instructions are to be used. Information on other pressure flu- ings. In particular, he must fully comprehend the range of func-
ids can be found in the Operating Instructions or are available tions of the integrated safety components as part of the overall
on request. safety concept.
Filling the pressure fluid tank must always take place through a
suitable filter unit. Experience has shown that even new pres-
sure fluid can often have more than the maximum permissible
level of contamination. 9.2 Before bringing into first use
All information specific to assembly and bringing into first use
can be found in the Operating Instructions. 1. Check the scope of delivery for transport damage.
Pay attention to cleanliness: 2. Check that the Operating Instructions for the Rexroth
hydraulic product are present and complete.
Ø Do not use cleaning wool or cloths containing fibres for Contact us if the Operating Instructions are not there or
cleaning. are incomplete.
Depending on the condition of the system or machine, 3. Assemble the hydraulic product.
cleaning with fibre-free cloths may be sufficient. Use suit-
able liquid cleaning agents to remove lubricants and other • Observe the Operating Instructions and this product
stronger contaminants. Make sure that cleaning agent information.
does not get into the hydraulic system. • Assemble the hydraulic components, so that they are
Ø Never use hemp and putty as sealants. mounted strain-free on even surfaces.
• Tighten the fastening bolts evenly using the specified
The functional or failure behaviour of identical hydraulic prod- tightening torque.
ucts may vary due to conditions specific to the machine or sys- 4. Ensure that the interfaces of the system/machine and the
tem in which the hydraulic product is installed (mass, speed, installation conditions provide for safe operation of the
electrical triggering at setpoint values, etc.), see also Section hydraulic product. If in doubt, consult the people responsi-
11 Trouble-shooting. ble for the overall system/functional machine.
5. Check the construction of the hydraulic product against
the circuit diagrams, lists of equipment and assem-
bly drawings. If there are any differences, draw this to
9.1 Safety advice for assembly and the attention of the people responsible. If important
bringing into first use documents are missing, they can be requested from
Bosch Rexroth. Only documents issued by the bodies
authorised to do so shall be used.
DANGER 6. Based on the Operating Instructions for the system or
machine in which the hydraulic product is installed, check
Hydraulic products are generally intended for installation whether bringing the hydraulic system into use could lead
in machines/systems or devices. to uncontrolled, dangerous movements. Where appropri-
The function of the hydraulic product must therefore ate, take into account the hazard analysis/risk assessment
always be seen in relation to the function of this machine for the system or machine.
– i.e. seemingly identical hydraulic products may demon- 7. Take the precautions appropriate to the anticipated dan-
strate different functional behaviours as a result of the gers, e.g.
function of the machine in which they are installed.
• Ensure that the cylinder piston rod can move out with-
For this reason, a hydraulic drive must not be brought into out danger.
use until it has been determined that the machine in which
it is installed conforms to EU standards. • Use a hoist or other lifting device to additionally
secure lifted loads.
Do not bring hydraulic drives into use until you have famil-
iarised yourself completely, firstly with the function of the
hydraulic product and hydraulic equipment and secondly
with the hydraulically powered machine functions, and
have clarified and dealt with any possible dangers.
8. As part of bringing into (first) use, check whether the elec- 9.3 Bringing into first use,
tric motors and valve solenoids can be switched manually subsequent bringing into use
using the electrical controls of the system/machine. If they
cannot be switched manually – or can but with difficulty
– you must provide a remote control (e.g. test boxes for
Rexroth proportional valves) for the internal function test of DANGER
the hydraulic system.
Before bringing into (first) use, have all pressure accumu-
IMPORTANT lators and safety systems checked by an expert or special-
ist in accordance with national regulations.
Starting up the hydraulics solely by means of emergency man-
ual operation is not recommended, as several valves at once 1. Clean the lock on the transport and storage container
cannot be switched as required in the correct sequence. before opening.
9. Draw up a sequential program for bringing into (first) use 2. Clean the hydraulic unit and all other component groups,
and store it with the technical documentation as an appen- so that no dirt can get into the hydraulic system during
dix to the Operating Instructions. bringing into (first) use.
For this you should consider the following: 3. Check the paint on the tank for integrity.
Hydraulic drives basically consist of the following func-
tional groups 4. Flush the connection lines to remove dirt, scale, chips etc.
Ø Pump circuit (generation of pressurised oil flow); 5. Pickle and flush welded pipes.
pump, electric motor, oil tank, filters, monitoring
devices, etc.
CAUTION
Ø Control system for at least one hydraulic consumer
(cylinder, motor); directional control valves, pressure Remove all residues of water and cleaning agents
and flow control valves, check valves before performing further work.
Ø Hydraulic consumers (cylinders, motors) with spe-
cially assigned valves, e.g. braking valve.
6. Clean the interior of the hydraulic components to get rid of
contaminants:
10. Divide the functional circuit diagram into separate mini-cir-
cuits that can each be started up in succession. • Clean the filler plug of the pressure fluid tank.
11. Read the functional circuit diagram and seek clarification • Remove dust and chips using an industrial vacuum
of any unclear text or diagrams. More information about cleaner, by rinsing parts or similar cleaning method.
the functioning of components, e.g. a pump regulator, is • Completely remove any oil residues left over from the
available in the Technical Datasheet. factory test.
12. Establish into which position valves are to be switched, or • Remove any gummed oil which may have formed due
how valves are to be set. to incorrect storage.
13. Put up any necessary directional, prohibitive or informative
signs and check whether the meaning of these signs are 7. Connect up all connection lines.
explained in the Operating Instructions.
14. Follow this sequence for bringing into (first) use IMPORTANT
Ø Pump circuit Observe the installation instructions from the manufacturer
of the connection components.
Ø Parts of control system:
e.g. pressure cut-off and switchover,
open centre, DANGER
pressure reduction etc.
Make sure that pipes and hoses are connected at all
Ø Cylinder and motor circuits:
ports or that the ports are sealed with screw plugs.
First move,
fill and bleed, 8. Carry out a special check to make sure that the union nuts
then finally optimise all settings. and flanges are correctly tightened at the pipe connec-
tions and flanges.
IMPORTANT
CAUTION
Mark all the checked connections, e.g. with paint.
Make sure that all pipes and hoses and every combination of Use oil filler units (filter units) suitable for pres-
connection pieces, couplings or connection points with hoses sure fluids.
or pipes are checked for their operational safety by someone • Do not remove the filter strainers from filler necks or the fil-
who has the appropriate knowledge and experience. ter element from filters before filling the pressure fluid tank.
13. Fill the pressure fluid tank up to the upper mark on the
9. Connect the hydraulic consumers. Dimension the connec- inspection window. Observe the maximum fluid level, tak-
tion lines in accordance with the performance data in the ing into consideration the volume in the connection lines
Circuit Diagram and the Operating Instructions. and hydraulic consumers.
10. Install the electrical system for the drive and control sys- 14. Set the pressure and flow control valves, pump regula-
tem: tor, signalling elements such as pressure switches, limit
• Check the connected loads. switches and temperature regulators to the settings and
values defined in the sequential program (see 9.2 Before
• Connect coolant water if necessary. bringing into first use).
• Check the direction of rotation of the pumps
(e.g. as indicated by attached arrow markings). DANGER
11. Check the pressure fluid to ensure that no water has Do not change the settings of valves with a safety
entered it. function, valves with a position switch or valves with
preset electronics.
12. Before filling the pressure fluid tank, please observe the
following requirements: • Set operating-pressure valves and flow control valves
to the lowest possible values.
Ø The pressure fluid must conform to the specification
in the Operating Instructions. • Set directional control valves to their basic setting.
• Reduce the setpoint values of proportional valves to
CAUTION minimum values.
• Do not remove the tamperproof lead seals. Damaged
Never fill new hydraulic products with used pressure or removed tamperproof lead seals indicate improper
fluid. use of the hydraulic product.
Ø The drums of pressure fluid must be sealed and clean 15. If applicable:
on the outside. Fill the pressure accumulator to the specified gas pre-
charge pressure and then check the pressure, see Operat-
ing Instructions.
IMPORTANT 16. Fill the pump body:
If the pressure fluid has a high level of initial contamination Use the leakage oil port to fill pump bodies that have this
(see 4 Technical data and ambient conditions): feature, see Operating Instructions.
Use a filter unit to fill the pressure fluid tank. Ensure that the fil- 17. If applicable:
ter element is clean. Open the cocks in the suction line.
18. Start the drive motors:
IMPORTANT
• With electric motor in jogging mode, allow to start
The fineness of the filter shall correspond to the cleanliness
briefly
class required by the overall system and if possible be even
finer. • Combustion engines in idle
The filter unit used shall fulfil the requirements for functional
• Pay attention to the direction of rotation.
safety and service life.
• If possible, fill the pressure fluid tank via a filling coupling,
using a return filter if possible.
19. Bleed the hydraulics (valve, pump, motor, line, cylinder). 23. After bringing the machine into first use, have a sample of
the pressure fluid analysed to ensure that it achieves the
IMPORTANT required cleanliness class. Change the pressure fluid if the
required cleanliness class is not achieved.
Details on bleeding can be found in the Operating Instruc- If the pressure fluid is not tested in the laboratory after
tions. bringing the machine into first use:
• Operate the hydraulic product at low pressure until it Change the pressure fluid.
is fully bled. 24. Replace the pressure fluid filter.
• Bleed the hydraulics lines to consumers or measuring 25. Document and file all set values.
points at the highest point, if possible.
• Operate the directional valves in jogging mode.
• Next, advance and retract all hydraulic consumers DANGER
several times.
26. To ensure the safety of persons and the system, after
• Increase the load slowly. Check the pressure fluid
bringing the machine into first use, perform the following
level in the pressure fluid tank. If necessary, top it up
tests using the defined maximum values:
with pressure fluid.
• Function test
Bleeding has been accomplished fully and correctly if the pres- • Pressure test.
sure fluid in the tank does not foam, if the hydraulic consumers
do not make any jerky movements and if no abnormal noises Prepare a record of the bringing into (first) use or accep-
can be heard. tance and have it signed by the plant operator. This record
is an important document and requires to be filed.
20. Set the valves and sensors and start up the machine:
• Set the switching operations of valves with a switch- IMPORTANT
ing time adjustment/ramp in accordance with the Information on how to perform the function test and pres-
dynamic conditions, see Operating Instructions. sure test can be found in the Operating Instructions.
• Finely adjust and optimise the setting of proportional
valves without on-board electronics (OBE).
Manufacturing tolerances mean that valves and amplifiers have

to be adjusted in line with one another. Valves with in-built elec-
tronics (OBE, On Board Electronics) have the valve and ampli-
fiers adjusted in line with one another at the factory.
Amplifiers for valves without OBE are supplied from the fac-
tory with a basic setting. Depending on the type of valve and
amplifier, you may have to fine-tune the null point and sensitivity
before bringing the valve into use.
IMPORTANT
Details on fine-tuning can be found in the Operating Instruc-
tions.
21. Check the operating temperature after the machine has
been running continuously for several hours. Too high an
operating temperature indicates that there are faults that
need to be analysed and rectified.
22. Rectify any leakages, e.g. by relieving couplings from pres-
sure and then retightening.
IMPORTANT
Apart from moisture, which should not be sufficient to form one
drop, no measurable, unintentional leakage shall be found.
10 Operation Ø Is there a machine record book that may document similar

malfunctions in the past?
IMPORTANT
Please refer to the Operating Instructions for all information on 11.2.2 Recommended way of working when
how to operate the Rexroth hydraulic product.
trouble-shooting
Successful trouble-shooting for a hydraulic product requires

precise knowledge about the structure and method of opera-
11 Trouble-shooting tion of the individual components.
Where hydraulics are combined with electrics/electronics, in
particular, trouble-shooting is rendered more difficult and co-
operation between electricians and hydraulic specialists is
11.1 What to do in the event of a fault required.
• Even if you are under time pressure, proceed systemati-
cally and methodically.
DANGER Indiscriminate, hasty dismantling and readjustments may,
in the worst case, result in the original cause of failure
In the event of abnormal occurrences or malfunctions, stop being impossible to determine.
all work on the Rexroth hydraulic product immediately and
inform the responsible personnel. • Make sure that you gain an overview of the function of the
hydraulics in respect of the overall system in which the
IMPORTANT hydraulics are installed.
A table for product-specific trouble-shooting can be found in • Try to find out whether the hydraulics performed the
the Operating Instructions. required function in the overall system prior to the occur-
rence of the fault.
If the responsible personnel are unable to rectify the problem
immediately: • Try to determine any modifications to the overall system in
which the hydraulics are installed:
• Switch off the main switch. If applicable, turn off any com-
bustion engines used as drive motors. Ø Have the operating conditions or operating range of
the hydraulics been changed?
• Secure the main switch against being unintentionally
switched on again. Ø Have modifications (e.g. retrofitted equipment)
or repairs been carried out on the overall system
• Inform the machine manufacturer. (machine/system, electrics, control system) or on the
hydraulics? If yes: What were they?
Ø Have the set values of the hydraulics been changed?
11.2 The basic approach to trouble-shooting Ø Have the hydraulics recently undergone mainte-
nance?
The information in this section is intended to help you create
the ideal conditions for carrying out trouble-shooting as effi- Ø Has the hydraulic product/machine been operated
ciently as possible. improperly?
Ø How does the malfunction manifest itself?
11.2.1 General conditions • Form a clear picture of the cause of the fault. Ask the
machine operators directly, if necessary.
Ø Is all the necessary technical documentation to hand? • Document any work undertaken, changed set values, etc.
Ø If no hydraulic circuit diagram is available: • Document any amendments/additional information that
Can a hydraulic circuit diagram be drawn using the struc- should be included in the Operating Instructions.
ture, signs and labelling of the equipment?
Ø Are there enough measuring points?
Ø Has the customer provided useful information about how
the malfunction manifests itself and about the functional
behaviour of the system/component prior to the malfunc-
tion?
11.2.3 Systematic trouble-shooting procedure 11.3 Trouble-shooting tables
Ø Is there an inspection and maintenance book which might

provide information about the trend of test parameters IMPORTANT
(e.g. temperature of hydraulic fluid, replacement intervals The causes of failure in hydraulic systems can be extremely
of filter elements, noises)? complex. Therefore, general rules for trouble-shooting can only
Ø Have there been any identical or similar failures in the be laid down to a limited degree.
past? Please refer to the relevant Operating Instructions for product
• Make a note of causes of failures with a low probabil- specific information about trouble-shooting the Rexroth hydrau-
ity. Only investigate the failure causes you have noted lic product.
down if all failure causes with a high probability have
been proven to be inapplicable.
• Draw up a list of priorities of the most probable failure
causes.
• Verify these listed failure causes one after the other
(by means of theoretical conclusions, disassembly,
measurements or tests).
• Document the causes of failure you have discovered,
and note down how you discovered them.
12 Maintenance Before undertaking any manual intervention in the Rexroth

hydraulic product:
12.1 Definitions of terms DANGER

The term Maintenance as defined in DIN 31051 encompasses Please refer to the Operating Instructions for all the neces-
all measures to maintain and restore the desired conditions sary information on depressurisation and on those parts of
and to determine and assess the actual condition of the techni- the Rexroth hydraulic product that are not depressurised
cal devices of a system . automatically.
These measures are divided into the following categories: • Advance all cylinders to their safe end position.
Ø Inspection (determining the actual condition) • Lower all loads.
Ø Servicing (maintaining the desired condition) • Switch off all pumps.
Ø Repair (restoring the desired condition). • Mechanically support vertical cylinders so that they
cannot drop. Never perform any maintenance work on
The above measures include:
raised units without external support.
Ø Adapting maintenance objectives to suit company objec-
• Relieve any accumulators of pressure in the proper
tives
manner.
Ø Determining appropriate maintenance strategies.
• Switch off the pressure supply and secure the hydrau-
lic product against being inadvertently switched on
again.
12.2 Safety during maintenance tasks • Ensure that only authorised personnel remain in the
work zone.
• Wear safety glasses, gloves and boots.
DANGER
• Allow pressure lines and sections of the system which
In the interests of safety, please observe all the following have to be opened to cool down before commencing
safety instructions carefully and at all times. maintenance work.
• Check safety devices regularly to see that they are work- • Open with care any segments that have to remain
ing properly. under pressure.
• Perform all maintenance work properly, completely and

within the stipulated periods and make a record of the Since check valves are located in the pressure lines above the
work. pumps, the hydraulic system may still be under pressure even
after it has been disconnected from the actual pressure supply.
• Inform all personnel before commencing maintenance
work. Certain segments, such as servo cylinders, also continue to
remain under pressure because the proportional valves remain
• Generously cordon off the maintenance zone before com- in the closed position (all valves are illustrated in their basic
mencing work. position in the hydraulics diagram).
• Inform all persons of ongoing maintenance work by means Observe the following:
of the appropriate signs.
In particular, attach warning signs to the control cabinet, Ø Only new, interchangeable and tested components,
main switch, actuators and points of access. replacement parts and lubricants in original-equipment
quality are approved for use/replacement.
If you have to switch off the hydraulic product, secure it against
being unintentionally switched on again as follows: Ø For reasons of safety, the installation of used and/or
untested components is strictly prohibited and leads to
• Switch off all drives, disconnect the hydraulics from the loss of EU Conformity.
mains at the main switch.
• Depressurise the hydraulic product (relieve any pressure Exercise extreme vigilance when operating the hydraulic prod-
accumulators of pressure). uct in maintenance mode, which may in certain circumstances
• Secure the main switch against being unintentionally necessitate the temporary removal of certain safety devices.
switched on again.
Make sure that all safety devices are properly installed and • Document and file details of any work undertaken,
have undergone a function test before bringing the system changed set values, etc.
(back) into use.
• Document and file details of any amendments/additional
• Perform welding, burning or grinding work on the hydrau- information that should be included in the Operating
lic unit or its attachments only with the approval of local Instructions.
safety authorities/fire brigade and with suitable protective
• Modifications and additions could affect the validity of the
covering to prevent ingress of contaminants.
EU Conformity Declaration/Manufacturer’s Declaration.
• When performing assembly work above your height, use Always consult Bosch Rexroth about any proposed modifi-
the steps and platforms provided by the plant operator. Do cations or additions.
not climb on any parts of the system.
• Remove all tools and materials needed for maintenance
from the hydraulic product.
• Always rectify any leakage from the hydraulic product
immediately.
• Always inform personnel before (re)starting the hydraulic
product.
12.3 Inspection and servicing
The objective of inspection and servicing is

Ø To maintain all system functions along with the initial
parameters of the system
Ø To ensure continual availability of the system
Ø To detect weak points
Ø To ensure that the system attains the required service life.
IMPORTANT
The following general specifications are based on use of the
hydraulic product in central Europe and under the usual operat-
ing conditions of commercial and industrial plants.
We strongly recommend the use of an inspection and servicing
book, in which all work specific to that site, and all inspection
and servicing intervals should be defined and documented.
An inspection and servicing book is also helpful in that
Ø It provides comparison values to aid with early detection of
malfunctions
Ø It allows warranty claims to be dealt with more easily.
CAUTION
Ensure cleanliness during all work.
• Please observe the requirements for pressure fluids men-
tioned in Section 9 Assembly and bringing into first use.
• Clean the external environment of couplings/joints and
devices before disassembly. Do not use cleaning wool or
cloths containing fibres for cleaning.
• Seal all openings using protective caps.
• Bleed the hydraulic product after each item of servicing
work.
12.3.1 Inspection procedures and test equipment, 12.3.2 Location of testing and measuring points
general
IMPORTANT
The following are some of the typical inspection and testing
procedures that are regularly used in connection with hydraulic Please refer to the Operating Instructions for the installation
systems and components. location of filling level indicators, filling points, drainage points,
filters, testing points, strainers, solenoids, etc. that require reg-
IMPORTANT ular inspection and servicing.
Keep the indicated typical test equipment ready for this type of
work.
12.3.3 Inspection and servicing plan, hydraulic
Type of test Typical test Typical products, general
equipment testing activities
The graph illustrates the concept of wear/wear margin.
Pressure Pressure gauge Checking of The wear margin is a characteristic feature used to describe
measure- or sensor with the condition of the system for the purpose of maintenance.
• specified pressure
ment suitable measuring
range and connec- • opening pressure 5
tion pipe and con-
• pressure difference
nection coupling
before and after the ��
object under test ��
Visual – Checks for

inspection
• all components
securely seated 1
• damage
4
• wear 6
• leakage (formation of �
oil droplets) ��
• presence of all 2
3
warning and
informative signs 1 Wear margin Z0
2 Time t
Touch – Checks for
inspection 3 Repair (corrective maintenance) time (ti2 – ti1)
• unusual local
vibrations 4 Damage threshold (damage time tS)
5 Desired condition after corrective maintenance
Temperature Temperature Checks for 6 Failure
inspection measuring
• unusual local
instrument
temperature zones
The reduction in the wear margin reflects wear. The curve rep-
resents one possible form of the wear profile during the period
Acoustic – Checks for
of use. It is determined during inspection and varies depend-
inspection
• changes in running ing, firstly, on the system itself (e.g. material selection, sur-
noise of the unit face treatment, quality) and secondly on external influences
or boundary conditions such as servicing levels, corrosive cir-
• changes in flow culating air and dust. Thirdly, it depends on how the system
noise is operated; whether with partial load or partially with excess
• changes in operating load, whether it is subject to surge loads or steady load, etc.
noise in the unit and Where hydraulic systems are concerned, the curve is also influ-
valve control. enced by the cleanliness class and degree of fouling of the
pressure fluid, the number of cycles and the ambient condi-
tions.
All the factors mentioned above can exert an influence on the 12.3.5 Inspection and servicing plan: electrics and
curve but this need not necessarily adversely affect the quality control system
of its information, as wear always signifies the reduction in the
wear margin, which is understood to be the primary initial vari-
able before wear commences. IMPORTANT
Consequently, this means that a sudden change in the wear The product-specific inspection and servicing plan for electrics
margin must also count as wear, and that the element of time and control systems can be found in the Operating Instruc-
on its own is not of decisive importance for wear, but is of con- tions.
siderable interest in the assessment and evaluation of such
wear.
An increase in the wear margin to over 100 % above its base-
line may be achieved through corrective maintenance, if such 12.3.6 Lubrication points, lubricants, intervals
measures entail an improvement and this increase is estab-
lished as the new desired condition for future corrective main- IMPORTANT
tenance.
The details of the specified lubricants, lubrication points and
Certain system parts may be subject to a wear margin which associated lubrication cycles can be found in the Operating
diminishes in such a way that the time available for use is insuf- Instructions.
ficient for the requirements of the plant or operation. In this
case, investigations must be carried out to ascertain whether
the introduction of suitable technical measures might counter
this reduction in the wear margin to a satisfactory extent. The
time and expenditure required for such measures must natu-
12.3.7 Set values of valves, regulators and
rally be kept in reasonable proportion to the expected degree signalling elements
of success.
Pressure and flow control valves, pump regulators and signal-
If such conditions arise, we refer to these parts as weak points. ling elements such as pressure sensors, pressure switches,
Since their elimination may provide economic and safety limit switches and temperature regulators are given their opti-
advantages, weak points require to be rectified immediately. mum setting when the system is brought into first use.
IMPORTANT Check regularly whether all values are correctly set with the aid
of the hydraulics diagram and the documented values.
The inspection and servicing plan for your particular product
can be found in the Operating Instructions.
DANGER
The set values of valves with position switches shall only
12.3.4 Inspection and servicing plan, be calibrated or readjusted at the factory.
electrohydraulic systems The set values of safety valves shall not be altered by the
user. Any readjustment shall be performed by authorised
Electrohydraulic systems with proportional valves must be ser- testing bodies only.
viced in accordance with hydraulic requirements and strate-
Too low a pressure difference between the operating pres-
gies. However, technical control components must also be
sure and the opening pressure can lead to frequent opening
incorporated in these servicing cycles.
of safety valves. This leads to increased power losses and an
On this basis, an overall strategy for system servicing must be unacceptable increase in temperature of the pressure fluid. In
developed and documented. this event, select a lower operating pressure.
IMPORTANT
The appropriate component characteristics relevant to servic-
ing can be found in the Operating Instructions.
12.3.8 Replacement of pressure fluid filters and

ventilation filters CAUTION
In certain circumstances the contamination indicator does
not show a required filter replacement.
CAUTION
If the check function never indicates filter replacement and the
Unfiltered pressure fluid filters lead to increased wear of contamination indicator is functioning correctly, this may have
all the system’s hydraulic products and can cause func- the following causes:
tional failures with dangerous effects. Therefore, always Ø Faulty filter
replace contaminated oil filters immediately.
Ø A bypass valve may have been installed and is not closing
Clogged ventilation filters result in inadequate cooling and correctly, e.g. due to the entry of dirt particles.
can therefore cause excessive heating up and malfunc-
tions of the hydraulic system. Therefore, always replace
contaminated ventilation filters immediately.
• Clogged filters must always be replaced immediately. 12.4 Service and storage lives of hose lines
Do not clean clogged filters.
• Allow the contents of the replaced oil filter to drip and ful- IMPORTANT
ly drain. In terms of the service life of hydraulic hose lines in these
• Dispose of the filter in accordance with the applicable reg- Operating Instructions, replacement and storage lives are mea-
ulations. sured from the date of manufacture of the hose line.
Even when properly stored and subjected to permissible loads,
Exact instructions on how to replace a filter can be found in the seals, hoses and hose lines undergo a natural ageing process.
Filter manufacturer’s instructions for use. The replacement and storage lives of seals, hoses and hose
lines are therefore limited (see 8.2 Seals, hoses and hose
lines).
12.3.9 Checking filters with a contamination indicator

DANGER
Filters with contamination indicators continuously measure the
degree of fouling. The dirt-retention capacity of the filter is uti- Hose lines must be replaced in accordance with the provi-
lized to the full. sions of the servicing plan, even if there are no detectable
technical defects in the hose line.
IMPORTANT Hoses that have already been used as part of a hose line
Check the contamination indicator when the pressure fluid is shall not be reused in a hose line.
warm (during or immediately after operation).
The first use may have changed the properties of the hose
If the ambient temperature is low or the pressure fluid is cold, material to such an extent that reuse of the hose repre-
its high viscosity may cause clogging to be indicated, although sents a very high risk.
the pressure fluid is in fact clean.
Procedure:
1. Wait until the hydraulic product has reached operating
temperature.
2. Press the indicator button (check function):
If the indicator button pops out again immediately, the filter
must be replaced by the end of the shift at the latest.
Due to the progressive loss in pressure as the filter becomes

increasingly contaminated, the indicator point has a certain
reserve capacity, i.e. generally sufficient for a work shift of 8 h.
If the filter is not replaced after 8 h, dirt may penetrate the sys-
tem, resulting in contamination of the hydraulic product.
12.5 Topping up the pressure fluid 12.7 Repair
IMPORTANT IMPORTANT
Only pressure fluids specified in the Operating Instructions are Repair (corrective maintenance) is the restoring of the desired
to be used. condition.
When changing or topping up the pressure fluid, fill the pres- In addition, observe the special safety instructions in
sure fluid tank on the hydraulic product as follows: 12 Maintenance and the safety instructions in the Operating
Instructions.
1. Fill the pressure fluid tank using a special filling unit with
an integral filter (min. 10 µm).
2. Drop the system pressure right down by resetting the
pump. Set the pressure setting value on the pump pres- DANGER
sure control to minimum or zero pressure.
Ensure cleanliness during all work.
3. Fill and bleed the line system of the hydraulic product from
the unit to the cylinder. To do this actuate the cylinder in • Clean the external environment of couplings/joints and
both directions, see Operating Instructions. devices before disassembly. Do not use cleaning wool or
cloths containing fibres for cleaning.
4. Top up the pressure fluid volume to the specified quantity.
• Seal all openings using protective caps.
5. Raise the pump pressure to the system pressure.
• Bleed the hydraulic product after each item of repair work.
The hydraulic product is ready for operation.
• If appropriate, follow the procedure for bringing into first
6. Carry out a test run. use, see 9.3 Bringing into first use, subsequent bringing
7. Check the level of the fluid after the hydraulic product has into use.
warmed up to the operating temperature and adjust if nec- • Document any amendments/additional information that
essary. should be included in the Operating Instructions.
IMPORTANT
Check the contamination indicator when the pressure fluid is
warm (during or immediately after operation).
If the ambient temperature is low or the pressure fluid is cold,
its high viscosity may cause clogging to be apparently indi-
cated.
12.6 Servicing pressure accumulators
DANGER
Pressure accumulators are subject to the national legisla-
tion on safety requirements for pressure vessels applica-
ble in the place of installation.
Observe the Pressure Equipment Directive 97/23/EC.
IMPORTANT
The gas precharge pressure is measured with a testing and fill-
ing device.
Details of the procedure can be found in the Operating Instruc-
tions.
Inspection and servicing
• Carry out the tests required by law.
• Test and monitor the gas precharge pressure regularly.
12.7.1 General safety instructions for repair work

WARNING
Do not perform any welding, soldering or mechanical work
DANGER on accumulator vessels.
Repair work shall only be done by an authorised hydraulics Welding and soldering carry a risk of explosion!
expert who has the required specialist hydraulics knowl-
Mechanical tampering may cause the vessel to burst and
edge.
the operating permit will be withdrawn.
Specialist hydraulics knowledge means, among other things,
Do not charge hydrostatic accumulators with oxygen or air.
that the person can read and fully understand hydraulics draw-
Risk of explosion!
ings. In particular, he must fully comprehend the range of func-
tions of the integrated safety components. Depressurise the system before working on hydraulic
installations.
Components may only be dismantled for the purpose of repair
to the extent described in the Operating Instructions. Improper installation can lead to serious damage to per-
sons and property.
Never repair a defective safety valve. It must be completely
replaced.
Faulty parts may only be replaced by new, interchangeable,
tested components in original-equipment quality. Any devia- 13.2 Safety devices relating to
tions from this can be found in the Operating Instructions.
hydraulic pressure accumulators
Before each subsequent bringing into use after repair work, the
hydraulic product shall be accepted by a hydraulics expert. The equipping, installation and operation of hydrostatic accu-
The operator of the hydraulic product is required to check by mulators is regulated by the national implementation of the EU
means of a servicing record that the inspection and servicing Pressure Equipment Directive 97/23/EC and additionally in the
plan as been complied with. Federal Republic of Germany by the Technical Regulations for
Pressure Vessels (TRB). This legislation requires the following
Pressure vessels have to be pressure tested every 10 years safety equipment:
and the information recorded in accordance with the Pressure
Equipment Directive 97/23/EC or its implementation in national Ø Device to protect against excessive pressure
legislation. (prototype-tested)
Ø Pressure relief device
Ø Pressure measuring device
Ø Test gauge connection
13 General information about
Ø Shut-off device
hydraulic pressure accumulators
Ø Optional: electromagnetically operated pressure relief
device
13.1 General Ø Safety device to protect against overheating.
The regulations applicable at the place of installation concern-

ing hydraulic pressure accumulators (hydrostatic accumula- IMPORTANT
tors) must be observed before bringing into use and during
operation. See the Operating Instructions.
The plant operator bears sole responsibility for compliance with

the existing regulations.
Hydrostatic accumulators are subject to the national implemen-
tation of the EU Pressure Equipment Directive 97/23/EC.
Documents supplied with accumulators must be preserved
with care; they will be required during recurring inspections by
specialists.
The bringing into use of hydrostatic accumulators shall be car-
ried out by trained expert personnel only.
14 Hydraulic systems 14.1 Effects of leaks in the hydraulic system

on the machine
Hydraulic systems are generally intended for installation in
machines or systems. In addition to the basic information about If pressure fluid escapes from the hydraulic system and comes
the installed components, the information contained in the into contact with hot surfaces on the machine, this can lead to
Operating Instructions made available for each hydraulic sys- the generation of life-threatening smoke, fire and/or other dan-
tem by Bosch Rexroth also applies to hydraulic systems. gerous operating conditions.
By installing the hydraulic system in a machine or system, the These risks shall be determined by the machine manufacturer
interaction of the hydraulic system with the overall machine by means of a hazard analysis and if necessary provision made
may give rise to changes in the potential dangers. In particular for the appropriate safety devices.
the effect of hydraulic and electrical control of hydraulic drives
that create mechanical movement are to be considered.
This information shall be included in the hazard analysis/risk
assessment of the overall machine carried out by its supplier
and in the Operating Instructions of the overall machine. This
also applies to the specification of the interfaces between the
hydraulic system and the overall machine.
Hydraulic systems are subject to legislation including the Pres-
sure Equipment Directive and other relevant EU directives that
have been implemented in national legislation. Exact informa-
tion can be found in the EU Conformity Declaration or Manu-
facturer’s Declaration that is supplied with the hydraulic system
or the hydraulic product.
WARNING
Before installing a hydraulic system in a machine or mod-
ifying an existing hydraulic system in a machine, satisfy
yourself that
Ø the hydraulic system is suitable for its application in the
machine
Ø the ambient conditions in the machine are suitable and/or
permissible for the use of the hydraulic system
Ø other installed items on or in the machine cannot disturb
or endanger the functioning or the safe operation of the
hydraulic system.
If the overall machine is to be used in a potentially explosive

atmosphere, then it must be ensured that the hydraulic system
has been designed and is suitable for this use.
DE Bestellinformation für deutsche Produktinformation: RD 07008

EN Ordering Information for Product Information in English: RE 07008
FR Information de commande pour la notice française Informations générales sur les produits : RF 07008
IT Informazioni d’ordine per le informazioni tedesche sul prodotto: RI 07008
ES Información para el pedido de la información del producto en español: RS 07008
FI Tilaustiedot - suomenkieliset tuotetiedot: RSF 07008
NL Bestelinformatie voor Nederlandse productinformatie: RNL 07008
SV Beställningsnummer för svensk produktinformation: RSK 07008
PT Informação dos dados de encomenda para informação de produto alemã: RP 07008
DA Bestillingsinformationer vedr. dansk produktinformation: RDK 07008
EL Πληρφρίε παραγγελία για τι γερµανικέ πληρφρίε πρϊντ: RGR 07008
http://www.boschrexroth.com/bri-products
→ Datenblatt-Suche/Datasheet search
→ Suche nach Datenblatt/Search by datasheet
07008
Bosch Rexroth AG © All rights reserved, Bosch Rexroth AG, including applications for intellec-
Hydraulics tual property rights. We reserve all power of disposal, rights of reproduction
Zum Eisengiesser 1 and issue.
97816 Lohr am Main, Germany
The data specified above only serve to describe the product.
Tel. + 49 (0) 93 52 / 18-0
No statements concerning a certain condition or suitability for a certain
Fax + 49 (0) 93 52 / 18-23 58
application can be derived from our information. The given information does
documentation@boschrexroth.de
not release the user from the obligation of own judgement and verification. It
www.boschrexroth.de
must be remembered that our products are subject to a natural process of
wear and aging.
Bosch Rexroth AG
Training Systems and Teachware
Maria-Theresien-Straße 23
97816 Lohr a. Main, Germany
Phone +49 9352 18-1041
Fax +49 9352 18-1040
trainingsystems.brs@boschrexroth.de
www.boschrexroth.com
© This document, as well as the data, specifi-

cations and other information set forth in it, are
the exclusive property of Bosch Rexroth AG.
It may not be reproduced or given to third par-
ties wihout its consent.
Made in Germany
Document number: RE 00845/04.07

Material number: R961003790

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Electric Drives Linear Motion and

and Controls Hydraulics Assembly Technologies Pneumatics Service

Project Manual RE 00845/04.07

Restructuring of industrial metalworking and electrical professions

Training period (years)

Restructuring of industrial metalworking professions (source: DIHK 06/2004)

1st step 2nd step

Analysis of qualification Synthesis of

requirements qualification contents

→ Training pattern → Time frame

(technical structure) (time structure)

- Core qualifications In the sense of fields of

- Specialist qualifications + work/activities within the

Time frame - method (source: DIHT 06/2004)

Imparting knowledge through project work

Training section 6, which is geared to hydraulic control technology, is described below.

Training Installing and commissioning 2nd year of training

Possible questions: • Was the control properly installed?

Project designation with short description of the industrial application

No. Project designation Industrial application (example)

16 Pressure switch, Working out the hysteresis of a mechanical pressure

Comparison of project exercises of Bosch Rexroth AG/BIBB

04 Single-rod cylinder/flow Traversing speeds B 1.2

05 Hydraulic motor Lifting platform drive B2

Control of direction, single-rod

09 Throttle valve, adjustable Conveyor belt drive D1

10 Throttle check valve Traversing an advance slide D3

11 Flow control valve Tool drive D2

12 Pressure relief valve Characteristic curve E 1.2

Pressure relief valve controls Pressure pre-selection on punch-

14 Pressure reducing valve Tool advance E3

Workpiece pressing with monitor-

16 Pressure switch hysteresis Characteristic curve E4

Storing energy in view of a hydrau-

19 Rapid speed/creep speed control Production line, lifting of a pallet G2

20 Valve circulation control Lifting and lowering of a load G3

Note on the utilization of the matrix:

Symbol Component designation Type designation

Fixed displacement motor with external

4/2 directional valve with solenoid actua-

4/3 directional valve with direct actuation

Check valve with spring, flow possible in

Pilot operated check valve, with spring, pi-

Shut-off valve, actuated by turning DZ 2.1

Direct operated pressure relief valve, the

3-way pressure reducing valve DD 2

Pressure switch, electromechanical,

Throttle valve, adjustable DF 1.2

Throttle check valve, adjustable,

2-way flow control valve, adjustable, for one

Accumulator safety block

Pressure gauge with hose

Hose with quick release coupling with

Distributor plate with four ports DZ 4.1

This symbol refers to supplementary information.

Work carried out improperly on electrohydraulic components and systems

Basic principles of hydraulics

Comparison of System technologies such as hydraulics, pneumatics, electrics/electronics and mechanics

Hydraulics Pneumatics Electrics Mechanics

Source of energy El. motor El. motor Mains El. motor

Pressure vessel Weight

Comparison of system technologies

Drive Hydraulic system Drive

Energy conver- Open, closed- Energy conver-

Filter types Return flow filter