Bosch Rexroth M4-12 Betriebsanleitung

Repair manual

RE 64276-01-R/10.2017

Replaces: 10.2014

English

Load sensing control block

M4-12

Basic document

also regarding any disposal, exploitation,

reproduction, editing, distribution, as well

as in the event of applications for industrial

property rights. The data speciﬁed within only

serves to describe the product. No statements

concerning a certain condition or suitability

for a certain application can be derived from

our information. The information given does

not release the user from the obligation of

own judgment and veriﬁcation. It must be

remembered that our products are subject to a

natural process of wear and aging.

An example conﬁguration is shown on the title

page. The product delivered may therefore

diﬀer from that shown.

The original repair manual was created in the

German language.

RE 64276-01-R/10.2017, M4-12, Bosch Rexroth AG

3/32Contents

1 About this manual 4

1.1 Validity of the documentation 4

1.2 Required and supplementary documentation 4

1.3 Display of information 5

1.3.1 Safety instructions 5

1.3.2 Symbols 6

1.3.3 Designations 6

1.3.4 Abbreviations 6

2 Safety instructions 7

2.1 About this section 7

2.2 Personnel qualiﬁcations 7

2.3 Product-speciﬁc safety instructions 8

2.4 Personal protective equipment 11

3 General instructions on damage to property and the product 12

4 Product description 16

4.1 Identiﬁcation of the product 16

4.2 Connection designation 16

4.3 Flange interface 17

4.4 Control block segments 17

4.4.1 Inlet plate 17

4.4.2 Directional valves M4-12 – general 18

4.4.3 Directional valves M4-12 with purely mechanical actuation 19

4.4.4 Directional valves M4-12 with hydraulic actuation 20

4.4.5 Directional valves M4-12 with electrohydraulic actuation 21

4.4.6 Directional valves M4-12 with on-board electronics 22

4.4.7 Directional valves M4-12 with servohydraulic actuation 23

4.4.8 End plate 23

4.5 Control block versions 24

5 General instructions for assembly 25

5.1 Screw connection for hydraulic connections 25

5.2 Screw connection on the control block segment 25

5.3 Fixing the control block in place 26

6 Testing and re-commissioning 27

7 Fault ﬁnding 28

8 Accessories and spare parts 29

8.1 Accessories and spare parts on the Internet 29

8.2 Contact partners for accessories and spare parts 29

Contents

4/32 About this manual

Bosch Rexroth AG, M4-12, RE 64276-01-R/10.2017

1 About this manual

This repair manual is made up of the following parts:

Part 01 Basic document

Part 10 Control block assembly

Part 20 Repairing the directional valve

Part 30 Repairing the electro-proportional pressure relief system

Part 40 Repairing the electronics (EPM2)

Part 41 Repairing the electronics (CPM)

Part 50 Repairing the inlet plate

Part 51 Repairing the inlet plate for safety-related applications

1.1 Validity of the documentation

This documentation applies to the following products:

•Load sensing control block M4-12

This manual is aimed at vehicle manufacturers, assemblers and service technicians,

as well as authorized specialist companies and dealers.

This documentation contains important information on the safe and proper repair of

the control block.

▶ Read this documentation in its entirety and in particular the sections 2 “Safety

instructions” page7 and 3 “General notes on damage to equipment and the

product” on page12 before working with the product.

1.2 Required and supplementary documentation

▶ Only commission the product if the documentation marked with the book

symbol is available to you and you have understood and observed it.

Table 1: Required and supplementary documentation

Title Document number Document type

Control blocks for mobile applications

Contains important information for safely and professionally transporting, installing,

commissioning, servicing and removing the Load sensing control block M4-12.

64025-B Operating

instructions

Load sensing control block M4-12 for safety-related applications

Contains important information for safely and professionally transporting, installing,

commissioning, servicing and removing the Load sensing control block M4-12 for

safety-related applications.

64276-01-B Operating

instructions

Load sensing control block M4-12

Contains the permissible technical data.

64276 Data sheet

Load sensing control block M4-12

Contains the spare parts available to order.

64276-E Spare parts list

Related documents for the assembly and repair can be found in Table 21 on page

25 and can be obtained where necessary via

www.boschrexroth.com/mobile-hydraulics-catalog

Documents relating to the general circuit diagram of the machine are available

from the vehicle manufacturer.

About this manual 5/32

RE 64276-01-R/10.2017, M4-12, Bosch Rexroth AG

1.3 Display of information

Standardized safety instructions, symbols, terms and abbreviations are used

throughout this documentation so that you can work quickly and safely with your

product. To give you a better understanding, these are explained in the sections

below.

1.3.1 Safety instructions

This manual includes safety instructions in the sections 2.3 “Product-speciﬁc safety

instructions” on page8 and 3 “General notes on damage to equipment and the

product” on page12 , as well as prior to sequences of actions or instructions

where there is a risk of injury or material damage. The measures described to avert

danger must be observed.

Safety instructions are set out as follows:

SIGNAL WORD

Type and source of danger

Consequences of non-compliance

▶ Measures to avert danger

•Warning sign: draws attention to the danger

•Signal word: identiﬁes the degree of danger

•Type and source of the hazard: identiﬁes the type and source of the danger

•Consequences: describes what will happen if the safety instructions are not

complied with

•Precautions: states how the danger can be avoided

Table 2: Hazard classes as deﬁned in ANSI Z535.6

Warning sign, signal word Meaning

DANGER Identiﬁes a dangerous situation that will result in death or

serious injuries if it is not avoided.

WARNING Identiﬁes a dangerous situation that may result in death or

serious injuries if it is not avoided.

CAUTION Identiﬁes a dangerous situation that may result in minor to

moderate injuries if it is not avoided.

NOTE Property damage: The product or the environment may be

damaged.

6/32 About this manual

Bosch Rexroth AG, M4-12, RE 64276-01-R/10.2017

1.3.2 Symbols

The following symbols indicate information that is not directly relevant to safety but

increases understanding of the manual.

Table 3: Meaning of the symbols

Symbol Meaning

If this information is disregarded, the product cannot be used or operated

to its optimum potential.

▶ Single, independent step

Numbered instruction:

The numbers indicate that the steps must be completed one after the

other.

Black circle with white number:

Markings for better understanding.

White circle with black number: Item or assembly with a reference to the

parts list and to the graphics within a section.

White circle with black letters: Assembly with reference to the parts list

and the graphics within a section.

White circle with black Roman numeral:

Variants

Views

1.3.3 Designations

This documentation uses the following designations:

Table 4: Designations

Designation Meaning

M4-12 Directional valve

KBPS Proportional pressure relief

1.3.4 Abbreviations

This manual uses the following abbreviations:

Table 5: Abbreviations

Abbreviation Meaning

IP Inlet Plate

PRV Pressure Relief Valve

EP End Plate

IPC Individual Pressure Compensator

FDP Fixed Displacement Pump

LS Load Sensing

SOV Shut-Oﬀ Valve

VP Variable Pump

Safety instructions 7/32

RE 64276-01-R/10.2017, M4-12, Bosch Rexroth AG

2 Safety instructions

2.1 About this section

Before working on the product, read the appropriate instruction manual thoroughly

and completely. If necessary, request the manual from Rexroth.

2.2 Personnel qualiﬁcations

This repair manual is aimed at skilled personnel with specialist knowledge in

hydraulics who have taken part in a service training course at Rexroth.

Skilled personnel are individuals who:

•Have acquired suﬃcient knowledge through professional training and experience

•Are able to evaluate the work assigned to them

•Can identify potential dangers

•Can implement the measures required in order to eliminate dangers

•Are aware of the potential health risks posed by hydraulic ﬂuids

•Have the necessary knowledge to carry out repair and assembly work

Specialist knowledge of hydraulics means:

•Reading and fully understanding hydraulic diagrams

•Speciﬁcally, fully understanding the relationships with regard to the installed safety

devices

•Understanding how hydraulic components work and are put together

Bosch Rexroth oﬀers training support for specialist ﬁelds. An overview of the

training contents can be found on the Internet at:

http://www.boschrexroth.com/training.

8/32 Safety instructions

Bosch Rexroth AG, M4-12, RE 64276-01-R/10.2017

2.3 Product-speciﬁc safety instructions

The following safety instructions apply to section 5 to 7.

WARNING

Danger from suspended loads!

Risk of death or injury, or property damage.

Improper transportation may cause the control block to fall down and result in

injury, e.g. crushing or fractures, or damage to the product.

▶ Make sure that the lifting capacity of the lifting device is suﬃcient to safely bear

the weight of the control block.

▶ Never stand or put your hands under a suspended load.

▶ Make sure the unit remains stable during transport.

▶ Wear your personal protective equipment (e.g., safety goggles, safety gloves,

suitable working clothes, safety shoes).

▶ Use suitable lifting devices for transportation.

▶ Observe the prescribed position of the lifting strap.

▶ Observe the national laws and regulations on work and health protection and

transportation.

Machine under pressure!

Danger to life or risk of injury, serious injuries when working on machines not shut

down! Risk of property damage.

▶ Turn oﬀ the entire system and secure it against being restarted as speciﬁed by

the machine manufacturer.

▶ Make sure that all relevant components of the hydraulic system are

depressurized. Please follow the machine manufacturer's instructions.

▶ Note that the hydraulic system may still may be under pressure even after the

pressure supply itself has been disconnected.

▶ Do not disconnect any line connections, ports and components while the control

block is under pressure.

Escaping oil mist!

Risk of explosion and ﬁre, health hazard, risk of environmental pollution.

▶ Depressurize all relevant components of the hydraulic system and repair

theleak.

▶ Only perform welding work when the machine is depressurized.

▶ Keep open ﬂames and ignition sources away from the control block.

▶ If control blocks are located in the vicinity of ignition sources or powerful

thermal radiators, a shield must be erected to ensure that any escaped hydraulic

ﬂuid cannot be ignited, and to protect hose lines from premature aging.

Electrical voltage!

Risk of death or injury from electric shock or risk of property damage!

▶ Always set up the relevant part of the machine so that it is deenergized before

you install the product or when connecting and disconnecting connectors.

▶ Secure the machine against being re-energized.

Safety instructions 9/32

RE 64276-01-R/10.2017, M4-12, Bosch Rexroth AG

WARNING

Restriction of the control function!

Risk of death or injury, or property damage.

Moving parts in control and regulation systems (e.g. control spools) may in certain

circumstances become stuck in an undeﬁned position due to contamination

(e.g.contaminated hydraulic ﬂuid, abrasion or residual dirt from components). The

volume ﬂow of the driven consumer will then no longer follow the commands of the

operator.

▶ Secure the machine against rolling away and unintentional movements

according to the speciﬁcations of the machine manufacturer.

▶ Observe the speciﬁed cleanliness level of the hydraulic ﬂuid in accordance with

a data sheet.

Risk of pressurized hydraulic ﬂuid leaking or ﬂy-away parts!

Danger to life or risk of injury. If fasteners without suﬃcient high pressure

resistance are used, they can cause rupturing and leakage of hydraulic ﬂuid and/or

ﬂy-away parts. The ports and fastening threads of the control block are designed

for the speciﬁed maximum pressure.

▶ Only ever connect connecting elements and lines that match the ports of the

control block and can resist the intended application conditions (e.g. pressure

level, ﬂow, hydraulic ﬂuid, temperature) with the necessary safety factors.

Faulty power supply!

Danger to life or risk of injury due to uncontrolled valve settings! These settings can

lead to unexpected behavior of the control block.

▶ Always connect the ground connection of the control block to the corresponding

ground system in your installation.

▶ Only ever use a power supply unit with safe separation. Always take into

account your country-speciﬁc speciﬁcations.

10/32 Safety instructions

Bosch Rexroth AG, M4-12, RE 64276-01-R/10.2017

CAUTION

Risk of injury from sharp edges and rough surfaces!

Risk of injury when working with and transporting the control block, e.g. due to

sharp edges on the valve housing, on threads or attachments.

▶ Wear safety shoes with steel toecaps.

▶ Wear safety gloves and appropriate working clothes to protect against injuries.

Crushing and impact hazard for limbs!

In the gap between the actuation element and the valve housing, you can injure

yourself.

▶ Do not put any parts of your body in the gap between the actuation

element/hand lever and the valve housing.

High noise levels during operation!

Risk of hearing damage or hearing loss!

The noise emission of control blocks depends, among other factors, on the working

pressure and the installation conditions. The sound pressure level may rise above

70 dBA under certain application conditions.

▶ Always wear hearing protection when you are in the vicinity of the running

control block.

Hot surfaces on the control block!

Risk of burns.

▶ Allow the control block to cool down suﬃciently before touching it.

▶ Wear heat-resistant protective clothing, e.g., gloves.

Cold surfaces on the control block!

Sticking skin, frostbite by touching the cold valve housing!

▶ Wear personal protective clothing, e.g. cold-resistant gloves.

Improper routing of cables and lines!

Risk of stumbling and property damage. Improper routing of cables and lines can

cause a risk of stumbling as well as damage to equipment and components, e.g.,

lines and connectors tearing.

▶ Always route cables and lines in such a way that no one can trip over them,

that they do not become kinked or twisted, do not rub on edges and do not run

without adequate protection through sharp-edged ducts.

Contact with hydraulic ﬂuid!

Risk of adverse health eﬀects, e.g., eye injury, skin irritation, poisoning from

inhalation.

▶ Avoid contact with hydraulic ﬂuids.

▶ When working with hydraulic ﬂuids, strictly observe the safety instructions

provided by the lubricant manufacturer.

▶ Wear your personal protective equipment (e.g., safety goggles, safety gloves,

suitable working clothes, safety shoes).

▶ Consult a doctor immediately if hydraulic ﬂuid gets in your eyes or bloodstream,

or is swallowed.

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