Industrial hydraulics-MANUAL PDF

Electric Drives
and Controls
Hydraulics
Linear Motion and

Assembly Technologies
Project Manual
Industrial Hydraulics
Trainers manual
Pneumatics
Service
RE 00845/04.07
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 training 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
qualification
Core qualification
Profession-specific specialist qualifications, e.g. the manufacture, assembly and disassembly of

assemblies and systems are to imparted in conjunction with core qualifications, e.g. planning
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 professions.
Practice-oriented
project tasks
With all practice-oriented project tasks core and specialist qualifications are imparted in an
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 project manager is reduced. In this way the trainees learn to actively proceed in line with project
management requirements.
Foreword
Notes
Introduction
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
Subject
area-specific
specialized
training
Training period (years)
Subject
area-specific
specialized
training
Profession-specific specialized training
Interdisciplinary specialized training

Basic training
Profession-specific
specialized training
over 21 months, including
specialized task in the
companys field of
activities
Integrated training
1
Common
core qualification
21 months
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 assessing. Mastering and internalizing the multitude of qualifications finally results in the professional
competence to act.
Time frame - method (source: DIHT 06/2004)
ns
at
io
Synthesis of
qualification contents
al
ns
qu
ifi
ca
tio
ist
ia
l
ec
al
qu
re
- Core qualifications
- Specialist qualifications +
Fields of activities
Sp
Training pattern
(technical structure)
2nd step
ifi
c
Analysis of qualification
requirements
Co
1st step
Field of
activities
Time frame
(time structure)
In the sense of fields of
work/activities within the
context of professionspecific business
processes
Introduction
Imparting knowledge through project work

The present Project Manual Industrial Hydraulics is intended for imparting the required specialist 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 possible 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
curriculum
The project tasks and project work described in the Project Manual Industrial Hydraulics provide 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.
Introduction
Training section 6, which is geared to hydraulic control technology, is described below.

(Training framework curriculum 10 section 1 No. 10/Control technology)
Training
section 6:
Installing and commissioning

control systems
2nd year of training

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 optimization 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
Training schedule
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.
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.
Introduction
Specialist
competence
The objectives described are geared to the development of competence to act. The trainee will
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 independently on the basis of technical knowledge and skills.
Professional
competence to act
The projects described in the project definition are oriented towards practical needs and are
characterized by a high level of conformity with customer orders from industry and trade. Customer 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 documentation 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 interrelationships 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 execution", 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.
Introduction
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
knowledge
In this manual, we do not give notes on procedural knowledge (explanatory knowledge). It is

the knowledge of how to achieve a certain result with which measures, procedures or processes - 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 specialist qualification that must be imparted in an integrated form through independent planning,
executing and checking according to the regulations for vocational training in industrial metalworking 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.
Introduction
Project designation with short description of the industrial application

The knowledge of basic principles of hydraulic control technology is to be imparted with relation 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,
pressure intensification
Safety aspects when using a single-rod cylinder and a

meter-out throttle, e.g. for an advance movement.
04
Single-rod cylinder,
flow
Different traversing speeds when extending and retracting 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 lifting 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,
pilot operated
Protection of a vertical cylinder with suspended load by

means of a pilot operated check valve. Opening the check
valve by means of a 4/2 directional valve, adjustable lowering speed.
09
Throttle valve,
adjustable
Powering a conveyor belt by means of a hydraulic motor

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,

direct operated
Preparation of a characteristic curve for the pressure/flow

relationship.
Possible use of direct operated pressure relief valves.
13
Pressure relief valve,

controls
Electrical pre-selection of various pressures (series, parallel 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.
Introduction
16
Pressure switch,
hysteresis
Working out the hysteresis of a mechanical pressure

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
21
Commissioning,
Observing regulations, safety rules and generally recinspection, maintenance, ognized technical rules when handling production and
...
hydraulic systems in everyday work.
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.
Introduction
Comparison of project exercises of Bosch Rexroth AG/BIBB

The comparison below refers to the BIBB training course Hydraulics, recommended and published by the Bundesinstitut fr Berufsbildung (BIBB).
Project
no.
Project designation
Project content
BIBB
01
Component selection for hydraulic

power unit
A1
02
Hydraulic variable displacement

pump
Pump characteristic curve
A2
03
Single-rod cylinder/pressure
Safety aspects with regard to pressure intensification
B 1.1
04
Single-rod cylinder/flow
Traversing speeds
B 1.2
05
Hydraulic motor
Lifting platform drive
B2
06
Control of direction, single-rod

cylinder
B3
07
Check valve
Protection of a hydraulic cylinder,

negative load
C1
08
Check valve, pilot operated
Check valve, flow possible from

both sides
C1
09
Throttle valve, adjustable
Conveyor belt drive
D1
10
Traversing an advance slide
D3
11
Flow control valve
Tool drive
D2
12
Pressure relief valve
Characteristic curve
Pressure relief valve controls
Pressure pre-selection on punching equipment
E1
14
Tool advance
E3
15
Pressure switch
Workpiece pressing with monitoring
E4
16
Pressure switch hysteresis
Characteristic curve
E4
17
Storing energy in view of a hydraulic pump failure
F1
18
Increasing the velocity by using the

returning oil flow
G1
19
Rapid speed/creep speed control
Production line, lifting of a pallet
G2
20
Valve circulation control
Lifting and lowering of a load
G3
21
Commissioning
Commissioning, troubleshooting,
maintenance
H1
13
E 1.2
Introduction
Component matrix
The matrix below provides an overview of the components, which are required for the individual project exercises.
Project 01 02
Component designation
ZY 1.3
Double-acting cylinders
ZY 1.Load
Double-acting cylinders with load
DM 2.N
Hydraulic motor
DW 3E
4/2 directional valve C
DW 4E
4/3 directional valve G
DW 10E
4/3 directional valve J
DW 13E
4/3 directional valve E
DS 2.1
Check valve
DS 1.1
DZ 2.1
1
Shut-off valve
DD 1.1
DD 2
DF 1.2
1
Throttle valve
DZ 2.2
DF 3
Flow control valve
DD 6.E
Pressure switch
DZ 3.2
DE 2
Limit switch
DZ 4.1
2
Distributor plate
DZ 1.4
1
Pressure gauge/minimess connection
DZ 25.1
1
Hydraulic hose/minimess connection
03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
3
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
Overview of components
Symbol
Type designation
Double-acting cylinder
with single-sided piston rod
ZY 1.3
with single-sided piston rod with load
ZY 1.Load
Fixed displacement motor with external

leakage line and two directions of rotation
DM 2.N t
4/2 directional valve with solenoid actuation, spring return
DW 3E
4/3 directional valve with direct actuation

by two solenoids, spring centering of the
central position and central position P - T,
A, B
DW 4E

central position and central position P, A
-B-T
DW 10E

central position and central position P, T,
A, B
DW 13E
Check valve with spring, flow possible in

only one direction, rest position closed,
cracking pressure 1 bar
DS 2.1
Pilot operated check valve, with spring, pilot pressure enables flow in both directions
DS 1.1
Shut-off valve, actuated by turning
DZ 2.1
Direct operated pressure relief valve, the

cracking pressure can be adjusted by
means of a spring
DD 1.1
Introduction
11
3-way pressure reducing valve
DD 2
Pressure switch, electromechanical,

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

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

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

for diaphragm-type accumulator
DZ 3.2
Pressure gauge with hose

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

check valve
DZ 25.1
Hose
VSK 1
Introduction
12
Distributor plate with four ports
DZ 4.1
Flow-meter
DZ 30
Tachometer
1)
red
black
Limit switch, inductive
blue
1)
Stopwatch
1)
No symbol according to DIN ISO 1219
DE 2.2
Introduction
13
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 instructions 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 severest 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.
Introduction
Qualification of
personnel
14
Installation, commissioning and operation, disassembly, upkeep and maintenance require fundamental 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 potential 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.
Warning
Liability
Work carried out improperly on electrohydraulic components and systems

involves the risk of injury and represents a safety risk during operation of
the system, including danger to life!
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--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--vis Bosch Rexroth AG shall
be void as well.
When using competitors' products, observe the safety notes of the manufacturer 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

Introduction
Hydraulics, derived from the Greek word hydro = water, refers, in a scientific sense, to the science 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
systems
System technologies such as hydraulics, pneumatics, electrics/electronics and mechanics

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.
Source of energy
(drive)
Hydraulics
Pneumatics
Electrics
Mechanics
El. motor
El. motor
Mains
El. motor
Combustion engine
Combustion engine
Battery
Combustion engine
Pressure vessel
Weight
Tension force by
spring
Energy transmission elements
Pipes and hoses
Pipes and hoses
Electric cables
Mechanical parts:
Levers, shafts, etc.
Magnetic field
Energy carriers
Fluids
Air
Electrons
Rigid and elastic

bodies
Force density
(power density)
High
Relatively low
Low
High
High pressures
Low pressures
cf. power/weight
ratio of el. motor to
hydraulic motor 1:10
Volume and assignment of required

installation space is
often less favorable
than with hydraulics
Good via pressure

and flow
Good to excellent
Poor
Large forces
Small installation
space requirement
Smooth control
(accelerating,
decelerating)
Excellent via pressure and flow
Motion types of
drives
Linear and rotary

movements can easily be achieved with
hydraulic cylinders
and hydraulic motors
Electrical open and

closed-loop control
Comparison of system technologies
Linear and rotary

movements can easily be achieved with
pneumatic cylinders
and pneumatic motors
Mainly rotary movements
Linear and rotary

movements
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 hydraulic systems
Transmission of large forces within a minimum of space;

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 elements
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
Electric motor,
combustion engine,
manual drive
Hydraulic system
Drive
Energy conversion
Open, closedloop control
Energy conversion
Hydraulic pump
Hydraulic open
and closed-loop
control valves
Hydraulic cylinder, hydraulic

motor
Electric energy,
thermal energy,
mechanical energy
Hydraulic energy
Working element
to be actuated
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
Check valve
Pressure relief
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
Basic symbols
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.
Supply line, return flow line, frames for components and symbols
Internal and external pilot line, leakage line,
flushing line, venting line
The crossing of two lines without connection point indicates that there is no connection
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
Throttle valve/orifice
Directional poppet valve
Two-way flow control valve
Directional spool valve
Sequencing valve
Overview of symbols according to DIN ISO 1219, part 1 (excerpt)
Hydraulic circuit
systems
In the field of hydraulics, we differentiate between three circuit 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
n = constant
Schematic
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 motor 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
diagram
Auxiliary pump for

leakage compensation
Flow
qV = variable
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.
10
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.
11
drive and control *
driving, controlling and moving

* Rexroth-specific statement
Driving machines
and systems
Hydraulic cylinders and motors

as machine elements
Driving and controlling

hydraulic cylinders and motors
Flow
Pumps
+
storage tank
Hydraulic fluids
Direction + position
are to be controlled
Start direction stop
Directional seat valves

Spool, poppet and
isolator valves
The required force

is to be adjustable
Pressure
Pressure control valves

limit reduce switch
The required velocity

is to be adjustable
Velocity
Flow control valves

Throttles orifices
System technology optimized

to suit the specific application
Demands made on hydraulic cylinders / motors as drive elements
Power units & accessories

accumulators pressure
switches pressure gauges
heat exchangers
12
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:
p=
F
A
or:
A=
F
p
F = pA
Force = pressure area
F
Pascal is the SI unit of pressure. It was named after Blaise Pascal.

1 Pa =
1 kg
m s
= 1 N/m2
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 transmission
13
In a closed system with two cylinders of different size, only one pressure (p) can prevail. If both
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.
Cylinder 1 means:
p=
F1
Cylinder 2 means:
p=
F2
A1
A2
F1
If p is identical in both cylinders, this means:
F1
Rearranged by force:
A2
A1
A1
F2
A2
A2
= F2
A1
is the area ratio of the cylinders and is identified by letter .
Consequently:
Example:
Area A1
Area A2
Weight force F1
Weight force F2
F1 = F2
Solution:
=
50 cm2
= 750 cm2
= 1.000 daN
=
?
F1
750 cm2
1.000 daN
or with =
A2
= F2
A1
50 cm2
A2
A1
= 15.000 daN
750
= 15
50
F1 = 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 intensification
14
The extending speed of a piston is to be adjustable by means of a meter-out throttle.

Which risk arises, when the throttle is completely closed, e.g. due to dirt?
Example:
pK = 100 bar
= 2 : 1
AK
AR
Solution:
pK = pR
2
100 bar
= 200 bar
1
pR = 200 bar
Conclusion:
Meter-out throttling involves the risk of pressure intensification!
ASt
AK
pK
pR
AR
Flow
15
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 displaces 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 generated by the pump.
The pump only displaces fluid into the system.
qV in l/min
t in
s in mm
A in cm2
qV in l/min
V
As
=
t
t
qV = A v 6 in l/min
qV =
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:
qV =
Vg n
1.000
in l/min
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
16
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
qV =
V
t
Fluid volume V is the product from area A times distance s

If A s is subsituted for V, q is then given by
qV =
Distance s divided by time t provides velocity v
V=As
As
t
v=
s
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

=
A
v 2 = v1 1 > v1
A2
A2 v2
17
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
Resistant to aging
Demands made on hydraulic fluids
Not detrimental to health

No tendency towards
foaming
Good air separation
capacity
Neutral against bearings,

good shear stability
18
Requirements of
the market
None of the fluids offered on the market today can meet all of the requirements listed on the
previous page. Even in view of ongoing discussions about environmental compatibility of hydraulic 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
data
For determining the application limits of a hydraulic system and consequently for the selection
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.
19
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

mineral oils
Flame-retardant hydraulic
oils
Fast bio-degradable
hydraulic oils
Hydraulic oils compatible

with foodstuffs
DIN 51 502, ISO 6743/4
7. Lux. report,
ISO 6743/4, ISO/CD
12922, DIN 51 502,
Factory Mutual - USA
VDMA sheet 24568, ISO

6743/4 and ISO 15380
FDA, USDA and NSF

classification
DIN 51
524
ISO/DIS
11158
Containing
water
HL
HLP
HLPD
HVLP
HVLPD
HH
HL
HM
HR
HV
HS
HG
HFAE
HFAS
HFB
HFC
Source: Specialist magazine 0 + P
Water-free
HFDR
HFDU
Waterinsoluble
Watersoluble
HETG
HEES
HEPR
HEPG
HSF H1
NSF H2
Basis white
oil
Basis white
oil
Basis PAO
Basis PAO
Basis
mineral oil
20
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
(symbol) DIN
Code letter
(symbol) ISO-L
Composition
Typical properties
Field of application
Operating temperature
HH
Mineral oils without active additives (base oils)
Hydraulic systems without specific

requirements (only in rare applications today)
-10 to 90 C
HL
Mineral oils with active additives

to increase the resistance to
aging and to improve corrosion
protection
Hydrostatic drives with high thermal stress, good water separation

capacity
-10 to 90 C
HM
Mineral oils of type HL with active

additives to improve wear protection in the mixed friction area
Hydrostatic drives with high thermal stress, which require additives

for the reduction of wear, good
water separation capacity
-20 to 90 C
--
HR
Mineral oils of type HL with active

additives to improve viscosity /
temperature characteristics
Extended operating temperature

range when compared with HL
oils
-35 to 120 C
HVLP
HV
Mineral oils of type HM with active

additives to improve viscosity /
temperature characteristics
Among others, hydrostatic drives

in mobile hydraulics
-35 to 120 C
--
HS
Synthetic fluids without specific

flame-retardant properties
Special applications in hydrostatic

systems
-35 to 120 C
HG
Mineral oils of type HM with active additives to improve stick-slip

characteristics
Hydrostatic systems with plain

bearings at intermittent, low velocities
-30 to 120 C
--
Mineral oils of type HM with

detergent / dispersive (DD) additives; DD additives reduce friction
values
Hydrostatic drives with high thermal stress, which require EP/AW

additives; DD additives hold contaminations in balance, e.g. in machine tools and mobile systems.
--
HL
HLP
(HLPD)
HLPD
21
Classification of
flame-retardant
hydraulic fluids
and water-free,
fast bio-degradable hydraulic
fluids
Code letter according to
Composition
7th Luxemb. report,
Typical properties
DIN 51 502 and
DIN EN ISO 6743/4: April 2002
Operating temperatures
(Notes)
Flame-retardant, water-containing hydraulic fluids

HFA-E
Oil-in-water emulsions, mineral oil / Power hydraulics of about 300 bar, for
synth. esters
example in shield tunneling in the field
Concentrate share < 20 %
of mining
HFA-S
Mineral oil-free watery solutions of Hydrostatic drives - working pressures

chemicals
< 160 bar
Concentrate share < 20 %
5 to < 55 C
HFB
Water-in-oil emulsion
Share of mineral oil 60 %
For example in British mining

5 to 60 C
HFC
Watery polymeric solution

Water share > 35 %
Hydrostatic drives, industrial and mining

hydraulics
-20 to 60 C
Water-free, synthetic, flame-retardant hydraulic fluids
HFD-R
Lubrication and control of steam turSynthetic fluids based on phosphate bines, industrial hydraulics
esters,
-20 to 150 C
water-free
in hydrostatic systems often
10 to 70 C
HFD-U
Synthetic fluids of other composition

Hydrostatic drives, industrial hydraulics
(mostly carboxylic acid, polyesters)
-35 to 90 C
water-free
Code letter according to

VDMA 24568 and ISO 15380
Composition
Typical properties
Operating temperatures
(Notes)
Water-free, fast bio-degradable hydraulic fluids

HEPG
Polyalkylene glycol
Water-soluble
Hydrostatic drives,
e.g. ship lock hydraulics
-30 to < 90 C
HETG
Triglycerides (vegetable oils)

Not water-soluble
Hydrostatic drives,
mobile hydraulics
-20 to 70 C
HEES
Synthetic esters
Not water-soluble
Hydrostatic drives,
mobile and industrial hydraulics
-35 to 90 C
HEPR
Hydrostatic drives,
Polyalpha olefins (synth. hydrocarbons)
mobile and industrial hydraulics
Not water-soluble
-35 to < 80 C
10.000
Viscosity mm2/s
Viscosity/
temperature
diagram
22
1.000
* Max. permitted
* Permitted briefly for

cold start (cavitation)
100
Recommended range for

continuous operation
36
20
12
10
9
8
0
68
10
G
VG V
46
2
O SO
2
G
I
3
2
15
V
IS
VG VG
VG
O
O
IS
IS
Ideal operating point

Reference point for all data
* Min. permitted
(lubrication problems)
IS
IS
5
4
3,0
-40
-30
-20
-10
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
Comparison of
different
viscosity classes
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.
SAE classes
ISO - VG
(DIN 51519)
SAE classes
30
100
68
68
20, 20 W
46
10 W
32
5W
22
49
36
25
16
(15)
10
Additives
23
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
24
Practical notes
Effects of air
in the oil
Air can be present in hydraulic oils in the following forms: as dissolved air (invisible), as surface
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
aspects
Hydraulic systems are closed systems. When hydraulic systems are used properly, hydraulic fluid
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 connections 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 inflammable. Pressure fluids may only be used, if the corresponding safety data
sheet of the manufacturer is at hand and all precautions prescribed therein
are observed.
Danger
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
25
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 surroundings 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 components, 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 produced.
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 m

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
26
Gear pump
J1 from 0.5 to
J2 from 0.5 to
5 m
5 m
Vane pump
J1 from 0.5 to 5 m
J2 from 5 to 20 m
J3 from 30 to 40 m
Piston pump
J1 from 5 to 40 m
J2 from 0.5 to
1 m
J3 from 20 to 40 m
J4 from 1 to 25 m
Valve
J1 from 5 to 25 m
Servo-valve
J1 from 0.5 to 8 m
J2 from 100 to 450 m
J3 from 20 to 80 m
Causes and
sources of
contamination
1
2
3
4
5
External contamination
Installation + repair
Fresh oil
Abrasion in the pump
Abrasion of seals
27
Arrangement of
filters in the open
circuit
28
The task of filters is directly related to their arrangement in the system.

Filters perform certain tasks depending on their location in the system.
Main flow filtration
Control
1
8
10
3
2
5
4
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
Off-line filtration
Filter types
29
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.
30
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
31
Filler and breather

filter
Symbol for filler and breather filter without (on the left-hand
side) and with by-pass valve (on the right-hand side)
Filler and breather filter with and without filling filter
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
32
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

filtration rating
33
Finest particle
contamination
Finest particles (3 to 5 m)
cause an impairment of
function and reduction in the
performance due to:
the erosive effect of finest
particles (often erosion on
control lands)
fine sedimentation in narrow gaps (through edge
filtration effect - risk of
clogging)
Changes of the operating
medium (oil aging) as a result of chemical reactions
on the particle surface
Finest filtration
Fine particle
contamination
Fine particles (5 to 20 m)
cause cratering mainly in
narrow fits.
The consequences are:
Increase in clearance due
to abrasion (increased
internal leakage)
Temporary failure (brief
seizing effect on sliding
spool valves or leakage on
valve seats)
Coarse particle
contamination
Coarse particles > 20 m
often cause a sudden total
failure due to clogging and
blocking effects or direct
destruction.
Typical:
Blocking of nozzles
Jamming or seizing of
spools
Material breakouts due to
effect of large forces
Total failure due to severe

abrasion
Fine filtration
Effective separation of finest- Partial separation of fine

dispersed particles
particle contamination and
(b3 to 5 100)
complete separation of
coarse-grain contamination
High differential pressure(b5 to 20 100)
stable finest filters safeguard
the function
Fine filters reliably control
the acceptable degree of
They minimize the formacontamination of the system
tion and further development of erosion
They protect components
optimally against contami They prevent clogging of
nation
narrow gaps
They reduce cratering
They provide protection
against aging of oil
They prevent sudden
failures of components
They prevent system
malfunction
Coarse filtration
Separation of mainly coarse
particles (bX 100)
X = m particle size, which
can cause a sudden failure
on the component to be
protected.
Coarse filters protect the
system against coarse
particle contamination
They reduce the risk of a
sudden failure or total loss.
Classification
systems for the
degree of contamination of the
hydraulic fluid
34
The solid particle content in the hydraulic fluid is determined with the help of classification
systems (standardized cleanliness classes).
The most common standards today are NAS 1638 (National Aerospace Standard) and DIN
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.
Contamination class
Particle size in m
5 - 15
15 - 25
25 - 50
50 - 100
> 100
00
125
22
250
44
500
89
16
1000
178
32
2000
356
63
11
4000
712
126
22
8000
1425
253
45
16000
2850
506
90
16
32000
5700
1012
180
32
64000
11400
2025
360
64
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
according to
ISO DIS 4406
Assignment of
scale numbers
35
Number of particles per milliliter

more than
Scale number
up to and including
2500000
> 28
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
10
10
2.5
1.3
2.5
0.64
1.3
0.32
0.64
0.16
0.32
0.08
0.16
0.04
0.08
0.02
0.04
0.01
0.02
0.00
0.01
Filter clogging
indicators
36
Inside the clogging indicators, each change in pressure is recorded as change in travel by means
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
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' products 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.
Warning
For this reason, commissioning is prohibited until it was established that the
electrohydraulic components and systems to be used meet the stipulations
of all relevant EU Directives.
Fundamental, general safety notes
Observe
Warning
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, precautions must be taken to ensure that no dangerous situation can arise. The higher-order machine
operating instructions must be observed.
Safety notes
Adjustment features on components may exclusively be operated or changes to programmable 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 unknowingly 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:
Project 01: Hydraulic power unit

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 technological 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.
01
Project 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
01
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 provision 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
Notes
Informing:
Accepting and understanding the order, among others, through discussions

with the customer.
Planning:
Planning and organizing the execution of the customer order; among others, 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?
Project 01:
01
Hydraulic schematic diagram
Item 10.0
Item 9.0
Measuring glass
Item 6.0
Item 2.0
Item 4.0
Item 7.0
Item 8.0
Item 3.0
Item 1.0
Fig. 01.2 Hydraulic schematic diagram: Drive power unit
Item 5.0
Project 01:
01
Component selection with parts list

Item
Qty
Type designation
1.0
Reservoir with cover
2.0
Variable displacement pump,

pilot operated
3.0
Level control
FSK
4.0
Electric motor
4 KW/1450 rev/
min.
5.0
Shut-off valve, operated by turning
6.0
Check valve with spring, flow

enabled in only one direction;
closed at rest position
S6-1X/...
7.0
Filter with by-pass valve and

pressure measuring device
RF 060...
8.0
Tank breather filter
9.0
Connection block with 1/4" coupler

plug
10.0
Measuring glass
Symbol
100 L/steel
PV7-1X/16-30...
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.
Warning
Caution
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.
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
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
Flow control valve

Change in velocity
Force F
Force = pressure area
v
Pressure differential p
Energy converter
e.g. cylinder
Annulus area AA
Directional valve
Start, direction, stop
Force
pA
10
F =
F = force in N
p = pressure in bar
A = area in mm2
Velocity
v=
s
t
v = velocity in
s
s = travel in m
t = time in s
Displacement/flow
Vg n vol
qV =
1000
qV = flow in
l
min
cm3
rev
n = Speed of the pump shaft in rev
min
Vg = geometric displacement in
= volumetric efficiency in %
Pressure control
valve
Force / pressure
limitation
Motor power
PM =
PM
p
qV
total,P
Energy converter
e.g. fixed displacement pump
Fig. 01.3 Physical basic principles with formulas
p qV
600 total ,P
=
=
=
=
power in kW
pressure in bar
l
flow in
min
overall efficiency in %
Project 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
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 specified by the component manufacturer. State of art with regard to minimum requirements is,
for example, NAS class 9 and a minimum retention rate of 10 100; ISO 4406 (c) class
20/18/15.
A reliable calculation of cleanliness is impossible, because the ingress of dirt in relation to
the 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.
01
Project 01:
10
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:
qV =
Vg n
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=
p qV
600
in kW
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 previous page.
01
Project 01:
11
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.
01
Project 01:
Notes
12
01
Project 01:
Project schedule: Project 01

13
Q.
Public, John
Last name, first name
Project handler
Customer requirement:
Hydraulic circuit diagram
Parts list
Information about components
Project designation
Informing
from the project definition.
Planning steps
Planning
of the project objective and
the proceeding.
System rating/calculation
Understand the circuit diagram
Identifiy components
Supplement parts lists
Rate components
Evaluate the result
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
Decision-making
Deciding on
and selecting components;
complementing the circuit
diagram and parts list.
(Overleaf)
01
Project 01:
14
01
Summarize the information obtained
Execution
Set-up of the electrohydraulic control and acquisition of required data.
Special points?
Pump data sheet RE 10515 is very complex
Comparison of summary with customer requirements
Quality check
Checking
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
Project 02: Hydraulic pump/characteristic curve of variable displacement pump

In a hydraulic system, fluid flow generators/hydraulic pumps convert the mechanical energy
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 resistances 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
02
Project 02:
Project definition
In a hydraulic power unit, the hydraulic energy is to be provided by a variable, pilot operated
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 qualification)
02
Project 02:
Project steps
Notes
Informing:

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, documenting the characteristic curve required by the customer and providing
explanations with regard to the characteristic curves and power losses.
Checking:
Evaluating:

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

Item
Qty
Type designation
1.0
Direct operated pressure relief

valve; the cracking pressure can be
adjusted by means of a spring
DD 1.1
1.1
DF 1.2
1.2
Shut-off valve, operated by turning
DZ 2.1
0.1
Pressure gauge with hose and

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

minimess connection
DZ 25.1
Hose with quick-release coupling,

with check valve
1
Symbol
VSK 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.
02
Project 02:
Component arrangement
Connection block
Measuring glass
02
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 Rexrothspecific designations. Also the grid layout is Rexroth-specific and adapated for use on the
training system.
Notes
Project 02:
Safety notes
Warning
Caution

injury and a safety risk can arise operation of the system, including danger
to life.
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.
Warning
Caution
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
and cause a slipping risk.
Before commissioning the hydraulic control, i.e. before switching the hydraulic pump on, check, whether all pressure control valves are set to minimum
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).
02
Project 02:
Flow measurement
5. Open shut-off valve item 1.2.
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.
Caution
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.
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
bar
15
30
40
45
50
Time
10
10
10
10
10
Volume
1.32
1.25
1.20
1.10
Flow
qV
l/min
7.92
7.50
7.20
6.60
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 %.
02
Project 02:
Flow qV in l/min
02
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:
10
Notes
02
Project 03:
Single-rod cylinder / pressure intensification
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:
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
p in bar; A in cm
m2
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 intensification 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 pressure 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 meterout 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
03
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.
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)
03
Project 03:
Project steps
Notes
Informing:

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, 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 explanations with regard to pressure intensification on the basis of a calculation
example.
Checking:
Evaluating:

03
Project 03:
03
Item 1.0
Item 0.2
Item 0.3
Item 1.3
Item 1.1
Item 0.1
Item 1.2
Power unit limit
Fig. 03.2 Hydraulic circuit diagram: Feeding cylinder
Measuring
glass
Project 03:
Electrical circuit diagram
03
Control 4/2 directional valve

Retraction
-Single-rod cylinderNote:
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:

Item
Qty
1.0
ZY 1.3
1.1
4/2 directional valve with solenoid

actuation, spring return
DW 3 E
1.2

valve, the cracking pressure can be
DD 1.1
1.3
DF 1.2
DZ 4.1

without check valve
DZ 1.4
Hose with quick release coupling

with check valve
DZ 25.1
0.1 - 0.3
Hose
Type designation
VSK 1
Symbol
03
Project 03:
Connection block
Measuring glass
03
Note:
Fig. 03.4 Recommended component arrangement with component designations for parts list Table 03.1 and hydraulic circuit diagram Fig. 03.2
Note:
The designations of components in the parts list and the component arrangement are Rexrothspecific designations. Also the grid arrangement is Rexroth-specific and adapted for use on
the training system.
Notes
Project 03:
Safety notes
Warning
Caution

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
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
Caution
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.
03
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 intensification. Note the measured values and enter them in Table 03.2.
Caution
After having completed practical work on the training system switch the
hydraulic pump off! Turn pressure relief valve Item 1.2 back to minimum
pressure. No pressure gauge may indicate a pressure!
Measured values
Hydraulic
cylinder
Measuring point M1
System pressure p in bar
M2 piston side
p in bar
M3 piston rod side

p in bar
48
48
82
Extending/
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:
Piston rod diameter:
25 mm
18 mm
Apiston = 4,91 cm2

Arod = 2,54 cm2
Aannulus = 2,3
37 cm2
4,91 cm2
2,54 cm2
= 2,07 : 1
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
03
Project 03:
10
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.
Single-rod cylinders are pressure intensifiers.
Velocities can be kept constant over the entire stroke.
03
Project 04:
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
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
AK
AR
AR
Area ratio of the single-rod cylinder

40
20
10
Values in l/min
20
e.g.

qV = 20 l/min
= 2 : 1
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 extension 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 filtration 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 piston 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
04
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
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)
04
Project 04:
Project steps
Notes
Informing:

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).
Deciding:
Executing:
Set-up of the hydraulic control on the training system. Prepration and documentation of the information and explanations with regard to the single-rod
cylinder as demanded by the customer.
Checking:
Evaluating:

04
Project 04:
Item 1.0
04
Item 0.2
Item 0.3
Item 1.1
Item 0.1
Item 1.3
Item 1.2
Power unit limit
Fig. 04.2 Hydraulic circuit diagram: Feed cylinder
Measuring
glass
Project 04:
04

Retraction
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:

Item
Qty
Type designation
1.0
Double-acting cylinder with singlesided piston rod
ZY 1.3
1.1

DW 3 E
1.2

DD 1.1
1.3
DF 1.2
DZ 4.1

without check valve
DZ 1.4

with check valve
DZ 25.1
0.1 - 0.3
Hose
1
Stopwatch
Flowmeter
VSK 1
DZ 30
Symbol
04
Project 04:
04
Measuring glass
Note:
The component arrangement
shows the optional variant with
electronic flow measurement
Connection block
Note:
Note:
Notes
Project 04:
Safety notes
Warning
Caution

danger to life.
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
depressurized.


of hoses.
Warning
Caution
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 directional 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.
04
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
pressure gauge may indicate a pressure!
Measured values
Hydraulic
cylinder
Piston position
Position
4/2 directional
valve
M1
M2
M3
p in bar p in bar p in bar
t
in s
v
in m/s
V
in l
Extending
49
0.051
Extended
50
49
0.098
Retracting
49
3.2
0.073
Retracted
50
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
Bore:
25 mm
Piston rod diameter:
16 mm

Piston stroke:
Apiston = 4.91 cm2

Arod
= 2.01 cm2
Aannulus = 2.90 cm2
200 mm = 20 cm
V = A s
Fill:

Piston volume:

Type: CD T3...25/16...200
A in cm2
s in mm
V in l
V = 4.91 cm2 20 cm = 98.2 cm3 = 0.098 l

V = 2.90 cm2 20 cm = 58.0 cm3 = 0.058 l
04
Project 04:
10

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
Project 05: Hydraulic motor

If the hydraulic force is to be transmitted via a rotary movement to an actuator in a hydraulic system, 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.
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
05
Project 05:
Hydraulic motor
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 desirable 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.
Fig. 05.1 Practical example: Winch for lifting heavy loads
Project tasks
technology
Analyzing the technical data sheet of a hydraulic motor (specialist qualification)
05
Project 05:
Hydraulic motor
Project steps
Notes
Informing:

with the customer.
Planning:
through the selection of hydraulic components from the data sheet collection
(RE 91001 Axial piston motor).
Deciding:
Executing:
documenting the system parameters required by the customer.
Checking:
Evaluating:

05
Project 05:
Hydraulic motor
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
Item 1.2
Power unit limit
Fig. 05.2 Hydraulic circuit diagram: Lifting platform control
Measuring
glass
Project 05:
Hydraulic motor
05
Stop

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

Item
Qty
1.0
Fixed displacement motor with

external leakage line and two
directions of rotation
1.1
4/3 directional valve with direct

actuation by two solenoids, spring
centering of the central position
and central position P, T, A, B
DW 13 E
1.2/1.4

DD 1.1
1.3
DF 1.2
DZ 4.1

without check valve
DZ 1.4

with check valve
DZ 25.1
0.1 - 0.4
Hose
1
Stopwatch
Tachometer
Flowmeter
Type designation
Symbol
DM 8
05
VSK 1
DZ 30
Project 05:
Hydraulic motor
Connection block
Measuring glass
05
Note:
Note:
Notes
Project 05:
Hydraulic motor
Component arrangement/optional
Note:
Connection block
Measuring glass
05
Note:
Note:
Notes
Project 05:
Hydraulic motor
Safety notes
Warning
Caution

danger to life.
depressurized.


of hoses.
Warning
Caution
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
of slipping.
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.
05
Project 05:
Hydraulic motor
10
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.
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 measurement 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
Throttle valve Item 1.3
M1
M2
M3 M2 - M3 M4
qV
n
p in bar p in bar p in bar Dp in bar p in bar in l/min in min-1
Throttle closed
50
turn opened
49
20
17.5
2.5
15
264 *
turn opened
48
22
19
16
2.6
335 *
1 turn opened
48
25
21
17.5
3.7
435 *
1 turn opened
48
30
25
18
4.7
540 *
2 turns opened
48
31
25
19
5.1
595 *
More than 2 turns opened
48
34
27
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.

05
Project 05:
Hydraulic motor
11
Additional tasks:
Calculation of the output power at maximum speed using the formulas below.
P=
qV =
n=
p qV
600
in kW
V
60
t
qV vol
Vg
1000
P = output power in kW
p = pressure in bar
qV = swept volume in l/min
V = content of the measuring glass in l
t = measuring time in s
n = drive speed in min-1
hvol = volumetric efficiency of the motor
Vg = geometric swept volume (displacement) of the
motor in cm3/rev
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.
05
Project 05:
Hydraulic motor
12
Notes
05
Project 06:
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.
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 actuators.
With the help of the control set up on the training system the trainee gets familiar with the possible 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 differentials 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
06
Project 06:
Project definition
A single-rod cylinder is to shift and position tools horizontally in a fixture. When in the rest position 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
Notes
Informing:

with the customer.
Planning:
collection (RE 23178/4/3 directional valve).
Deciding:
Executing:
documenting the system parameters as required by the customer.
Checking:
Evaluating:

06
Project 06:
Hydraulic circuit diagram/task 1
Item 1.0
Item 0.2
Item 0.3
06
Item 1.1
Item 0.1
Item 1.3
Power unit limit
Fig. 06.2 Hydraulic circuit diagram: Tool carriage control 1
Measuring
glass
Project 06:
Electrical circuit diagram/task 1
06
Circulation

Extension Retraction
-Single-rod cylinder-
Project 06:
Hydraulic circuit diagram/task 2
Item 1.0
Item 0.2
Item 0.3
06
Item 1.2
Item 0.1
Item 1.3
Power unit limit
Fig. 06.4 Hydraulic circuit diagram: Tool carriage control 2
Measuring
glass
Project 06:
Electrical circuit diagram/task 2
06
Stop

Retraction Extension
Project 06:

Item
Qty
1.0
ZY 1.3

and central position P - T, A, B
DW 4E
1.2

DW 13E
1.3

DD 1.1
DZ 4.1

without check valve
DZ 1.4

with check valve
DZ 25
Hose
VSK 1
1.1
0.1 - 0.3
Flowmeter
Table 06.1 Parts list for hydraulic circuit diagrams Fig. 06.2 and 06.04
Type designation
Symbol
06
DZ 30.N
Project 06:
Note:
Connection block
Measuring glass
Component arrangement/task 1
06
Note:
Note:
Notes
Project 06:
10
Note:
Connection block
Measuring glass
Component arrangement/task 2
06
Note:
Note:
Notes
Project 06:
11
Safety notes
Warning
Caution

danger to life.
depressurized.

Task 1
Set-up of the controls as described below:


of hoses.
Warning
Caution
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 energized. 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.
06
Project 06:
12
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
Task 2
6. Modify the hydraulic control according to hydraulic circuit diagram 06.4. Proceed as described in task one, steps 1 and 2.

Check the electrical control for correct wiring.
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 energized. 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
Position
Directional valve
position
M1
p in bar
M2
p in bar
M3
p in bar
qV
in l/min
Piston extended
30
30
7.66
Piston retracted
30
30
7.66
Rest position of piston
Table 06.2 4/3 directional valve with circulation position
06
Project 06:
13
Measured values for task 2

Hydraulic cylinder
Position
Directional valve
position
M1
p in bar
M2
p in bar
M3
p in bar
qV
in l/min
Piston extended
30
30
7.66
Piston retracted
30
30
7.66
Piston at rest position
30
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:
14
Notes
06
Project 07:
Check valve
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.
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 operating 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
07
Project 07:
Check valve
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 protected 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 documentation.
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:
Check valve
Project steps
Notes
Informing:

with the customer.
Planning:
collection (RE 20375 Check valve).
Deciding:
Executing:
documenting the system parameters requred by the customer.
Checking:
Evaluating:

07
Project 07:
Check valve

Item 1.0
Item 0.3
Item 1.6
Item 0.2
Item 1.5
Item 1.3
07
Item 1.4
Item 1.1
Item 0.1
Item 1.2
Power unit limit
Fig. 07.2 Hydraulic circuit diagram: Control of a vertical cylinder with suspended load
Measuring
glass
Project 07:
Check valve
07
(Emergency stop)
Stop

Retraction
-Single-rod cylinder* Solenoid Y1.b
is not energized
Fig. 07.3 Wiring diagram re hydraulic circuit diagram 07.2
Project 07:
Check valve

Item
Qty
1.0
with single-sided piston rod with
load
1.1

and central position P, A - B - T
DW 10E
1.2/1.5

DD 1.1
1.3

possible in only one direction, rest
position closed, cracking pressure
1 bar
DS 2.1
1.4
Shut-off valve, actuated by turning
DZ 2.1
1.6
DF 1.2
DZ 4.1

without check valve
DZ 1.4

with check valve
DZ 25
Hose
VSK 1
0.1 - 0.3
Type designation
Symbol
ZY 1.Last
07
Project 07:
Check valve
Measuring glass
Connection block
07
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:
Check valve
Safety notes
Warning
Caution

danger to life.
depressurized.


of hoses.
Warning
Caution
of slipping.

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).
07
Project 07:
Check valve
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
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 practical applications, e.g. in a welding fixture. The upward stroke is accomplished via a check
valve installed in parallel.
Caution
hydraulic pump off! Set the throttle valve and the pressure relief valves to
minimum pressure. For the disassembly, the load must be lowered. No pressure 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 direction of flow.
A check valve can be used as safety valve, e.g. to provide protection against pressure
peaks.
07
Project 07:
Check valve
10
Notes
07
Project 08:
Project 08: Check valve, pilot operated

In contrast to simple check valves, pilot operated check valves can also be opened in the direction 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 direction, if it is opened by means of a hydraulic control signal.
The check valve can only be closed when the pilot line is depressurized.
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
08
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 qualification)
Project 08:
Project steps
Notes
Informing:

with the customer.
Planning:
collection (RE 21460 / pilot operated check valve).
Deciding:
Executing::

Checking:
Evaluating:

08
Project 08:

Item 1.0
Item 0.3
Item 1.6
Item 0.2
Item 1.4
Item 1.3
Item 1.5
08
Item 1.1
Item 0.1
Item 1.2
Power unit limit
Fig. 08.2 Hydraulic circuit diagram: Check valve, hydraulically pilot operated
Measuring
glass
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:

Item
Qty
1.0
Double-acting cylinder with piston

rod with load on one side
ZY 1.Last
1.1

centring of the central position and
central position P, A - B - T
DW 10E
1.2/1.5

DD 1.1
1.3

operation, spring return
DW 3E
1.4
Pilot operated check valve, with

spring, flow possible in both
directions due to pilot pressure
DS 1.1
1.6
DF 1.2
Distributor plate with four

connections
DZ 4.1

check valve
DZ 1.4

with check valve
DZ 25
Hose
VSK 1
0.1 - 0.3
Type designation
Symbol
08
Project 08:
Measuring glass
Connection block
08
D
Note:
Note:
training system.
Project 08:
Safety notes
Warning
Caution

injury and a safety risk can arise operation of the system, including danger
to life.
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
Caution
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:
Caution
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
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 extend.

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.
Caution
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 vertical cylinder. This causes underpressure in the piston chamber and hence
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.
Caution
Notes
Before converting the circuit for the further execution of the order, switch
the hydraulic pump off!
08
Project 08:
10
Measured values
M1
p in bar
M2
p in bar
M3
p in bar
Lower cylinder via the pressure relief valve
45
45
70
Lower cylinder via the check valve
20
10
15
Measuring point
Table 08.2 Lowering pressures

08
Caution
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 minimum pressure. No pressure gauge may indicate a pressure!

Fluid can only flow through a hydraulically pilot operated check valve in the checking direction, 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:
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 changing 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 constant.
The control set up on the training system allows the trainee to measure various differential pressures 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
09
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 documentation.
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
Informing:

with the customer.
Planning:
collection (RE 27219 Throttle check valve).
Deciding:
Executing:
documenting the system parameters requred by the customer.
Checking:
Evaluating:

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
09
Item 1.4
Load pressure
Item 0.1
Item 1.2
Power unit limit
Fig. 09.2 Hydraulic circuit diagram: Throttle valve, adjustable
Measuring
glass
Project 09:
Stop
09

Rotation
Rotation
-Hydraulic motor-
Project 09:

Item
Qty
1.0

external leakage line and two
DM 2.N
1.1

DW 13E
1.2/1.4

DD 1.1
1.3
DF 1.2
DZ 4.1

without check valve
DZ 1.4

with check valve
DZ 25
Hose
VSK 1
0.1 - 0.3
Stopwatch
Flowmeter
Type designation
DFF 1
Symbol
09
Project 09:
Connection block
Measuring glass
Note:
Fig. 09.4 Recommended component arrangement with component designation for parts list 09.1 and hydraulic circuit diagram Fig. 09.2
Note:
Notes
09
Project 09:
Safety notes
Warning
Caution

danger to life.
depressurized.
09


hoses.
Warning
Caution
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.
Caution
After having completed practical work on the training system, switch the
hydraulic pump off! Open the throttle valve and set the pressure relief valves
to minimum pressure. No pressure gauge may indicate a pressure!
10. Optional: Carry the measured values over in a Diagram 09.1.
Measured values
Throttle
Item 1.3
1st
position
Throttle
Item 1.3
2nd
position
Throttle
Item 1.3
3rd
position
M3
p in bar
M2
p in bar
M2 - M3
p in bar
q
in l/min
M3
p in bar
M2
p in bar
M2 - M3
p in bar
q
in l/min
M3
p in bar
M2
p in bar
M2 - M3
p in bar
q
in l/min
20
25
30
35
40
50
46
46
47
47
47
48
26
21
17
12
1.98
1.74
1.47
1.20
0.87
20
25
30
35
40
50
44
45
45
46
47
48
24
20
15
11
3.64
3.22
2.77
2.26
1.71
20
25
30
35
40
50
39
41
43
44
45
48
19
16
13
6.40
5.82
5.09
4.20
3.18
Table 09.2 Measurement results from execution of the order
09
Project 09:
10

1st position
2nd position
3rd position
Differential pressure p in bar
30
25
20
15
10
5
09
0
0
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 crosssection 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:
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 pressure 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).
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 throttling 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
10
Project 10:
Project definition
In a machining station (bending of a roll seam) the hydraulic advance velocity is to be adjustable.
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 understand 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 technology
Analyzing the technical data sheet of a throttle check valve (specialist qualification)
Project 10:
Project steps
Informing:

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.
Deciding:
Executing:
Checking:
Evaluating:

10
Notes
Project 10:
Hydraulic circuit diagram 1

Item 1.0
Item 0.2
Item 0.3
Item 1.3
Item 1.1
10
Item 0.1
Item 1.2
Power unit limit
Fig. 10.2 Hydraulic circuit diagram: Meter-in throttle - extending a single-rod cylinder
Measuring
glass
Project 10:

Item 1.0
Item 0.2
Item 0.3
Item 1.3
Item 1.1
10
Item 0.1
Item 1.2
Power unit limit
Fig. 10.3 Hydraulic circuit diagram: Meter-out throttle - extending a single-rod cylinder
Measuring
glass
Project 10:

Item 1.0
Item 0.2
Item 0.3
Item 1.3
Item 1.1
10
Item 0.1
Item 1.2
Power unit limit
Fig. 10.4 Hydraulic circuit diagram: Meter-in throttle - retracting a single-rod cylinder
Measuring
glass
Project 10:

Item 1.0
Item 0.2
Item 0.3
Item 1.3
Item 1.1
10
Item 0.1
Item 1.2
Power unit limit
Fig. 10.5 Hydraulic circuit diagram: Meter-out throttle - retracting a single-rod cylinder
Measuring
glass
Project 10:
Stop
10

Fig. 10.6 Wiring diagram for hydraulic schematic diagrams Fig. 10.2 to 10.5
Project 10:

Item
Qty
Type designation
1.0
1.1

DW 13E
1.2

DD 1.1
1.3

DF 2.2
Symbol
ZY 1.3
10
0.1 - 0.3
DZ 4.1

without check valve
DZ 1.4

with check valve
DZ 25
Hose
VSK 1
Table 10.1 Parts list for hydraulic circuit diagrams 10.2 to 10.5
Project 10:
10
Connection block
Measuring glass
Component arrangement 1
Note:
Fig. 10.7 Recommended component arrangement with component designation for parts list Table 10.1 and hydraulic circuit diagram 10.2
Note:
Notes
10
Project 10:
11
Connection block
Measuring glass
Note:
Note:
Notes
10
Project 10:
12
Connection block
Measuring glass
Note:
Note:
Notes
10
Project 10:
13
Measuring glass
Connection block
Note:
Fig. 10.10 Recommended component arrangement with component designation for parts list Table 10.1 and hydraulic circuit diagram 10.5
Note:
Notes
10
Project 10:
14
Safety notes
Warning
Caution

danger to life.
depressurized.

Set up the controls as described in the following:

hoses.
Warning
Caution
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.
10
Project 10:
15
Before making any conversion for further order processing, switch the hydraulic 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 adjustment 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.
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 adjustment 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.
Caution
hydraulic pump off! No pressure gauge may indicate a pressure! Open the
throttle check valve.
10
Project 10:
16
Measured values
M2
p in bar
M3
p in bar
Meter-in throttle, piston side

extending
Meter-out throttle, piston rod side

extending
50
77
Meter-in throttle, piston rod side

retracting
Meter-out throttle, piston side

retracting
27
50
Measuring points
Table 10.2 Measurement results from the execution of the order
The measurement results were obtained at an oil temperature of approx. 20 C.

Warning
Safety note from accident prevention regulations:

If there is a riks of pressure intensification on the piston rod side, protection
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 pressure.
To provide protection against pressure intensification a pressure relief valve can be installed.
The flow through a throttle check valve depends on the differential pressure p.
10
Project 11:
Flow control valve
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 traversing velocity.
A flow control valve comprises a control loop and consists of an adjustable orifice and an upstream 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.
Notes on the detailed technical information about the flow control valve:
Technical data sheet RE 28163/2-way flow control valve
11
Project 11:
Flow control valve
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 motor. 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:
Flow control valve
Project steps
Notes
Informing:

with the customer.
Planning:
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 components.
Executing:
Set-up of the hydraulic control on the training system and preparation and
documentation of the system parameters requested by the customer.
Checking:
Evaluating:

11
Project 11:
Flow control valve
Item 0.2
Item 0.3
Item 1.3
Item 1.0
Item 1.1
Item 0.4
Item 1.4
Load pressure
11
Item 0.1
Item 1.2
Power unit limit
Fig. 11.2 Hydraulic circuit diagram: Load-independent speed control of a tool spindle
Measuring
glass
Project 11:
Flow control valve
Stop
11

Rotation
Rotation
-Hydraulic motor-
Project 11:
Flow control valve

Item
Qty
Type designation
1.0

external leakage line and two directions of rotation
DM 2.N
1.1
4/3 directional valve direct operated by two solenoids, spring

central position P, T, A, B
DW 13E
1.2/1.4

DD 1.1
2-way flow control valve, adjustable, for one direction of flow,

largely independent of viscosity
and pressure diferential, adjustable,
DF 3
1.3
0.1 - 0.4
11

check valve
DZ 1.4

with check valve
DZ 25.1
Hose
1
Stopwatch
Table 11.1 Parts list for hydraulic circuit diagram 11.2
Symbol
VSK 1
Project 11:
Flow control valve
Connection block
Measuring glass
Note:
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
11
Project 11:
Flow control valve
Safety notes
danger to life.
Warning
Caution
depressurized.

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.

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 measurement table.
11
Project 11:
Flow control valve
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
p in bar
M3
p in bar
Pressure differential
Dp in bar
Flow
qV in l/min
Scale
position 2
Scale
position 4
Load
pressure
Scale
position 2
Scale
osition 4
Scale
position 2
Scale
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
0.31
1.30
42
42
40
11
Table 11.2 Values measured during the execution of the order, increasing load pressure

Scale position 2
Scale position 4
2,5
Flow qV in l/min
2
1,5
1
0,5
0
0
10
15
20
25
Pressure differential Dp in bar

Diagram 11.1 Flow/pressure differential curve, increasing load pressure
30
35
40
Project 11:
Flow control valve
Task 2
10
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.
Caution
After completion of the practical work on the training system, switch the hydraulic pump off! Set the throttle valve and pressure relief valves to minimum
Measured values
Measuring point M1 Measuring point M3 Pressure differential
p in bar
p in bar
Dp in bar
Flow
qV in l/min
40
35
0.5
35
30
0.5
30
35
0.5
25
20
0.5
20
15
0.5
15
10
0.5
10
0.4
Table 11.3 Falling system pressure
The results above were measured at an oil temperature of approx. 20 C.

11
Project 11:
Flow control valve
11
0,6
Flow qV in l/min
0,5
0,4
0,3
0,2
0,1
0
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 pressure 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:
Flow control valve
12
Notes
11
Project 12:
Pressure relief valve, direct operated
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 construction 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 characteristic 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 operated 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 observed;
in the case of a parallel connection of throttle and pressure relief valves the flow is divided;
pressure relief valves can be used, for example, as overload protection.
On the basis of the set up control the trainee can work out the characteristic curves of a pressure 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
12
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 requiring 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
Informing:

with the customer.
Planning:
Planning and organizing the customer order, among others, by dealing

intensively with technical data sheets RE 25402.
Deciding:
Executing:
Checking:
Evaluating:

Notes
12
Project 12:
Item 1.1
Item 1.5
Item 0.1
Item 1.0
Power unit limit
Fig. 12.2 Hydraulic circuit diagram: Determination of technical data of a pressure relief valve, direct operated
Measuring
glass
12
Project 12:

Item
Qty
Type designation
1.0

DD 1.1
1.1
DF 1.2
DZ 4.1

without check valve
DZ 1.4

with check valve
DZ 25
Hose
VSK 1
0.1
Stopwatch
Flowmeter
DZ 30
Symbol
12
Project 12:
Connection block
Measuring glass
Note:
Note:
Notes
12
Project 12:
Safety notes
Warning
Caution

danger to life.
depressurized.

1. Mount the components required according to the parts list in a clearly arranged form on the

of hoses.
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.
12
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.
Caution
Measured values
Throttle valve
System pressure M1
p in bar
Flow
qV in l/min
through pressure relief
valve
Closed
30
7.6
25
4.3
20
1.8
15
10
Open
Table 12.2 Measured values: Pressure relief valve - pressure/flow

12
Project 12:
35
System pressure M1 p in bar
30
25
20
15
10
5
0
0
Flow qV across the pressure relief valve in l/min

Diagram 12.1 Pressure/flow characteristic curves, falling system pressure

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 pressure.
12
Project 12:
10
Notes
12
Project 13:
Pressure relief valve control
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 optionally connected in parallel or in series.
Notes on the detailed technical information about the direct operated pressure relief
valve:
Technical data sheet RE 25402/Pressure relief valve, direct operated
13
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
Informing:

with the customer.
Planning:
Planning and organizing the execution of the customer order, among others,
by dealing intensively with data sheet RE 25402.
Deciding:
Executing::

Checking:
Evaluating:

Notes
13
Project 13:
Hydraulic circuit dagram 1
Item 0.3
Item 1.2
Item 0.2
Item 1.1
Item 1.0
Measuring
glass
Item 0.1
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
glass
Item 0.1
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
glass
Item 0.1
System
Power unit limit
Fig. 13.4 Hydraulic circuit diagram: Series pressure circuit
13
Project 13:
Circulation
13

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

Item
Qty
Type designation
1.0

operated by two solenoids, spring
central position P - T, A, B
DW 4E
1.1/1.2

DD 1.1
Distributor plate with four

connections
DZ 4.1

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

with check valve
DZ 25
Hose
VSK 1
0.1 - 0.3
Table 13.1 Parts list for hydraulic circuit diagrams Fig. 13.2 to 13.4
Symbol
13
Project 13:
Connection block
Measuring glass
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.
Notes
13
Project 13:
10
Connection block
Measuring glass
Note:
Note:
training system.
Notes
13
Project 13:
11
Connection block
Measuring glass
Note:
Note:
training system.
Notes
13
Project 13:
12
Safety notes
danger to life.
Warning
Caution
depressurized.

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
Warning
Caution
Task 1
also to minimess lines or that the connections are plugged by means of plug
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, correct it to 50 bar.
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).
13
Project 13:
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.
Caution
Notes
After completion of the practical work on the training system, switch the
hydraulic pump off! No pressure may indicate a pressure! Open the throttle
check valve.
13
Project 13:
14
Measured values
Spool position
DW 4E
Measuring point M1 Measuring point M2 Measuring point M3

p in bar
p in bar
p in bar
23
20
18
15
Table 13.2 3-stage pressure circuit
Spool position
DW 4E
Measuring point M1
p in bar
Measuring point M2
p in bar
18
15
Table 13.3 Parallel pressure circuit
Spool position
DW 4E
Measuring point M1 Measuring point M2 Measuring point M3

p in bar
p in bar
p in bar
38
35
20
Table 13.4 Series pressure circuit


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 effective.
In the case of pressure relief valves connected in series, the set pressures add up.
13
Project 14:
Project 14: Pressure reducing valve

If a secondary actuator in a hydraulic control is to be controlled at a lower pressure independently 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 pressure 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 different 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 hydraulically 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
Informing:

with the customer.
Planning:
Planning and organizing of the customer order by, among others, dealing
intensively with technical data sheet RE 26564.
Deciding:
Executing:
Set-up of the hydraulic control on the training system. Preparation and

documentation of the measured data.
Checking:
Evaluating:

Notes
14
Project 14:

Item 0.1
Item 2.0
Rotate
Clamp
Item 0.3
Item 1.3
Item 0.2
Item 2.1
Item 1.4
Item 1.1
Item 0.1
Item 1.2
Measuring
glass
14
Power unit limit
Fig. 14.2 Hydraulic circuit diagram: Machine tool control
Project 14:
Stop
14

-Single-rod cylinderClockwise rotation
-Hydraulic motor-
Project 14:

Item
Qty
1.0
ZY 1.3
2.0

exteral leakage oil lines and two
DM 2.N
1.1

DW 13E
1.2/2.1

DD 1.1
1.3
3-way pressure reducing valve

1 bar
DS 2.1
DZ 4.1

without check valve
DZ 1.4

with check valve
DZ 25
Hose
VSK 1
1.4
0.1 - 0.3
Type designation
Symbol
DD 2
14
Project 14:
Connection block
Measuring glass
Note:
Note:
Notes
14
Project 14:
Safety notes
Warning
Caution

danger to life.
depressurized.


of hoses.
Observe installation direction of check valve Item 1.4!
Warning
For the 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
Warning
Caution
of slipping.
14
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 clamping 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.
Caution
14
Project 14:
10
Measured values
Measuring point
With by-pass check valve

DS 2.1
Without by-pass check valve

DS 2.1
M1
p in bar
M2
p in bar
M3
p in bar
M1
p in bar
M2
p in bar
M3
p in bar
Clamping cylinder
extending
20
15
20
15
Clamping cylinder
extended
45
40
20
45
40
20
Clamping cylinder
retracting
45
15
20
48
26
Clamping cylinder
retracted
50
50
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
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.
14
Project 15:
Pressure switch
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:
Pressure switch
Project definition
Two hydraulic workpieces are to be pressed together in a fixture by means of a hydraulic cylinder. 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 process. 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.
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)
15
Project 15:
Pressure switch
Project steps
Informing:

with the customer.
Planning:
Planning and organizing of the customer order by, among others, dealing
intensively with technical data sheet RE 50060.
Deciding:
Executing:
Set-up of the hydraulic control on the training system. Working out the setting options of the pressure switch at different, given system pressures.
Checking:
Evaluating:

Notes
15
Project 15:
Pressure switch

Item 1.0
Item 0.2
Item 1.3
Item 1.4
Item 0.3
Item 1.1
Item 0.1
Item 1.2
Power unit limit
Fig. 15.2 Hydraulic circuit diagram: Pressure switch
Measuring
glass
15
Project 15:
Pressure switch
15
Extension
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:
Pressure switch

Item
Qty
1.0
ZY 1.3
1.1

DW 3E
1.2

DD 1.1
1.3
Pressure switch, electromechanical, adjustable
DD 6E.1
1.4

DZ 2.2
DZ 4.1

without check valve
DZ 1.4
hose with quick release coupling

with check valve
DZ 25
Hose
VSK 1
0.1 - 0.3
Type designation
Symbol
15
Project 15:
Pressure switch
Connection block
Measuring glass
Note:
Note:
Notes
15
Project 15:
Pressure switch
Safety notes
Warning
Caution

danger to life.
depressurized.


of hoses.
Observe direction of installation of the throttle check valve!
Danger
Warning
Caution
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.
15
Project 15:
Pressure switch
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 automatically.

Enter the results in Table 15.2.
Measured values
p in bar
Retracts automatically
Yes/no
20
No
28
No
30
Yes
32
Yes
40
Yes
Table 15.2 Pressure monitoring of the hydraulic cylinder

Caution

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.
15
Project 15:
Pressure switch
10
Notes
15
Project 16:
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).
P
SP
rP
1
0
1
0
Hysteresis
Hno (normally open)

Hnc (normally closed)
Diagram 16.1 Hysteresis
Adjustable hysteresis on electronic pressure switches

Hysteresis maintains the switched state of the output stable, when the system pressure fluctuates 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 adjustable: 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.
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 hysteresis 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
16
Project 16:
Project definition
Scatter
min.
Switching pressure differential in bar
Pressure stage 100 bar
max.
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.
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
Informing:

with the customer.
Planning:
Planning and organizing the customer order using, among others, technical
data sheet RE 50060.
Deciding:
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 pressures.
Checking:
Evaluating:

Notes
16
Project 16:
Item 1.1
Item 1.2
Item 0.1
Item 1.0
Measuring
glass
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:

Item
Qty
Type designation
1.0

DD 1.1
1.2
DF 1.2
1.1
Pressure switch, electromechanical, adjustable
0.1

without check valve
DZ 1.4

with check valve
DZ 25
Hose
VSK 1
Symbol
DD 6E.1
16
Project 16:
Connection block
Measuring glass
Note:
Note:
Notes
16
Project 16:
Safety notes
Warning
Caution

danger to life.
depressurized.


of hoses.
Warning
Caution
of slipping.
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.
16
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:
10
Notes
16
Project 17:
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 testing must comply with AD sheets. The installation, equipment and operation
are regulated by "Technischen Regeln Druckbehlter (TRB) (technical rules
for pressure vessels).
Warning
Caution
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
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.
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
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 working pressure.
If the system pressure falls below the nitrogen pre-charge pressure, the hydraulic accumulator is completely discharged.
On the basis of the control set up on the training system the trainee is to work out the possible 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.
17
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
Informing:

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.
Deciding:
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 precharge pressure.
Checking:
Evaluating:

17
Project 17:
Item 0.2
Item 1.0
Item 1.4
Lead-
sealed
Item 1.1
Item 0.1
Item 1.3
Item 1.2
Measuring
glass
Power unit limit
17
Fig. 17.2 Hydraulic circuit diagram: Hydraulic accumulator
Project 17:
Circulation

17
Project 17:

Item
Qty
1.0
1.1

DW 13E
1.2

DD 1.1
1.3

1 bar
DS 2.1
1.4
Accumulator safety block

for diaphragm-type accumulator
DZ 3.2
DZ 4.1

without check valve
DZ 1.4
hose with quick release coupling

with check valve
DZ 25
Hose
VSK 1
0.1 - 0.2
Type designation
Symbol
ZY 1.3
17
Project 17:
Connection block
Measuring glass
Note:
Note:
Notes
17
Project 17:
Safety notes
Warning
Caution

danger to life.
depressurized.


of hoses.
Warning
Warning
Caution
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
closed.
of slipping.
17
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 accumulator safety valve Item 1.4. The system pressure is now isolated in the accumulator.

Task 2
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 pressure value at which the pressure starts to fall quickly is the nitrogen charging pressure.
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 results in Table 17.2. Repeat the experiment with the accumulator charging pressures given
in Table 17.2.
Caution
hydraulic pump off! No pressure gauge may indicate a pressure! Unload the
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.
V =
d K2
4
( a s + x ) + (d
2
K
- d St2
e s z
4
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
dm3
17
Project 17:
10
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
accumulator
Extending a Retracting e
charging pressure
M2 p in bar
Residual stroke in mm
Retracting x
Extending z
Useful
volume
V in dm3
10
15
195
0.25
20
95
0.36
25
50
0.42
30
10
0.47
35
100
0.52
40
160
0.55
45
0.57
Table 17.2 Useful volume of hydraulic accumulator

17
Project 17:
11
0,6
Useful volume V in l
0,5
0,4
0,3
0,2
0,1
0
0
10
20
30
Charging pressure M2 p in bar
40
50
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 maximum working pressure.
If the system pressure falls below the nitrogen pre-charge pressure, the hydraulic accumulator is completely unloaded.
The hydraulic accumulator is charged when the system pressure is higher than the nitrogen
pre-charge pressure.
17
Project 17:
12
Notes
17
Project 18:
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 identical 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
Informing:

with the customer.
Planning:
Planning and organizing the customer order by, among others, working out
the technical data sheets relating to velocity controls.
Deciding:
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.
Checking:
Evaluating:

Notes
18
Project 18:

Item 1.0
Item 0.2
Item 0.3
Item 1.1
Item 1.2
Item 0.1
Item 1.3
Measuring
glass
Power unit limit
18
Fig. 18.2 Hydraulic circuit diagram: Regenerative circuit
Project 18:

Extension
18
Project 18:

Item
Qty
1.0
1.1

1.2
2-way flow control valve, adjustable, for one direction of flow, largely independent of viscosity and
pressure differential, adjustable,
1.3

DD 1.1
DZ 4.1

without check valve
DZ 1.4

with check valve
DZ 25
Hose
VSK 1
0.1 - 0.3
Type designation
Symbol
ZY 1
DW 3E
DF 3
18
Project 18:
Connection block
Measuring glass
Note:
Note:
Notes
18
Project 18:
Safety notes
Warning
Caution

danger to life.
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 relevant minimess connection of the hydraulic hose.
Warning
Caution

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.
18
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.
Caution
After having completed practical work on the training system, switch the
Scale position Cylinder piston

Flow control
valve
M2
p in bar
M3
p in bar
Travel
time
t in s
Velocity
v in mm/s
1.0
Extended
Retracted
50
0
50
50
19
28
10.5
7.1
1.2
Extended
Retracted
50
0
50
50
16.5
20.7
12.1
9.7
1.4
Extended
Retracted
50
0
50
50
11.6
14.7
17.2
13.6
1.6
Extended
Retracted
50
0
50
50
8.6
10.5
23.3
19.0
1.8
Extended
Retracted
50
0
50
50
6.8
8.4
29.4
23.8
2.0
Extended
Retracted
50
0
50
50
5.3
6.5
37.7
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
Piston rod diameter d
Solution:
D2
= 4,9 cm2
4
D2 - d 2
A2 =
= 2,9 cm2
4
4, 9 cm2 : 2,9 cm2 = 1,689
A1 =
Area ratio A1 : A2 = 1.69 : 1
= 2.5 cm
= 1.6 cm
18
Project 18:
10
Cylinder in
Cylinder out
4
3,5
Velocity v in cm/s
3
2,5
2
1,5
1
0,5
0
0
0,5
1
1,5
Position of flow control valve DF3
2,5
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 controlled 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
18
Fext = p ASt
= p (AK AR )
and the piston velocity with pump displacement qP
Vext =
qP
AK AR
qP
AK
AR
ASt
ASt
because the pump flow must only fill the space that corresponds to the piston rod area.
Project 18:
11
For retracting of the cylinder with spool position of the directional valve, the force is calculated 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
=2
AR
the extension and retraction velocities become identical.

Vext =
qP
AK AR
qP
2 AR AR
qP
AR
= Vretr
The following is valid:

Vext
Vretr
where
AK
AR
consequently
Vext
Vretr
Vext
Vretr
qP AR
(AK AR ) qP
AR
AK AR
AK = AR
AR
AR AR
AR
AR ( 1)
1
1
1
1
18
Project 18:
12
AK
AR
ASt
F1 (out)
F2 (back)
pmin
pA
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.
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.
18
Project 19:
Rapid speed / creep speed control
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 velocity 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
technology
Analyzing the technical data sheet of velocity controls (specialist qualification)
19
Project 19:
Project steps
Informing:

with the customer.
Planning:
Planning and organizing the customer order, by, among others, examining
the technical data sheet for velocity controls.
Deciding:
Executing:
Set-up of the hydraulic control on the training system and preparation of a

travel/time diagram.
Checking:
Evaluating:

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
Item 1.3
Measuring
glass
Power unit limit
19
Fig. 19.2 Hydraulic circuit diagram: Rapid speed advance circuit
Project 19:
red
red
black
blue
black
blue

Extension Rapid speed

-Hydraulic cylinder-
Note on sensor B1/B2

Blue red black = plug colors
19
Project 19:

Item
Qty
1.0
ZY 1.3
1.1 - 1.2

DW 3E
1.3

DD 1.1
2-flow control valve, adjustable, for

one direction of flow, largely independent of viscostiy and pressure
differential, with by-pass check
valve
DF 3
DZ 4.1

without check valve
DZ 1.4

with check valve
DZ 25
Hose
VSK 1
1.4
0.1 - 0.3
Type designation
Symbol
red
B1/B2
Limit switch, inductive
black
DE 2
blue
19
Project 19:
Connection block
Measuring glass
Note:
Note:
Notes
19
Project 19:
Safety notes
Warning
Caution

danger to life.
depressurized.


of hoses.
Warning
Caution
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.
Caution
pump off! No pressure gauge may indicate a pressure! Open the throttle
check valve.
Measured values
Flow control valve
scale position
Hydraulic cylinder
Rapid speed
Advance
Return stroke
1.0
1.5
M3
bar
M2
bar
Time
<1
<1
M3
bar
50
50
M2
bar
80
80
Time
23
12
M3
bar
19
19
M2
bar
38
38
Time
<1
<1
Table 19.2 Measured values from the project order

19
Project 19:
10
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
Rapid speed
Advance
t
Time
Return stroke
Diagram 19.1 Travel/time diagram
Item 1.1
Item 1.2
Rapid speed lifting
Advance lifting
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.
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.
19
Project 20:
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 hydraulic 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
Informing:

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.
Deciding:
Executing:
Set-up of the hydraulic control on the training system. Acquisition of measured values and preparation of a comparison table.
Checking:
Evaluating:

Notes
20
Project 20:

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

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
Item 1.4
Measuring
glass
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:

Item
Qty
1.0
ZY 1.3

and central position P - T, A, B
DW 4E
1.2

DW 13E
1.3

DW 3E
1.4

DD 1.1
DZ 4.1

without check valve
DZ 1.4

with check valve
DZ 25
Hose
VSK 1
1.1
0.1 - 0.3
Type designation
Symbol
Table 20.1 Parts list for hydraulic circuit diagram Fig. 20.2 and 20.4
20
Project 20:
Connection block
Measuring glass
Note:
Note:
Notes
20
Project 20:
10
Connection block
Measuring glass
Note:
Note:
Notes
20
Project 20:
11
Safety notes
Warning
Caution

danger to life.
depressurized.


of hoses.
Warning
Caution
of slipping.
To make clear that in the central position the total amount of fluid flows through 4/3 directional valve Item 1.1, port T of directional valve Item 1.1 can be connected to the measuring
glass (option).

The system pressure can only be adjusted while the cylinder is at its end position.
20
Project 20:
Task 1
12
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.
Warning
Caution
of slipping.
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-buttons 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.
Caution
pump off! No pressure gauge may indicate a pressure! Open the throttle
check valve.
20
Project 20:
13
Measured values
Task 1
M1 p in bar
Circulation
Task 2
p in bar
p in bar
50
50
50
50
Cylinder end position
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:
14
Notes
20
Project 21:
Commissioning, troubleshooting, maintenance
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 operation. 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 personnel. 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 commissioning 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, inspection, maintenance, repair)
General product information on hydraulic products
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 machining position.
The customer wishes to obtain the required machine documents such as hydraulic and electrical 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
Informing:

with the customer.
Planning:
Planning and organizing the customer order, among others, by dealing

intensively with technical data sheets.
Deciding:
Executing:
Set-up of the hydraulic control on the training system. Acquisition of measured values and preparation of the technical documentation requested by
the customer.
Checking:
Evaluating:

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
Item 1.3
Item 1.1
Set to
text = 5 sec
Item 2.1
Item 0.1
Item 1.2
Measuring
glass
Power unit limit
Fig. 21.2 Hydraulic circuit diagram: Machine tool control
21
Project 21:
Stop


Lifting Lowering

Fig. 21.3 Wiring diagram for the machine control
Rotation
-Hydraulic motor-
21
Project 21:

Item
Qty
1.0
Double-acting cylinder with singlesided piston rod with load
1.1

DW 13E
1.2/2.3

DD 1.1
1.3
DF 1.2
2.0

external leakage oil line and two
DM 8N
2.1

DW 3E
2-way flow control valve, adjustable, for one direction of flow, largely independent of viscosity and
pressure differential, adjustable,
DF 3
DZ 4.1

without check valve
DZ 1.4

with check valve
DZ 25.1
2.2
0.1 - 0.4
hose
Type designation
VSK 1
Symbol
21
Project 21:
Connection block
Measuring glass
Note:
Note:
21
Project 21:
10
Safety notes
Warning
Caution

danger to life.
depressurized.


of hoses.
Warning
Caution
of slipping.

21
Project 21:
11
Commissioning: Lifting cylinder

3. Activate 4/3 directional valve Item 1.1 by means of electrical push-buttons S2 (extending/lifting) 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!
Caution
Measured values
Actuator
Lifting cylinder
Lifting cylinder
Hydraulic motor
Function
Lifting
Lowering
Rotating
Measuring point
Value in bar
M1
48
M2
M3
M1
48
M2
47
M3
30
M1
48
M4
20
Table 21.2 System parameters of machine tool control

21
Project 21:
12
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
Lifting cylinder
Hydraulic
motor
Y1.a
Y1.b
Y2
Lifting
Lowering
Holding
Rotating
Stop
Table 21.3 Function sequence/machine tool control
Legend:

1 Valve spool energized

0 Valve spool not energized
21
Project 21:
13
Machine tool control

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

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 clockwise). 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
for troubleshooting
Workpiece correctly
put down?
yes
no
System pressure
available?
Check loading
Are faults/fault messages present such as: filter, oil level, temperature?
no
Is the pump running?
no
Check motor
no
Check pump controller
Check by activating
emergency stop
yes
Lifting cylinder Item

1.0 at end position?
no
Check and, if
required, correct
position
no
Is the valve spool

jammed?
no
Check settings
yes
Valve Y2
activated
Pump pressure
available?
yes
yes
yes
Flow control valve

Item 2.2 open?
yes
Note:
Possibly mechanical fault of the
hydraulic motor?
Load pressure too

high?
yes
Check DB valve
Item 2.3/20 bar
21
Project 21:
14
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 measuring 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:
15
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:
16

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 function and the operating principle of all hydraulic components.
21
Project 21:
17
Notes
21
General product information on

hydraulic products
DE
EN
FR
IT
FI
ES
NL
SV
PT
DA
EL
RE 07008/02.05
Ihre Sprache? Siehe Rckseite!

Your language? See back page!
Votre langue ? Voir au dos !
La vostra lingua? Vedi retro!
Kohdekielet? Katso takankatta!
Su idioma? Vea al dorso!
Uw taal? Zie achterzijde!
Ditt sprak? Se omslagets baksida!
O seu idioma? Consulte a contracapa!
Dit sprog? Se bagside!
; !
1/32
2/32
Bosch Rexroth AG
Hydraulics
Contents
1
General product information
Page
Important basic information
1.1
Conventions used in this product information
1.2
What you need to know about this product information
1.3
The contents of this product information
Scope of delivery and responsibilities
2.1
Scope of delivery and responsibilities of Bosch Rexroth
2.2
Responsibilities of the plant operator
2.3
Liability, guarantee, warranty
2.4
Copyright
Important basic safety instructions
3.1
What to do in an emergency
3.2
Safety labelling on the hydraulic product
3.3
Proper use
3.4
Requirements for personnel, duty of care
3.5
General ancillary dangers and protective measures

when operating hydraulic products
Technical data and ambient conditions
11
4.1
Information about pressure fluids
11
4.2
Ambient conditions
11
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
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
Moving hydraulic units/components
16
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
RE 07008
Hydraulics
Bosch Rexroth AG
Contents
9
3/32
Page
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
13
14
Maintenance
24
12.1
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
General information about hydraulic pressure accumulators
30
13.1
General
30
13.2
Safety devices relating to hydraulic pressure accumulators
30
Hydraulic systems
31
14.1
31
Effects of leaks in the hydraulic system on the machine
4/32
1
1.1
Bosch Rexroth AG
Hydraulics
Important basic information

Conventions used in this product
information
Cross-references are printed in italics.
DANGER
This symbol indicates a threat of danger which will result
directly in death or very serious injury if not avoided.
WARNING
This symbol indicates a threat of danger which may result
in death or very serious injury if not avoided.
CAUTION
This symbol indicates possible danger which may lead to
minor or serious injury and/or to material damage.
IMPORTANT
Observing the product information and Operating Instructions
reduces downtimes and maintenance costs
increases the service life of your hydraulic products.
The Operating Instructions must be directly accessible to one

of the personnel at the hydraulic product and kept readily available 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
operative personnel. We recommend that a record is made in
writing of the employees familiarisation with all the relevant
parts.
The cross-references to directives, standards and regulations
contained in this product information refer to the versions current at the time of writing of this product information, which can
be obtained from the title page of this product information.
1.3
What you need to know about this

product information
This product information applies to the following types of

hydraulic products:
Hydraulic components
Hydraulic power units
Hydraulic systems.
The contents of this product information
In addition to this document, product information for Rexroth

hydraulic products normally includes Operating Instructions
consisting of three parts:
Part I, the general Operating Instructions for the relevant

class of products
Part II, the Technical Datasheet
Part III, the Product- and Application-specific Operating

Instructions.
This symbol indicates additional information.
1.2
RE 07008
If you do not have all three parts, please request the missing
part from Bosch Rexroth. Only if all the information contained
in all parts of the three-part Operating Instructions is observed
can safe operation of Rexroth hydraulic products be ensured.
Specific cross-references are used to draw your attention to
information that you can find in the Operating Instructions.
The Operating Instructions contain detailed information about
the product, including
Information about the scope of delivery
Safety instructions
This product information applies exclusively to hydraulic products that are operated with mineral-oil-based pressure fluids, if
the Operating Instructions do not expressly permit the use of
other pressure fluids.
Technical data and operating limits
Information about bringing into (first) use and maintenance
Information about the mode of operation
IMPORTANT
Layouts, drawings
As this product information for Rexroth hydraulic products

applies in a general sense, some of the content may not necessarily apply to the hydraulic product you have purchased.
Parts lists if appropriate
Information about replacement parts and accessories.
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.
RE 07008
Hydraulics
Bosch Rexroth AG
5/32
Scope of delivery and responsibilities
Installation of Rexroth hydraulic products in a machine or system may increase this value, and if so, the manufacturer of the
machine/system must document this.
2.1
Scope of delivery and responsibilities of

Bosch Rexroth
At or above 85 dB(A), the plant operator must make suitable

hearing protection available to the personnel.
Rexroth hydraulic products fulfil all safety requirements applicable to fluid power systems and their components.
IMPORTANT
For the scope of delivery and the responsibilities of
Bosch Rexroth with respect to the product, please refer to the
Product-specific Operating Instructions.
2.2
Responsibilities of the plant operator
CAUTION
If Rexroth hydraulic products are positioned in the vicinity
of sources of ignition or strong radiators of heat, protection must be put in place that would prevent any escaping
pressure fluid from igniting and the hose lines from aging
prematurely.
Mineral-oil-based pressure fluid is hazardous to water and
flammable. It may only be used if the relevant safety datasheet from the manufacturer is available and all the measures stipulated therein have been implemented.
If there is a risk of fluid leaking from the hydraulic product and contaminating water or the ground, the hydraulic
product in question must be placed in a suitable collecting trough. In connection with this, the applicable statutory
regulations must be observed.
You must also observe the EU directives for the use of work
equipment (Directive 89/391/EC) and the associated individual directives, especially Directive 1999/92/EC for the protection
from the danger arising from potentially explosive atmospheres
and their implementations in national legislation. The legislation contains minimum requirements with respect to the making
available by the employer of work equipment and for the use
of work equipment by employees at work, including the regulations for operating equipment requiring supervision and the
obligation to produce explosion protection documentation. This
involves, for example, dividing areas endangered by potentially
explosive atmospheres into zones and specifying suitable work
equipment and procedures for these areas.
2.2.1 Noise protection

The A-weighted equivalent continuous sound power level of
Rexroth hydraulic products can be obtained from the relevant
Operating Instructions. If no values are documented then it can
be taken that the value is less than 70 dB(A).
2.2.2 Special points concerning the installation of

certain products
A Rexroth hydraulic product is intended above all for installation in machines, systems and power units as a part machine
or a component for installation into another machine or system
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.
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
make sure that the hydraulic product is also suitable without
restriction for the proposed application at the installation location. The interfaces with the overall machine and the operating conditions are also of the greatest importance. We recommend that the results of the hazard analysis (risk assessment)
of the overall machine are taken into account in the design of
the hydraulic product.
The functioning of the hydraulic product is also influenced by
the machine or system in which it is installed.
For this reason, you must also always observe the Operating
Instructions of the overall system in which your hydraulic product is installed. It is most important for you to also consider the
possible use of the hydraulic product in a potentially explosive
atmosphere (see 94/9/EC).
IMPORTANT
Bosch Rexroth points out that, at the time of their first introduction on to the market, hydraulic products comply with the
requirements of all relevant EU directives and/or their implementation into national legislation in Germany. If the scope of
delivery is intended to be installed in a machine or system, then
the Machinery Directive applies as appropriate including the
then currently applicable amendments in that the scope of
delivery does not necessarily comply with the requirements
of the Machinery Directive because the scope of delivery is
intended for installation in a machine or because the scope of
delivery is intended for combination with other machines into a
machine or a hydraulic system.
The bringing into use of the scope of delivery shall therefore not be permitted until the machine or system in which the
scope of delivery is to be installed or of which it represents a
component complies with the requirements of all relevant EU
directives.
Details of further responsibilities can be found in
3 Important basic safety instructions and in the Operating
Instructions.
6/32
2.3
Bosch Rexroth AG
Hydraulics
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 specified by the manufacturer.
Please refer to our general terms of supply or your contract for
details of the guarantee and manufacturers warranty.
2.4
Copyright
This product information may only be reproduced electronically or mechanically, in whole or in part with the express written permission of Bosch Rexroth. It may likewise not be distributed, amended, transmitted, translated into another language
or employed or copied for other purposes or by other parties
without such consent.
RE 07008
RE 07008
3
3.1
Hydraulics
7/32
Important basic safety instructions
IMPORTANT
What to do in an emergency
The hydraulic product shall be operated exclusively with pressure fluids complying with DIN 51524. Where other pressure
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 occurrences:

1.
Switch off the hydraulic system.
2.
Secure the main switch against being unintentionally

switched on again.
3.
Secure the danger area so that no one can enter the danger area unknowingly or uncontrolled.
4.
Notify the relevant specialist personnel immediately.
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
plant operators operating manual.
For details on proper use see 4 Technical data and ambient

conditions.
The following information can be found in the Operating
Instructions:
the proper use, specific to the hydraulic product
where applicable, the safety category in accordance with

EN 954-1
non-permitted and improper use.
3.3.1 Proper use, requirements before operation
WARNING
Fighting fires with materials other than those permitted
can lead to explosions and/or more rapid spread of the
fire!
Danger to life from smoke inhalation!
3.2
Bosch Rexroth AG
Safety labelling on the hydraulic product
Rexroth hydraulic products may only be operated if they

are in perfect technical condition.
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
switched on again without authorisation.
Report and rectify all faults and damage indicated by

the system or discovered by other means.
The connections, operating conditions and performance

data specified in the Operating Instructions must be
observed and never changed.
Rexroth hydraulic products shall not be converted or

otherwise modified without prior consultation with
Bosch Rexroth.
IMPORTANT
The meanings of the safety labelling on the Rexroth product are explained in the Operating Instructions.
The plant operator shall not modify the program code of

programmable control systems.
For a diagram of the nameplate and an explanation of the

information on it please refer to the Operating Instructions.
Dependencies and time factors shall not be modified without prior consultation.
Rexroth hydraulic products are designed and constructed for

the provision, transmission, control or regulation of energy and
signals using the flow of oil.
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.
They shall not be relocated, bypassed or rendered ineffective.
Unless otherwise agreed, the Rexroth hydraulic product satisfies at least safety category B in accordance with EN 954-1.
Safety components such as limit switches, valves and

other control components shall not be rendered inoperative.
If the hazard analysis/risk assessment of the overall machine

in which the Rexroth hydraulic product is to be installed indicates that a safety category higher than category B in accordance with EN 954-1 is required for the Rexroth hydraulic
product, then a correspondingly higher rated hydraulic product
can be supplied and installed only after special agreement with
Bosch Rexroth.
Tamperproof lead seals installed by the manufacturer shall

not be removed or damaged except when this is necessary in the course of maintenance tasks defined in the
Operating Instructions.
The specified maintenance tasks in the Operating Instructions shall be carried out at the intervals stated in the
3.3
Proper use
8/32
3.4
Bosch Rexroth AG
Hydraulics
RE 07008
Uncontrolled access by persons unfamiliar with the system to the immediate operating zone of Rexroth hydraulic
products is prohibited (even if the product in question has
been shut down).
Servicing personnel (who carry out filter and oil changes, for
example) shall fulfil the following requirements:
They have been instructed in the relevant activity.
Rexroth hydraulic products must never be assembled,

operated or maintained by persons under the influence of
alcohol, drugs or other medication which affect ones ability to react.
Specialist knowledge of hydraulics is not required to carry

out servicing work.
Requirements for personnel,

duty of care
3.4.1 Qualifications of specialist personnel

A specialist person is someone who, using his specialist training, knowledge and experience as well as familiarity with the
relevant conditions, can
safely carry out the tasks allocated to him and correctly

assess the scope and implications of his work
recognise possible dangers
undertake the necessary measures to eliminate possible

accidents.
3.4.2 Requirements for hydraulics maintenance

personnel
In accordance with DIN 31051, maintenance comprises the
individual activities of inspection, servicing and repair. All
personnel involved in maintenance shall be familiar with and
observe all parts of the Operating Instructions and this product
information.
Inspection personnel shall fulfil the following requirements:
Repair personnel shall fulfil the following requirements:
The personnel must be hydraulics experts, who have been

instructed and meet the definition given above,
Repair personnel must be familiar with the function of the

hydraulic system as a whole, from subsystems to their
interaction with the function of the entire machine.
Repair personnel must be able to read hydraulic circuit

diagrams, interpret individual functions from their symbols
and understand function diagrams.
Repair personnel must possess knowledge of the function

and construction of hydraulic elements.
3.4.3 Requirements for electrical maintenance

personnel
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 products.
3.4.4 Minimum age

Persons under the age of 18 who are currently receiving
instruction or training or are working under supervision may not
work on Rexroth hydraulic products.
They have been instructed in the relevant activity.
This does not apply to young persons of 16 or over if
Specialist knowledge of hydraulics is not required for

purely inspection activities but the personnel must be
aware of the particular dangers associated with hydraulic
products.
working on Rexroth hydraulic products is necessary in

order for them to accomplish a training objective
their protection is guaranteed by the supervision of an

experienced, competent person
they are allowed to use only tools, work implements and

protective gear that preclude the risk of injury.
RE 07008
3.4.5 Training
Hydraulics
Observation and use of the Operating Instructions and

legal requirements
Proper operation of the Rexroth hydraulic product
Observation of the instructions of safety officers and the

plant operators operating manual
What to do in an emergency.
IMPORTANT
Bosch Rexroth can provide you with training support in specialist areas.
9/32
3.5.1 Dangers from pressure fluid
The plant operator using Bosch Rexroth hydraulic products

shall train his personnel regularly in the following subjects:
Bosch Rexroth AG
CAUTION
Handling pressure fluid without protection is hazardous to
health.
Please observe the manufacturers safety instructions and the
safety datasheets for the pressure fluid that you are using.
DANGER
Serious damage to health or death may result if pressure fluid
enters the blood stream or is swallowed. If this occurs, contact
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

protective measures when operating
hydraulic products
Contamination of the pressure fluid can be caused by:
Wear during operation of the machine/system (metallic

and non-metallic abrasion)
Leaks of the hydraulic product
Contaminants introduced during servicing/repair
In the interests of your safety, all safety instructions shall be

carefully observed, especially those in the Operating Instructions.
The use of dirty (unfiltered) pressure fluid when the pressure fluid is changed.
In spite of the high intrinsic safety of Rexroth hydraulic products, the risk of personal injury or damage to the environment
cannot be excluded, even when the equipment is properly
used.
Contaminants lead to malfunctions, increased wear and shorter

service life of the hydraulic product. This can have negative
effects on the safety and reliability of the hydraulic product.
DANGER
New, additional dangers may arise if the hydraulic product is

installed in another machine or installed with other machines
in a system. This shall apply in particular to mechanical movements generated by the hydraulic product.
Information on these additional dangers can be found in the
overall operating manual of the supplier of the overall system in
which the hydraulic product is installed.
Therefore the maintenance tasks specified in the Operating

Instructions shall be carried out at regular intervals and the
utmost cleanliness is required during work on the hydraulic
product.
CAUTION
When changing the pressure fluid, always use factory-fresh
pressure fluid and filter it before filling to remove any contaminants in the pressure fluid that it often contains from the packaging container (drum). Flush out lines and hoses before installation.
The cleanliness class of a pressure fluid is specified in accordance with ISO 4406. Detailed information can be obtained
from the relevant datasheet or the Operating Instructions.
10/32
Bosch Rexroth AG
Hydraulics
In older datasheets, the cleanliness class is sometimes specified in accordance with NAS 1638. The following table can
be used to convert this to an equivalent ISO 4406 cleanliness
class:
Comparison table for cleanliness classes
Earlier class to
Current class to
NAS 1638
ISO 4406 (c)
Class 7
Class 18/16/13
Class 9
Class 20/18/15
3.5.3 Electrical dangers
RE 07008
3.5.4 Product-specific ancillary dangers

All product-specific ancillary dangers and precautions can be
found in the relevant Operating Instructions.
3.5.5 Disposal
Take metal, cable and plastic ducts to a recycling materials collection centre.
Dispose of electronic components as electronic waste.
Dispose of back-up batteries as special waste.
Cleaning agents, operating fluids and other materials:
When working on electrical systems:
De-energise the hydraulic system before beginning any

maintenance work.
Cordon off the working area with red-white safety chain

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:
Electrics, electronics, hydraulics (e.g. accumulators,

rechargeable batteries)
Main switch
Power supply cables
Points identified with an electric shock warning sign.
CAUTION
Please observe the disposal regulations specified in
the appropriate Safety Datasheets.
RE 07008
Technical data and ambient conditions
IMPORTANT
The product-specific technical data, operating limits and ambient conditions for the operation of your Rexroth hydraulic product can be found in the Operating Instructions.
This includes the following information:
Minimum flow rate for adequate cooling
Permissible maximum temperature of the coolant
Performance data
Type of control and regulation functions
Permissible pressures, flow rates
Connections.
4.1
Information about pressure fluids
Unless otherwise indicated in the Operating Instructions, the

following specification applies to the pressure fluid to be used:
Mineral-oil-based pressure fluid complying with the

requirements of DIN 51524.
Operating temperature range 0 C+80 C
(in tank < 72 C).
Any deviations from this can be found in the Operating Instructions.
IMPORTANT
Bosch Rexroth recommends a maximum operating temperature 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.
Viscosity ranges:
see RE 07075 and RE 90220
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 = approx. 46 mm2/s).
Hydraulics
4.2
Bosch Rexroth AG
11/32
Ambient conditions
4.2.1 Use in potentially explosive atmospheres
DANGER
Rexroth hydraulic products shall be used in potentially
explosive atmospheres only if they are designed for this
purpose and this is expressly stated in the Operating
Instructions.
IMPORTANT
Directive 1999/92/EC of the European Parliament and Council dated 16 December 1999 concerning the minimum requirements for improving the safety and health protection of workers potentially at risk from explosive atmospheres governs
protection from danger from potentially explosive atmospheres.
Observe the requirements contained in the regulations for
operating equipment requiring supervision and the obligation to
produce explosion protection documentation.
This involves, for example, dividing areas endangered by potentially explosive atmospheres into zones and specifying suitable
work equipment and procedures for these areas.
Observe the requirements of Directive 94/9/EC of the European Parliament and Council dated 23 March 1994 on the
approximation of laws of the member states concerning equipment and protective systems intended for use in potentially
explosive atmospheres (ATEX Product Directive) and/or the
corresponding national legislation by means of which the Directive was implemented in law in the EU member states. The
directive contains requirements for the use of equipment and
protective systems in potentially explosive atmospheres.
12/32
Bosch Rexroth AG
Hydraulics
4.2.2 Climatic operating conditions

Unless otherwise indicated in the Operating Instructions,
the permissible ambient temperature
for control units: 0 C+50 C
for drive units with electric motors without heat exchangers, surface-cooled by free air circulation:
0 C+30 C
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
In relation to the electronic equipment, the permissible ambient

conditions apply to installed and protected electrical connections of class IP 55.
Ambient temperature +5 C+40 C

assuming that the average air temperature over a 24 hour
period does not exceed +35 C.
Relative air humidity: 2395 %, non-condensing.
Altitude: up to 1000 m above national datum.
DANGER
Rexroth hydraulic products shall not be used in aeronautical equipment, except where they have been specially
approved and appropriately labelled to this effect.
RE 07008
RE 07008
5.1
What you need to know about

pressure fluids
Hydraulics
Bosch Rexroth AG
13/32
IMPORTANT
Observe the following rules of thumb:
At pressure fluid temperatures >70 C, the rate of ageing doubles for each 10 C.
How to handle pressure fluids safely

5.3
Viscosity
DANGER
Mineral-oil-based pressure fluid is hazardous to water and
flammable.
It may only be used if the relevant safety datasheet from
the manufacturer is present and all the measures stipulated therein have been implemented.
5.3.1 Viscosity grades

The most important characteristic of a pressure fluid is its viscosity, i.e. stickiness. Viscosity range always plays a priority
role in the selection of a pressure fluid.
Viscosity is measured in the SI unit [mm2/s]. Many manufacturers still provide their information in centiStoke [cSt], the equivalent of [mm2/s].
5.2
Functions and effectiveness
Due to the many tasks of pressure fluid, its selection, inspection and maintenance are of vital importance for:
proper functioning
operating safety
service life
and the cost effectiveness of the hydraulic product.
The tasks of pressure fluid:
to transmit hydraulic energy from the pump to the hydraulic cylinder/motor
to lubricate parts moving against one another
corrosion protection
to remove contaminants
to remove locally accumulated heat.
5.2.1 Reduced function due to ageing

The effectiveness of pressure fluid diminishes as it ages
(undergoes chemical changes). Acids and resinous residues
form, which may cause valve spools to stick.
The following factors accelerate the ageing process:
high temperatures
oxygen in the pressure fluid
air humidity
water
metallic catalysers
operating pressure
contaminants.
The viscosity grades (VG = viscosity grade) in accordance with

ISO 3448 relate to the viscosity at 40 C. The viscosity grade
is appended to the type designation or the commercial name of
the pressure fluid.
Example: A pressure fluid with a viscosity grade of ISO VG 46
has a viscosity of 46 mm2/s at 40 C.
The relationship between medium temperature and viscosity for
hydraulic oil (example)
Medium
temperature
3 C
8 C
25 C
60 C
77 C
Viscosity
800 mm2/s
500 mm2/s
100 mm2/s
20 mm2/s
12 mm2/s
Too high a viscosity leads to the formation of air and vapour

bubbles as a result of low pressure (cavitation). Too low a viscosity 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.
Valves, pumps and hydraulic motors, in particular, require exact
compliance with the defined viscosity ranges.
For certain ambient and operating temperatures, not all the
requirements can always be covered with the available ranges
of the viscosity grades.
In order to comply with all the requirements, high viscosity
pressure fluids with viscosity index improvers or a pressure
fluid cooler/heater may be used.
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5.4
Bosch Rexroth AG
Hydraulics
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.
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6.1
Bosch Rexroth AG
Hydraulics
Construction and mode of operation

of a hydraulic system
Hydraulics (fluid technology)
Transmission, control and distribution of energy and signals

using a pressurised fluid medium.
Hydraulic system
Arrangement of interconnected components for transferring

and controlling hydraulic energy.
4
3
Component
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
hydraulic system.
Drive
A component that converts the energy of the hydraulic fluid
into mechanical energy (e.g. motor, cylinder).
6.2
Schematic
In a system operated with hydraulic oil, first of all mechanical energy is converted into hydraulic energy, transported and
controlled in this form, to finally be converted once more into
mechanical work.
The hydraulic elements are arranged in accordance with these
functions. The following diagram shows a schematic representation of the elements of a complete hydraulic system.
To demonstrate their operating principle, standardised symbols
(ISO 1219) are used instead of sectional diagrams of the various devices. Line connections are represented by simple lines,
as can be seen in the example.
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2
1
1
Tank
Filter
Pump
Pressure limiting valve
Directional valve
Check valve
Throttle valve
Hydraulic cylinder
Hydraulic motor
6.3
Oil preparation
Energy conversion
Energy control
Energy conversion
Safety concept
Hydraulic products contain sensors and actuators, the interaction of which is particularly important with regard to the fulfilment of technical safety functions.
Individual hydraulic products form part of an overall safety concept.
Applications required to perform safety functions are designed
using special hydraulic components that satisfy the requirements of the relevant directives, such as the Pressure Equipment 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 specific 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.
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Bosch Rexroth AG
Hydraulics
Moving hydraulic units/components
Hydraulic units or components may be moved by a fork-lift

truck or a hoist, depending on their size and the local conditions.
IMPORTANT
For details see the Operating Instructions.
RE 07008
IMPORTANT
The factory-applied corrosion protection is adequate provided
that
no condensation or leakage water can enter the system
long standstills are avoided.
Contact Bosch Rexroth if you are not clear about the consequences of long standstills on the state of the hydraulic product.
CAUTION
Always ensure hydraulic products are empty of pressure
fluid for transportation.
Rexroth hydraulic products are delivered empty of pressure
fluid. However, products may contain oil residues left over from
the final inspection at our factory.
Storage and longer standstills
8.1
Hydraulic systems - subsequent bringing

into use after storage
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 abrasive wear (erosion), which detrimentally affects the functioning
of the hydraulic system.
CAUTION
If a hydraulic system is to be brought into use again following 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 compatibility with seals and the pressure fluid to be used.
8.1.2 Storage times in relation to the ambient

conditions
Delays in bringing into use, long shipping and storage times or
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
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 hydraulic product by nine months.
After the specified storage time has expired, in any event not
longer than 24 months, the corrosion protection must be
checked and further conservation measures applied if necessary.
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8.2
Seals, hoses and hose lines
CAUTION
Seals:
Observe the requirements of ISO 2230 and/or DIN 7716
and the specific manufacturers 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 manufacturers data
on hoses and hose lines.
In addition, the following conditions shall be observed:
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 %.
Do not store elastomers below 10 C. The ideal storage conditions for seals are temperatures from +10 C
to +20 C and a relative humidity of between 65 % and
75 %.
Store hoses and hose lines in the original packaging if

possible. Prevent the entry of air.
Avoid direct sunlight and UV radiation and shield from

nearby sources of heat.
Darkened storage locations are preferred.
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.
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).
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
NBR seals: 4 years
FKM seals: 10 years
Hoses: 4 years
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 maintained. If you are not clear about the storage times and/or storage conditions then you should not use the product.
Hydraulics
Bosch Rexroth AG
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Bosch Rexroth AG
Hydraulics
Assembly and bringing into first use
IMPORTANT
RE 07008
Bringing into (first) use shall only be done by an instructed,

authorised hydraulics expert who has the required specialist knowledge.
Only the permissible pressure fluids given in the Operating

Instructions are to be used. Information on other pressure fluids can be found in the Operating Instructions or are available
on request.
Specialist hydraulics knowledge means, among other things,

that the person can read and fully understand hydraulics drawings. In particular, he must fully comprehend the range of functions of the integrated safety components as part of the overall
safety concept.
Filling the pressure fluid tank must always take place through a
suitable filter unit. Experience has shown that even new pressure fluid can often have more than the maximum permissible
level of contamination.
9.2
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.
Contact us if the Operating Instructions are not there or
are incomplete.
3.
Assemble the hydraulic product.
Do not use cleaning wool or cloths containing fibres for

cleaning.
Depending on the condition of the system or machine,
cleaning with fibre-free cloths may be sufficient. Use suitable liquid cleaning agents to remove lubricants and other
stronger contaminants. Make sure that cleaning agent
does not get into the hydraulic system.
Observe the Operating Instructions and this product

information.
Assemble the hydraulic components, so that they are

mounted strain-free on even surfaces.
Tighten the fastening bolts evenly using the specified

tightening torque.
Never use hemp and putty as sealants.
The functional or failure behaviour of identical hydraulic products may vary due to conditions specific to the machine or system in which the hydraulic product is installed (mass, speed,
electrical triggering at setpoint values, etc.), see also Section
11 Trouble-shooting.
9.1
Before bringing into first use
4.
Ensure that the interfaces of the system/machine and the

installation conditions provide for safe operation of the
hydraulic product. If in doubt, consult the people responsible for the overall system/functional machine.
5.
Check the construction of the hydraulic product against

the circuit diagrams, lists of equipment and assembly drawings. If there are any differences, draw this to
the attention of the people responsible. If important
documents are missing, they can be requested from
Bosch Rexroth. Only documents issued by the bodies
authorised to do so shall be used.
6.
Based on the Operating Instructions for the system or

machine in which the hydraulic product is installed, check
whether bringing the hydraulic system into use could lead
to uncontrolled, dangerous movements. Where appropriate, take into account the hazard analysis/risk assessment
for the system or machine.
7.
Take the precautions appropriate to the anticipated dangers, e.g.
Safety advice for assembly and

bringing into first use
DANGER
Hydraulic products are generally intended for installation
in machines/systems or devices.
The function of the hydraulic product must therefore
always be seen in relation to the function of this machine
i.e. seemingly identical hydraulic products may demonstrate different functional behaviours as a result of the
function of the machine in which they are installed.
For this reason, a hydraulic drive must not be brought into
use until it has been determined that the machine in which
it is installed conforms to EU standards.
Do not bring hydraulic drives into use until you have familiarised 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.
Ensure that the cylinder piston rod can move out without danger.
Use a hoist or other lifting device to additionally

secure lifted loads.
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8.
As part of bringing into (first) use, check whether the electric motors and valve solenoids can be switched manually
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
the hydraulic system.
IMPORTANT
Starting up the hydraulics solely by means of emergency manual operation is not recommended, as several valves at once
cannot be switched as required in the correct sequence.
9.
Hydraulics
9.3
Bosch Rexroth AG
19/32
Bringing into first use,

subsequent bringing into use
DANGER
Before bringing into (first) use, have all pressure accumulators and safety systems checked by an expert or specialist in accordance with national regulations.
1.
Clean the lock on the transport and storage container

before opening.
Draw up a sequential program for bringing into (first) use

and store it with the technical documentation as an appendix to the Operating Instructions.
For this you should consider the following:
Hydraulic drives basically consist of the following functional groups
2.
Clean the hydraulic unit and all other component groups,

so that no dirt can get into the hydraulic system during
bringing into (first) use.
3.
Check the paint on the tank for integrity.
4.
Flush the connection lines to remove dirt, scale, chips etc.
Pump circuit (generation of pressurised oil flow);

pump, electric motor, oil tank, filters, monitoring
devices, etc.
5.
Pickle and flush welded pipes.
Control system for at least one hydraulic consumer

(cylinder, motor); directional control valves, pressure
and flow control valves, check valves
Hydraulic consumers (cylinders, motors) with specially assigned valves, e.g. braking valve.
CAUTION
Remove all residues of water and cleaning agents
before performing further work.
6.
10. Divide the functional circuit diagram into separate mini-circuits that can each be started up in succession.
Clean the interior of the hydraulic components to get rid of

contaminants:
Clean the filler plug of the pressure fluid tank.
11. Read the functional circuit diagram and seek clarification

of any unclear text or diagrams. More information about
the functioning of components, e.g. a pump regulator, is
available in the Technical Datasheet.
Remove dust and chips using an industrial vacuum

cleaner, by rinsing parts or similar cleaning method.
Completely remove any oil residues left over from the

factory test.
12. Establish into which position valves are to be switched, or

how valves are to be set.
Remove any gummed oil which may have formed due

to incorrect storage.
13. Put up any necessary directional, prohibitive or informative

signs and check whether the meaning of these signs are
explained in the Operating Instructions.
7.
IMPORTANT
14. Follow this sequence for bringing into (first) use
Pump circuit
Parts of control system:

e.g. pressure cut-off and switchover,
open centre,
pressure reduction etc.
Cylinder and motor circuits:

First move,
fill and bleed,
then finally optimise all settings.
Connect up all connection lines.
Observe the installation instructions from the manufacturer

of the connection components.
DANGER
Make sure that pipes and hoses are connected at all
ports or that the ports are sealed with screw plugs.
8.
Carry out a special check to make sure that the union nuts
and flanges are correctly tightened at the pipe connections and flanges.
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Bosch Rexroth AG
Hydraulics
IMPORTANT
CAUTION
Mark all the checked connections, e.g. with paint.

Make sure that all pipes and hoses and every combination of
connection pieces, couplings or connection points with hoses
or pipes are checked for their operational safety by someone
who has the appropriate knowledge and experience.
9.
Connect the hydraulic consumers. Dimension the connection lines in accordance with the performance data in the
Circuit Diagram and the Operating Instructions.
10. Install the electrical system for the drive and control system:
Check the connected loads.
Connect coolant water if necessary.
Check the direction of rotation of the pumps

(e.g. as indicated by attached arrow markings).
11. Check the pressure fluid to ensure that no water has

entered it.
12. Before filling the pressure fluid tank, please observe the
following requirements:
The pressure fluid must conform to the specification

in the Operating Instructions.
Use oil filler units (filter units) suitable for pressure fluids.
Do not remove the filter strainers from filler necks or the filter element from filters before filling the pressure fluid tank.
13. Fill the pressure fluid tank up to the upper mark on the
inspection window. Observe the maximum fluid level, taking into consideration the volume in the connection lines
and hydraulic consumers.
14. Set the pressure and flow control valves, pump regulator, signalling elements such as pressure switches, limit
switches and temperature regulators to the settings and
values defined in the sequential program (see 9.2 Before
bringing into first use).
DANGER
Do not change the settings of valves with a safety
function, valves with a position switch or valves with
preset electronics.
Set operating-pressure valves and flow control valves

to the lowest possible values.
Set directional control valves to their basic setting.
Reduce the setpoint values of proportional valves to

minimum values.
Do not remove the tamperproof lead seals. Damaged

or removed tamperproof lead seals indicate improper
use of the hydraulic product.
CAUTION
Never fill new hydraulic products with used pressure
fluid.
The drums of pressure fluid must be sealed and clean

on the outside.
IMPORTANT
RE 07008
15. If applicable:
Fill the pressure accumulator to the specified gas precharge pressure and then check the pressure, see Operating Instructions.
If the pressure fluid has a high level of initial contamination

(see 4 Technical data and ambient conditions):
16. Fill the pump body:

Use the leakage oil port to fill pump bodies that have this
feature, see Operating Instructions.
Use a filter unit to fill the pressure fluid tank. Ensure that the filter element is clean.
17. If applicable:
Open the cocks in the suction line.
IMPORTANT
18. Start the drive motors:
The fineness of the filter shall correspond to the cleanliness

class required by the overall system and if possible be even
finer.
The filter unit used shall fulfil the requirements for functional
safety and service life.
If possible, fill the pressure fluid tank via a filling coupling,

using a return filter if possible.
With electric motor in jogging mode, allow to start

briefly
Combustion engines in idle
Pay attention to the direction of rotation.
RE 07008
19. Bleed the hydraulics (valve, pump, motor, line, cylinder).
IMPORTANT
Details on bleeding can be found in the Operating Instructions.
Operate the hydraulic product at low pressure until it

is fully bled.
Bleed the hydraulics lines to consumers or measuring

points at the highest point, if possible.
Operate the directional valves in jogging mode.
Next, advance and retract all hydraulic consumers

several times.
Increase the load slowly. Check the pressure fluid

level in the pressure fluid tank. If necessary, top it up
with pressure fluid.
Bleeding has been accomplished fully and correctly if the pressure fluid in the tank does not foam, if the hydraulic consumers
do not make any jerky movements and if no abnormal noises
can be heard.
20. Set the valves and sensors and start up the machine:
Set the switching operations of valves with a switching time adjustment/ramp in accordance with the
dynamic conditions, see 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 electronics (OBE, On Board Electronics) have the valve and amplifiers adjusted in line with one another at the factory.
Amplifiers for valves without OBE are supplied from the factory 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 Instructions.
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 pressure and then retightening.
IMPORTANT
Apart from moisture, which should not be sufficient to form one
drop, no measurable, unintentional leakage shall be found.
Hydraulics
Bosch Rexroth AG
21/32
23. After bringing the machine into first use, have a sample of
the pressure fluid analysed to ensure that it achieves the
required cleanliness class. Change the pressure fluid if the
required cleanliness class is not achieved.
If the pressure fluid is not tested in the laboratory after
bringing the machine into first use:
Change the pressure fluid.
24. Replace the pressure fluid filter.
25. Document and file all set values.
DANGER
26. To ensure the safety of persons and the system, after
bringing the machine into first use, perform the following
tests using the defined maximum values:
Function test
Pressure test.
Prepare a record of the bringing into (first) use or acceptance and have it signed by the plant operator. This record
is an important document and requires to be filed.
IMPORTANT
Information on how to perform the function test and pressure test can be found in the Operating Instructions.
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10
Bosch Rexroth AG
Hydraulics
Operation
RE 07008
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
how to operate the Rexroth hydraulic product.
11
Trouble-shooting
11.1 What to do in the event of a fault
11.2.2 Recommended way of working when

trouble-shooting
Successful trouble-shooting for a hydraulic product requires
precise knowledge about the structure and method of operation of the individual components.
Where hydraulics are combined with electrics/electronics, in
particular, trouble-shooting is rendered more difficult and cooperation between electricians and hydraulic specialists is
required.
Even if you are under time pressure, proceed systematically and methodically.
Indiscriminate, hasty dismantling and readjustments may,
in the worst case, result in the original cause of failure
being impossible to determine.
Make sure that you gain an overview of the function of the

hydraulics in respect of the overall system in which the
hydraulics are installed.
Try to find out whether the hydraulics performed the

required function in the overall system prior to the occurrence of the fault.
Try to determine any modifications to the overall system in

which the hydraulics are installed:
DANGER
In the event of abnormal occurrences or malfunctions, stop
all work on the Rexroth hydraulic product immediately and
inform the responsible personnel.
IMPORTANT
A table for product-specific trouble-shooting can be found in
the Operating Instructions.
If the responsible personnel are unable to rectify the problem
immediately:
Switch off the main switch. If applicable, turn off any combustion engines used as drive motors.

switched on again.
Inform the machine manufacturer.
11.2 The basic approach to trouble-shooting

The information in this section is intended to help you create
the ideal conditions for carrying out trouble-shooting as efficiently as possible.
11.2.1 General conditions
Have the operating conditions or operating range of

the hydraulics been changed?
Have modifications (e.g. retrofitted equipment)

or repairs been carried out on the overall system
(machine/system, electrics, control system) or on the
hydraulics? If yes: What were they?
Have the set values of the hydraulics been changed?
Have the hydraulics recently undergone maintenance?
Has the hydraulic product/machine been operated

improperly?
How does the malfunction manifest itself?
Form a clear picture of the cause of the fault. Ask the

machine operators directly, if necessary.
Is all the necessary technical documentation to hand?
Document any work undertaken, changed set values, etc.
If no hydraulic circuit diagram is available:

Can a hydraulic circuit diagram be drawn using the structure, signs and labelling of the equipment?
Document any amendments/additional information that

should be included in the Operating Instructions.
Are there enough measuring points?
Has the customer provided useful information about how

the malfunction manifests itself and about the functional
behaviour of the system/component prior to the malfunction?
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11.2.3 Systematic trouble-shooting procedure
Is there an inspection and maintenance book which might

provide information about the trend of test parameters
(e.g. temperature of hydraulic fluid, replacement intervals
of filter elements, noises)?
Have there been any identical or similar failures in the
past?
Make a note of causes of failures with a low probability. Only investigate the failure causes you have noted
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.
Hydraulics
Bosch Rexroth AG
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11.3 Trouble-shooting tables
IMPORTANT
The causes of failure in hydraulic systems can be extremely
complex. Therefore, general rules for trouble-shooting can only
be laid down to a limited degree.
Please refer to the relevant Operating Instructions for product
specific information about trouble-shooting the Rexroth hydraulic product.
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12
Bosch Rexroth AG
Hydraulics
Maintenance
RE 07008
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

all measures to maintain and restore the desired conditions
and to determine and assess the actual condition of the technical devices of a system .
Please refer to the Operating Instructions for all the necessary information on depressurisation and on those parts of
the Rexroth hydraulic product that are not depressurised
automatically.
These measures are divided into the following categories:
Advance all cylinders to their safe end position.
Inspection (determining the actual condition)
Lower all loads.
Servicing (maintaining the desired condition)
Switch off all pumps.
Repair (restoring the desired condition).
Mechanically support vertical cylinders so that they

cannot drop. Never perform any maintenance work on
raised units without external support.
Relieve any accumulators of pressure in the proper

manner.
Switch off the pressure supply and secure the hydraulic product against being inadvertently switched on
again.
Ensure that only authorised personnel remain in the

work zone.
Wear safety glasses, gloves and boots.
Allow pressure lines and sections of the system which

have to be opened to cool down before commencing
maintenance work.
Open with care any segments that have to remain

under pressure.
The above measures include:
Adapting maintenance objectives to suit company objectives
Determining appropriate maintenance strategies.
12.2 Safety during maintenance tasks
DANGER
In the interests of safety, please observe all the following
safety instructions carefully and at all times.
Check safety devices regularly to see that they are working properly.
Perform all maintenance work properly, completely and

within the stipulated periods and make a record of the
work.
Inform all personnel before commencing maintenance

work.
Generously cordon off the maintenance zone before commencing work.
Inform all persons of ongoing maintenance work by means

of the appropriate signs.
In particular, attach warning signs to the control cabinet,
main switch, actuators and points of access.
If you have to switch off the hydraulic product, secure it against

being unintentionally switched on again as follows:
Switch off all drives, disconnect the hydraulics from the

mains at the main switch.
Depressurise the hydraulic product (relieve any pressure

accumulators of pressure).

switched on again.
Since check valves are located in the pressure lines above the
pumps, the hydraulic system may still be under pressure even
after it has been disconnected from the actual pressure supply.
Certain segments, such as servo cylinders, also continue to
remain under pressure because the proportional valves remain
in the closed position (all valves are illustrated in their basic
position in the hydraulics diagram).
Observe the following:
Only new, interchangeable and tested components,

replacement parts and lubricants in original-equipment
quality are approved for use/replacement.
For reasons of safety, the installation of used and/or

untested components is strictly prohibited and leads to
loss of EU Conformity.
Exercise extreme vigilance when operating the hydraulic product in maintenance mode, which may in certain circumstances
necessitate the temporary removal of certain safety devices.
RE 07008
Make sure that all safety devices are properly installed and
have undergone a function test before bringing the system
(back) into use.
Perform welding, burning or grinding work on the hydraulic unit or its attachments only with the approval of local
safety authorities/fire brigade and with suitable protective
covering to prevent ingress of contaminants.
When performing assembly work above your height, use

the steps and platforms provided by the plant operator. Do
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
To maintain all system functions along with the initial

parameters of the system
To ensure continual availability of the system
To detect weak points
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 operating 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
It provides comparison values to aid with early detection of

malfunctions
It allows warranty claims to be dealt with more easily.
CAUTION
Ensure cleanliness during all work.
Please observe the requirements for pressure fluids mentioned 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.
Hydraulics
Bosch Rexroth AG
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Document and file details of any work undertaken,

changed set values, etc.
Document and file details of any amendments/additional

information that should be included in the Operating
Instructions.
Modifications and additions could affect the validity of the

EU Conformity Declaration/Manufacturers Declaration.
Always consult Bosch Rexroth about any proposed modifications or additions.
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Bosch Rexroth AG
Hydraulics
12.3.1 Inspection procedures and test equipment,

general
The following are some of the typical inspection and testing
procedures that are regularly used in connection with hydraulic
systems and components.
IMPORTANT
RE 07008
12.3.2 Location of testing and measuring points
IMPORTANT
Please refer to the Operating Instructions for the installation
location of filling level indicators, filling points, drainage points,
filters, testing points, strainers, solenoids, etc. that require regular inspection and servicing.
Keep the indicated typical test equipment ready for this type of
work.
Type of test
Typical test
equipment
Typical
testing activities
Pressure
measurement
Pressure gauge
or sensor with
suitable measuring
range and connection pipe and connection coupling
Checking of
Visual
inspection
specified pressure
opening pressure
pressure difference
before and after the
object under test
Temperature
inspection
Acoustic
inspection
all components
securely seated
damage
wear
leakage (formation of
oil droplets)
presence of all
warning and
informative signs
Checks for
Temperature
measuring
instrument
The graph illustrates the concept of wear/wear margin.

The wear margin is a characteristic feature used to describe
the condition of the system for the purpose of maintenance.
5
Checks for
Touch
inspection
12.3.3 Inspection and servicing plan, hydraulic

products, general
unusual local
vibrations
Checks for
unusual local
temperature zones
Checks for
changes in running
noise of the unit
changes in flow
noise
changes in operating
noise in the unit and
valve control.
1
4
1
2
Wear margin Z0
Time t
Repair (corrective maintenance) time (ti2 ti1)
Damage threshold (damage time tS)
5
6
Desired condition after corrective maintenance

Failure
The reduction in the wear margin reflects wear. The curve represents one possible form of the wear profile during the period
of use. It is determined during inspection and varies depending, firstly, on the system itself (e.g. material selection, surface treatment, quality) and secondly on external influences
or boundary conditions such as servicing levels, corrosive circulating air and dust. Thirdly, it depends on how the system
is operated; whether with partial load or partially with excess
load, whether it is subject to surge loads or steady load, etc.
Where hydraulic systems are concerned, the curve is also influenced by the cleanliness class and degree of fouling of the
pressure fluid, the number of cycles and the ambient conditions.
RE 07008
Hydraulics
Bosch Rexroth AG
27/32
All the factors mentioned above can exert an influence on the

curve but this need not necessarily adversely affect the quality
of its information, as wear always signifies the reduction in the
wear margin, which is understood to be the primary initial variable before wear commences.
12.3.5 Inspection and servicing plan: electrics and

control system
Consequently, this means that a sudden change in the wear

margin must also count as wear, and that the element of time
on its own is not of decisive importance for wear, but is of considerable interest in the assessment and evaluation of such
wear.
The product-specific inspection and servicing plan for electrics

and control systems can be found in the Operating Instructions.
An increase in the wear margin to over 100 % above its baseline may be achieved through corrective maintenance, if such
measures entail an improvement and this increase is established as the new desired condition for future corrective maintenance.
Certain system parts may be subject to a wear margin which
diminishes in such a way that the time available for use is insufficient 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 naturally be kept in reasonable proportion to the expected degree
of success.
IMPORTANT
12.3.6 Lubrication points, lubricants, intervals
IMPORTANT
The details of the specified lubricants, lubrication points and
associated lubrication cycles can be found in the Operating
Instructions.
12.3.7 Set values of valves, regulators and

signalling elements
If such conditions arise, we refer to these parts as weak points.

Since their elimination may provide economic and safety
advantages, weak points require to be rectified immediately.
Pressure and flow control valves, pump regulators and signalling elements such as pressure sensors, pressure switches,
limit switches and temperature regulators are given their optimum 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.
12.3.4 Inspection and servicing plan,

electrohydraulic systems
Electrohydraulic systems with proportional valves must be serviced in accordance with hydraulic requirements and strategies. However, technical control components must also be
incorporated in these servicing cycles.
On this basis, an overall strategy for system servicing must be
developed and documented.
IMPORTANT
The appropriate component characteristics relevant to servicing can be found in the Operating Instructions.
DANGER
The set values of valves with position switches shall only
be calibrated or readjusted at the factory.
The set values of safety valves shall not be altered by the
user. Any readjustment shall be performed by authorised
testing bodies only.
Too low a pressure difference between the operating pressure and the opening pressure can lead to frequent opening
of safety valves. This leads to increased power losses and an
unacceptable increase in temperature of the pressure fluid. In
this event, select a lower operating pressure.
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Bosch Rexroth AG
Hydraulics
12.3.8 Replacement of pressure fluid filters and

ventilation filters
CAUTION
Unfiltered pressure fluid filters lead to increased wear of
all the systems hydraulic products and can cause functional failures with dangerous effects. Therefore, always
replace contaminated oil filters immediately.
Clogged ventilation filters result in inadequate cooling and
can therefore cause excessive heating up and malfunctions of the hydraulic system. Therefore, always replace
contaminated ventilation filters immediately.
Clogged filters must always be replaced immediately.

Do not clean clogged filters.
Allow the contents of the replaced oil filter to drip and fully drain.
Dispose of the filter in accordance with the applicable regulations.
Exact instructions on how to replace a filter can be found in the

Filter manufacturers instructions for use.
12.3.9 Checking filters with a contamination indicator

Filters with contamination indicators continuously measure the
degree of fouling. The dirt-retention capacity of the filter is utilized to the full.
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 indicated, although
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 system, resulting in contamination of the hydraulic product.
RE 07008
CAUTION
In certain circumstances the contamination indicator does
not show a required filter replacement.
If the check function never indicates filter replacement and the
contamination indicator is functioning correctly, this may have
the following causes:
Faulty filter
A bypass valve may have been installed and is not closing

correctly, e.g. due to the entry of dirt particles.
12.4 Service and storage lives of hose lines
IMPORTANT
In terms of the service life of hydraulic hose lines in these
Operating Instructions, replacement and storage lives are measured from the date of manufacture of the hose line.
Even when properly stored and subjected to permissible loads,
seals, hoses and hose lines undergo a natural ageing process.
The replacement and storage lives of seals, hoses and hose
lines are therefore limited (see 8.2 Seals, hoses and hose
lines).
DANGER
Hose lines must be replaced in accordance with the provisions of the servicing plan, even if there are no detectable
technical defects in the hose line.
Hoses that have already been used as part of a hose line
shall not be reused in a hose line.
The first use may have changed the properties of the hose
material to such an extent that reuse of the hose represents a very high risk.
RE 07008
Hydraulics
Bosch Rexroth AG
29/32
12.5 Topping up the pressure fluid
12.7 Repair
IMPORTANT
IMPORTANT
Only pressure fluids specified in the Operating Instructions are

to be used.
Repair (corrective maintenance) is the restoring of the desired

condition.
When changing or topping up the pressure fluid, fill the pressure fluid tank on the hydraulic product as follows:
In addition, observe the special safety instructions in

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 m).
2.
Drop the system pressure right down by resetting the

pump. Set the pressure setting value on the pump pressure control to minimum or zero pressure.
3.
Fill and bleed the line system of the hydraulic product from
the unit to the cylinder. To do this actuate the cylinder in
both directions, see Operating Instructions.
4.
Top up the pressure fluid volume to the specified quantity.
5.
Raise the pump pressure to the system pressure.
The hydraulic product is ready for operation.

6.
Carry out a test run.
7.
Check the level of the fluid after the hydraulic product has
warmed up to the operating temperature and adjust if necessary.
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 indicated.
12.6 Servicing pressure accumulators
DANGER
Pressure accumulators are subject to the national legislation on safety requirements for pressure vessels applicable in the place of installation.
Observe the Pressure Equipment Directive 97/23/EC.
IMPORTANT
The gas precharge pressure is measured with a testing and filling device.
Details of the procedure can be found in the Operating Instructions.
Inspection and servicing
Carry out the tests required by law.
Test and monitor the gas precharge pressure regularly.
DANGER
Ensure cleanliness during all work.
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 repair work.
If appropriate, follow the procedure for bringing into first

use, see 9.3 Bringing into first use, subsequent bringing
into use.
Document any amendments/additional information that

should be included in the Operating Instructions.
30/32
Bosch Rexroth AG
Hydraulics
12.7.1 General safety instructions for repair work
DANGER
Repair work shall only be done by an authorised hydraulics
expert who has the required specialist hydraulics knowledge.
Specialist hydraulics knowledge means, among other things,
that the person can read and fully understand hydraulics drawings. In particular, he must fully comprehend the range of functions of the integrated safety components.
Components may only be dismantled for the purpose of repair
to the extent described in the Operating Instructions.
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 deviations from this can be found in the Operating Instructions.
Before each subsequent bringing into use after repair work, the
hydraulic product shall be accepted by a hydraulics expert.
The operator of the hydraulic product is required to check by
means of a servicing record that the inspection and servicing
plan as been complied with.
Pressure vessels have to be pressure tested every 10 years
and the information recorded in accordance with the Pressure
Equipment Directive 97/23/EC or its implementation in national
legislation.
13
General information about

hydraulic pressure accumulators
13.1 General
The regulations applicable at the place of installation concerning hydraulic pressure accumulators (hydrostatic accumulators) must be observed before bringing into use and during
operation.
The plant operator bears sole responsibility for compliance with
the existing regulations.
Hydrostatic accumulators are subject to the national implementation 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 carried out by trained expert personnel only.
RE 07008
WARNING
Do not perform any welding, soldering or mechanical work
on accumulator vessels.
Welding and soldering carry a risk of explosion!
Mechanical tampering may cause the vessel to burst and
the operating permit will be withdrawn.
Do not charge hydrostatic accumulators with oxygen or air.
Risk of explosion!
Depressurise the system before working on hydraulic
installations.
Improper installation can lead to serious damage to persons and property.
13.2 Safety devices relating to

hydraulic pressure accumulators
The equipping, installation and operation of hydrostatic accumulators is regulated by the national implementation of the EU
Pressure Equipment Directive 97/23/EC and additionally in the
Federal Republic of Germany by the Technical Regulations for
Pressure Vessels (TRB). This legislation requires the following
safety equipment:
Device to protect against excessive pressure

(prototype-tested)
Pressure relief device
Pressure measuring device
Test gauge connection
Shut-off device
Optional: electromagnetically operated pressure relief

device
Safety device to protect against overheating.
IMPORTANT
See the Operating Instructions.
RE 07008
14
Hydraulic systems
Hydraulic systems are generally intended for installation in

machines or systems. In addition to the basic information about
the installed components, the information contained in the
Operating Instructions made available for each hydraulic system by Bosch Rexroth also applies to hydraulic systems.
By installing the hydraulic system in a machine or system, the
interaction of the hydraulic system with the overall machine
may give rise to changes in the potential dangers. In particular
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 Pressure Equipment Directive and other relevant EU directives that
have been implemented in national legislation. Exact information can be found in the EU Conformity Declaration or Manufacturers Declaration that is supplied with the hydraulic system
or the hydraulic product.
WARNING
Before installing a hydraulic system in a machine or modifying an existing hydraulic system in a machine, satisfy
yourself that
the hydraulic system is suitable for its application in the

machine
the ambient conditions in the machine are suitable and/or

permissible for the use of the hydraulic system
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.
Hydraulics
Bosch Rexroth AG
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14.1 Effects of leaks in the hydraulic system

on the machine
If pressure fluid escapes from the hydraulic system and comes
into contact with hot surfaces on the machine, this can lead to
the generation of life-threatening smoke, fire and/or other dangerous operating conditions.
These risks shall be determined by the machine manufacturer
by means of a hazard analysis and if necessary provision made
for the appropriate safety devices.
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Bosch Rexroth AG
DE
Bestellinformation fr deutsche Produktinformation:
RD 07008
EN
Ordering Information for Product Information in English:
RE 07008
FR
Information de commande pour la notice franaise Informations gnrales sur les produits :
RF 07008
IT
Informazioni dordine per le informazioni tedesche sul prodotto:
RI 07008
ES
Informacin para el pedido de la informacin del producto en espaol:
RS 07008
FI
Tilaustiedot - suomenkieliset tuotetiedot:
RSF 07008
NL
Bestelinformatie voor Nederlandse productinformatie:
RNL 07008
SV
Bestllningsnummer fr svensk produktinformation:
RSK 07008
PT
Informao dos dados de encomenda para informao de produto alem:
RP 07008
DA
Bestillingsinformationer vedr. dansk produktinformation:
RDK 07008
EL
RGR 07008
Hydraulics
RE 07008
http://www.boschrexroth.com/bri-products
Datenblatt-Suche/Datasheet search
Suche nach Datenblatt/Search by datasheet
07008
Bosch Rexroth AG
Hydraulics
Zum Eisengiesser 1
97816 Lohr am Main, Germany
Tel. + 49 (0) 93 52 / 18-0
Fax + 49 (0) 93 52 / 18-23 58
documentation@boschrexroth.de
www.boschrexroth.de
All rights reserved, Bosch Rexroth AG, including applications for intellectual property rights. We reserve all power of disposal, rights of reproduction
and issue.
The data specified above only serve to describe the product.
No statements concerning a certain condition or suitability for a certain
application can be derived from our information. The given information does
not release the user from the obligation of own judgement and verification. It
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-Strae 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, specifications and other information set forth in it, are
the exclusive property of Bosch Rexroth AG.
It may not be reproduced or given to third parties wihout its consent.
Made in Germany
Document number: RE 00845/04.07
Material number:
R961003790

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Electric Drives

Linear Motion and

Bosch Rexroth AG I RE 00845/04.07

Profession-specific specialist qualifications, e.g. the manufacture, assembly and disassembly of

Bosch Rexroth AG I RE 00845/04.07

Bosch Rexroth AG I RE 00845/04.07

Restructuring of industrial metalworking and electrical professions

Training period (years)

Profession-specific specialized training

Interdisciplinary specialized training

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

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

Bosch Rexroth AG I RE 00845/04.07

Imparting knowledge through project work

Bosch Rexroth AG I RE 00845/04.07

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

Installing and commissioning

2nd year of training

Bosch Rexroth AG I RE 00845/04.07

Have I chosen the correct sequence?

Bosch Rexroth AG I RE 00845/04.07

Was the control properly installed?

In this manual, we do not give notes on procedural knowledge (explanatory knowledge). It is

Bosch Rexroth AG I RE 00845/04.07

Project designation with short description of the industrial application

Industrial application (example)

Hydraulic power unit

Pressure oil supply to a hydraulic cylinder by a hydraulic

Hydraulic pump, charac- Typical features of a pressure-compensated vane pump.

Safety aspects when using a single-rod cylinder and a

4/3 directional valve

Controlling the direction of a single-rod cylinder by means

Protection of a vertical cylinder with suspended load in

Protection of a vertical cylinder with suspended load by

Powering a conveyor belt by means of a hydraulic motor

Throttle check valve

Traversing a tool carriage at different speeds.

Flow control valve

Rotary drive (hydraulic motor) with constant speed.

Pressure relief valve,

Preparation of a characteristic curve for the pressure/flow

Pressure relief valve,

Electrical pre-selection of various pressures (series, parallel circuit) on punching equipment.

Pressure reducing valve

Swiveling a clamped workpiece by means of a hydraulic

Hydraulic pressing of two workpieces with monitoring by a

Bosch Rexroth AG I RE 00845/04.07

Working out the hysteresis of a mechanical pressure

Increasing the velocity by using the oil returning from the

Valve by-pass control

Lifting and lowering of a load by a single-rod cylinder,

Bosch Rexroth AG I RE 00845/04.07

Comparison of project exercises of Bosch Rexroth AG/BIBB

Hydraulic power unit

Component selection for hydraulic

Hydraulic variable displacement

Pump characteristic curve

Safety aspects with regard to pressure intensification

Lifting platform drive

4/3 directional valve

Control of direction, single-rod

Protection of a hydraulic cylinder,

Check valve, pilot operated