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Mobile hydraulics
Load sensing control 2M4-12
Trainer's manual
RE 09970/03.11 I Foreword Bosch Rexroth AG 1
Foreword
The present project manual for the area mobile hydraulics serves as accompanying and
work book for the knowledge transfer by means of project works. Projects are described
that are especially based on practical examples from the mobile control technology. The
trainees are expected to have basic hydraulic knowledge.
It must generally be noted that the project results documented in this manual may slightly
vary depending on the relevant circumstances.
For the projects with mobile hydraulics, the device set has been extended. For explana-
tions on the practice stand, please refer to the corresponding operating instructions.
Before the projects are carried out, the hydraulic basics should be discussed and intro-
ductory practice described must have been completed.
We recommend carrying out the projects in the specified order starting with project 01.
The description of a project practice comprises information for trainers as well as project/
trainer information for the completion of the relevant project.
This information is only contained in the trainer manual.
2 Bosch Rexroth AG Foreword I RE 09970/03.11
Notes
RE 09970/03.11 I Introduction Bosch Rexroth AG 3
Introduction
Since the 1960s, construction machines have increasingly been operated with hydraulics.
Before, mainly fully mechanical rope machines were used.
With these machines, the force was transmitted by means of gears and couplings.
The machine operator must operate the mechanical couplings with large levers.
Operation was a real feat of strength.
As compared to today's machines, the working speed were relatively slow.
The efficiency of excavator applications on construction sites was not perfect.
A rope excavator with gripper can hardly penetrate solid ground and often only scratches
at the surface.
Thanks to the hydraulics, the force transmission is more flexible and easier than with pure
mechanics.
The large, heavy gears and couplings as well as the rope drums could be omitted.
As then, the hydraulics often did not have today's tried and tested components, there
were many problems to lose for the piping and hose material for the high pressures had to
be developed and improved first. The same was true for pumps and control blocks.
The working movements of the first hydraulic excavators were much slower and more
jerky than with today's hydraulic excavators.
4 Bosch Rexroth AG Introduction I RE 09970/03.11
In the beginning, the hydraulic control blocks were arranged under the operator who oper-
ated the directional valve spools by means of mechanical levers.
The introduction of the hydraulic remote control was another step; it simplified the opera-
tion and made the arrangement of the control blocks in the machine more flexible. Now,
the control block could be mounted in places where it was e.g. most favorable for the
piping.
The machines became faster and faster and increasingly powerful.
Arm
Adjustment boom
Slew drive
Hydraulic control block
Diesel motor
Bucket
Operating elements
Hydraulic
pumps
Fig. 0-2: Hydraulic excavator today
RE 09970/03.11 I Introduction Bosch Rexroth AG 5
With the increased working speeds, the jerky motion sequence had more and more nega-
tive effects. The advancement focused on the optimization of the controls regarding the
best and jerk-free controllability of the working movements possible
(load sensitivity).
The previously used throttle control was amended by load sensing systems in the 1980s.
Load sensing reduces the power loss and simplifies the operation as the control is load
pressure-independent. Apart from that, the multi-circuit systems with several pumps nec-
essary in the throttle control could be replaced by one-circuit systems with one pump.
Another development is the LUDV system, in which the flow is load pressure-independent
of all operated actuators (LUDV = abbreviation of the German term for load pressure
independent flow distribution).
The special advantage of this system is that no actuator stops when all operated actua-
tors require more oil than can be delivered by the pump. In this case, the LUDV system
reduces the actuator velocities proportionally according to the pump delivery volume.
In the future, also electronic systems will be used by means of which the actuator veloci-
ties and pumps will be controlled.
Notes
RE 09970/03.11 I Introduction Bosch Rexroth AG 7
By means of the mobile hydraulic project manuals, the necessary expert knowledge regarding
the hydraulic control technology can be transferred in practice-oriented applications.
• To understand physical principles like pressure differential, opening cross-section and Teaching
flow, contents
• To read specific switching symbols,
• To identify the function of the throttle control,
• To understand the connection between control and velocity,
• To get to know the function of the throttle control in parallel operation,
• To work out the function and application of the hydraulic pilot control,
• To carry out measurements of specific values.
The project tasks and project works described in the mobile hydraulic project manuals
provide the trainers and trainees with information and instruments for satisfying the re-
quirements on the knowledge transfer regarding the hydraulic expert knowledge.
Due to the preparedness and ability to solve tasks and problems on the basis of technical Technical
knowledge and skills in a target-oriented, appropriate, method-guided and independent competence
way and to evaluate the result, the trainees develop their technical competence.
8 Bosch Rexroth AG Introduction I RE 09970/03.11
Professional As mentioned above, the trainee is to work off the project task and/or the project order in
competence 6 steps.
of action
1. Information
On the basis of the project definition, the trainee is to get a clear idea of the complete
solution including the necessary details. This is possible by the systematic analysis of the
project documents and queries, if necessary.
2. Planning
3. Decision-making
After the planning phase, the trainee makes the decision regarding the determination of
the aids, e.g. which data sheets are necessary for processing the project task. He also
makes the decision regarding the sequence and the dependencies of the individual proj-
ect steps. It must also be decided whether the project task can be completed more easily
in a team.
Possible auxiliary questions: a) Which hydraulic and electrical components are used?
b) How do you recognize the up-to-dateness of the
data sheets?
c) Have I used all possible sources of information?
d) Do I have the prescribed safety instructions?
RE 09970/03.11 I Introduction Bosch Rexroth AG 9
4. Execution
The order will be executed according to the work instructions in Order execution chap-
ter complying with the safety instructions. After a careful preparation phase, the trainee
should execute the project order as independently as possible. After preparation of the
written solution, it should be verified and/or asked whether the correct solution has been
chosen.
5. Checks
The trainer checks the intermediate results already during the execution phase. Some-
times, the result can be compared to manufacturer documents. In measurement practice it
has to be checked whether the measurement results are realistic.
The documentation is also to be finally corrected, improved, finished and completed. This
includes the preparation of the final report. Upon completion, there is a final check by the
trainer.
6. Evaluation
In the final evaluation face, the comparison of project order documents, assembled control
and measurement and control results is to be used as basis for an external or own evalua-
tion.
Possible errors and error causes are to be analyzed and the possibilities for avoiding
future errors are to be discussed.
The trainees are to learn to assess their strengths and weaknesses and to develop objec-
tive quality standards for their actions which will finally lead to personal competence. The
evaluation can be completed by a technical discussion, also with a customer discussion, if
applicable.
10 Bosch Rexroth AG Introduction I RE 09970/03.11
General instructions:
For didactic reasons, the present manual only talks of trainees and trainers. It is express-
ly stated that it also refers to all other parties involved in the training and further develop-
ment: The female trainees and trainers, the female and male teachers, project managers,
etc.
Procedural In this manual, we do not provide any information on procedural knowledge (explanatory
knowledge knowledge). It is the knowledge on which measures, procedures or processes are nec-
essary to achieve a certain result. In this case how the learning target can be achieved.
The present manual is to be understood as tool for transferring the required core and
technical qualifications that are to be transferred in the industrial metal professions in
an integrated form according to the regulation on the professional training considering
independent planning, executing and controlling.
Pictogram As recurring individual symbols, the listed pictograms are to transfer information as simpli-
fied graphical presentation in a language-independent form and as fast as possible.
Notes
RE 09970/03.11 I Introduction Bosch Rexroth AG 11
Safety aspects
So that the possible dangers of machines and systems are recognized, safety regulations,
product information and operating instructions must be observed.
The present mobile hydraulic project manual contains information referring to the risk of
personal injury or damage to property.
The measures described foravoiding dangers must be adhered to.
The following table summarizes the application of the most important pictograms and
signal words.
Signal
Application
word
Important:
The electrohydraulic components and systems described in the project manual are tech-
nical equipment and not designed for private use.
The intended use also includes having read and understood the subsequently listed
safety regulations, product information and operating instructions.
12 Bosch Rexroth AG Introduction I RE 09970/03.11
Qualification Assembly, commissioning and operation, disassembly, service and maintenance require
of personnel basic mechanical and electrohydraulic knowledge as well as knowledge of the appropri-
ate technical terms. In order to guarantee operational safety, these activities may only be
carried out by a corresponding expert or an instructed person under the direction and
supervision of an expert.
Experts are those who can recognize potential hazards and apply the appropriate safety
measures due to their professional training, knowledge and experience, as well as their
understanding of the relevant conditions pertaining to the work to be undertaken. An
expert must observe the relevant specific professional rules.
This means that the trainer must finally inform the trainee about possible dangers and the
related prevention of dangers.
Liability In case of damage resulting from the improper use and from unauthorized interventions
not intended in the mobile hydraulics project manual, any liability for defects and any liabil-
ity claim vis-à-vis Bosch Rexroth AG will be forfeited.
If the projects 01 to 11 described in the mobile hydraulics project manual are carried out
at practice stands and with electrohydraulic components not supplied by Bosch Rexroth,
i.e. competitor makes, any liability for defects and any liability claim vis-à-vis Bosch
Rexroth AG will be forfeited in this case, as well.
The commissioning is therefore prohibited until it was confirmed that the hy-
draulic components and systems that are to be used comply with the provisions
of all relevant EU directives.
Warning
Important:
The necessary safety provisions, product information* and operating instructions must be
handed over to and/or be accessible to the trainee in the latest version.
In the mobile hydraulics project manual, no explicit reference is made in the project prac-
tice 01 to 11 to the correct handling of hydraulic fluids. For corresponding information,
please refer to the safety data sheet.
* Bosch Rexroth product information only applies to hydraulic products that are oper-
ated with hydraulic fluid on mineral oil basis unless other hydraulic fluids are explicitly
admitted in the operating instructions.
RE 09970/03.11 I Basics of mobile hydraulics Bosch Rexroth AG 1
In mobile machines, the force is transmitted from the diesel motor to the working equip-
ment by means of hydraulic fluid. The processes are controlled by hydraulic control tech-
nology.
1) The principle of the closed circuit with hydraulic pump and hydraulic motor is mainly
used for traction drives, winches and slew drives.
In the closed circuit, the return oil from the actuator is directly fed back into the pump.
Volumenstrom
Hilfspumpe zum Flow = variabel
q
Auxiliary pump for leak-
Leckageausgleich q = variable
age compensation
Output speed
Abtriebsdrehzahl
n=
n variable
= variabel
Cooler
2. The open circuit with hydraulic pump, cylinders and hydraulic motors is used for appli-
cations with working equipment and several simultaneously operated actuators.
In the open circuit, the return oil from the actuators is led into the tank and is then
sucked in again by the pump.
For controlling the actuators, valves are necessary.
With the circuit diagram shown, there is high power loss in the unoperated condition
of the directional valves as the entire pump delivery volume is delivered to the tank at
maximum pressure.
Volumenstrom Flow
q = konstant q = constant
The machines are controlled by a machine operator. This operator controls the move-
ments having the working equipment or the load in view. Automatic operation as in indus-
trial systems is normally not possible.
A control that can easily be controlled and easily be operated is important.
With mobile machines, low component weight and good efficiency are important.
Bad efficiency means high losses and makes itself felt in high fuel consumption rates.
In 11 projects, this manual deals with the control technology in the open circuit with the
load sensing control.
4 Bosch Rexroth AG Basics of mobile hydraulics I RE 09970/03.11
Load sensing systems (LS systems) have been developed in order to eliminate the de-
pendency of the throttle control on the load pressure and to reduce the high power loss.
This resulted in more efficient systems that can be operated more easily. The efficiency
could be achieved by means of pumps controlled by the load pressure, which are always
adjusted to the relevant load conditions.
Due to the load pressure compensation, the machine operation could be simplified.
There are numerous applications for load sensing systems like e.g. construction machinery,
forestry machinery, drilling equipment, cranes, stackers and stationary applications.
Load sensing is the recording (measurement) of the load by the load pressure. This load
pressure signal is used for controlling the pump and pressure compensators.
The load pressure signal is generally also referred to as LS signal.
For the correction functioning, it is important to always record and forward the highest
load pressure signal.
For that purpose, the pressure is recorded by the relevant working port by means of bores
in the directional valve spools and forwarded to the pump controller via shuttle valves.
The shuttle valves guarantee that in parallel operation, always the highest load pressure is
forwarded to the pump controller.
= 100 bar
Shuttle valve
pP = 110 bar
pLS = pL2 pP 110 bar
100 bar
Fig. 0-7: Displacement-controlled pump with load pressure signal (LS) for individual actuator operation (load 100 bar)
RE 09970/03.11 I Basics of mobile hydraulics Bosch Rexroth AG 5
The pump controller is a so-called displacement controller and controls the pressure differ-
ential ΔpLS.
The pump controller has been designed so that the pump pressure pP always exceeds the
load sensing signal p LS by a certain value (e.g. 10 bar).
Here, you also talk of ΔpLS = pP – pLS.
With the pressure differential ΔpLS, the oil is delivered through the resistances of lines and
control block.
The pump controller always keeps the pressure differential ΔpLS constant, i.e. changes in
the load pressure also result in changes in the pump pressure.
Energy balance
Of 33 kW drive power, only 2 kW are utilized for the working movement and 31 kW are
converted into heat. The pump efficiencies have not been considered.
6 Bosch Rexroth AG Basics of mobile hydraulics I RE 09970/03.11
The calculation of the power for the specified conditions results in:
Of 8 kW drive power, 2 kW are utilized for the working movement and only 6 kW are
converted into heat. The pump efficiencies have not been considered.
A considerable improvement as compared to the fixed displacement pump.
The calculation of the power for the specified conditions results in:
Power loss throttle: PLoss 2 = (60 bar – 50 bar) • 25 l/min / 600 = 0.4 kW
Of 2.5 kW drive power, 2.1 kW are utilized for the working movement and only 0.4 kW
are converted into heat. The pump efficiencies have not been considered.
Another considerable improvement as compared to the constant pressure system.
RE 09970/03.11 I Basics of mobile hydraulics Bosch Rexroth AG 7
In order to understand the hydraulic control technology, a certain basic knowledge is nec-
essary.
The flow through a directional valve and thus the actuator velocity depend on two factors.
The opening cross-section and the pressure differential across this cross-section.
The larger the cross-section (A) and the higher the pressure differential (Δp), the higher is
the flow (q). This is expressed by the equation qV = aD • A• √2/r • √Δp.
The factor f is a flow and viscosity coefficient by means of which the properties of oil are
taken into consideration.
A clear example is to clarify the connection between cross-section, pressure differential
and flow.
Load 2 = 30 bar
Load 1 = 30 bar
Load 0 = 10 bar
psys pL
d = 5 mm
psys – pL = Δp → q
Pressure
controller Load 0 100 – 10 = 90 bar 127 l/min
Load 1 100 – 40 = 60 bar 103 l/min
Load 2 100 – 70 = 30 bar 73 l/min
Control spring = 100 bar
Fig. 0-8: Pressure differential and flow in the constant pressure system
The valve opening corresponds to a bore d = 5 mm, the system pressure is 100 bar, the
load on the cylinder changes with the charging and thus the load pressure.
Using the formula qV = aD • A• √2/r • √Δp, the flow in l/min can be calculated
(A = d2 • π/4). The exact calculation depends on more factors and conditions which are
not to be addressed here in more detail. With hydraulic valves, the flow values are mea-
sured as calculations are difficult due to the flow conditions and the geometry in the hous-
ing.
It can be seen that with increasing load, the pressure differential Δp and thus also the flow
increasingly decrease. This means in practice that with identical valve opening, the cylin-
der moves faster without load than with load.
8 Bosch Rexroth AG Basics of mobile hydraulics I RE 09970/03.11
Using the load sensing system, the pressure differential Δp at the throttling point is kept
constant, at e.g. 10 bar. For that purpose, the load pressure is recorded and forwarded to
the pump's displacement controller.
Together with the control spring, the load pressure acts on the actuating piston, the pump
pressure on the same actuating cylinder surface. Together with the control spring, the
load pressure results in an increase in the delivery volume (→ qmax.).
If the pump pressure pP exceeds the load pressure together with the control spring, this
results in a decrease in the delivery volume (→ qmin.). The pressure in front of the throttle
is therefore always 10 bar higher than the load pressure. The spring force of the control
spring determines the pressure differential Δp at the throttling point.
Load 2 = 30 bar
LS signal
(load pressure) Load 1 = 30 bar
Load 0 = 10 bar
pp pL
Displacement
controller
d = 5 mm
psys – pL = Δp → q
Fig. 0-9: Pressure differential and flow in the load sensing system
The valve opening corresponds to a bore d = 5 mm, the displacement controller is set to
a pressure differential = 10 bar, the load on the cylinder changes with the charging and
thus the load pressure.
Using the formula qV = aD • A• √2/r • √Δp, the flow in l/min can be calculated
(A = d2 • π/4).
With increasing load, the pressure differential Δp remains constant at 10 bar and thus,
the flow is constant, as well. This means in practice that with identical valve opening, the
cylinder moves as fast without load as with load. This behavior is also referred to as load
pressure compensation.
RE 09970/03.11 I Basics of mobile hydraulics Bosch Rexroth AG 9
Pressure compensators
In mobile hydraulic applications, you often carry out two movements simultaneously.
The loads of the relevant actuators are mostly different, i.e. the load pressures are differ-
ent, as well.
The pressure pP always exceeds the load pressure of the actuator with the highest load by
the pressure differential ΔpLS.
In this case, the pressure differential Δp1 of the actuator with the lower load pressure is
higher.
Z2 = 20 → 100 bar
Z1 = 20 bar
Shuttle valve
pL1 = 20 bar
pL2
20 → 100 bar
pP2
30 → 110 bar
pLS = pL2
20 → 100 bar
d = 5 mm A1 = A2 = 19.64 mm2
Fig. 0-10: Pressure differential and flow in the load sensing system with 2 actuators (without pressure compensators)
The valve openings correspond to a bore d = 5 mm, the displacement controller is set to
a pressure differential Δp = 10 bar, the load pressure of cylinder 2 is changed with the
charging from 20 to 100 bar. The loading of cylinder 1 remains constant with 20 bar.
It must be noted that the flow qV1 strongly increases if the load pressure p2 increases, while
the flow qV2 remains constant due to the load pressure compensation.
In the operation of the machine, this behavior is very annoying.
For a perfect behavior, it is therefore necessary to individually compensate the load pres-
sures for every actuator.
pL
pL
pV
pV AK (2)
Spool (1)
pP
pP pP
By means of pressure compensators, the pressure differential ΔpV at the relevant valve
openings is kept constant.
The pressure compensator comprises a symmetric spool (1) that loaded on the area AK
(2) with the pressure in front of the valve opening and on the other area AK (3) with the
load pressure pL and a control spring (4).
The pressure compensator is opened by the load pressure pL and a control spring (4).
The pressure in front of the valve opening pV closes the pressure compensator.
The control spring (4) corresponds e.g. to 10 bar and the load pressure pL = 20 bar; thus,
the pressure compensator is opened with 30 bar.
The pressure pP = 100 bar is available up to the directional valve due to the opened pres-
sure compensator.
RE 09970/03.11 I Basics of mobile hydraulics Bosch Rexroth AG 11
The pressure in front of the valve opening, however, acts on the spool area (2) and closes the
pressure compensator if 30 bar have been reached. The opening grooves (5) of the pressure
compensator (DW) throttle the oil flow and now, a pressure differential ΔpDW results.
With a pressure differential ΔpDW = 70 bar, 100 bar – 70 bar = 30 are available in front of the
valve opening and the pressure compensator will stop closing as the forces at the spool (1) bal-
anced. If the pressure differential ΔpDW is increased to above bar, the pressure compensator will
be re-opened as in front of the valve opening, 30 bar are no longer achieved.
The pressure compensator is in a control position.
The pressure in front of the valve opening is controlled to 30 bar.
As the load pressure pL amounts to 20 bar, the pressure differential ΔpV at the valve opening is
10 bar.
When the load pressure changes, the pressure compensator will also change the control posi-
tion until a pressure differential ΔpV = 10 bar is reached.
If the pressure pP changes, the pressure compensator will change the control position in this
case, as well, until a pressure differential ΔpV = 10 bar is reached.
That means that the pressure compensator compensates all pressure changes.
By means of the control spring, the pressure differential ΔpV at the metering orifice A1 is
kept constant.
= 100 bar
= 20 bar
In systems with pressure compensators, the pump controller setting must exceed the setting of
systems without pressure compensators by the control pressure differential. The pressure com-
pensator of actuator 1 with the lower load pressure generates a pressure differential ΔpDW of
90 bar and keeps the pressure differential ΔpV = pV1 – pL1 = 30 – 20 = 10 bar constant.
With the pressure compensator, the annoying behavior with different load pressures no longer
exists as the pressure differential ΔpV1 = ΔpV2 = 10 bar remains constant.
The pressure compensator of actuator 2 with the high load pressure generates a pressure dif-
ferential ΔpDW = 10 bar.
12 Bosch Rexroth AG Basics of mobile hydraulics I RE 09970/03.11
For simplification, we have until now always assumed a constant valve opening d = 5 mm.
In the control block, the valve opening A with the control spool stroke and the control
grooves can be selected by the operator using the operating levers.
As the pressure differential Δp at the control grooves is kept constant by the pressure
compensator, the position of the operating lever always corresponds to the same velocity,
regardless whether with or without load, in individual and parallel operation (in the satu-
rated condition).
With stroke limitations, the maximum flow rates of the individual actuators can be set, e.g.
the max. actuator flow shall only be 60 l/min instead of the possible 100 l/min. Using the
set screw, the control spool stop is adjusted so that only 60 % of the stroke are possible.
In this regard, it has to be considered that 40 % of the possible control stroke can no
longer be utilized.
If now, only 25 l/min shall flow, only 25 % of the control stroke are available. This resolu-
tion is quite bad and may often be reflected in bad controllability.
For good controllability, the actuator velocity is to be resolved to the largest control spool
stroke possible.
That is way control spools with graduated flow rates are available.
A spool E25/25 has, with a stroke of 100 %, a flow in A and B of 25 l/min each. In the
same way, the resolution deteriorates if spools for 100 l/min are used with a pump deliv-
ery volume of 50 l/min. In this case, there will be no more velocity increase from 50 % of
the stroke, i.e. 50 % of the control stroke are not utilized.
The control pressure differential Δp is not achieved. The pressure compensator opens
from 50 % of the control stroke.
Notes
RE 09970/03.11 I Basics of mobile hydraulics Bosch Rexroth AG 13
qActuator
100 %
50 %
Spool stroke
0% 50 % 100 %
Control range
Stroke limitation 60 %
q pump 50 %
q = f (A)
Δp1 = Δp2
In individual cases in which certain actuators must not work with the maximum system
pressure, the actuator pressure must be limited.
You can do so using the secondary pressure relief valves. When the actuator pressure
is reached, the entire actuator flow will then, however, be discharged to the tank (high
power loss).
By means of limitation of the LS pressure, the pressure in the spring chamber of the pres-
sure compensator is limited. If the actuator pressure has been reached, the pressure in
the spring chamber will stop increasing and the pressure compensator closes.
There is only a relatively small pilot oil flow of approx. 2.5 l/min.
The operating limit of a load sensing system has been exceeded if the entire actuator
volume requested by the directional valves is greater than the maximum displacement of
the pump possible. In this case, the pump is in the maximum stop. The required system
pressure for the actuator with the highest load pressure can no longer be maintained as
the oil preferably flows to the actuator with the lower load pressure.
For the actuator with the highest load pressure this means that it is only supplied with the
residual oil quantity or it also stops completely, if applicable.
The resistance of valve opening 1 is not sufficient for generating a pressure differential Δp
= 10 bar. The pressure compensator cannot be closed with 28 bar. This is only possible
from 30 bar. The pressure loss of a completely opened pressure compensator is only
minor and thus, the system pressure is now also on the lower level of 28 bar.
For the actuator 2 with a load pressure of 100 bar, this means standstill. If actuator 1 is
only open for 75 l/min, 25 l/min remain for actuator 2.
In this case, there resistance of valve opening 1 is sufficient for generating a pressure dif-
ferential Δp = 10 bar and closing.
Now, the system pressure can rise to values above 100 bar and move cylinder 2.
When operating a machine, this behavior may be annoying; therefore, the delivery volume
of the pump in the load sensing system must always be sufficient for all simultaneously
operated actuators.
RE 09970/03.11 I Basics of mobile hydraulics Bosch Rexroth AG 15
↑qV1 =
8 bar 100 l/min = 0 bar
28 bar qV2 =
0 l/min ↑ = 100 l/min
= 10 bar 10 bar =
28 bar 28 bar
↑qP =
100 l/min
With the "Load pressure-independent flow distribution" (LUDV) system, the velocity of all
actuators is reduced in the same ratio in case of undersupply.
In the example specified above, every cylinder would be operated with 50 l/min.
In the LUDV system, the pressure compensators are located downstream the metering
orifice and they are all provided with the highest load pressure.
The pressure compensators are symmetrical spools without spring.
The load pressure acts in the closing direction. The pressure after the valve opening acts
in the opening direction.
If the pressure in front of the pressure compensator (after the valve opening) is larger than
the load pressure, the pressure compensator starts to open. In this way, this pressure
always corresponds to the highest load pressure.
The displacement controller of the pump controls the pump pressure pP to a value 10 bar
higher than the load pressure.
16 Bosch Rexroth AG Basics of mobile hydraulics I RE 09970/03.11
Δp1 = 10 bar
Δp2 = 10 bar
qV1 = ↑ = 50 l/min 50 l/min = qV2 = 50 l/min
50 l/min pP = 110 bar
qP = 100 l/min
If there is an undersupply, the pump is maximally deflected. Due to the reduced pressure
differential Δp at all valve openings, a reduced flow results. The closing of both pressure
compensators prevents the standstill of both actuators.
As the reduced pressure differential Δpred. is the same again at all valve openings, the flow
rates are in the same ratio again, as well.
Important:
If the LUDV system returns into the full supply from the undersupply (command value
cancellation), the actuators are accelerated. This unwanted acceleration is not admis-
sible with mobile machines (e.g. crane) (see EN 13000).
qP = 100 l/min
In practice, the reduction of the actuator flow rates takes effect correspondingly faster in
case of fast actuation of the second actuator and may lead to an abrupt deceleration of
the first actuator.
Disadvantage: If the command values are canceled, the actuators are accelerated.
18 Bosch Rexroth AG Basics of mobile hydraulics I RE 09970/03.11
The primary pressure valve is located at the input element. This pressure relief valve is
used to set the maximum system pressure in channel P.
The secondary valve is installed in the actuator ports. This pressure relief valve is used
to limit the max. actuator pressure. The secondary valves are used as protection against
pressure peaks and external forces; they take effect when the control spool is not oper-
ated.
Secondary valves are designed as pure pressure valves or as valves with pressure and
feed function. The feed function is a check valve that opens when the pressure in the
actuator is lower than the pressure in channel T.
This function is important in order to prevent vacuum and cavitation in the actuators.
Vacuum in cylinders results in air separations from the oil leading to seal damage and
unwanted delays in the working behavior of the machine.
Vacuum in hydraulic motors leads to cavitation destroying the motor and the machine may
completely get out of control.
This is very dangerous with winches and carriages; for safety reasons, there is therefore
additional safety equipment like lowering brake valves in order to prevent this.
The operation with mechanical handle-operated levers requires the operator to be directly
at the control block.
With many construction machines, the control block is in a central position and the con-
struction machine operator sits in a cabin having good view of the working area.
An operation using rods is too inflexible and complex.
With most construction machines, the operating elements e.g. hydraulic pilot control units
are integrated in the driver's seat armrest and in this way allow for comfortable operation
of the machine.
The signal is transmitted by means of hydraulic pressure from the hydraulic pilot control
unit to the control spool.
In the hydraulic pilot control unit, a pressure reducing valve is used to set a pressure con-
tinuously, depending on the characteristic curve, from 6 to 24 bar. This pilot pressure acts
on the pilot spool that is clamped by the centering springs.
The spring force increases with an increasing stroke.
Proportionately to the lever deflection of the pilot control unit, a pilot pressure is gener-
ated that again adjusts the directional valve main spool until the forces at the directional
valve spool are balanced.
RE 09970/03.11 I Basics of mobile hydraulics Bosch Rexroth AG 19
Cover A
Cover B
The sectional drawing shows a directional valve element with mechanical and
electrohydraulic actuation.
Using the handle-operated lever (10), the main spool (2) can be operated in
both directions.
The stroke limitations (6.1, 6.2, 6.3) can be used to set the maximum flow rate.
Two set screws (6.1 or 6.2) influence the flow of P → A, one set screw (6.3) the
flow P → B.
20 Bosch Rexroth AG Basics of mobile hydraulics I RE 09970/03.11
The hydraulic pilot pressure can either be controlled using the hydraulic pilot control unit
4TH6 or using the electrical pressure reducing valves (9.1, 9.2).
The hydraulic control connections are always located in the cover A. Through a bore in
the housing, the pilot pressure reaches the cover B.
The pilot oil supply X comes from the input element into which a pilot oil supply has been
installed.
The pilot oil drain Y must be led to the tank at zero pressure.
Using the main spool (2), the flow direction is controlled and using the stroke the
flow rate.
Apart from that, the load pressure is recorded by means of bores in the main spool (2).
Grooves are milled into the main spool (2), the opening cross-section of which determines
the flow rate in the supply and also the flow rate to the T channel.
The pressure compensator consists of a spool (3) with milled-in grooves and a bore for
recording the pressure in front of the main spool (2). The spool (3) is loaded with a spring
determining the pressure differential Δp at the main spool.
By means of shims, the spring force and consequently the pressure differential Δp and
thus the maximum flow with identical opening cross-section of the valve can be changed.
The pressure compensator shown has moreover a load holding function. This prevents the
lowering of the load if the pressure in P is less than the load pressure.
The LS signal is recorded by bores in the main spool and led into the pressure compensa-
tor spring chamber. In this area, the LS signal can be limited by means of the LS pressure
relief valve for every actuator port. At the measuring points MA and MB, the LS pressure
can be measured or also influenced by means of external valves.
The LS signal is forwarded to the pump controller via the shuttle valve (7).
The actuator ports A and B can be protected from excessive pressure by means of sec-
ondary pressure valves (5.1). The secondary valve shown is not adjustable.
It simultaneously offers a feed function by acting as check valve of T → A.
The plug screw (5.2) is necessary if neither the pressure limitation nor the feed-in is nec-
essary.
RE 09970/03.11 I Basics of mobile hydraulics Bosch Rexroth AG 21
The input element accommodates the primary pressure valve and the pilot oil supply.
P line, T line, LS line and pilot oil line (X, Y) are connected at the input element.
There are input elements in different designs (see data sheet RE 64276).
End elements
In the end elements, the LS pressure is discharged. Alternatively to the discharge, there
may be an external LS port for more LS actuators.
Discharge of the LS pressure to the tank in the non-operated condition of the directional
valves is important for the failure-free functioning of the system. In this connection, the
pump's displacement controller is notified a low pressure level (standby pressure).
This must also be ensured with an external LS connection (see data sheet RE 64276).
6
8
1
1 Housing 7 Shuttle valve
2 Directional valve main spool 8 Handle-operated lever
3 Pressure compensator 9 Proportional pressure reducing valve
4 LS pressure relief valve
5 Secondary pressure relief valve (with
cavitation protection) and plug screw
6 Stroke limitation
Fig. 0-19: Circuit diagram M4-12
22 Bosch Rexroth AG Basics of mobile hydraulics I RE 09970/03.11
The sectional drawing shows a directional valve element with mechanical actuation.
The hydraulic pilot pressure can be set using the hydraulic pilot control unit 4TH6. With
hydraulic actuation, stroke limitations are possible.
Using the main spool (2), the flow direction is controlled and using the stroke the
flow rate.
Grooves are milled into the main spool (2), the opening cross-sections of which determine
both, the flow rate in the supply and the flow rate to the T channel.
RE 09970/03.11 I Basics of mobile hydraulics Bosch Rexroth AG 23
The pressure compensator consists of a spool (4) with milled-in grooves and a bore for
recording the pressure after the main spool (2).
The spool (4) is symmetrical and not loaded with a spring.
The pressure differential Δp at the main spool is determined by the pump controller and in
case of undersupply results due to reduced flows. (See basics)
The check valves (3) have the load holding function. This prevents the lowering of the load
if the pressure in P is less than the load pressure.
The load pressure is recorded by means of a bore in the spool of the pressure compensa-
tors (4).
The pressure compensator of the actuator with the highest load is always complete-
ly open.
Only in this case is the bore open.
That means that only the load pressure of the actuator with the highest load is recorded
and forwarded to the pump and the other pressure compensators.
The pressure compensators of the actuators with lower load pressure are in a control
position in which the bore is overlapped.
Shuttle valves are therefore not required.
The actuator ports A, B can be protected from excessive pressure by means of secondary
pressure valves (5). It simultaneously offers a feed function by acting as check valve of T
→ B.
The plug screw (6) is screwed in if neither the pressure limitation nor the feed-in is neces-
sary.
The input element accommodates the primary pressure limitation and the LS unloading.
The primary pressure limitation is effected by limiting the LS signal.
As option, the input element can be equipped with a flushing valve, opening a connection
P → T.
The P line, T line, LS line and pilot oil X, Y are connected at the input element.
There are input elements in different designs (see data sheet RE 64128).
End elements
As end element, there may be an end plate or a plate with additional port P3 (see data
sheet RE 64128).
24 Bosch Rexroth AG Basics of mobile hydraulics I RE 09970/03.11
Notes
RE 09970/03.11 I Safety instructions Bosch Rexroth AG 25
So that the possible dangers of machines and systems are recognized, safety regulations,
product information and operating instructions must be observed.
Trainer must make the necessary documentation available to the trainee. When us-
ing competitive products, the safety instructions prescribed by the manufacturer apply,
whereas it has to be ensured that the components and systems comply with the currently
valid and relevant EU directives.
The commissioning is therefore prohibited until it was confirmed that the elec-
trohydraulic components and systems that are to be used comply with the pro-
visions of all relevant EU directives.
Warning
The operating instructions are to provide information and avoid dangers when
installing the hydraulic components into the system – in this case the installa-
tion of the electrohydraulic components into the practice stand - and it provides
information and notes for transport, storage and maintenance (inspection, ser-
vice, repair) of the hydraulic system.
Only in case of strict compliance with the operating instructions can accidents
and damage to property be avoided and failure-free operation of the hydraulic
system be guaranteed.
Apart from that, compliance with the operating instructions results in:
• Reduced down times and repair costs
• Increased service life of the hydraulic system.
26 Bosch Rexroth AG Safety instructions I RE 09970/03.11
Hydraulic oil on mineral oil basis is water-endangering and inflammable. It may only
be used if the corresponding safety data sheet is available and all measures prescribed
therein have been realized.
The intended use, performance data and operating conditions must not be changed.
You must not decommission protective devices / components, e.g. by bridging end
switches, valves and other control components.
If for maintenance works, protective devices have to be bridged, safety measures have
to be taken in advance which guarantee that no dangerous situation can result. The supe-
rior machine operating instructions have to be observed.
Important:
Those are general safety provisions that have to be observed in detail in every proj-
ect task.
Effects of air Air may be available in hydraulic oils in the following forms: As dissolved air (invisible), as
in the oil surface foam (visible) and as undissolved, dispersed air (visible). While dissolved air and
a little bit of surface foam have hardly any disadvantageous effects, dispersed air can lead
to major problems. As the oil contains very small air bubbles in a very finely dispersed
form that can only rise to the surface very slowly, the following faults may occur:
• Unequal or jerky movements of the hydraulic pistons, vibration in the system due to an
increase in the compressibility, changed actuating times of servo valves
• Noise in the pump
• Cavitation damage at pumps, lines and seals
• Accelerated aging of the oil
• Microdiesel effect, one form of thermal cracking due to high temperatures in com-
pressed small air bubbles
RE 09970/03.11 I Safety instructions Bosch Rexroth AG 27
In order to avoid undissolved air in the oil, the following has to be observed: Leak-tight-
ness of the system on the suction side, perfect size of the storage tank, installation of
baffles in the oil storage tank, favorable design of the suction system without throttling
points, sufficient oil level, low oil circulation speeds, submersible pumps instead of high
suction heads.
Hydraulic systems are closed systems. I.e. in case of intended use, the hydraulic oil is not Environmental
released in the environment. Leak-tightness of the units and timely maintenance / repair aspects
have to be ensured. Particularly hydraulic hoses and hose connections are to be closely
monitored and checked. The oil change has to be completed appropriately and profession-
ally; the used oil has to be disposed of complying with all legal provisions.
Hydraulic fluids on mineral oil basis are water-endangering and inflammable. Safety aspects
Hydraulic fluids may only be used if the corresponding safety data sheet of the
manufacturer is available and all measures prescribed therein have been real-
ized.
If leakage at the hydraulic product can lead to water and soil contamination, the
hydraulic product must be put into a suitable drain tray. Danger
One of the basic prerequisites for the failure-free operation of a hydraulic system is the Filtration
unobjectionable condition of the hydraulic fluid as pollution still is one of the main reasons
for failure of hydraulic components. The following sketch shows different types of pollution
that may lead to pollution of the hydraulic fluid.
Notes
28 Bosch Rexroth AG Safety instructions I RE 09970/03.11
1 External pollution
2 Assembly + Repair
3 New oil
4 Wear debris in pump
5 Wear debris of seals
Classification The technical data sheets of the component manufacturers include information on the
evaluation of the solid share in the hydraulic fluid by means of classification ‑ systems
(standardized cleanliness classes).
Today, the standards NAS 1638 (National American Standard) and ISO DIS 4406 are
most widely used.
Today, specification of the filtration rating in μm is no longer common; it is, however, still
frequently used in the preparation of circuit diagrams.
Important:
The detailed topic "Filtration and maintenance" is not dealt with in the mobile hydraulic
project manuals.
The sources of information mentioned in this project manual like data sheets, operating
instructions and reference books contain information on the "Filtration" topic.
RE 09970/03.11 I Operation LS unit Bosch Rexroth AG 29
The 3-way ball valves (7.1, 7.2) are in position P → L (lever downwards). Function
In this position, the line from the pump is blocked and the connection block to the leakage
oil is unloaded and depressurized.
After switch-on of the electric motor, the pumps are controlled to a pressure of 15 bar. By
operation of the 3-way ball valve by 90°, the connection block P is connected with P1 of
the pump (operating position).
Without pressure in port LS, the pressure P remains at 15 bar, according to the spring
value at the displacement controller X.
In order to get a higher pressure in P, a pressure signal must be available at the port LS.
Together with the spring, this LS pressure acts on the displacement controller X.
The pressure P is therefore always 15 bar higher than the LS pressure.
If the LS pressure is taken from port P1, the pump behaves like a pressure-
controlled pump.
The controlled pump pressure is set using the LS pressure relief valve (2.0).
In order to prevent overloading of the LS pressure relief valve (2.0) with excessive flow, a
limitation nozzle 0.8 (3.0) has been installed upstream.
The LS pressure relief valve (2.0) has a 50 bar compression spring.
With max. load, a controlled pressure P of 65 bar can be set.
In practices with constant pressure (industrial hydraulics), the LS pressure must be taken Operation in
from P1. training mode
The controlled pressure P is set to 50 bar using the LS pressure relief valve (2.0).
In practices with load sensing (mobile hydraulics), the LS pressure must be taken from the
LS port of the control blocks used.
The control pressure is set to 60 bar using the LS pressure relief valve (2.0).
In the rest position (lever vertically downwards), the connection block to the leakage oil is
unloaded and the P line is blocked.
In the operating position (lever horizontal), the 3-way ball valve is used to connect the con-
nection block P with P1 or P2 pump.
• The pressure P only amounts to 15 bar and increases very slowly after the 3-way ball Error possibilities
valve has been brought into operating position.
• Cause: No LS pressure at controller X (measuring point MX)
→ In this case, the LS pressure will only rise above the controller spool leakage.
• Constant pressure: No connection established from P1 to LS
• Load sensing: LS connection not established
• Nozzle 0.8 (3.0) blocked → Remove the LS coupling connector and check and clean
the nozzle, if necessary.
30 Bosch Rexroth AG Operation LS unit I RE 09970/03.11
For setting the maximum working pressure, an external pressure relief valve DD1.N-W
(item 02) is used for didactic reasons.
Important:
The primary valves that are usually installed in the SM12 control block are set at the test
stand with a flow qV = 5 l/min and 55 °C oil temperature.
Important:
The hydraulic accumulator used in the training system may be operated with the follow-
ing pressure ratio:
• Operating pressure p / pre-filling pressure p0 → 8 : 1
(e.g. max. operating pressure x jcyl. = 60 bar x 1.69 = 101.4 bar → p0 = > 13 bar
Size 4
Unit limit
70 bar
Fig. 0-23
In this practice, the behavior of a constant pressure system with throttle valve and change-
able load is to be worked out.
The practice is important to identify the function of displacement-controlled pumps in the
constant pressure system.
RE 09970/03.11 I Practice Bosch Rexroth AG 33
The pump has two control spools max. and min. and one controller (7). Function
The max. spool has a larger diameter and is moreover spring-loaded so that the pump can
deliver upon start-up.
The min. spool has a smaller diameter and is connected with P.
The controller (7) is kept in the position P → max. by a spring. In this position, the max.
spool is loaded with pressure from P. The stroke ring is moved in the displacement direc-
tion until the pressure P is greater than the pressure X + spring value. If the pressure P is
greater, the controller spool (7) is moved and the max. spool is unloaded. The stroke ring
is now moved from min. spool in the zero stroke direction. If the pressure P falls below the
pressure X + spring value, the controller spool (7) is pushed back by the spring and the
stroke ring moves back in the displacement direction. The control spool (7) controls the
stroke ring position.
The control pressure LS is recorded in front of the throttle (2) and corresponds to the
pressure P.
The pilot pressure valve (4) limits the pressure after the supply nozzle 0.8 and forwards it
to the controller (7).
As the pressure in P corresponds to the pressure in X, the stroke ring is maintained at max.
displacement until the pilot pressure relief valve (4) opens and limits the pressure X. The
nozzle 0.8 is necessary for the pilot oil limitation and the pressure drop in X.
Pressure X corresponds to pressure P minus the spring value.
Using the pilot pressure relief valve (4), the pressure P can be remotely adjusted.
The pilot pressure relief valve (4) is absolutely necessary as otherwise, the stroke ring is
not moved to zero stroke. In this case, the pump pressure would increase until the safety
pressure relief valves (6) open. If the entire delivery volume is discharged to the tank via
the safety pressure relief valves (6), the oil heats up considerably.
pL p pX qV ΔpR ΔpDr PV
(in bar) (in bar) (in bar) (in l/min) (in bar) (in bar) (in kW)
5 48.8 35.1 5 13.7 43.8 0.365
10 49 35.1 4.7 13.9 39 0.31
15 49.1 35.1 4.4 14 34.1 0.25
20 49.2 35.1 4.0 14.1 29.2 0.19
25 49.4 35.2 3.6 14.2 24.4 0.15
30 49.5 35.2 3.1 14.3 19.5 0.10
35 49.6 35.1 2.6 14.5 14.6 0.06
40 49.8 35.1 2.1 14.7 9.8 0.03
45 50 35.2 1.4 14.8 5 0.01
Device
arrangement
Fig. 0-25
Result Using the pilot pressure relief valve (4), the pressure p can be adjusted.
The pressure in the line P and the pressure pX are always almost constant.
Using the throttle valve (2), the flow 5 l/min can be set.
If the load pressure is increased, the flow continuously decreases as the pressure differ-
ential Δp at the throttle decreases.
With low load pressure, the power loss is highest.
Important:
With real machine for example, the pressure in line P is > 250 bar and the delivery vol-
ume is > 100 l/min.
Here, the power loss with low load pressures is much higher.
250 bar • 5 l/min / 600 = 2 kW or 250 bar • 100 l/min / 600 = 41.7 kW
RE 09970/03.11 I Practice Bosch Rexroth AG 35
Size 4
Unit limit
70 bar
Fig. 0-26
In this practice, the behavior of a load sensing system with throttle valve under the influ-
ence of changeable load is to be worked out.
The practice is important to identify the function of displacement-controlled pumps in the
load sensing system.
36 Bosch Rexroth AG Practice I RE 09970/03.11
Function The V7 pump has a controller (item 7.0) and two control spools with different diameter.
The spool with the smaller diameter is connected with port P. The spool with the larger
diameter is spring-loaded in order to bring the stroke ring in idle run into an eccentric
position. Consequently, pump delivery upon start-up is possible.
A spring keeps the controller (item 7.0) in the position p → max. In this position, the larger
spool is loaded with pressure from line P. The stroke ring is moved in the displacement di-
rection until the pressure p is greater than the pressure "pX + spring value". If the pressure
p is greater, the controller spool is moved and the larger spool is unloaded. The stroke
ring is now moved from the smaller spool in the zero stroke direction. If the pressure p
falls below the pressure "pX + spring value", the controller spool is pushed back by the
spring and the stroke ring moves back in the displacement direction. The control spool
controls the stroke ring position.
The pilot pressure X is measured after the throttle (item 2.0) and corresponds to the pres-
sure pL.
The pressure pL = pX with an unloaded load pressure valve corresponds to approx. 0 bar.
The pressure p moves the control spool against the control spring on position P → L and
the larger spool is unloaded, the pressure p moves the stroke ring on zero stroke. The
spring value corresponds to the zero stroke pressure.
The pressure p therefore always exceeds the pressure pLS, namely by the spring value.
The pressures pX and pLS always fall below the pressure p, namely by the spring value.
In this way, the pressure differential Δp at the throttle is kept constant.
Using the pilot pressure relief valve (item 4.0), the pressure after the supply nozzle is
limited. Opening this valve limits the pressure pX. The nozzle (0.8) is necessary for limiting
the pilot oil and for the pressure drop at port X.
Using the pilot pressure relief valve, the maximum pressure at port P can be set.
The pilot pressure relief valve (item 4.0) is absolutely necessary as otherwise, the stroke
ring is not moved to zero stroke. In this case, the pump pressure would increase until the
safety pressure relief valves (item 6.0) open. If the entire delivery volume is discharged to
the tank via the safety pressure relief valves, the oil heats up considerably.
Practice
implementation Set-up according to circuit diagram.
RE 09970/03.11 I Practice Bosch Rexroth AG 37
The flow meter must be installed after the load pressure relief valve in order to record the
actuator volume.
It is important to measure the pilot pressure after the throttle.
pL p pX qV ΔpR ΔpDr PV
(in bar) (in bar) (in bar) (in l/min) (in bar) (in bar) (in kW)
5 19.4 5.7 5 13.7 14.4 0.12
10 24.5 10.8 5 13.7 14.5 0.12
15 29.4 15.7 5 13.7 14.4 0.12
20 34.4 20.7 5 13.7 14.4 0.12
25 39.4 25.7 5 13.7 14.4 0.12
30 44.4 30.7 5 13.7 14.4 0.12
35 47.8 34 4.3 13.8 12.8 0.09
40 49 34.7 3 14.3 9 0.05
45 49.6 35 1.4 14.6 4.6 0.01
Fig. 0-27: Table 1 (LS)
Device
arrangement
Fig. 0-28
38 Bosch Rexroth AG Practice I RE 09970/03.11
Result Using the pilot pressure relief valve (4), the maximum pressure p can be limited.
The pressure differential ∆p at the throttle valve is constant until the maximum pump pres-
sure is achieved.
Using the throttle valve (2), the flow 5 l/min can be set.
If the load pressure is increased, the flow remains almost constant as long as the pres-
sure differential ∆p at the throttle remains constant.
If the maximum pump pressure is reached, the pilot pressure pX is limited and the pres-
sure differential ∆p at the throttle and the flow decrease.
A load sensing system only functions if the pressure differential ∆p at the throttle can be
kept constant.
If the maximum pump pressure set is achieved and the load pressure continues to in-
crease, the pressure differential decreases and the flow delivered to the actuator decreas-
es.
Important:
With real machines, the pressure p is e.g. > 250 bar and the delivery volume is > 100 l/min.
Here, the constantly low power loss for energy saving has very positive effects.
Using the spring pretensioning at the displacement controller (item 7.0), the pressure
differential ∆pR can be changed.
Notes
RE 09970/03.11 I Project 01: Primary pressure limitation Bosch Rexroth AG 1
A large rotary drill is operated with a load sensing control for the top drive and the cylinder
feed.
Settings are to be made in the commissioning.
The maximum system pressure is to be limited so that the device cannot be overloaded.
The maximum safety pressure is set using the primary pressure valve.
The maximum operating pressure is set using the load sensing pressure limitation (LS-
DB) at the connection block.
Project tasks
01
Project steps
Notes
RE 09970/03.11 I Project 01: Primary pressure limitation Bosch Rexroth AG 3
01
Circuit diagram hydraulic power unit
Size 4
Unit limit
70 bar
01
Circuit diagram hydraulic set-up
Measuring glass
Size 4
01
Component select with parts list
03 1 Distributor DZ4
Fig. 01-4: Parts list for hydraulic circuit diagram Fig. 01-3
6 Bosch Rexroth AG Project 01: Primary pressure limitation I RE 09970/03.11
01
Device arrangement
Fig. 01-5: Device arrangement for parts list Fig. 01-4 and hydraulic circuit diagram Fig. 01-2
Notes
RE 09970/03.11 I Project 01: Primary pressure limitation Bosch Rexroth AG 7
01
Safety instructions
Warning
Risk from pressurized oil.
Risk of injury from leaking oil and oil jet.
Connect the return line T properly.
Only assemble/disassemble circuits at zero pressure. Caution
Pressure release:
1) Lower the load
2) 3-way ball valve in rest position (vertical)
3) Switch the directional valve several times
4) Unload accumulator
5) Control by means of pressure gauge: 0 bar in P, A, B
01
Order execution
Set up the circuit. In this connection, proceed according to the following points:
1. Hydraulic control
Work out the circuit diagram and the parts list in order to satisfy the requirements.
Hang in the hydraulic components according to the circuit diagram and establish the hose
connections.
For connecting pressure gauges with DZ1.4 measuring line, pressure hoses DZ 25.1 are
used.
Manually tighten the pressure gauge measuring lines at the relevant measuring port of the
pressure hose.
Check the correct tight connection of the components with the pressure hoses by turning
the hoses.
01
3. Determining the power loss
With P (kW) = p (bar) • qP (l/min) / 600, the power loss can be calculated.
Power loss at safety pressure = 0.63 kW (~ 6.5 l/min • 65 / 600)
Power loss at operating pressure = 0.07 kW (~ 1.0 l/min • 40 / 600)
Project/trainer information
In the present project 01, knowledge of the correct pressure setting is developed in a
practical set-up.
01
Notes
RE 09970/03.11 I Project 02: Actuator flow with stroke limitations Bosch Rexroth AG 1
Project definition
A large rotary drill is operated with a load sensing control for the rotary disk and the cylin-
der feed.
Settings are to be made in the commissioning. 02
The maximum speed of the rotary disk is to be limited so that the drill works perfectly and
is not overloaded. The max. actuator flows shall be A1 = 4 l/min and B1 = 5 l/min.
Project tasks
Project steps
Notes
RE 09970/03.11 I Project 02: Actuator flow with stroke limitations Bosch Rexroth AG 3
02
Measuring glass
Measuring glass
Size 4
05 1 Motor DM8
Fig. 02-3: Parts list for hydraulic circuit diagram Fig. 02-2
RE 09970/03.11 I Project 02: Actuator flow with stroke limitations Bosch Rexroth AG 5
Device arrangement
02
Fig. 02-4: Device arrangement for parts list Fig. 02-3 and hydraulic circuit diagram Fig. 02-2
Notes
6 Bosch Rexroth AG Project 02: Actuator flow with stroke limitations I RE 09970/03.11
Safety instructions
02
Danger due do flying component parts.
Do not disassemble components under pressure.
Warning
Risk from pressurized oil.
Risk of injury from leaking oil and oil jet.
Connect the return line T properly.
Caution Only assemble/disassemble circuits at zero pressure.
Pressure release:
1) Lower the load
2) 3-way ball valve in rest position (vertical)
3) Switch the directional valve several times
4) Unload accumulator
5) Control by means of pressure gauge: 0 bar in P, A, B
Order execution
Set up the circuit. In this connection, proceed according to the following points:
1. Hydraulic control
Work out the circuit diagram and the parts list in order to satisfy the requirements.
Hang in the hydraulic components according to the circuit diagram and establish the hose
connections. For connecting pressure gauges with DZ1.4 measuring line, pressure hoses
DZ 25.1 are used.
Manually tighten the pressure gauge measuring lines at the relevant measuring port of the
pressure hose.
a) Which actuating elements are used to set the max. actuator flow volume?
Stroke limitations are used to set the max. actuator flow volume.
b) Why can the max. actuator flow volume be set with the stroke limitations?
02 The max. actuator flow rate can - because of the constant pressure differential Δp at
the directional valve spools - be set with the stroke limitations.
c) Which component is used to keep the pressure differential Δp at the directional valve
spools constant?
Pressure compensators keep the pressure differential Δp at the directional valve
spools constant.
Project/trainer information
In the present project 02, knowledge of the setting of maximum flow rates is developed in
a practical set-up.
Notes
RE 09970/03.11 I Project 03: Load pressure compensation Bosch Rexroth AG 1
Project definition
A large rotary drill is operated with a load sensing control for the rotary disk and the cylin-
der feed.
Now, the speed of the rotary disk is to be check with different loads.
In case of loading by solid ground, the speed of the rotary disk is to remain constant, if
possible, so that the drilling power is not reduced.
The max. actuator flow for drilling is A1 = 4 l/min.
03
Project tasks
Project steps
Notes
RE 09970/03.11 I Project 03: Load pressure compensation Bosch Rexroth AG 3
03
Measuring glass
Measuring
glass
Measuring glass
Size 4
03
04 1 Flow meter + Multi-handy DZ30
05 1 Motor DM8
Fig. 03-3: Parts list for hydraulic circuit diagram Fig. 03-2
RE 09970/03.11 I Project 03: Load pressure compensation Bosch Rexroth AG 5
Device arrangement
03
Fig. 03-4: Device arrangement for parts list Fig. 03-3 and hydraulic circuit diagram Fig. 03-2
Notes
6 Bosch Rexroth AG Project 03: Load pressure compensation I RE 09970/03.11
Safety instructions
03 Warning
Risk from pressurized oil.
Risk of injury from leaking oil and oil jet.
Connect the return line T properly.
Caution Only assemble/disassemble circuits at zero pressure.
Pressure release:
1) Lower the load
2) 3-way ball valve in rest position (vertical)
3) Switch the directional valve several times
4) Unload accumulator
5) Control by means of pressure gauge: 0 bar in P, A, B
Order execution
1. Hydraulic control
Work out the circuit diagram and the parts list in order to satisfy the requirements.
Hang in the hydraulic components according to the circuit diagram and establish the hose
connections.
For connecting pressure gauges with DZ1.4 measuring line, pressure hoses DZ 25.1 are
used.
Tighten the pressure gauge measuring lines at the relevant measuring port of the pressure
hose manually.
Measure the load pressure in front of the pressure sequence valve and MpL at A of the motor.
Smallest load pressure: 17 bar
a) How has the motor speed changed in case of load changes behavior?
The motor speed has changed only slightly.
Project/trainer information
In the present project 03, the independence of the motor speed from the load pressure is
developed in a practical set-up.
Project definition
04
Project tasks
Project steps
Notes
RE 09970/03.11 I Project 04: Pressure losses in P line Bosch Rexroth AG 3
04
Measuring glass
Measuring glass
Size 4
05 1 Motor DM8
04
06 1 Throttle valve DF1
Fig. 04-3: Parts list for hydraulic circuit diagram Fig. 04-2
RE 09970/03.11 I Project 04: Pressure losses in P line Bosch Rexroth AG 5
Device arrangement
04
Fig. 04-4: Device arrangement for parts list Fig. 04-3 and hydraulic circuit diagram Fig. 04-2
Notes
6 Bosch Rexroth AG Project 04: Pressure losses in P line I RE 09970/03.11
Safety instructions
Warning
Risk from pressurized oil.
Risk of injury from leaking oil and oil jet.
Connect the return line T properly.
Caution Only assemble/disassemble circuits at zero pressure.
04
Pressure release:
1) Lower the load
2) 3-way ball valve in rest position (vertical)
3) Switch the directional valve several times
4) Unload accumulator
5) Control by means of pressure gauge: 0 bar in P, A, B
Order execution
Set up the circuit. In this connection, proceed according to the following points:
1. Hydraulic control
Work out the circuit diagram and the parts list in order to satisfy the requirements.
Hang in the hydraulic components at the grid according to the circuit diagram and estab-
lish the hose connections.
For connecting pressure gauges with DZ1.4 measuring line, DZ25.1 pressure hoses are
used.
Tighten the pressure gauge measuring lines at the relevant measuring port of the pressure 04
hose manually.
Primary pressure valve setting: 65 bar
Pressure loss Mp1 – Mp. Pressure Mp1 Pressure Mp Pressure MpLS Displacement qP
calculated (in bar) (in bar) (in bar) (in bar) (in l/min)
5 21 16 9.0 8.0 4.0 3.8
6 21 15 8.0 8.0 3.8 3.7
7 21 14 8.0 7.0 3.5 3.3
8 21 13 7.0 6.6 3.1 3.0
9 20 11 3.0 5.7 0.2 2.3
10 18 8 0 4.0 0 1.0
This means in practice that the control pressure difference at the pump controller must
be set accordingly high for each device depending on the losses in the P line. It must be
ensured that the maximum displacement required can flow.
a) How did the increase in the pressure losses in the P line influence the winch performance?
The winch performance has decreased as the displacement decreased.
Project/trainer information
In the present project 04, the influence of the pressure loss in the P line is developed in a
practical set-up.
Project definition
The drill is equipped with a winch for lifting the drilling equipment.
The winch is remotely controlled from the driver's cab.
By deflecting the hydraulic control lever in the direction of the operator (pulling), the which
is to rotate counterclockwise.
By deflecting the hydraulic pilot control lever away from the operator (pushing), the which
is to rotate clockwise.
The maximum speed possible is to be achieved.
In order to evaluate the winch control, a characteristic curve of the winch against the pilot
pressure is to be prepared.
In order to always ensure the pilot oil supply, even with low load pressure or if the drive
motor is standing still, a pilot oil accumulator is to be provided.
05
Project tasks
• Working out the correct pinout for the specified directions of rotation.
• Working out the "hydraulic remote control" function.
• Correct installation of the pilot oil accumulator.
• Checking the "hydraulic remote control" function.
• Preparation of a characteristic curve motor speed / pilot pressure.
2 Bosch Rexroth AG Project 05: Hydraulic pilot control I RE 09970/03.11
Project steps
Notes
RE 09970/03.11 I Project 05: Hydraulic pilot control Bosch Rexroth AG 3
Measuring
glass
05
Measur-
ing glass
Measuring glass
Size 4
03 2 Distributor DZ4
05 1 Motor DM8
Fig. 05-3: Parts list for hydraulic circuit diagram Fig. 05-2
RE 09970/03.11 I Project 05: Hydraulic pilot control Bosch Rexroth AG 5
Device arrangement
05
Fig. 05-4: Device arrangement for parts list Fig. 05-3 and hydraulic circuit diagram Fig. 05-2
Notes
6 Bosch Rexroth AG Project 05: Hydraulic pilot control I RE 09970/03.11
Safety instructions
Warning
Risk from pressurized oil.
Risk of injury from leaking oil and oil jet.
Connect the return line T properly.
Caution Only assemble/disassemble circuits at zero pressure.
Pressure release:
1) Lower the load
2) 3-way ball valve in rest position (vertical)
3) Switch the directional valve several times
05 4) Unload accumulator
5) Control by means of pressure gauge: 0 bar in P, A, B
Order execution
Set up the circuit. In this connection, proceed according to the following points:
1. Hydraulic control
Work out the circuit diagram and the parts list in order to satisfy the requirements.
Hang in the hydraulic components at the grid according to the circuit diagram and estab-
lish the hose connections.
For connecting pressure gauges with DZ1.4 measuring line, pressure hoses DZ 25.1 are
used.
Manually tighten the pressure gauge measuring lines at the relevant measuring port of the
pressure hose.
Check the correct tight connection of the components with the pressure hoses by turning
the hoses.
In order to be able to load the pilot oil accumulator, the a2 hydraulic operation is con-
nected at the pilot control unit.
Connect the pilot oil accumulator and close the unloading valve.
As the motor load pressure is not sufficient to charge the accumulator with 30 bar, the
hydraulic operation a2 is operated.
Actuator port A2 of the directional valve 2 is closed and upon operation, the maximum
operating pressure of 50 bar results.
The accumulator pressure now increases up to 30 bar.
If afterwards, the motor is operated using directional valve 1 at b1, the control spool can
be operated with 30 bar even if the load pressure is much less.
Measure the achievable motor speed. Result: 600 min–1.
(Press the pilot control lever 1)
Fig. 05-5: Table Pressure pst. b1 with all deflections: 0.1 bar
Ad 2.:
With the standby pressure of 15 bar, the directional valve spools cannot be fully con-
trolled properly.
If the load pressure of the controlled actuator is too low, the directional valve spool
cannot be fully controlled either. Therefore, the required actuator velocity cannot
be achieved.
With the pilot oil accumulator there is always sufficient pilot oil pressure, irrespective of
the system pressure. Another important function of the pilot oil accumulator is to always
have pilot pressure available even if the pumps are switched off. In this case, a load can
e.g. be lowered with the pilot oil from the accumulator or the system pressure can be
relieved.
RE 09970/03.11 I Project 05: Hydraulic pilot control Bosch Rexroth AG 9
Ad 3.:
It is important to see that the pilot pressure increases linearly from 9 bar and rapidly from
25 bar to 30 bar. Thereafter, the pilot pressure remains at 30 bar in order to safely hold
the directional valve spool in the end position.
This characteristic curve corresponds to control curve 70, please refer to the data sheet
RE 64552, page 5.
Different control curves are provided for the relevant control block types. This is neces-
sary as the directional valve spools have different diameters, springs and strokes.
d) How is the pilot oil supply ensured also in case of low load pressure?
The pilot oil supply is ensured by means of a pilot oil accumulator.
Project/trainer information
In the present project 05, knowledge of the function of the hydraulic remote control is
developed in a practical set-up.
Notes
05
RE 09970/03.11 I Project 06: Boom cylinder with external action of forces Bosch Rexroth AG 1
Project definition
External forces can e.g. act on a non-operated actuator by means of working movements
(secondary protection).
The maximum cylinder pressure must not exceed 70 bar.
For simulating the external forces, a hydraulic circuit is to be developed.
06
Project tasks
• Working out the correct pinout for the specified stroke direction.
• Simulation of an external cylinder load.
• Checking the function of the secondary valve with external load.
2 Bosch Rexroth AG Project 06: Boom cylinder with action of external forces I RE 09970/03.11
Project steps
Notes
RE 09970/03.11 I Project 06: Boom cylinder with external action of forces Bosch Rexroth AG 3
item 05
06
Mea-
suring
glass
Measuring glass
Size 4
08 3 Distributor DZ4
Fig. 06-3: Parts list for hydraulic circuit diagram Fig. 06-2
RE 09970/03.11 I Project 06: Boom cylinder with external action of forces Bosch Rexroth AG 5
Device arrangement
06
Fig. 06-4: Device arrangement for parts list Fig. 06-3 and hydraulic circuit diagram Fig. 06-2
Notes
6 Bosch Rexroth AG Project 06: Boom cylinder with action of external forces I RE 09970/03.11
Safety instructions
Warning
Risk from pressurized oil.
Risk of injury from leaking oil and oil jet.
Connect the return line T properly.
Only assemble/disassemble circuits at zero pressure.
Caution
Pressure release:
1) Lower the load
2) 3-way ball valve in rest position (vertical)
3) Switch the directional valve several times
4) Unload accumulator
5) Control by means of pressure gauge: 0 bar in P, A, B
Order execution
A pressure relief valve is to be used to set the max. primary pressure to 65 bar.
On the cylinder piston side, external loads are to be simulated with hydraulic pressure.
During the load simulation, a corresponding LS signal for the pump controller
must result.
The simulation of the external load shall be adjustable by means of a valve. The load pres-
sure must be so high that the secondary valve opens at 70 bar.
Set up the circuit. In this connection, proceed according to the following points:
06
1. Hydraulic control
Work out the circuit diagram and the parts list in order to satisfy the requirements.
Hang in the hydraulic components at the grid according to the circuit diagram and estab-
lish the hose connections.
For connecting pressure gauges with DZ1.4 measuring line, pressure hoses DZ 25.1 are
used.
Manually tighten the pressure gauge measuring lines at the relevant measuring port of the
pressure hose.
Check the correct tight connection of the components with the pressure hoses by turning
the hoses.
Important:
The cylinder must not be in the extended end position (counterforce cylinder, spring).
Using the secondary pressure valve, overloads can be limited by external forces, even
if the control spool is not operated. External forces may e.g. result from superimposed
working movements or from the fast deceleration of large weights like excavator booms,
slew drives, etc.
Secondary pressure valves aim at protecting the machine against overloads.
Normally, the cracking pressure of secondary pressure valves should at least be 20 bar
higher than the primary pressure.
The cracking pressure of secondary pressure valves may also be lower than the primary
pressure if the actuator must not be loaded with the primary pressure.
Project/trainer information
In the present project 06, knowledge of the protection against overload is developed in a
practical set-up.
Project definition
A large rotary drill is operated with a load sensing control for the rotary disk and the cylin-
der feed.
The bore rods are to be lifted by pulling the lever towards the operator.
By pushing the lever away from the operator the bore rods are to be lowered and the feed
is to be controlled.
In order not to overload the bore rods, the maximum feed pressure may only be 35 bar.
For the additional functions of the device, 60 bar are necessary.
07
Project tasks
• Working out the correct pinout for the specified stroke direction.
• Setting the maximum cylinder force for the feed.
• Checking the function of the secondary valve for force limitation.
• Power loss calculation upon response by the secondary pressure valve.
2 Bosch Rexroth AG Project 07: Secondary pressure limitation I RE 09970/03.11
Project steps
Notes
07
RE 09970/03.11 I Project 07: Secondary pressure limitation Bosch Rexroth AG 3
item 05
Measuring
glass
07
Measuring glass
Size 4
08 2 Distributor DZ4
Fig. 07-3: Parts list for hydraulic circuit diagram Fig. 07-2
RE 09970/03.11 I Project 07: Secondary pressure limitation Bosch Rexroth AG 5
Device arrangement
Fig. 07-4: Device arrangement for parts list Fig. 07-3 and hydraulic circuit diagram Fig. 07-2
07
Notes
6 Bosch Rexroth AG Project 07: Secondary pressure limitation I RE 09970/03.11
Safety instructions
Warning
Risk from pressurized oil.
Risk of injury from leaking oil and oil jet.
Connect the return line T properly.
Caution Only assemble/disassemble circuits at zero pressure.
Pressure release:
1) Lower the load
2) 3-way ball valve in rest position (vertical)
3) Switch the directional valve several times
4) Unload accumulator
5) Control by means of pressure gauge: 0 bar in P, A, B
Order execution
A pressure relief valve is to be used to set the max. primary pressure to 60 bar.
By means of the secondary valve in A2, the maximum feed force = pressure in the cylinder
piston chamber is to be set to 35 bar.
For the system evaluation, a flow meter is installed in the P line.
Set up the circuit. In this connection, proceed according to the following points:
1. Hydraulic control
Work out the circuit diagram and the parts list in order to satisfy the requirements.
Hang in the hydraulic components at the grid according to the circuit diagram and estab-
lish the hose connections.
For connecting pressure gauges with DZ1.4 measuring line, pressure hoses DZ 25.1 are
used.
Manually tighten the pressure gauge measuring lines at the relevant measuring port of the
pressure hose.
07
Check the correct tight connection of the components with the pressure hoses by turning
the hoses.
The cracking pressure of secondary pressure valves lies below the primary pressure if
the actuator must not be loaded with the primary pressure.
If the secondary valve is open, a power loss results corresponding to q • Δp. This can be
accepted temporarily, e.g. for limiting short overload peaks. If this is, however, the case
for a longer period of time, e.g. in order to continue drilling with maximum feed, this may
lead to inadmissibly high oil temperatures. Apart from that, the fuel consumption is high.
These findings are important for the next project.
Project/trainer information
In the present project 07, knowledge of the limitation of working forces is developed in a
practical set-up.
07 In the practical set-up, the following knowledge is to be gained:
• The secondary pressure valves opens if the pressure in the actuator channel is larger
than the set pressure.
• The secondary pressure valve limits the pressure in the cylinder and thus the maximum
force.
• This type of force limitation results in high power loss.
RE 09970/03.11 I Project 08: Load sensing pressure limitation Bosch Rexroth AG 1
Project definition
A large rotary drill is operated with a load sensing control for the rotary disk and the cylin-
der feed.
The bore rods are to be lifted by pulling the lever towards the operator.
By pushing the lever away from the operator the bore rods are to be lowered and the feed
is to be controlled.
So that the bore rods do not get stuck, the maximum feed pressure may only be 35 bar.
The pressure limitation with the secondary valve cannot be used due to the high power
loss.
For the additional functions of the device, 60 bar are necessary.
08
Project tasks
• Working out the correct pinout for the specified stroke direction.
• Setting the maximum cylinder force for the feed using the LS pressure limitation.
• Checking the "LS pressure limitation" function for the force limitation.
• Power loss calculation upon response by the LS DB valve.
2 Bosch Rexroth AG Project 08: Load sensing pressure limitation I RE 09970/03.11
Project steps
Notes
08
RE 09970/03.11 I Project 08: Load sensing pressure limitation Bosch Rexroth AG 3
item 05
Measuring
glass
08
Measuring glass
Size 4
08 2 Distributor DZ4
Fig. 08-3: Parts list for hydraulic circuit diagram Fig. 08-2
RE 09970/03.11 I Project 08: Load sensing pressure limitation Bosch Rexroth AG 5
Device arrangement
Fig. 08-4: Device arrangement for parts list Fig. 08-3 and hydraulic circuit diagram Fig. 08-2
Notes
08
6 Bosch Rexroth AG Project 08: Load sensing pressure limitation I RE 09970/03.11
Safety instructions
Warning
Risk from pressurized oil.
Risk of injury from leaking oil and oil jet.
Connect the return line T properly.
Caution Only assemble/disassemble circuits at zero pressure.
Pressure release:
1) Lower the load
2) 3-way ball valve in rest position (vertical)
3) Switch the directional valve several times
4) Unload accumulator
5) Control by means of pressure gauge: 0 bar in P, A, B
Order execution
A pressure relief valve is to be used to set the max. primary pressure to 60 bar.
By means of the LS pressure relief valve in A2, the maximum feed force = pressure in the
cylinder piston chamber is to be set to 35 bar.
For the system evaluation, a flow meter is installed in the P line.
In order to recognize this, the flow meter is installed in the P line and the flow is measured.
With the relatively low flow volumes in the teaching system, the difference in the power
loss (see project 07) is not very large; with real systems with e.g. 150 l/min flow rate,
the difference is much clearer.
Set up the circuit. In this connection, proceed according to the following points:
1. Hydraulic control
Work out the circuit diagram and the parts list in order to satisfy the requirements.
Hang in the hydraulic components at the mounting grid according to the circuit diagram
and establish the hose connections.
For connecting pressure gauges with DZ1.4 measuring line, pressure hoses DZ 25.1 are used.
Manually tighten the pressure gauge measuring lines at the relevant measuring port of the
pressure hose.
Check the correct tight connection of the components with the pressure hoses by turning 08
the hoses.
So that the LS pressure valve and the secondary pressure relief valve do not influence
each other, the secondary pressure relief valve is set to 50 bar. Thus, the secondary pres-
sure relief valve has an additional safety function.
At which pressure does the LS pressure valve open?
Set the LS pressure valve so that there are max. 35 bar in the cylinder piston chamber.
Measure and note down the flow during the cylinder movement and in the extended end
position and re-calculate the power loss.
8 Bosch Rexroth AG Project 08: Load sensing pressure limitation I RE 09970/03.11
Project/trainer information
In the present project 08, knowledge of the limitation of working forces is developed in a
08 practical set-up.
Project definition
Project tasks
• Working out the correct pinout for the specified stroke directions.
• Setting the specified flow values.
• Checking the function in individual and parallel operation.
2 Bosch Rexroth AG Project 09: Parallel operation with sufficient displacement I RE 09970/03.11
Project steps
Notes
09
RE 09970/03.11 I Project 09: Parallel operation with sufficient delivery volume Bosch Rexroth AG 3
Measuring glass
Measuring
glass
Measuring glass
09
Size 4
04 1 Motor DM8
08 2 Distributor DZ4
Fig. 09-3: Parts list for hydraulic circuit diagram Fig. 09-2
RE 09970/03.11 I Project 09: Parallel operation with sufficient delivery volume Bosch Rexroth AG 5
Device arrangement
Fig. 09-4: Device arrangement for parts list Fig. 09-4 and hydraulic circuit diagram Fig. 09-2
Notes
09
6 Bosch Rexroth AG Project 09: Parallel operation with sufficient displacement I RE 09970/03.11
Safety instructions
Warning
Risk from pressurized oil.
Risk of injury from leaking oil and oil jet.
Connect the return line T properly.
Caution Only assemble/disassemble circuits at zero pressure.
Pressure release:
1) Lower the load
2) 3-way ball valve in rest position (vertical)
3) Switch the directional valve several times
4) Unload accumulator
5) Control by means of pressure gauge: 0 bar in P, A, B
Order execution
Work out the function of the directional valve element particularly that of the pressure com-
pensators and the shuttle valves by means of circuit diagram and sectional diagram.
In parallel operation, the actuator with the highest load determines the LS pressure. This
is achieved via the LS shuttle valves.
The pressure compensator controls the pressure differential Δp at the control spool (me-
tering orifice); consequently, the pressure differential is always constant.
I.e. in parallel operation, changed pressure conditions are automatically compensated
by the pressure compensators. This makes the operation of the machine easier for the
operator as with constant lever deflection, the actuator velocity will also remain constant.
Parallel operation with the LS system will only function if the pump displacement is suf-
ficient for all actuators. If the flow rate of all actuators becomes larger than the maximum
pump displacement, the pressure compensators can no longer work properly. Conse-
quently, the actuator with the highest load will become slower or come to a complete
standstill.
In order to avoid this effect in this project, the actuator volumes are set to 4 l/min.
The pump delivery volume is 8 l/min and is - with 2x4 l/min - not exceeded.
Set up the circuit. In this connection, proceed according to the following points:
1. Hydraulic control
Work out the circuit diagram and the parts list in order to satisfy the requirements.
Hang in the hydraulic components at the grid according to the circuit diagram and estab-
lish the hose connections.
For connecting pressure gauges with DZ1.4 measuring line, pressure hoses DZ 25.1 are
used.
Manually tighten the pressure gauge measuring lines at the relevant measuring port of the
pressure hose.
Check the correct tight connection of the components with the pressure hoses by turning
the hoses.
09
2. Individual operation of winch and boom
For checking the stroke directions, the actuators are individually operated in both direc-
tions. The flow rates are set as follows:
Motor A1, B1 = 4 l/min
Cylinder A2, B2 = 4 l/min
(For the setting, short-circuit A2, B2 with hose.)
8 Bosch Rexroth AG Project 09: Parallel operation with sufficient displacement I RE 09970/03.11
3. Parallel operation with max. motor speed first; then operate the boom cylinder
The motor is operated with max. speed, i.e. the lever is first of all switched through com-
pletely.
Then, the boom cylinder is connected in the Lift direction.
Observe the behavior of the two actuators.
4. Parallel operation: Lift boom cylinder first, then operate the motor
The boom cylinder is slowly lifted, i.e. the lever is operated first.
Then, the motor is slowly connected up to the max. speed.
Observe the behavior of the two actuators.
5. Parallel operation with 50 % motor speed and lift boom cylinder
Using the lever, the motor is first of all brought to 50 % speed.
The lever position for the motor actuation remains unchanged while the cylinder is slowly
operated in the Lift direction.
Observe the behavior of the two actuators.
6. Parallel operation with 50 % motor speed and lower boom cylinder
Using the lever, the motor is first of all brought to 50 % speed.
The lever position for the motor actuation remains unchanged while the cylinder is slowly
operated in the lower direction.
Observe the behavior of the two actuators.
7. Parallel operation with const. 50 % motor speed and lift and lower boom
Using the lever, the motor is first of all brought to 50 % speed.
The lever position for the motor actuation is now changed so that the speed remains con-
stant while the cylinder is slowly operated in the Lift and Lower direction.
Observe the behavior of the two actuators.
Ad 3., 4.:
It is important to see that with 100 % operation of the first element with 4 l/min = max.
motor speed, the cylinder performs a movement corresponding to the lever deflection. In
parallel operation, the actuators with the higher load pressures (lift cylinder) and those
with the lower load pressure are to be operated independently of each other.
09 Ad 5., 6.:
It is important to see that the two actuators do not influence each other in parallel opera-
tion.
If the lever position for the motor is maintained without changes while the boom is oper-
ated, the motor speed does not change.
In order to lift the cylinder, higher pressure is necessary than the pressure for the motor.
By increasing the pressure p (Mp), the pressure differential Δp at the pressure compensator
for the motor is increased. Consequently, the pressure compensator reduces the opening
cross-section, the flow is identical and the motor keeps the speed almost constant.
By means of the pressure compensator, the pressure differential Δp at the control spools
is kept constant.
If the cylinder is lowered, the lower load pressure is here. In this case, the pressure com-
pensator for the cylinder will now reduce the opening cross-section.
RE 09970/03.11 I Project 09: Parallel operation with sufficient delivery volume Bosch Rexroth AG 9
Ad 7.:
Here, it now becomes clear why pressure compensators are advantageous for controlling a
machine with different load pressures. Thus the term "load pressure compensation".
This is much more difficult with the throttle control as the operator must provide for the
load pressure compensation.
With mobile machines, superimposed movements are common like in this project in
which a crane winch has to be operated simultaneously with the boom movement.
The pressure compensators are able to compensate changes in the pressure differential
Δp in order to keep the speed constant.
The faster the movements are operated and the faster the pressure conditions change,
the more advantageous is the operation.
So it is also possible to supply all actuators jointly with one pump circuit.
b) Which component simplifies the parallel operation with different load pressures?
The pressure compensator keeps the pressure differential Δp at the control spool
constant and in this way simplifies the operation.
d) How does the pressure compensator of the actuator with the lower load pressure react?
Due to the larger pressure differential Δp, the pressure compensator reduces the
opening cross-section. At the actuator grooves, Δp remains constant.
Project/trainer information
In the present project 09, knowledge of the behavior in parallel operation with sufficient
delivery volume for all simultaneously operated actuators is developed in a practical 09
set-up.
Notes
09
RE 09970/03.11 I Project 10: Parallel operation with insufficient delivery volume Bosch Rexroth AG 1
Project definition
The boom of a crane is operated by means of a cylinder. The winch is driven by a hydrau-
lic motor. By moving the pilot control lever 1 away from the operator (pushing), the which
is to rotate clockwise.
By deflecting the pilot control lever 2 in the direction of the operator (pulling), the boom is
to be lifted.
By deflecting the lever to the right, the winch is to be operated clockwise and the load is
to be lifted (only with 4TH6).
The boom is to be lifted by deflecting the lever towards the operator.
The winch functions analogously to the boom.
Winch and boom are to be moved simultaneously.
The winch speed is to be kept constant, if possible, while the boom is moved simultane-
ously. For increasing the working speeds, the flow rates are to be increased.
10
Project tasks
• Working out the correct pinout for the specified stroke directions.
• Setting the specified flow values.
• Checking the function in individual and parallel operation.
2 Bosch Rexroth AG Project 10: Parallel operation with insufficient displacement I RE 09970/03.11
Project steps
Notes
10
RE 09970/03.11 I Project 10: Parallel operation with insufficient delivery volume Bosch Rexroth AG 3
Measuring glass
Measuring
glass
Measuring glass
Size 4
10
Fig. 10-2: Hydraulic circuit diagram
4 Bosch Rexroth AG Project 10: Parallel operation with insufficient displacement I RE 09970/03.11
04 1 Motor DM8
08 2 Distributor DZ4
Fig. 10-3: Parts list for hydraulic circuit diagram Fig. 10-2
RE 09970/03.11 I Project 10: Parallel operation with insufficient delivery volume Bosch Rexroth AG 5
Device arrangement
Fig. 10-4: Device arrangement for parts list Fig. 10-5 and hydraulic circuit diagram Fig. 10-3
Notes
10
6 Bosch Rexroth AG Project 10: Parallel operation with insufficient displacement I RE 09970/03.11
Safety instructions
Warning
Risk from pressurized oil.
Risk of injury from leaking oil and oil jet.
Connect the return line T properly.
Caution Only assemble/disassemble circuits at zero pressure.
Pressure release:
1) Lower the load
2) 3-way ball valve in rest position (vertical)
3) Switch the directional valve several times
4) Unload accumulator
5) Control by means of pressure gauge: 0 bar in P, A, B
Order execution
10
Requirements on the control:
The hydraulic circuit is set up so that the winch can be operated with the control block
M4-12 ports A1, B1.
Using A2, B2, the boom is lifted and lowered.
RE 09970/03.11 I Project 10: Parallel operation with insufficient delivery volume Bosch Rexroth AG 7
Work out the function of the directional valve element particularly that of the pressure com-
pensators and the shuttle valves by means of circuit diagram and sectional diagram.
In parallel operation, the actuator with the highest load determines the LS pressure. This
is achieved via the LS shuttle valves.
The pressure compensator controls the pressure differential Δp at the control spool (me-
tering orifice); consequently, the pressure differential is always constant.
I.e. in parallel operation, changed pressure conditions are automatically compensated
by the pressure compensators. This makes the operation of the machine easier for the
operator as with constant lever deflection, the actuator velocity will also remain constant.
Parallel operation with the LS system will only function if the pump displacement is suf-
ficient for all actuators. If the flow rate of all actuators becomes larger than the maximum
pump displacement, the pressure compensators can no longer work properly. Conse-
quently, the actuator with the highest load will become slower or come to a complete
standstill.
In order to get this effect in this project, the actuator volumes are set to 6 l/min.
The pump delivery volume is 8 l/min and is - with 2x6 l/min - exceeded if the actuators
are fully controlled.
Set up the circuit. In this connection, proceed according to the following points:
1. Hydraulic control
Work out the circuit diagram and the parts list in order to satisfy the requirements.
Hang in the hydraulic components at the grid according to the circuit diagram and estab-
lish the hose connections.
For connecting pressure gauges with DZ1.4 measuring line, pressure hoses DZ 25.1 are
used.
Manually tighten the pressure gauge measuring lines at the relevant measuring port of the
pressure hose.
Check the correct tight connection of the components with the pressure hoses by turning
the hoses.
3. Parallel operation with max. motor speed first; then operate the boom cylinder
The motor is operated with max. speed.
Then, the boom cylinder is connected in the "Lift" direction.
Observe the behavior of the two actuators.
4. Parallel operation: Lift boom cylinder first, then operate the motor
The boom cylinder is slowly lifted until 50 % pump delivery volume, i.e. the lever is oper-
ated first.
Then, the motor is slowly connected up to the max. speed.
Observe the behavior of the two actuators.
5. Parallel operation with 50 % motor speed and lift boom cylinder
Using the lever, the motor is first of all brought to 50 % speed.
The lever position for the motor actuation remains unchanged while the cylinder is slowly
operated in the "Lift" direction until 50 % pump delivery volume.
Observe the behavior of the two actuators.
6. Parallel operation with 50 % motor speed and lower boom cylinder
Using the lever, the motor is first of all brought to 50 % speed.
The lever position for the motor actuation remains unchanged while the cylinder is slowly
operated in the "Lower" direction until 50 % pump delivery volume.
Observe the behavior of the two actuators.
7. Parallel operation with const. 50 % motor speed and lift and lower boom
Using the lever, the motor is first of all brought to 50 % speed.
The lever position for the motor actuation is now changed so that the speed remains con-
stant while the cylinder is slowly operated in the "Lift and Lower" direction.
Observe the behavior of the two actuators.
Ad 3., 4.:
It is important to see that with 100 % operation of the first element with 6 l/min = max.
motor speed, the cylinder only performs a slow movement. In parallel operation with
insufficient displacement, actuators with higher load pressure (lift cylinder) are slower.
In this case, both pressure compensators go in the direction of the close position. The
actuators can no longer be operated independently of each other. That means throttle
control of both actuators.
Ad 5., 6.:
It is important to see that as with the throttle control, the two actuators influence each
other in parallel operation with insufficient delivery volume.
10 In order to lift the cylinder, higher pressure is necessary than the pressure for the motor.
The cylinder slows down.
If the cylinder is lowered, the lower load pressure is here.
The motor slows down.
The oil always flows the path of least resistance.
RE 09970/03.11 I Project 10: Parallel operation with insufficient delivery volume Bosch Rexroth AG 9
Ad 7.:
Here, the effect of insufficient delivery volume in parallel operation does now be-
come clear.
The pump delivery volume must - for independent parallel operation - always be suffi-
cient for all simultaneously operated actuators.
a) Has the increase in the actuator flow rate to 2x6 l/min led to an increase in the working
velocities?
In individual operation, the working velocity increased.
In parallel operation, the working velocity did not increase and interfering influences
of the actuators resulted.
Project/trainer information
In the present project 10, knowledge of the behavior in individual and parallel operation is
developed in a practical set-up.
10
10 Bosch Rexroth AG Project 10: Parallel operation with insufficient displacement I RE 09970/03.11
Notes
10
RE 09970/03.11 I Project 11: Stroke cylinders with alternating direction of force Bosch Rexroth AG 1
Project definition
Project tasks
• Working out the correct pinout for the specified stroke direction.
• Examination of the described operation sequence.
• Working out measures for an operation sequence without interruptions.
11
2 Bosch Rexroth AG Project 11: Stroke cylinder with alternating force direction I RE 09970/03.11
Project steps
Notes
11
RE 09970/03.11 I Project 11: Stroke cylinders with alternating direction of force Bosch Rexroth AG 3
Measuring
glass
Measuring glass
Size 4
11
4 Bosch Rexroth AG Project 11: Stroke cylinder with alternating force direction I RE 09970/03.11
Measuring
glass
Measuring glass
Size 4
11
RE 09970/03.11 I Project 11: Stroke cylinders with alternating direction of force Bosch Rexroth AG 5
03 2 Distributor DZ4
Fig. 11-4: Parts list for hydraulic circuit diagram Fig. 11-2
11
6 Bosch Rexroth AG Project 11: Stroke cylinder with alternating force direction I RE 09970/03.11
03 2 Distributor DZ4
Fig. 11-5: Parts list for hydraulic circuit diagram Fig. 11-3
11
RE 09970/03.11 I Project 11: Stroke cylinders with alternating direction of force Bosch Rexroth AG 7
Device arrangement
Fig. 11-6: Device arrangement for parts list Fig. 11-5 and hydraulic circuit diagram Fig. 11-3
Notes
11
8 Bosch Rexroth AG Project 11: Stroke cylinder with alternating force direction I RE 09970/03.11
Safety instructions
Warning
Risk from pressurized oil.
Risk of injury from leaking oil and oil jet.
Connect the return line T properly.
Caution Only assemble/disassemble circuits at zero pressure.
Pressure release:
1) Lower the load
2) 3-way ball valve in rest position (vertical)
3) Switch the directional valve several times
4) Unload accumulator
5) Control by means of pressure gauge: 0 bar in P, A, B
11
RE 09970/03.11 I Project 11: Stroke cylinders with alternating direction of force Bosch Rexroth AG 9
Order execution
For the system evaluation, the following measurement points are necessary:
• Pressures in Mp, MpLS, MA2
Set up the circuit. In this connection, proceed according to the following points:
1. Hydraulic control
Work out the circuit diagram and the parts list in order to satisfy the requirements.
Hang in the hydraulic components at the grid according to the circuit diagram and estab-
lish the hose connections.
For connecting pressure gauges with DZ1.4 measuring line, pressure hoses DZ 25.1 are
used.
Manually tighten the pressure gauge measuring lines at the relevant measuring port of the
pressure hose.
Check the correct tight connection of the components with the pressure hoses by turning
the hoses.
3. System optimization
As the vacuum in the cylinder piston chamber is the reason for the interruption in the mo-
tion, it has to be avoided.
The vacuum is generated during lowering as the load pulls the cylinder out faster than the
oil from the control block flows in. In this case, there is a charging deficit.
There can only be hydraulic traction if the charging deficit has been remedied. During this
period, no motion is possible as the oil flowing in must first of all re-fill the cylinder. 11
I.e. it has to be ensured that the pressure on the supply side (cylinder piston chamber)
10 Bosch Rexroth AG Project 11: Stroke cylinder with alternating force direction I RE 09970/03.11
Ad 3.:
It is important to see that the charging deficit is only completely excluded with a pres-
sure > 1 bar during the entire lowering stroke. The motion is now continued without
delay in the load cycle as no air has to be compressed any more.
As compared to throttle valves, another advantage of pressure valves and lowering brake
valves that are used as hydraulic counterpressure is that they block the discharge line
and hold the load.
In safety-relevant applications (e.g. lifting gear), these valves must be directly mounted at
the cylinder.
In this project, only the charging deficit at the cylinder can be considered.
The charging deficit at hydraulic motors is much more critical!
If here, a charging deficit results, the dissolved air is - together with the pistons of the rota-
tional unit - carried forward to the discharge side. On the discharge side, the pistons must
be supported by an oil column, that is not available in case of a charging deficit.
The pistons fall into nothingness and the motor rotates faster which even increases the
charging deficit. An uncontrolled overspeed results and the motor may be destroyed.
It is fatal if this happens with a crane winch with loads in great height or with a carriage
11 on a slope.
RE 09970/03.11 I Project 11: Stroke cylinders with alternating direction of force Bosch Rexroth AG 11
a) What interrupts the motion sequence after the load has been lowered? During the low-
ering of the load, there is a charging deficit in the cylinder piston chamber which must
first of all be removed.
Project/trainer information
In the present project 11, knowledge of the effect and compensation of negative forces is
developed in a practical set-up.
11
Load-sensing control block in RE 64276/08.2010
Replaces: 08.2008
1/64
Type M4-12
Nominal size 12
Unit series 2X
Nominal pressure 350 bar (pump side)
Nominal pressure 420 bar (actuator side)
Maximum flow
– Pump side: 200 l/min for central inlet element
150 l/min for lateral inlet element
– Actuator side: 130 l/min with pressure compensator and
load holding function
HAD 7407
Table of contents
Content Page
Types of operation cover B 41, 4242
Features 2
Secondary valves 43, 44
Function 2
Housing options that can be ordered 45
Cross-section 3
End elements 46, 47
Symbol 3
Dimensions 48 to 60
Technical data 4
On-board electronics (EPM) 61
Modular structure 5 to 7
Electronic pilot module: Pin assignment 62
Order details 8 to 11
Electronic pilot module: Accessories 63
Order examples 12 to 16
Inlet elements 17
Closed Center (J) 17 to 21
Open Center (P) 22
Monoblock Closed Center (JM) 23
Monoblock Open Center (PM) 24
Directional valve elements
Pressure compensator 25
LS pressure relief function 26 to 30
Main spool 31, 32
Flow 33
Types of operation cover A – mechanical 34 to 40
Voltage supply and plugs 40
2/64 Bosch Rexroth AG M4-12 | RE 64276/08.2010
Features
System Flow
•• Load pressure-independent flow control •• Load pressure compensated
–– Open center for fixed displacement pump •• High repeatability
–– Closed center for variable displacement pump •• Low hysteresis
•• Adjustable via stroke limitation
Type
•• Sandwich plate design Pressure relief function
–– Inlet element •• Inlet element:
–– Up to 10 directional valve elements –– Pilot-operated pressure valves with large nominal width
–– Up to 20 directional valves with central inlet element •• Directional valve element / actuator ports
–– End element –– Compact shock valves with feed function
•• Monoblock (single)
LS pressure relief function
–– Inlet element combined with 1 spool axis
–– Up to 9 directional valve elements flangeable •• Adjustable for each actuator port
•• External pressure adjustment for each actuator port
Types of operation possible
•• Mechanical: •• Electro-proportional per section
–– Handle-operated lever
Areas of application
–– Tongue
•• Truck applications •• Construction machines
•• Hydraulic
•• Drilling machinery •• Lifting platforms
•• Servohydraulic
•• Forestry machines •• Heavy load vehicles
•• Electrohydraulic (switching, proportional)
•• Large-size and telescopic •• Ship engineering
•• Electrohydraulic with on-board electronics (EPM2)
forklifts •• Mining applications
•• Municipal vehicles •• Stationary applications
•• Cranes
Function
Cross-section
1 Housing 6.1 A side stroke limitation 9.2 Pressure reducing valve
2 Main spool 6.2 B side stroke limitation (pilot valve “b”)
3 Pressure compensator 7 LS shuttle valve 10 Compression spring
4 LS pressure relief valves 8 Spring chamber 11 Handle-operated lever
5.1 Shock valve with feed function 9.1 Pressure reducing valve 12 Cover A
5.2 Plug screw (pilot valve “a”) 13 Cover B
� ��� ���
� �
���
��
��� ���
� �
���
��� �
� ���
��� �
���
�� � �� �� � � � � �� � ��
Symbol
Connections:
� � � ��� ���
P Pump �� ��� �
A, B Actuator �
T Tank
X Pilot oil supply
Y Tank, depressurized ��
��
LS Load-sensing (LS)
�
MA, MB External LS ports ��� � �
�
���
� �
� �
4/64 Bosch Rexroth AG M4-12 | RE 64276/08.2010
Technical data (Please inquire in case the intended use of unit is outside the given values!)
general
Installation position Any
Type of connection Pipe thread according to ISO 228/1
Mass – Inlet element: Closed center J kg 4.3
Open center P kg 6.0
Central inlet element: Closed center JZ kg 8.4
Monoblock kg 5.6
Directional valve element Operation
Mechanical Hydraulic El.-hydraulic with EPM2
kg 4.9 4.2 4.5 4.8
Excess weight of handle-operated lever kg 0.6
End element kg 2.6
Hydraulic fluid and ambient temperature range ϑ °C –20 to +80
Painting Standard painting
hydraulic
max. flow at port P qV max l/min 200 with central inlet element
l/min 150 with lateral inlet element
A, B qV max l/min 140
Nominal pressure pnom bar 350 (400 on inquiry)
max. operating pressure P pmax bar 350 (400 on inquiry)
at port A, B pmax bar 420
LS pmax bar 330
T pmax bar 30, or 20 for purely mechanic model
Y pmax bar Depressurized to the tank
max. pilot pressure at port X pctrl bar 35
a, b pctrl bar 35
Pilot pressure range Hydraulic pctrl bar 8.5 to 22.5
Electrohydraulic pctrl bar 6.5 to 17.2
Required control Δp at the Versions S; C p bar 18
control block
Recommended hydraulic pilot control units Characteristic curve TH 6... , see RE 64552
LS pressure relief function (adjustment ranges) bar 50 to 149; 150 to 330 (selected in the factory)
Hydraulic fluid Mineral oil (HL, HLP) according to DIN 51524, other hydraulic fluids,
such as HEES (synthetic esters) according to VDMA 24568 as well as
hydraulic fluids as specified under RE 90221, on inquiry
Viscosity range ν mm²/s 10 to 380
Maximum permitted degree of contamination of the hydraulic fluid Class 20/18/15, for this we recommend a filter with a minimum reten-
cleanliness class according to ISO 4406 (c) tion rate of β10 ≥ 75
servohydraulic
STDS 0014 See data sheet RE 29617-B2
STDS 0015 See data sheet RE 29616-B2
STDS 0016 See data sheet RE 29618-B2 2)
electrical
Electrical pilot control valves FTWE 2 K...; see RE 58007 1)
FTDRE 2 K...; see RE 58032 1)
Recommended amplifiers RA 1-0/10; 1 axis, see RE 95230
(further control options on inquiry) RA 2-1/10; 4 to 6 axes, see RE 95230
Control units RC see RE 95200
On-board electronics (EPM2) Data from page 61; see also RE 64815-B
1) Plug-in connectors are not included in the scope of supply and
need to be ordered separately, see page 41.
2) Projected
Note!
You can find more information on using the hydraulic
Note! products of Bosch Rexroth in our publication “Hydraulic
The technical data were determined with a viscosity of valves for mobile applications - General information”,
= 32 mm²/s (HLP46: 50 °C). RE 64020-B1.
RE 64276/08.2010 | M4-12 Bosch Rexroth AG 5/64
2.2 2.4
2. B
A
C
B
A
3.
2.1
E C
D B
C
B A
A 1.
2.3 2.5
6/64 Bosch Rexroth AG M4-12 | RE 64276/08.2010
2.2 2.4
2. B
A
E
D 2.
C
3.
2.1
1.
D B
C
A
B
2.3 A
3.
2.5
RE 64276/08.2010 | M4-12 Bosch Rexroth AG 7/64
1 Monoblock (combining inlet, 1 spool axis and end element) 1.7 Operation cover “B”
1.1 LS pressure relief function A: Mechanical operation “Z”
1.2 Secondary valves B: Standard cover
1.3 Primary pressure relief function C: Mechanical operation “K” with handle-operated lever
1.4 Electro-proportional LS pressure relief function 2 Flangeable directional valve elements
1.5 LS shut-off
1.6 Operation cover “A”
A: Mechanical operation “A”
B: Hydraulic operation “H”
C: Electrohydraulic operation “W”
D: Servohydraulic operation “S”
E: Electrohydraulic operation with on-board
electronics EPM2 “CBA”
2.
1.7
1.4
C
1.
A
1.3
1.1 1.2
E 1.5
D
C
1.6 A
8/64 Bosch Rexroth AG M4-12 | RE 64276/08.2010
Order details
Short code Inlet element Directional valve element
1. Spool axis
M4 12 2X
2. Spool axis
Short code Example for a short code of the M4-12 control block with
Complete control blocks are defined three directional valve elements:
according to type key.
The order text is for detailing the technical M4 – 7654 – 2 0 / 3 M4 – 12 J W2 K V 01 –450
features and requirements.
The order text is used by the Rexroth sales
department to derive a short code as well as Control block No.
a material number. Unit series of the unit
series (2X)
Revision status of the
series
Number of Directional valve
elements
Inlet
Operation A side (prevalent operation)
Operation B side (prevalent operation)
Sealing material
Threaded connection
SO number if any
RE 64276/08.2010 | M4-12 Bosch Rexroth AG 9/64
Order details
End element Additional details
01 *
Further information in the clear text
SO numbers
–038 = Resistant to sea water 4)
–450 = Aluminum free
S = For safety-relevant applications
Q = Plug screw
W2 = Electrohydraulically proportional
W4 = Electrohydraulically switchable
Q = Plug screw
KKDER… = 4/2 way spool valve, according to RE 18136-05 (information in plain text)
LM = Monoblock, no end element
L8 … = Adapter plate for SP-08 directional valve elements, inlet pressure relief function (pressure info in bar, 3-digit)
LC = Adapter plate for Bosch Rexroth Oil Control 4)
Pressure compensator
with pressure compensator, with load holding function =S
without pressure compensator, with load holding function (not in combination with PM) =C
without pressure compensator, without load holding function =Q
with sensitive pressure compensator, with load holding function =F
with 3-way pressure compensator (only in combination with PM) =D
with pressure compensator, with priority function (only in connection with JM) =V
without pressure compensator bore for change-over axis =Z
LS valve
with LS pressure relief valve
= … …
(pressure information in bar, 3-digit) (no Z possible)
Spool symbol
E spool =E
J spool =J
Q spool =Q
Spool with regeneration function =R
Plunger cylinder as actuator = P 3)
Float position spool = W 3)
Float position spool = Y 3)
Flow in l/min, 3-digit, e. g. 070-070; actuator ports “A” and “B” =…–…
Spool with pressure function T, only in connection with E, J or Q spool 3) =…T…
Order example closed center with lateral inlet element and change-over axis
� � � � � �
� � � � � �
� � � �
�� ��
RE 64276/08.2010 | M4-12 Bosch Rexroth AG 13/64
� � �� �� � � �� �� �� �� ��
� �
� �
�
�� ��
���
���
� � � � � �
� � � � � �
� � � �
�� �� � ��
14/64 Bosch Rexroth AG M4-12 | RE 64276/08.2010
Order example closed center for central inlet with primary valve
��� ���
��� ���
� � � �
� � � �
� � �
�� � �� ��
�
RE 64276/08.2010 | M4-12 Bosch Rexroth AG 15/64
�� �� �� � � �� � �� �� �� ��
� � �
� � �
� � �
�� �� ��
� � � � � �
� � � � � �
� � �
�� �� � �� �� �� ��
16/64 Bosch Rexroth AG M4-12 | RE 64276/08.2010
� �
�
���
���
� �
� �
�
RE 64276/08.2010 | M4-12 Bosch Rexroth AG 17/64
Short description
•• For variable displacement pumps up to 150 l/min
Short description �
•• For variable displacement pumps up to 150 l/min � � �� �
Short description
•• For variable displacement pumps up to 150 l/min
•• Pressure information in bar after J ... required
(3-digit)
Short description �
•• For variable displacement pumps up to 150 l/min � � �� �
•• Pressure information in bar after J ... required (3-digit)
18/64 Bosch Rexroth AG M4-12 | RE 64276/08.2010
Attention!
ff In case of internal pilot oil supply, the X connection �
can also be used to lead way pilot oil for other
� � �� �
actuators. However, this may affect the switching
times at the M4-12. Consult Technical Sales
regarding possible effects.
ff In case of external pilot oil supply the “X” connection
is not closed in general. It needs to be closed when
not in use (e. g. in case of hydraulic control “H”).
With LS shut-off
Order details: �
M4 12 2X J Q Y A
Short description
•• LS line is connected de-energized with the Y line to
the tank �
•• All downstream M4-12 sandwich plates remain in � �� � �
the load-holding mode
RE 64276/08.2010 | M4-12 Bosch Rexroth AG 19/64
Central inlet elements Closed Center (JZ) for sandwich plate design
Without primary pressure relief valve,
for external pilot oil supply �
Order details:
��
M4 12 2X JZ Q X
�
Short description
� �
•• For variable displacement pumps up to 200 l/ ��
min
M4 12 2X JZ Q Y �
� �
��
Short description
•• For variable displacement pumps up to
200 l/min
Central inlet elements Close Center (JZ) for sandwich plate design
Central inlet elements Close Center (JZ) for sandwich plate design
M4 12 2X JK Q X �
� �
Short description ��
•• For variable displacement pumps up to 200 l/min M4-15
M4-12
For the connection of direction valve elements
of sizes 12 and 15 �
With primary pressure relief valve,
for external pilot oil supply ��
Order details: �
M4 12 2X JK … X � �
��
Short description M4-15
•• For variable displacement pumps up to 200 l/min
•• Pressure information in bar behind JK... required
(3-digit)
M4 12 2X P … X
�
Short description
� � � �� �
•• For fixed displacement pumps up to 150 l/min
•• Pressure information in bar after P ... required
(3-digit)
M4 12 2X P … Y
Short description
•• For fixed displacement pumps up to 150 l/min
•• Pressure information in bar after P ... required
(3-digit) �
� � �� �
With LS shut-off
Order details: �
M4 12 2X P … Y A
Short description
•• LS line is connected de-energized with the Y line to
the tank
•• All downstream M4-12 sandwich plates remain in
the load-holding mode �
� �� � �
RE 64276/08.2010 | M4-12 Bosch Rexroth AG 23/64
M4 12 2X JM Z Y ��
��
S QM… J …–… W2 1 – H… H… �
���
� �
LM V 01
���
� �
Short description
•• For variable displacement pumps up to 150 l/min
� � ��� �
��
With priority function, without primary pressure
relief valve, for external pilot oil supply �
Order details:
M4 12 2X JM Z X ��
��
V …M… J …–… W2 1 – H… H… �
���
� �
LM V 01
���
� �
Short description
•• For variable displacement pumps up to 150 l/min �
•• Priority for the integrated M4-12 axis
•• Remaining flow to external actuator
� � � �� �
M4 12 2X JM Z X
��
��
V …M… J …–… W2 1 – H… H… �
���
� �
Short description
•• For variable displacement pumps up to 150 l/min ���
� �
•• Priority for the integrated M4-12 axis
•• Remaining flow for flanged-on M4-12 axes
Note!
Please consult Technical Sales. � � � �� �
24/64 Bosch Rexroth AG M4-12 | RE 64276/08.2010
M4 12 2X PM Z Y ��
��
D …M… J …–… W2 1 – Q Q �
���
� �
LM V 01
���
� �
Short description
•• For fixed displacement pumps up to 130 l/min
•• Primary pressure relief via pressure compensator
and LS pressure relief valve
�
Note!
Please consult Technical Sales.
� � �
M4 12 2X PM Z X
�
D = M… J …–… W2 1 – H… H… �
���
� �
LM V 01
���
� �
Short description
•• For fixed displacement pumps up to 130 l/min
•• Primary pressure relief via pressure
compensator and LS pressure relief valve
�
Note!
Please consult Technical Sales.
� � �
RE 64276/08.2010 | M4-12 Bosch Rexroth AG 25/64
���
� �
��
Flow in L/min →
�� �
�
�� ���
�� �� ��
� � � � �
Characteristic curves
Reduction of the actuator flow through LS pressure
relief function ���
Minimum setting: 50 bar
Maximum setting: 330 bar ��
Flow in % →
��
��
��
� � � �� �
With LS pressure relief valve and LS plug
screw �
Order details:
S … M Q J …–… W2 1 – H… H…
��
Short description ��
•• Pressure information in bar for actuator port A �
��� � �
(3-digit)
•• Plug screw for actuation port B
���
•• For the QMQ version, the LS pressure relief � �
function can be retrofitted at the directional valve
element.
•• The LS pressure can be influenced externally
via the ports MA and MB. These ports can also
be used as measuring ports.
Short description ��
•• Pressure information in bar for actuator port A ��
(3-digit) �
•• Unloading plug for actuator port B ��� � �
Note!
Please consult Technical Sales.
RE 64276/08.2010 | M4-12 Bosch Rexroth AG 27/64
Short description
��
•• Only 1 LS pressure relief valve for identical ��
pressure setting in A and B, pressure �
information in bar (3-digit) ��� � �
•• 1 measuring port
���
� �
Short description
•• LS pressure relief valve cannot be retrofitted
•• Housing without measuring ports �
•• Max. flow of internal actuators 90 l/min ��� � �
���
� �
Z ZUZ J …–… W4 1 K Z Z
Short description
•• Housing for change-over axis
�
���
� �
���
� �
28/64 Bosch Rexroth AG M4-12 | RE 64276/08.2010
Short description � � � �� �
Differentiation between: �
1. Type KBPS – electrohydraulically proportional
2. Type MH2DAD and Type KBPS
3. Type KKDE – electrohydraulically switchable
4. Porting pattern KBPS and cover plate �
5. Housing KBPS and plug � �
�
The exact description of the valve is to be clear � �
�
text as follows. �
��� Addition
Falling Rising
��� SO no.
� characteristic characteristic
(Option:
��� curve curve
� 24 V; 0.8 A)
��� 50 bar KBPSC8BA KBPSC8AA
��� 100 bar KBPSF8BA KBPSF8AA
� � 150 bar KBPSH8BA KBPSH8AA
���
210 bar KBPSL8BA (2) KBPSL8AA (4)
–033
��� 250 bar KBPSN8BA KBPSN8AA
��� 315 bar KBPSP8BA KBPSP8AA
350 bar KBPSR8BA (1) KBPSR8AA (3)
��
420 bar KBPST8BA KBPST8AA
� �� �� �� ��� = Standard product range
Command value in % →
electrical standard
Supply voltage V 12 DC 24 DC
Maximum control current mA max. nominal current 1,760 mA max. nominal current 1,200 mA
Coil resistance – Cold value with 20°C Ω 2.3 4.8
– max. hot value Ω 3.65 7.2
Duty cycle % 100 1)
1) If use > 2,000 m via NN, we recommend consulting the 2) Due to the surface temperatures of solenoid coils, the standards
manufacturer. EN 563 and EN 982 must be adhered to!
30/64 Bosch Rexroth AG M4-12 | RE 64276/08.2010
electrical standard
Type of voltage Direct voltage
Supply voltage V 12 DC 24 DC
Voltage tolerance and ambient temperature See characteristic curve RE 18136-08 page 5
Power consumption Ω 22
Duty cycle % See characteristic curve RE 18136-08 page 5
Maximum coil temperature 2) °C 150
Switching time according to – ON ms ≤ 80
ISO 6403 (solenoid horizontal) – OFF ms ≤ 150
Maximum switching frequency cy/h 15,000
Protection type acc. to VDE – Version “K4” IP 65 with plug-in connector mounted and locked
0470-1 (DIN EN 60529), – Version “C4” IP 66 with plug-in connector mounted and locked
DIN 40050-9
IP 69K with Rexroth plug-in connector (material no. R901022127)
– Version “K40” IP 69K with plug-in connector mounted and locked
Note!
Consumer pressure does not become depressurized!
S …K… J …–… H – H… H… A
Cover plate
� �� �
� �� �� �
� �� �
� �� �� �
Application with defined residual opening
Q…–… (A/B → T)
Actuator port unloaded in neutral position
� �� �
� �� �� �
Regeneration function
R…–…
(P, B → A)
� �� �
� �� �� �
� �� �
� �� �� �
� �� �
� �� �� �
� �� �
� �� �� �
� �� �
32/64 Bosch Rexroth AG M4-12 | RE 64276/08.2010
P → A/B
���
�
��� �
�
���
Nominal flow →
�
Flow in l/min
��
�
��
�
��
�
�� �
�
��
��� ���� ��� ���� ��� ���� ��� ���� ��� (24 V actuation)
electrohydraulic
operation (12 V actuation)
���� ��� ���� ���� ���� ���� ���� ���� ���
hydraulic Current in amperes →
operation
� �� �� �� �� �� �� ����
���
Pilot pressure in bar →
digital on-board
electronics (EPM2)
�� ��� ��� ��� ���
� ���
Command value in digits (steps) →
servohydraulic
operation
� � �� �� �� �� �� �� ��
(at pctrl = 35 bar) �
Current in milliamperes →
RE 64276/08.2010 | M4-12 Bosch Rexroth AG 33/64
Asymmetric spools
Pressure
Spool type compen Flow in l/min
sator
100–073 100–052 052–034 034–023 023–014
S 085–065 085–045 045–030 030–020 020–012
E, J, Q
070–057 070–038 038–026 026–017 017–010
C 115–090 115–063 063–042 042–028 028–017
Note!
Please consult Technical Sales.
Example: Solution:
•• Spool type J → 85 liter spool + 2 washers = 100 l/min
•• Pressure compensator S → Set 90 liters via stroke limitation.
•• Command value: QActuator = 90 l/min
Pressure
Spool type Flow in l/min
compensator
100–100
E, J, Q S 085–085
070–070
Note!
Position directional valve elements with maximum flow as
close as possible to the inlet element.
34/64 Bosch Rexroth AG M4-12 | RE 64276/08.2010
S ZZZ J …–… A Z Z Z
Short description ��
��
•• Mechanical operation of the main spool. In case �
of non-operation centering in central position by � �
springs
� �
S …M… J …–… B1 N H… H…
��
Short description
��
•• Mechanical operation of the main spool. In case �
of non-operation centering in central position by � �
springs
� �
Note!
Handle-operated lever setting, please consult
Technical Sales.
Mechanical (encapsulated) � � � �� �
Order details: �
S …M… J …–… M K H… H…
Short description ��
•• Mechanical operation of the main spool. In case ��
of non-operation centering in central position by � ��
springs � �
•• All handle-operated lever position options are
���
available (K, L, M etc.) comp. also type key on
� �
page 11
���
1) Following handle-operated lever
2) Non-following handle-operated lever
��
RE 64276/08.2010 | M4-12 Bosch Rexroth AG 35/64
Hydraulic � � � �� �
Order details:
�
S …M… J …–… H – H… H…
Short description
��
•• Recommended hydraulic pilot control units: ��
Type TH6 according to RE 64555 �
� �
�
� �
�
Servohydraulic � � � �� �
Order details:
�
S ZZZ J …–… S – Q Q
Short description
•• Voltage: 7 VDC min.
•• Current type: Direct current �
•• Nominal current: ±20 mA � �
•• Max. current: ±25 mA
� �
STDS 0014; see RE 29617-B2
STDS 0015; see RE 29616-B2
STDS 0016; see RE 29618-B2
Note!
Rating by Technical Sales.
36/64 Bosch Rexroth AG M4-12 | RE 64276/08.2010
Electrohydraulically switchable � � � �� �
Order details: �
S …M… J …–… W4 1 – H… H…
Short description ��
•• Switching valves, type FTWE 2 K according to ��
RE 58007 �
���
� �
���
� �
� � � �� �
Electrohydraulically switchable with damping
orifice on both sides �
Order details:
S …M… J …–… W5 3 – H… H…
��
Short description ��
�
•• Switching valves, type FTWE 2 K according to ���
� �
RE 58007
���
� �
� � � �� �
Electrohydraulically switchable with
measuring ports on both sides �
Order details:
S …M… J …–… W6 3 – H… H…
��
Short description ��
� ���
•• Switching valves, type FTWE 2 K according to � �
RE 58007 ��
���
� �
��
RE 64276/08.2010 | M4-12 Bosch Rexroth AG 37/64
S …M… J …–… W7 1 – H… H…
��
Short description � ��
•• Switching valves, type FTWE 2 K according to ���
RE 58007 �� � �
���
��
� �
� � � �� �
Electrohydraulically switchable with orifice
and check valve for hydraulic override �
Order details:
S …M… J …–… G4 3 – H… H…
��
� ��
Short description
���
•• Switching valves, type FTWE 2 K according to � �
RE 58007 �
��� �
� �
electrical
Type of voltage Direct voltage
Nominal voltage V 12 24
Power consumption at 20 ℃ W 14.4 14.4
Coil resistance R20 Ω 10 40
Duty cycle % 100
Switching time ton ms ≤ 20
toff ms ≤ 30
Protection type according to •• – Solenoid IP 69K
DIN 40050-9 •• – Electrical C4 IP 69K 1)
connection K40 IP 69K 1)
Switching frequency Hz 5
S …M… J …–… W2 1 K H… H…
Short description ��
��
•• Proportional pressure reducing valve � ��
Type FTDRE 2 K according to RE 58032 ��� � �
S …M… J …–… W8 9 – H… H…
��
Short description ��
•• Proportional pressure reducing valve, �
���
type FTDRE 2 K according to RE 58032 � �
��
���
� �
��
� � � �� �
Electrohydraulically proportional with
damping orifice and check valve �
Order details:
S …M… J …–… G2 1 – H… H…
��
Short description � ��
electrical
Type of voltage Direct voltage
Nominal voltage of the amplifier V 12 24
Maximum control current A 1.8 0.8
Coil resistance (20 ℃) Ω 2.4 12
Duty cycle (with amplifier) % 100
Electrical connection See ordering codes
Protection type according to – Solenoid IP 69K
DIN 40050-9 – Electrical connection C4 IP 69K 1)
K40 IP 69K 1)
PWM frequency (recommended) 1) Hz 150
Short description ��
•• Digital interface, standard ��
see RE 64815-B �
��� � �
���
� �
� � � �� �
Electronic pilot module with position sensor
�
Order details:
Short description ��
��
•• Digital interface with position sensor, �
see RE 64815-B ��� � �
���
Note! � �
At request only. Rating by Technical Sales.
40/64 Bosch Rexroth AG M4-12 | RE 64276/08.2010
End
Inlet element
element
� � � �
� � �
� � �
Plug type
Supply voltage Junior Timer DT04-2P
2-pin (AMP) (Deutsch)
24 V 1 8
12 V 3 9
Note!
Plug-in connectors are not included in the scope of supply
and must be ordered separately.
RE 64276/08.2010 | M4-12 Bosch Rexroth AG 41/64
AZ AN
B1 Z B1 N B1 = Detent in 1
�� � �
B2 Z B2 N � B2 = Detent in 2
� � �
B4 Z B4 N � � B4 = Detent in 1, 2
Operating force:
•• Tongue < 250 N (spool axis)
Note!
Handle-operated lever setting, please consult Technical
Sales.
42/64 Bosch Rexroth AG M4-12 | RE 64276/08.2010
60˚ = K, N
60˚ = B, G
30˚ = B1, G1 1
0˚ = L, O 0˚ = F, H
2
-30˚ = D1, J1 3
-60˚ = D, J
-60˚ = M, P
Short description
•• Non-adjustable shock/feed valve ��
•• Pressure information in bar behind H ... required ��
(3-digit) �
��� � �
Example: H100, H150
H100: Shock/feed valve, set to 100 bar for actuator port A ���
� �
H150: Shock/feed valve, set to 150 bar for actuator port B
Note!
Suitable only to reduce pressure peaks, not to be
used as pressure relief valve!
Note!
Shock valves have a fixed setting!
Short description
��
•• Adjustable shock/feed valve ��
•• Pressure information in bar behind A ... required �
(3-digit) ��� � �
Short description
��
•• Secondary valves cannot be retrofitted
��
•• Actuator port G 3/4 �
��� � �
Order details:
���
S …M… J …–… W2 1 – X X � �
Short description
•• Secondary valves cannot be retrofitted
•• Actuator port G 1/2
S … M … J …–… W2 1 – F F … …
�
Short description ��
��
•• Secondary valves cannot be retrofitted
•• Information on the flange valves in clear text ��� � �
� ���
Note! � �
Dimensioning of the flanged installation housing
with screwable valves by Technical Sales.
RE 64276/08.2010 | M4-12 Bosch Rexroth AG 45/64
=M…
pressure setting in A and B
End elements
End element with LS unloading
Order details:
LA �� �
LZ
��
Short description
•• LS unloading must be ensured externally
LAPT
��
LZPT
Short description
•• LS unloading must be ensured externally
LA W4 W2
Short description
•• For 30 bar control pressure. �� �
LA … KKDER… … KKDER… Q Q
Short description �
•• Max. 40 l/min per working port
•• See also RE 18136-05
� � � �� �
RE 64276/08.2010 | M4-12 Bosch Rexroth AG 47/64
M4 12 2X LU
M4 12 2X LU Q W4
Short description:
�� � �� �� �
•• For 30 bar control pressure
L8 210
Short description:
•• With integrated 2-way pressure compensator
•• With LS pressure relief valve, set to 210 bar
•• Type key for flange-mounted SP-08 sandwich plates
according to RE 64139 � � � �� �
M4-12
•• Maximum 7 directional valve elements permitted
LC
Short description:
•• Type key for flange-mounted ED valves according to
RIE 00159
Attention!
Rating by Technical Sales.
48/64 Bosch Rexroth AG M4-12 | RE 64276/08.2010
��
��
�����������
deep �����������
deep
�� �� ����
�
�
�� � �
���
�
���
�
��
����
��
����
��
��
��
��
��
�� ��
�� � �� �
���� ��
�� ����
�� ���
���
�
��
��
�
��
�
�
�� ��
�� ���� ��
�����
���
���� ��
��
��
��
��
��
�� �� ��
�����������
deep ��
�� ��
��������������
deep
��
�
���
���
��
��
��
��
��
�
��
��
� �
��� �� ��� ��
��
� ��
��
��
�
��
��
�
��
��
� ��
�� ������ �� ������
�� ���
��
50/64 Bosch Rexroth AG M4-12 | RE 64276/08.2010
Standard monoblock Closed Center JM as inlet element with 1 axis; more directional valve elements flangeable
47
27
103
125 36,5
T
Y
20,5
93
LS
68
63
P
52
37,5
29
16,5
15 89
18 107,5
44,5
72
78,5
94
50
15,5
37
88
94
17,5
168
RE 64276/08.2010 | M4-12 Bosch Rexroth AG 51/64
43
95
125
124
119
98.5
87.5
72
33
19
15 40
18 67
72 114.5
78.5
94
50
41
98
52/64 Bosch Rexroth AG M4-12 | RE 64276/08.2010
��� ���
���
���� ��
�� �� ��
� � �
��
��
��
��
��
��
��
� �
�� ��
� ��
��
��
��
��
��
Dimensions: Operation
Purely mechanical operation with Purely mechanical operation with tongue and lever
tongue
Order details:
Order details:
… B1 N …
… A Z …
Ø8
280
8
X 41.5
52
X 128
RE 64276/08.2010 | M4-12 Bosch Rexroth AG 53/64
Dimensions: Operation
Mechanical / hydraulic operation with Cover A Cover B
standard cover
Order details:
… M – …
86.5
63
39
… H – …
64 56.5
Cover A Cover B
Electrohydraulic operation
… W. …
86.5
"a"
63
39
108
… C.A K …
230
60
152
135 86
46
54/64 Bosch Rexroth AG M4-12 | RE 64276/08.2010
LA LZ
103 103
15 25 25
15
M10 M10
125 125
114.5 114.5
30 67 30 67
15 46.5 15 46.5
114
114
83.5
83.5
63
63
27
LSZ
17
15
15
Order details: Order details:
LAPT LZPT
103 103
25 25
15
15
M10 M10
125 125
114.5 114.5
50 67 50 67
15 46.5 15 46.5
T T
114
114
P P
83.5
83.5
63
63
35
35
27
LSZ
87 37 87
15
15
RE 64276/08.2010 | M4-12 Bosch Rexroth AG 55/64
LU LU … …
103
123.5
25
45.5
20
20
M10
106 M10
47
12.5 18 28
8 16 17.5
33
33
T
50
64
C2
63
17
77
114
93.5
90
96
83.5
114
C1
83.5
P
46.5 35
67 24
15
15
67
87.5 35
114.5
135
125
145
M10
105
77
47
17.5 27 18
33
33
C2 T
50
64
64
75
88
84
93.5
C1
114
LSz
83.5
P1
Y1
35 67
15
87.5
135
150
56/64 Bosch Rexroth AG M4-12 | RE 64276/08.2010
230
"b"
152
Y LS
X
86.5
"a"
63
44.5
54
40
39
27
P
13
38.5
65
89
135 125 86
4 98
83.5 9
8 49
114
5.2 8
46 30
18
B2
28
A2
C 6.2
23
239
46
47
B1 3
23
46 4
A1 6.1
5.1 7
50
28
T M
46 114 4
2
4
108 48 56.5
85
114.5
15
67
46.5
83.5
1 Type plate
2 Inlet element J...Y
“Closed Center”
103 3 Directional valve elements
25 4 End element LA
12
MB
6.2 Control cover K (side B)
7 Stroke limitation
19
15
8 Secondary valves
25
30 9 Tie rod
72 10 Fastening screw thread
103 4 x M10; 15 deep
RE 64276/08.2010 | M4-12 Bosch Rexroth AG 57/64
1
"b"
X M
86.5 "a"
51.5
63
LS
50
39
25
35 79
108 45
91.5
132
317 114 34
125 86 86.5
98 56.5
9 83.5
39
52 27
4 49
6.3
13
46 41.5 LSZ
50
5.3 T
B3
A
46
5.2 A3
6.2 7
A B
23
B2
46
257
"a" "b"
5.1
A2
3
A B
13.5
B1
6.1
46
A1
8
B
Ø8
26
43
Y
65
T
P
2 50 45 7 4
64 91.5 48 92
114.5 114 31.5
15
87
35
83.5
46.5 P
1 Type plate
67 2 Inlet element P...Y
“Open Center”
3 Directional valve elements
103
30 4 End element LZPT
25 5.1 Control cover A (side A) for
19 mechanical operation
5.2 Control cover H (side A) for
12
hydraulic operation
10
5.3 Control cover W (side A) for
electrohydraulic operation
6.1 Purely mechanical operation
33
20
Control cover X (side B)
7 Stroke limitation
8 Secondary valves
9 Tie rod
15
"b"
86.5
83.5
"a"
63
39
15
46.5
9 67
114.5
125
137
125
10 83.5 4 114
49 6
6.2 8.5 3
18
28
46 30
B2
15
A2
1
27
X
P
30
7
53
65
65
270
80
MP
T LS
2
Y
B1
A
35 46
A1
B
6.1 3 8
108 28.5 4 7
67.5
90.5
5 25
43
125 93
135 125 170 114
97 114.5 86
46.5
15
52.5
83.5
1 Type plate
˚
152
60
236
157.5
135 133
440
98
46
8 25 78 114
4.1
15
9
46 30
3.2
23
A3 B3
6.2
7
46
1 A2 B2
12
44
T
30
2 118
40
45
76
344
90
63
MP 75 LS
20
40
P X
22
51
A1 B1
25.5
3.1 5 6.1
50
35
4.2
18 20 25
106 48.5 40
85 47
93.5 130
28
48 1 Type plate
113 2 Central inlet element JK...
141 “Closed Center”
125 64 3.1 Directional valve element M4-15
3.2 Directional valve element M4-12
4.1 End element LA
63
43
2 95
125
4
T 5
124
Y
98.5
72
P 33
3
15
18
1
72
78.5
94
50
41
A B
98
6
144.5
105.4 67
40
11
19
43
87.5
67
1 Type plate
90.5
119
2 Housing PM
3 Control cover W (side A) for
electrohydraulic operation
4 Control cover K (side B)
5 Stroke limitation
294.5
6 Fastening screw thread
4 x M10; 20 deep
RE 64276/08.2010 | M4-12 Bosch Rexroth AG 61/64
You can find the form for the parameterization specifications in the data sheet RE 64815-02.
Its purpose is to set the electronic pilot module according to the requirements of the client on delivery.
62/64 Bosch Rexroth AG M4-12 | RE 64276/08.2010
Pin assignment at the Bosch Kompakt plug-in Pin assignment at the CAN plug-in connector
connector Connection via Bosch Kompakt plug coding 1.
The second Bosch Kompakt plug, coding 2, can be used in
conjunction with CAN control to establish a connection to the
next module or to another CAN station.
Note!
Connecting cables and plugs are not included in the scope
of supply and must be ordered separately (see also page
63).
� � � � � � � �
Coding 1
(black plug-in
connector)
RE 64276/08.2010 | M4-12 Bosch Rexroth AG 63/64
R917c02581 Cable For the connection of two pilot modules (standard) 190 mm
R917c02599 Cable For the connection of two pilot modules 240 mm
R917c02628 Cable For the connection of two pilot modules via central inlet 370 mm
Special cable
Connecting cable
Plug-in
R900785606 connector Bosch Kompakt coding 1 (black)
kit
Plug-in
R900785607 connector Bosch Kompakt coding 2 (gray)
kit
64/64 Bosch Rexroth AG M4-12 | RE 64276/08.2010
Notes
Bosch Rexroth AG © This document, as well as the data, specifications and other
Hydraulics information set forth in it, are the exclusive property of Bosch Rexroth
Zum Eisengießer 1 AG. It may not be reproduced or given to third parties without its
97816 Lohr am Main, Germany consent.
Phone +49 (0) 93 52 / 18-0 The data specified above only serve to describe the product. No
Fax +49 (0) 93 52 / 18-23 58 statements concerning a certain condition or suitability for a certain
info.brm-mc@boschrexroth.de application can be derived from our information. The information given
www.boschrexroth.de does not release the user from the obligation of own judgment and
verification. It must be remembered that our products are subject to a
natural process of wear and aging.
Hydraulic pilot control unit of sandwich RE 64 552/05.06 1/8
Replaces: 05.03
plate design for the remote control of
directional valves, pumps, motors
Type 2TH6
Series 1X
Contents Features
Functional description, section 2 – Progressive, sensitive control
Symbol hydraulic 3 – Precise and play-free control characteristics
Technical data 3 – Low actuation force at the lever
Contact location within the plugs 8 • Pilot control unit type 2 TH 6 R, pedal version (see
RE 64551)
• Pilot control unit types 4 TH 6, 4 TH 5, 4TH 6 N, for arm rest
installation (see RE 64555)
• Pilot control device type TH 7, for instrument panel installati-
on or in pedal design (see RE 64558)
• Pilot control device with end position locking type 4/5 THF 6
(see RE 64553) or type 4/6 THF 5 (see RE 64557)
– Electronic pilot control device
• Electronic remote control device type THE6 for direct
controlling of electrical or electro-hydraulical pilot operated
actuators (see RE 29771)
• Electronic pilot control device type THE5 (see RE 29881)
– B2 TH 6 (see picture opposite)
• Recommended for use with a single 2 TH 6 control axis
• This pilot control unit cannot be flanged on
2/8 Bosch Rexroth AG Type 2 TH6 | RE 64 552/05.06
1
10
9
7 11
Holding
solenoid
6
3
13
8 �
4 12
�
2
�
� �
Symbol, hydraulic
Variants without electrical detent: L, M, P, T, N Variants with electrical detent: G, H, J
T P T P
1 2 1 2
Technical data, mechanical (for applications outside these parameters, please consult us!)
Inlet pressure bar up to 50
Back pressure at port T bar up to 3
Control fluid flow (P to 1 - 2) l/min up to 16
Hysterises bar up to 1
Pressure fluid
1)
suitable for NBR seals mineral oil (HL, HLP) to DIN 51524 1)
2)
suitable for FKM seals phosphate ester (HFD-R) 2)
Pressure fluid temperature range °C – 20 to + 80
Viscosity range mm /s
2
10 to 380
Degree of pressure fluid contamination Maximum permissible degree of contamination of the pressure
fluid is to NAS 1638 class 9. We, therefore, recommend a
filter with a minimum retention rate of ß10 ≥ 75
Max. permissible operating torque at lever Nm 10 in operation
Nm 80 for an exceptional, one time loading
Weight (dependent on the actuating element) kg 1.2 to 1.8
Technical data, electrical (for applications outside these parameters, please consult us!)
E-contact technical data for actuator N
• Switching capacity
- DC 1 A - 30 V 250 000 cycles
- AC 0.3 A - 250 V 250 000 cycles
0.6 A - 125 V 250 000 cycles
• Max. start contact resistance mW 50
• Min. isolation resistance at 500 V DC MW 1 000
• Dielectric strength 1 000 V eff. 50 Hz min. between outputs
1 500 V eff. 50 Hz min. between outputs and mass
Solenoid supply voltage V 24 (20 to 27) / DC
Power consumption of each solenoid 8.5 W at 24 V
Ordering details
Pilot control unit with N flangeable control axis Example
1st control axis
3-2 TH 6 L06-1X
- 2 TH 6 -1X / M70
2nd control axis L06 M01
N = number of control axes 1 to 6
� � � � � �
P and T P and T P and T P and T
� � � � � �
RE 64 552/05.06 | Type 2 TH6 Bosch Rexroth AG 5/8
� Inlet
Control pressure in bar
� Inlet
Control pressure in bar
� Inlet
Control pressure in bar
Inlet
Control pressure in bar
pressure
�� ���� � Inter-section point A C
Lever deflection 3° 25°
Actuation moment 0.8 3.3
for actuator L in N.m
� ���� �
�
Lever deflection
The actuation moments stated are theoritical values which do not take into account the rubber boot resistance.
6/8 Bosch Rexroth AG Type 2 TH6 | RE 64 552/05.06
16 16
2 holes Ø 9.5 1 2
39
50 60
Ø18 25°
1 25° 2
56
42
Ø10
Ø12
301
120
8,5
5
2
T
T 2 holes Ø 8.3
94
2 holes M8 x 1 *
62
37
P
1 2 deep 1±0.1
31 31 32
B2 TH6 (upper part is identical with the above depicted 2 TH 6 or 1-2 TH 6) counter bore
120 ports 01= Ø 25
100 ports 05= Ø 26
16 16
2 holes Ø 9.5 1 2
upper part
50 60
2
5
T
T
101
94
2 counter bores
ports 01= Ø 25
62
P P ports 05= Ø 26
37
16 16
1 2 6 O-rings: 17.5 x 1.5 (2 off per contact surface)
7 plug factory fitted
1 2
16 16
2 holes Ø 9.5 1 2
50 60
156
5 4 3
25°
25°
1 2
301
8,5
5
T
T
101
P
62
1 2 deep 1±0.1 7
16 16
39 39 6
78 114
Installation guidelines
– Mounting flange area: Flatness = 0.5 mm
– Screw head imensions = Ø13 mm
– Tightening torque for the flange fixing screws = Max. 10 Nm
– Tightening torque for the pipe connections = Max. 30 Nm
8/8 Bosch Rexroth AG Type 2 TH6 | RE 64 552/05.06
View F View F
DEUTSCH cover DT 04 - 2P - CE 04 AMP cover 350778 - 1
Contact location within the plugs for wiring the solenoids of the
electro-magnetic lock 2 TH 6 G / H / J
DEUTSCH sealed plug IP 67 (ordering code = 5)
View F
Bosch Rexroth AG Bosch Rexroth DSI S.A.S. © This document, as well as the data, specifications and other information set forth
Hydraulics BP 101 in it, are the exclusive property of Bosch Rexroth AG. It may not be reproduced or
Produktsegment 91, bd Irène Joliot-Curie given to third parties without its consent.
Axialkolbenmaschinen 69634 Vénissieux Cedex, France The data specified above only serve to describe the product. No statements
Werk Elchingen Tel. +33 (0) 4 78 78 52 52 concerning a certain condition or suitability for a certain application can be derived
Glockeraustraße 2 Fax. +33 (0) 4 78 78 52 26 from our information. The information given does not release the user from the
obligation of own judgment and verification. It must be remembered that our
89275 Elchingen, Germany www.boschrexroth.fr
products are subject to a natural process of wear and ageing.
Tel. +49 (0) 73 08 82-0
Fax. +49 (0) 73 08 72 74 Subject to revision.
info.brm-ak@boschrexroth.de
www.boschrexroth.com/brm
Hydraulic pilot control units for RE 64 555/04.06 1/12
Series 1X
Ports
P Supply
T Tank
� � � � 1, 2, 3, 4 Control ports
4TH6 4TH5
4TH6N
12
7
10 10
11
6
RE 64 555/04.06 | Type 4TH5, 4TH6, 4TH6N Bosch Rexroth AG 3/12
Technical data (for applications outside these parameters, please consult us!)
Mechanical
4TH6, 4TH6N 4TH5
Inlet pressure bar up to 50 up to 35
Back pressure at port T bar up to 3
Pilot oil flow (P to 1 - 2 - 3 - 4) l/mn up to 16 up to 13
Pressure fluid
1)
suitable for NBR seals mineral oil (HL, HLP) to DIN 51524 1)
2)
suitable for FPM seals phosphate ester (HFD-R) 2)
Pressure fluid temperature range °C -20 to +80
Viscosity range mm /s
2
10 to 380
Degree of pressure fluid contamination to NAS 1638 class 9. We, therefore, recommend a filter with a
minimum retention rate of ß10 ≥ 75
Max. permissible operating torque at lever Nm 10 during operation
Nm 80 with an exceptional, one time loading
Weight kg approx. 2,6 approx. 1,9
Electrical
Technical data for the grips switch EC2000
• Switching capacity
– minimal current resistive load 100mA at 12VDC or 24VDC
– maximal current resistive load 5A at 12VDC or 24VDC
• Microswitch lifetime
– resistive load at 12VDC 100 to 500mA 5 millions cycles
5A 300000 cycles
– resistive load at 24VDC 100 to 500mA 3 millions cycles
5A 150000 cycles
– inductive load L/R=5ms at 12VDC or 24VDC 1,25A 200000 cycles
• Maximal contact resistance m Ω 20
• Switching on/off with low loads
– minimum voltage V 12
– minimum current strength mA 100
• E-contact type high current
Grip protection IP65
Switching guidelines for DC voltages to ensure the service life of the electrical switch, we
recommend the use of free-wheeling diodes that are switched
parallel to the inductivity.
4/12 Bosch Rexroth AG Type 4TH5, 4TH6, 4TH6N | RE 64 555/04.06
Ordering details
4 TH 5
— 1X / *
Operating force deviations 4 TH 6
For 4 TH 5 :
– Reduced no code
For 4 TH 6 :
– Conventional no code
– Reduced =N
Grip range
Ergonomic EC2000 =E
Ergonomic EC4000 =H
Ergonomic EC2000+ =I
Ergonomic EC1000 = J1)
Customer's no code
Without grip =Z
1)
handle EC1000 for 4TH6 and 4TH6N only.
RE 64 555/04.06 | Type 4TH5, 4TH6, 4TH6N Bosch Rexroth AG 5/12
2 1 2 2 1
1 2 1
Orientation of the pilot control units at the driver‘s seat (viewed from above)
Pilot control unit left hand Pilot control unit right hand
4 TH 5 E XX - 1X / - - 43 - - - 4 TH 5 E XX - 1X / - - 23 - - -
4 TH 6 E XX - 1X / - - 43 - - - 4 TH 6 E XX - 1X / - - 23 - - -
4 TH 6 N E XX - 1X / - - 43 - - - 4 TH 6 N E XX - 1X / - - 23 - - -
3 3
2 4 2 P 4
1 T 1 T
P
6/12 Bosch Rexroth AG Type 4TH5, 4TH6, 4TH6N | RE 64 555/04.06
Lever deflection in °
1)
4TH5 control pressure in bar : 5,9 maxi - 19 mini (1 actuator – 2 actuators)
4TH6 4TH6N 4TH5
No. of actuated actuators 1 2 1 2 1 2
A 0,72 1,43 0,68 1,35 0,68 1,35
Operating torque in Nm B 1,99 3,99 1,46 2,92 1,45 2,90
C 2,93* 5,86* 2,10 4,19 2,08 4,16 *p = 35 bar
70 Control curve, identification No. 70 Inlet pressure
�
Control pressure in bar
� ���� �
� ���� �
� ���� �
4TH6
No. of actuated actuators 1 2
A 0,83 1,65
Operating torque in Nm B 2,21 4,42
C 2,93* 5,86* *p = 35 bar
� ���� �
� ��� �����
Lever deflection in °
(1 actuator – 2 actuators)
4TH6 4TH6N
No. of actuated actuators 1 2 1 2
A 0,72 1,44 0,68 1,36
Operating torque in Nm
C 2,45* 4,91* 1,77 3,53 *p = 35 bar
The operating torques stated are theoritical values which do not take into account the rubber boot resistance.
8/12 Bosch Rexroth AG Type 4TH5, 4TH6, 4TH6N | RE 64 555/04.06
– without E-contact
ST yellow
– single E-contact on
top
green
VT
black grey
– double E-contact
with rocker switch
red blue
YT
yellow black grey
– double E-contact
with rocker switch
– single E-contact on
top
green red blue
YU
yellow black grey white
– double E-contact
with rocker switch
– single E-contact on
top
– single E-contact to
the front green red blue brown
RE 64 555/04.06 | Type 4TH5, 4TH6, 4TH6N Bosch Rexroth AG 9/12
� � �
View F View F
Grip VT or YT Grip VT or YT
�
�
� � � � �
� �
� � �
� �
View F View F
cover DEUTSCH DT 04 - 6P - CE 04 cover AMP 350781 - 1
Identifica- Identifica-
wire Ergonomic grip type wire Ergonomic grip type
tion in the tion in the
colour colour
plug VT YT plug VT YT
1 red X X 1 grey X X
2 black X X 2 black X X
3 grey X X 3 red X X
4 blue X X 4 blue X X
5 yellow X 5 yellow X
6 green X 6 green X
Grip YU Grip YU
�
�
� � �
� � � �
� � � �
� � �
� � �
View F View F
cover DEUTSCH DT 04 - 8P - CE 04 cover AMP 350782 - 1
Installation hole 4 TH 5 D Ø7
100 x 100
85
Ø
Fixing bolts
– Nominal diameter / fixing via 4 screws
D = 92 to 100 mm or 100 to 108 mm
Installation hole 4 TH 6
Ø 108 Ø7
100 x 100
96
Ø
Fixing bolts
Notes
12/12 Bosch Rexroth AG Type 4TH5, 4TH6, 4TH6N | RE 64 555/04.06
Notes
Bosch Rexroth AG Bosch Rexroth DSI S.A.S. © This document, as well as the data, specifications and other information set forth
Hydraulics BP 101 in it, are the exclusive property of Bosch Rexroth AG. It may not be reproduced or
Produktsegment 91, bd Irène Joliot-Curie given to third parties without its consent.
Axialkolbenmaschinen 69634 Vénissieux Cedex, France The data specified above only serve to describe the product. No statements
Werk Elchingen Tel. +33 (0) 4 78 78 52 52 concerning a certain condition or suitability for a certain application can be derived
Glockeraustraße 2 Fax. +33 (0) 4 78 78 52 26 from our information. The information given does not release the user from the
obligation of own judgment and verification. It must be remembered that our
89275 Elchingen, Germany www.boschrexroth.fr
products are subject to a natural process of wear and ageing.
Tel. +49 (0) 73 08 82-0
Fax. +49 (0) 73 08 72 74 Subject to revision.
info.brm-ak@boschrexroth.de
www.boschrexroth.com/brm
Bosch Rexroth AG
Drive & Control Academy
Bahnhofplatz 2
97070 Würzburg
Phone: +49 (0)9352/18-1041
Fax: +49 (0)9352/18-6882
Email: academy@boschrexroth.de
www.boschrexroth.com/academy
Printed in Germany
RE 09970/03.11 Replaces: 05.08
Mat. no. R961005147