
Subject to change_RPEX3-06_14054_1en_03/2022
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7.6 Repairs carried out by specialist
A defective valve that is not caused by a malfunctioning solenoid coil must be removed and replaced with a new one.
Repairs to a defective valve may only be carried out by the manufacturer.
When replacing the defective valve with a new one, proceed as follows:
› Ensure that no explosive atmosphere is present during the repair period. (see also 7.5).
› Switch off the pressure source (pump) of the hydraulic circuit (see also 7.5).
› Relieve the hydraulic circuit including the accumulators by connecting it to the tank (see also 7.5).
› Ensure that the hydraulic circuit is pressure-free (see also 7.5).
› Switch off the electrical supply to the directional control valve solenoids (see also 7.5).
› Ensure that the surface of the valve and solenoid coils is cooled to a low enough temperature to prevent skin burns (see also 7.5).
› Disconnect the electrical supply cable to the coils (see 7.7.3).
› Switch off the electrical supply to the position sensor (if the valve is equipped with one) and disconnect the M12x1 connector.
› Remove the coil surface ground wire by loosening the M5x10 ground screw.
› Clean the surface and surroundings of the dirctional control valve.
› Allow the remaining working fluid from the valve to drain into the prepared smaller container.
› When installing the new replacement valve, follow section 7.2 Product installation.
Remove residual working fluid from the dismantled defective valve, seal the ports with a shipping plate and package it to prevent mechanical damage
and contamination of the area outside the package during transport. Send the packaged valve with a description of the manifestation of the defect
to the manufacturer. A new valve is warranted by the manufacturer for 1 year. However, a claim may not be accepted by the manufacturer if the
valve is mechanically damaged, the seal material is damaged by aggressive liquid, or the valve has been shown to have been used improperly and not
in accordance with these instructions of use.
7.6.1 Replacing a defective valve
A suitably qualified user is authorised to replace the seals on the valve body base, which are supplied as a kit. They can also replace a malfunctioning
solenoid coil.
7.6.2 Replacing the sealing rings at the base of the valve body
In case of leaks in the dividing plane, the sealing rings must be replaced with new ones. The disassembly and reassembly procedure is similar.
› Ensure that no explosive atmosphere is present during the repair (see also 7.5).
› Switch off the pressure source (pump) of the hydraulic circuit (see also 7.5).
› Lighten the hydraulic circuit including the accumulators by connecting it to the tank (see also 7.5).
› Ensure that the hydraulic circuit is depressurised (see also 7.5).
› Switch off the electrical supply to the directional control valve solenoids (see also 7.5).
› Make sure that the surface of the valve and solenoid coils is cooled to a low enough temperature to prevent skin burns (see also 7.5).
› Clean the surface and surroundings of the directional control valve.
› Loosen and unscrew the four fastening screws M5x45 DIN 912 using the inbus wrench a = 4. Carefully remove the valve from the
connection plate.
› Allow the remaining working fluid from the valve to drain into the prepared smaller container.
› Using a small screwdriver, remove the sealing rings from the recess in the body.
› Work carefully to avoid damaging the sealing surfaces.
› Clean the connection surfaces of the valve body and plate. Check them for damage.
› Insert new sealing rings into the recesses in the valve body so that they do not fall out when the valve is reassembled.
› Insert the four fastening screws into the holes in the valve body and fasten the valve to the plate using the inbus wrench a = 4. Tighten
the screws in a crosswise sequence to the specified torque of 8.9 + 1 Nm. Uneven tightening may cause deformation of the body and
unreliable valve function.
› If any of the fixing screws are damaged, replace them.
WARNING
Valve fastening screws
The screws must be fastening screws(SCREW M5x45 DIN 912 10.9), preferably from the valve manufacturer. A
screw of normal strength can be broken due to the high pressure in the hydraulic circuit and can cause
massive leakage of the working fluid.
ENVIRONMENTAL PROTECTION
Spilled working fluid must be removed immediately, e.g. with suitable absorbents, contaminated parts of the perimeter cleaned,
contaminated objects in the vicinity cleaned or disposed of. Contaminated objects and residues of leaked working fluid must be
disposed of in accordance with the applicable environmental regulations.
FIRST AID
Electric shock
› Switch off the power supply immediately
› Make sure the casualty is breathing.
› Call emergency medical services
› If the casualty is not breathing, initiate measures to restore basic life functions according to first aid abilities (CPR, artificial
respiration) and equip the workplace (defibrillator) with life-saving equipment.
Contamination by hydraulic working fluid
If contamination of persons occurs, contaminated parts of clothing must be removed immediately and the skin thoroughly washed
with soap or treated with a suitable cream.
If the eyes are contaminated, flush them with clean water and seek medical attention. Seek medical attention also in case of
accidental ingestion of working fluid or skin allergic reaction to splashes of working fluid.