Bosch Rexroth RE 07601-B User manual

Operating instructions
RE 07601-B/12.2013 English
Manifolds and modules

The data specified above serve to describe the
product. If there is also information on theuse,
it is only to be regarded as application examples
and proposals. Catalogue information does not
constitute warranted properties. Theinforma-
tion given does not release the user from the
obligation of own judgment and verification.
Our products are subject to anatural process
ofwear and aging.
© This document, as well as the data, specifica-
tions and other information set forth in it, are
the exclusive property of Bosch Rexroth AG.
Itmay not be reproduced or given to third par-
ties without its consent.
The cover shows an example configuration.
Theproduct supplied may therefore differ from
the photo shown.
The original operating instructions were pre-
pared in German.

RE 07601-B/12.2013, manifolds and modules, Bosch Rexroth AG
3/36Inhalt
Inhalt
1 About this documentation 5
1.1 Validity of the documentation 5
1.2 Required and amending documentation 5
1.3 Representation of information 5
1.3.1 Safety instructions 5
1.3.2 Symbols 6
1.3.3 Abbreviations 6
2 Safety instructions 7
2.1 General information on this chapter 7
2.2 Intended use 7
2.3 Improper use 7
2.4 Qualification of personnel 8
2.5 General safety instructions 8
2.6 Product-specific safety instructions 9
2.7 Personal protective equipment 12
3 General information on damage to property and damage to the product 13
4 Scope of delivery 14
5 Information on this product 15
5.1 Product identification 15
6 Transport and storage 16
6.1 Transporting the manifold/module 16
6.1.1 Transport using lifting tools 16
6.2 Storing the manifold/module 17
7 Assembly 19
7.1 Unpacking 19
7.2 Prior to assembly 19
7.3 Installation conditions 19
7.4 Necessary tools 19
7.5 Assembling the manifold/module 20
7.5.1 Mechanically assembling the manifold/module 21
7.5.2 Hydraulically connecting the manifold/module 21
7.5.3 Connecting the power supply 21
7.6 Painting the manifold/module 22
8 Commissioning 23
8.6.1 Bleeding the hydraulic system 24
9 Operation 24
10 Maintenance and repair 25
10.1 Cleaning and care 25
10.2 Repair 26
10.3 Spare parts 26
11 Disassembly and exchange 27
11.1 Necessary tools 27
11.2 Preparing for disassembly 27
11.3 Disassembling the product 27
12 Disposal 29
12.1 Environmental protection 29

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Bosch Rexroth AG, manifolds and modules, RE 07601-B/12.2013
12.2 Return to Bosch Rexroth AG 29
12.3 Packaging 29
12.4 Materials used 29
12.5 Recycling 30
13 Extension and modification 30
14 Troubleshooting 31
14.1 How to proceed for troubleshooting 31
14.2 Fault table 31
15 Technical data 31
16 Appendix 32
16.1 List of addresses 32
17 Alphabetical index 33

About this documentation 5/36
RE 07601-B/12.2013, manifolds and modules, Bosch Rexroth AG
1 About this documentation
1.1 Validity of the documentation
This documentation applies to:
•Manifolds and modules for industrial applications
This documentation is intended for assemblers, system end-users, machine and
system manufacturers.
This documentation contains important information on the safe and proper trans-
port, assembly, commissioning, operation, use, maintenance, simple troubleshoot-
ing, disassembly and disposal of the product.
▶ Read this documentation completely and particularly chapter 2 "Safety instruc-
tions" and chapter 3 "General information on damage to property and damage to
the product" before working with manifolds or modules.
1.2 Required and amending documentation
▶ The product must not be commissioned until you have been provided with the
documentation marked with the book symbol and you have understood and
observed it.
Table 1: Required and amending documentation
Title Document number Document type
Order confirmation
Installation drawing with parts list Drawing
Hydraulic valves for
industrial applications
RE 07600 Operating instructions
1.3 Representation of information
Consistent safety instructions, symbols, terms and abbreviations are used so that
you can quickly and safely work with your product. For a better understanding, they
are explained in the following sections.
1.3.1 Safety instructions
In this documentation, safety instructions are given in chapter 2.6 "Product-specific
safety instructions" and chapter 3 "General information on damage to property and
damage to the product" and whenever sequences of actions or instructions are ex-
plained which bear the danger of personal injury or damage to property. The mea-
sures described for preventing these hazards must be observed.
Safety instructions are set out as follows:
SIGNAL WORD
Type and source of danger!
Consequences in case of non-compliance
▶ Hazard avoidance measures
▶ <Enumeration>

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Bosch Rexroth AG, manifolds and modules, RE 07601-B/12.2013
•Warning sign: Draws attention to the danger
•Signal word: Identifies the degree of danger
•Type and source of danger!: Specifies the type and source of danger
•Consequences: Describes the consequences in case of non-compliance
•Precaution: Specifies how the danger can be prevented
Table 2: Risk classes according to ANSI Z535.6-2006
Warning sign, signal word Meaning
DANGER Indicates a dangerous situation which will cause death or
severe personal injuries if not avoided.
WARNING Indicates a dangerous situation which may cause death or
severe personal injuries if not avoided.
CAUTION Indicates a dangerous situation which may cause minor or
medium personal injuries if not avoided.
NOTICE Damage to property: The product or the environment could
be damaged.
1.3.2 Symbols
The following symbols indicate notices which are not safety-relevant but increase
thecomprehensibility of the documentation.
Table 3: Meaning of the symbols
Symbol Meaning
If this information is not observed, the product cannot be used and/or
operated optimally.
▶ Individual, independent action.
1.
2.
3.
Numbered instruction:
The numbers indicate that the actions must be carried out one after theother.
1.3.3 Abbreviations
The following abbreviations are used in this documentation:
Table 4: Abbreviations
Abbreviation Meaning
ANSI American National Standards Institute
EMC Electro-magnetic Compatibility
PE Protective Earth (protective earthing conductor)

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RE 07601-B/12.2013, manifolds and modules, Bosch Rexroth AG
2 Safety instructions
2.1 General information on this chapter
Bosch Rexroth manifolds and modules are manufactured according to the generally
accepted code of practice. However, there is still the risk of personal injury and dam-
age to property. You must therefore observe this chapter and the safety instructions
in this documentation.
▶ Read this documentation completely and thoroughly before working with the
manifolds and modules.
▶ Keep this documentation in a location where it is accessible to all users at
alltimes.
▶ Always include the required documentation when you pass the product on to
third parties.
2.2 Intended use
The product is a hydraulic system component. It is intended for use in industrial
machines and systems.
You may use the product as follows:
•To control the movement at machines and systems
•Complying with the application and environmental conditions according to the
datasheet.
•Complying with the specified performance limits.
•Use in the original condition, without damage.
•Repair by customers is not admissible.
The product is only intended for professional use and not for private use.
Intended use includes having read and understood this documentation completely,
especially the chapter 2 "Safety instructions".
2.3 Improper use
Any use deviating from the intended use is improper and thus not admissible.
Bosch Rexroth AG does not assume any liability for damage caused by improper use.
The user assumes all risks involved with improper use.
Improper use of the manifold or module includes:
•Use in explosive environments
•Incorrect transport
•Incorrect storage
•Lack of cleanliness during storage and assembly
•Incorrect installation
•Use of inappropriate/non-admissible media
•Exceedance of the specified maximum pressures
•Operation outside the approved temperature range

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Bosch Rexroth AG, manifolds and modules, RE 07601-B/12.2013
2.4 Qualification of personnel
The activities described in this documentation require basic knowledge of mechan-
ics, electrics and hydraulics as well as knowledge of the appropriate technical terms.
For transporting and handling the product, additional knowledge of how to handle
lifting tools and the necessary attachment devices is required. In order to ensure
safe use, these activities may only be carried out by an expert in the respective field
or an instructed person under the direction and supervision of an expert.
Experts are those who are able to recognize potential hazards and apply the appro-
priate 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 and have
the necessary expert knowledge.
Expert knowledge means for example for hydraulic products:
•Reading and completely understanding hydraulic schemes,
•In particular, completely understanding the correlations regarding the safety equip-
ment and
•Having knowledge of the function and set-up of hydraulic components.
Bosch Rexroth offers training measures in specific fields. An overview of the
training contents can be found online at: http://www.boschrexroth.com
2.5 General safety instructions
•Observe the valid regulations on accident prevention and for environmental
protection.
•Observe the safety regulations and provisions of the country where the product is
implemented/used.
•Exclusively use Rexroth products in technically perfect condition.
•Observe all notices on the product.
•Persons assembling, operating, disassembling or maintaining Rexroth products
must not be under the influence of alcohol, other drugs or medications influencing
the ability to react.
•Only use original Rexroth accessories and spare parts in order to exclude hazards
to persons due to unsuitable spare parts.
•Comply with the technical data and environmental conditions specified in the prod-
uct documentation.
•The installation or use of inappropriate products in safety-relevant applications
could result in unintended operating conditions when being used which in turn
could cause personal injuries and/or damage to property. Therefore, only use
aproduct for safety-relevant applications if this use is expressly specified and per-
mitted in the documentation of the product, e.g. in explosion protection zones or
in safety-related parts of control systems (functional safety).
•Do not commission the product until you can be sure that the end product (for ex-
ample a machine or system) where the Rexroth product is installed complies with
the country-specific provisions, safety regulations and standards of the application.

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RE 07601-B/12.2013, manifolds and modules, Bosch Rexroth AG
2.6 Product-specific safety instructions
WARNING
Non-compliance with functional safety!
Hydraulic manifolds and modules control movements in machines or systems.
Incase of mechanical and electric faults, e.g. failure of the energy supply, persons
may be caught by the system, kicked away or bruised due to incorrect control and
unexpected start-up.
▶ When setting up your circuit, observe functional safety e.g. according
toENISO13849.
▶ Install light barriers or protective grids, if necessary.
▶ Immediately exchange defective components.
Pressurized system parts and leaking hydraulic fluid!
When working at hydraulic systems with stored pressure energy (accumulator or
cylinders working under gravity), hydraulic manifolds and modules may even be
pressurized after the pressure supply has been switched off. During assembly and
disassembly works, attached and installed components may fly around and cause
personal injuries and/or damage to property. There is moreover the danger of seri-
ous injury caused by a powerful leaking hydraulic fluid jet.
▶ Ensure before working at the hydraulic product that the hydraulic system is de-
pressurized and the electrical control de-energized.
▶ Completely unload the pressure at machines and systems before working at
hydraulic products.
▶ Secure the system against restarting.
Faulty fastening!
Mounting of the manifold/module using mounting bolts of reduced stability, insuf-
ficient mounting or insufficient stability of the mounting surfaces may cause the
product to become loose and fall down. Manifolds/modules with high weight may
bruise or kill persons.
▶ Completely assemble the manifold/module according to the assembly specifica-
tions by means of suitable assembly aids.
▶ Mount the manifold/module only at suitable mounting surfaces.
▶ Comply with tightening torques and screw stabilities.
Easily inflammable hydraulic fluid!
Fire and risk of fire due to hydraulic fluid and leaking oil mist.
▶ Keep open fire and ignition sources away from the manifold/module.
▶ Do not use manifolds and modules in areas with open fire and only at sufficient
distance to hot heat sources.
▶ Immediately remove leaked hydraulic fluid and dispose of it properly.

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Bosch Rexroth AG, manifolds and modules, RE 07601-B/12.2013
WARNING
High pressure!
Risk of injury caused by pressurized leaking oil jet and parts shooting out due to
abroken system component.
▶ In case of a leaking oil jet, decommission the system and exchange the dam-
agedcomponents.
▶ Secure the pressure in the system by means of overpressure equipment.
▶ Lead the tank line to the tank freely, without reduction of the cross-section
andblocking.
▶ Use hydraulic lines and connections according to the max. operating pressure.
▶ Do not separate, open or disconnect pressurized lines and do not disassemble
pressurized components!
▶ Depressurize the system before the assembly and any other works at the mani-
folds/modules.
CAUTION
Leaking hydraulic fluid!
Hydraulic fluid may leak during assembly and disassembly of hydraulic components.
Consequently, persons may slip or fall!
▶ Only remove the protective caps at hydraulic manifolds/modules directly before
the assembly.
▶ After the disassembly, provide the bores containing the hydraulic fluid with suit-
able closing elements.
▶ Immediately remove leaked hydraulic fluid and dispose of it properly.
Harmful hydraulic fluid!
Health hazard due to contact with hydraulic oil (e.g. eye injuries, skin lesions, poi-
soning when inhaled and ingested).
▶ Check the hydraulic components and lines for wear and damage on a regular basis.
▶ Wear protective gloves, safety goggles and suitable working clothes when work-
ing with hydraulic oil.
▶ If nevertheless hydraulic fluid comes into contact with the eyes or penetrates
the skin, please consult a doctor immediately.
▶ When dealing with hydraulic fluids, you must imperatively observe the safety
instructions of the hydraulic fluid manufacturer.
Resonance or fluid noises!
Hearing damage and possible damage at hydraulic valves! In case of an unfavorable
arrangement of hydraulic manifolds and modules in the system, resonance or fluid
noises e.g. whistling may result.
▶ In this case, contact a service engineer.