Bosch Rexroth RE 07009-MON User manual

RE 07009-MON/11.17
Replaces: 09.09
English
General Assembly Instructions
with Information on the Transport
of the Hydraulic Power Units
Assembly instructions

The data specified below only serve to describe the
product. No statements concerning a certain condition
or suitability for a certain application can be derived
from our information. The information given does not
release the user from the obligation of own judgment
and verification. It must be remembered that our
products are subject to a natural process of wear and
aging.
ⓒ This document, as well as the data, specifications
and other information set forth in it are the exclusive
property of Bosch Rexroth AG. It may not be
reproduced or given to third parties without its consent.
The cover shows a sample configuration. The product
supplied may therefore differ from the photo shown.
The original assembly instructions were prepared in
German.

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Contents
Contents
1 About this document......................................................................................5
2 General safety instructions............................................................................5
2.1 Intended use ............................................................................................5
2.2 Qualification of personnel ........................................................................5
2.3 Safety instructions in this document ........................................................5
2.4 Adhere to the following instructions ......................................................... 6
3 Scope of delivery ............................................................................................7
4 Product description........................................................................................7
4.1 Product identification ...............................................................................7
5 Transport and storage....................................................................................8
5.1 Transporting hydraulic power units..........................................................8
5.2 Storing the hydraulic power units...........................................................14
6 Assembly and installation............................................................................14
6.1 Unpacking..............................................................................................14
6.2 Assembling the hydraulic power unit .....................................................15
6.3 Installing the hydraulic system...............................................................15
6.4 Connecting to the water supply .............................................................17
6.5 Installing the electrical system ...............................................................17
7 Technical data...............................................................................................18
8 Appendix........................................................................................................18
8.1 Address directory...................................................................................18
9 Glossary.........................................................................................................19

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Contents

RE 07009-MON/11.17 | Assembly Instructions for Hydraulic Power Units Bosch Rexroth AG 5/20
1 About this document
These instructions contain important information for the safe and appropriate
transport and assembly of hydraulic power units.
These are general assembly instructions with information on the transport of
hydraulic power units that are developed and produced in a customer-specific way.
Information on the commissioning (incl. the filling with operating media), the
operation, maintenance and simple troubleshooting is contained in the general
operating instructions for hydraulic power units and hydraulic assemblies.
2 General safety instructions
The hydraulic power unit was designed and manufactured considering the
provisions of directives, standards and specifications relating to this technology.
There is, however, still a risk of personal injury or damage to property if the
following safety instructions and warnings contained in this document are not
observed.
fYou should read these instructions completely and thoroughly before working
with the hydraulic power unit/hydraulic assembly.
fAlways include the operating instructions and the product-specific
documentation when passing the hydraulic power unit/hydraulic assembly on
to a third party.
2.1 Intended use
For information on the intended use please refer to the supplied general operating
instructions for hydraulic power units and hydraulic assemblies.
2.2 Qualification of personnel
Assembly requires a basic knowledge of mechanics, electrics and hydraulics,
as well as familiarity with the associated technical terms. In order to ensure
operational safety, these activities may only be carried out by qualified technical
personnel or an instructed person under the direction and supervision of a
qualified person.
Qualified personnel 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. Qualified personnel must observe the rules/laws
relevant to the specific subject area.
2.3 Safety instructions in this document
In these assembly instructions, there are safety instructions before the steps
whenever there is a risk of personal injury or damage to the equipment. The
measures described for preventing these hazards must be observed.

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Safety instructions are set out as follows:
Type of risk!
Consequences
fPrecautions
Warning sign (warning triangle): Draws attention to the hazard
Signal word: Identifies the degree of hazard
Type of risk: Specifies the type or source of the hazard
Consequences: Describes the consequences of non-compliance
Precautions: Specifies how the hazard can be prevented
Table 1: Meaning signal words
DANGER! Indicates an imminently hazardous situation which, if not
avoided, will certainly result in serious injury or even death.
WARNING! Indicates a potentially hazardous situation, which, if not
avoided, could result in serious injury or even death.
CAUTION! Indicates a potentially hazardous situation which, if not
avoided, could result in minor or moderate injury or damage
to equipment.
If this information is disregarded, it may result in machine
malfunction or breakdown.
Warning signs Meaning
Warning of a danger spot
2.4 Adhere to the following instructions
• The regulations regarding accident prevention and environmental protection
applicable in the country where the product is used and at the workplace must
be observed.
• Only persons who have been authorized by the operator may be granted
access to the immediate vicinity of operation. This also applies during
machine standstill.
• Persons who assemble products supplied by Bosch Rexroth must not consume
any alcohol, drugs or medication that may have a detrimental affect on
their reactions.
• Before installation, check the hydraulic power unit for visible transport damage
e.g. cracks, missing lead seals, screws, protective covers.
• Under no circumstances should the hydraulic power unit be subjected to
inadmissible mechanical loads. Do not place any objects on top of the power unit.
SIGNAL WORD!
General
Avoidance of hazards

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• Provide for sufficient stability of the hydraulic power unit.
– In this context, observe the maximum load-bearing capacity of the
foundations or ground as well as that of the attachment devices and vehicles
used for transport.
– You should use only the designated attachment points.
• Avoid damage of any kind on the pressurized or functional components of the
hydraulic power unit.
• If it does become necessary to work at height, entailing a fall hazard, suitable
safety precautions must be taken (e.g. provision of gratings, handrails or
harnesses).
• Suitable measures should be taken to prevent any slip hazard caused by oily
surfaces that may e.g. result from maintenance work.
3 Scope of delivery
These assembly instructions have been prepared for hydraulic power units.
In addition to the actual product itself, the scope of delivery for hydraulic power
units also includes both general and product-specific documentation.
These documents are listed in the following table:
Document Power unit
Product-specific
documentation
Technical specification x
Hydraulic diagram x
Component list to hydraulic diagram x
Assembly drawing x
EC Declaration of Incorporation x
General
documentation
Operating Instructions x
Assembly instructions (this document) x
4 Product description
Hydraulic power units are drive system for hydraulic machines. In this sense,
they are considered partly completed machinery according to EC Machinery
Directive 2006/42/EC.
The hydraulic power units, for which these assembly instructions have been
prepared, are exclusively intended for installation into machinery. As a general
rule, these are products that have been developed and manufactured to customer
specifications. For the specific description of your product, please refer to the
relevant product-specific documentation.
4.1 Product identification
The product is unambiguously identified by:
• The nameplate
• The product-specific documentation
• The delivery note and accompanying documents
Protective measures

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5 Transport and storage
fObserve the transport instructions, e.g. on the packaging.
fWhen storing and transporting the product, always observe the ambient
conditions specified in Chapter 15 “Technical data”.
fIf the package has to be opened e.g. for inspection purposes, you should
reseal the packaging to the condition in which it was supplied.
fWherever possible, the packaging should not be removed until directly before
assembling the unit.
5.1 Transporting hydraulic power units
Danger to life due to tumbling, falling or uncontrolled movement of the
hydraulic power unit!
If not transported appropriately, the hydraulic power unit may lose its stability and
thus be knocked over, fall or move in an uncontrolled way.
fCheck the weight and also the location of the center of gravity of the hydraulic
power unit.
fPlace the product on a suitable foundation / on suitable ground.
fBy means of additional suitable measures (e.g. by securing holding down
points or with the use of cranes) provide for sufficient stability before removing
any packing/transit materials or fixtures.
fOnly the intended locations and attachment points should be used for securing
or lifting the hydraulic power unit.
fHydraulic power units must never be attached to or lifted at the mounted
components (piping, hoses, manifolds, electric motors, accumulators, etc.).
fObserve the maximum load-bearing capacity of the attachment devices.
fObserve the maximum load-bearing capacity of the floor conveyors.
fEnsure that no unauthorized persons are within the hazard zone.
Danger to life due to the ejection of high-pressure oil or machine
malfunctions during operation!
In the case of improper transport of the hydraulic power unit, pressurized or
functional components may become damaged.
fEnsure that these components do not come into contact with the attachment
devices or lifting tools during transport.
fEnsure that hydraulic power units are not attached to or lifted at
these components.
WARNING!
WARNING!

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5.1.1 Preparing the power unit for transport
The following preparations must be carried out before transporting the hydraulic
power unit:
fCheck the space required for the installation of the hydraulic power unit at the
place of use.
fCheck the transport route. Depending on the method of transport, allow for
additional space around the hydraulic power unit.
fCheck the maximum admissible load bearing capacity of the roads, bridges,
crossings, etc.
fPrior to transportation of the hydraulic power unit, depressurize the installed
accumulators on the oil side. If possible, reduce the pressure on the gas side
to a value of 2 bar (200 kPa).
Bosch Rexroth always delivers hydraulic power units without first filling with
oil. Any deviations from this rule are described explicitly in the product-specific
documentation. From the factory inspection there may, however, still be oil
residues in the product.
5.1.2 Determination of the center of gravity
Wherever possible, the location of the center of gravity is marked on the
packaging by the following symbol.
Fig. 1: Symbol for marking the center of gravity
The location of the center of gravity is generally specified on the assembly
drawing. The diagrams below demonstrate how to mark the center of gravity on
drawings.
Fig. 2: Marking the center of gravity in drawings

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5.1.3 Use of attachment points
Danger to life due to tumbling, falling or uncontrolled movement of the
hydraulic power unit when using unsuitable attachment points!
After a longer period of use, the attachment points may no longer be in place, be
sufficiently stable or identifiable as such.
fRefer to the product-specific documentation for the intended attachment
points and only use the ones mentioned there.
fCheck the stability of the attachment points if you intend transporting the
hydraulic power unit after dismantling.
fReplace missing and/or defective attachment points, if possible. This work
should be carried out in a professional manner.
fInsert the screw-in attachment points into the tapped hole and hand-
tighten fully.
fIf necessary, mark the unrecognizable attachment points using easily
visible color.
Attachment points are fixtures in the form of lugs, collars or shackles that
are connected to the hydraulic power unit by means of welded or threaded
attachment. They are designed for lifting or holding down the hydraulic power unit
during transport.
Examples of attachment points of hydraulic power units are shown in Fig. 3:
12
Fig. 3: Examples of attachment points
1 Welded type
2 Screwed type
5.1.4 Manual transport
Risk of injury to persons undertaking manual lifting/handling due to
overloading and incorrect posture!
In the case of lifting/handling, there is the risk of damage to health due to
overloading and incorrect posture.
fThe limits of the respective persons involved in manual lifting/handling
must be realistically assessed. Muscular strength and constitution differs
considerably among human beings.
fWherever possible, suitable lifting aids should be used such as e.g. carrying straps.
fAlways use appropriate techniques when lifting, setting down and
moving products.
WARNING!
CAUTION!

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5.1.5 Transport using forklifts and similar floor conveyors
Danger to life due to falling or uncontrolled movement of the hydraulic
power unit!
If not transported appropriately, the hydraulic power unit may be knocked, fall or
move in an uncontrolled way.
fWhen using floor conveyors as a means of transport, ensure a stable center of
gravity position.
fThe hydraulic power unit must not deviate from its intended orientation.
fSecure the hydraulic power unit against any resulting acceleration forces as
required.
When using floor conveyors, the hydraulic power unit may only be transported
by personnel who can prove they hold the relevant qualifications, including
safety training, for the respective device.
You should proceed as follows:
fUsing suitable temporary protective devices e.g. wooden or plastic elements,
protect the hydraulic power unit against the contact surface of the fork, so that
the paintwork cannot be damaged during lifting and transport.
fSecure the hydraulic power unit at the forklift against tilting. To this purpose,
fuse suitable attachment devices like e.g. tie downs.
fCarefully lift the hydraulic power unit, taking into consideration the stable
center of gravity location and transport it to the desired position.
fEnsure that the built-on components of the hydraulic power unit do not come
into contact with the attachment device or lifting tools during transport
(see Fig. 4).
fCarefully set the hydraulic power unit down again and remove the holding
down / lifting equipment and any temporary protective devices.
Fig. 4: Transport using forklifts
WARNING!

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5.1.6 Transport using cranes and similar lifting tools
Danger to life due to falling or uncontrolled movement of the hydraulic
power unit!
If not transported appropriately, the hydraulic power unit may be knocked, fall or
move in an uncontrolled way.
fWhen using lifting tools, ensure a stable center of gravity position.
fThe hydraulic power unit must not deviate from its intended orientation. If
necessary, attach suitable safety and/or catch devices.
If using cranes as a means of transport, attachment device e.g. lifting straps,
harnesses or chains should be used.
fUse only the intended locations and attachment points when lifting (see Fig. 5
and 6).
fEnsure that the built-on components of the hydraulic power unit do not come
into contact with the attachment device or lifting tools during transport.
The edges of the hydraulic power unit may cause damage to the fabric lifting
straps or harnesses. An edge protector should therefore be used if necessary.
When using uncovered chains, scratches in the paintwork may result. If
necessary, use suitable protection for these surfaces e.g. blankets.
fLift and lower the hydraulic power unit slowly and carefully.
fOnly lift the device as far off the floor as necessary.
Fig. 5: Use of lifting straps and attachment points
WARNING!

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Fig. 6: Detailed view of Fig. 5
5.1.7 Freight transport
Danger to life due to tumbling, falling or uncontrolled movement of the
hydraulic power unit!
If not transported appropriately, the hydraulic power unit may be knocked, fall or
move in an uncontrolled way.
fSecure the hydraulic power unit against any resulting acceleration forces
as required.
The various regulations of the assigned forwarding agents e.g. shipping
companies, railway companies, forwarders, airlines must be observed.
fSecure the hydraulic power unit onto the transport vehicle, e.g. by the holding
down points.
fEnsure that the built-on components of the hydraulic power unit do not come
into contact with the attachment devices during transport.
fSome products need to be transported in a lying position e.g. accumulator
stands. Use the intended attachment points for laying the products down and
securing them.
WARNING!

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5.2 Storing the hydraulic power units
Observe the storage times specified in Table 2.
fIf the storage time exceeds the values specified, flush the hydraulic power unit
before commissioning using a suitable flushing fluid. The flushing procedure
should be carried out as described in Chapter 7.1.9 “Flushing the hydraulic
system” of the operating instructions.
fIf necessary, replace the components for which a maximum storage time is
specified e.g. hoses, compensators, accumulators.
Table 2: Storage times
6 Assembly and installation
This chapter describes the assembly of the product at its place of use as well as
the connection of the product to the hydraulic system, the electrical systems and
the water supply of the machine.
For information regarding the installation into the complete machine, particularly
regarding its overall function and logic mode of operation, please refer to the
instructions and/or the documentation for the complete machine.
Risk of personal injury and damage to property!
A basic knowledge of hydraulics is required for assembling the hydraulic power
unit.
fOnly qualified personnel (see Chapter “2.3 Personnel qualifications”) are
permitted to assemble the hydraulic power unit.
6.1 Unpacking
fRemove the product packaging.
fDispose of the packaging material in accordance with the national regulations
in your country and/or your company-internal specifications/procedures.
CAUTION!
Storage conditions Packaging Protective
agent
Storage time in months
Test with the protective agent Filling with the protective agent
Storage in dry rooms at
constant temperature
For carriage
overseas
A 12 24
B 12 24
Not for carriage
overseas
A 9 24
B 12 24
Outdoor storage
(protect the product against
damage and water ingress)
For carriage
overseas
A 6 12
B 9 24
Not for carriage
overseas
A 0 12
B 6 24
Inspection with protective agent A = Mineral oil
Filling with protective agent B = Corrosion protection oil

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6.2 Assembling the hydraulic power unit
Risk of injury due to tumbling, falling or uncontrolled movement of the
hydraulic power unit!
You should ensure that the product is sufficiently stable.
fObserve the information on handling the product in Chapter 5 “Transport
and storage”.
fAny packing/transit materials, straps, props or fixtures should only be removed
if stability has been ensured by other means.
fPlace the hydraulic power unit on a suitable foundation. Observe the
specifications of the overall weight.
To assemble the hydraulic power unit you should proceed as follows:
fPosition the hydraulic power unit or the assembly as specified in the product-
specific documentation.
fEnsure that the footprint contact associated with mounting is consistent.
fLevel the hydraulic power unit so that its longitudinal and transverse axes are
horizontal.
fPrevent possible bouncing by suitable means (e.g. height adjustment of the
feet, insertion of shims, packers).
fSecurely fix the product at the mounting positions specified in the product-
specific documentation.
6.3 Installing the hydraulic system
Risk of injury when assembling under pressure!
If you fail to depressurize the product before starting the installation, you may
suffer injury and also damage the unit or system components.
fAlways depressurize the relevant part of the system before assembling the
hydraulic power unit.
Damaging the hydraulic power unit!
When assembling hydraulic lines and hoses under mechanical stress, they are
exposed to additional mechanical forces during operation, which reduces the
service life of the hydraulic power unit and the complete machine or system.
fAssemble the piping and hose assemblies without mechanical stress.
WARNING!
CAUTION!
CAUTION!

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Wear, tear and malfunctions!
The cleanliness of the hydraulic fluid has a considerable impact on the cleanliness
and service life of the hydraulic system as a whole. Any pollution/contamination of
the hydraulic fluid will result in wear and malfunctions. In particular, foreign bodies
e.g. welding beads or metal swarf in the hydraulic lines may damage the hydraulic
power unit.
fAlways ensure absolute cleanliness.
fAssemble the hydraulic power unit free from any pollution/contamination.
fEnsure that all connections, hydraulic lines and add-on units
(e.g. measuring instruments) are clean.
fEnsure that no pollutants are able to penetrate when sealing the connections.
fEnsure that no detergents are able to penetrate the hydraulic system.
fDo not use cleaning rags/cotton waste or linty cloth for cleaning.
fDo not under any circumstances use hemp as a sealant.
Risk of injury from ejection of high-pressure oil!
If the nominal pressure is exceeded, the component may burst.
fThe connection lines should be dimensioned in accordance with the
performance data in the circuit diagram.
fYou should only use components that are designed for the required pressures.
Risk of injury from ejection of high-pressure oil!
Fittings with metric or Whitworth threads may for certain sizes be mis-matched
without this being immediately evident. Fittings with threads that are mis-matched
will not withstand the specified nominal pressure.
fYou should therefore ensure that there is no risk of confusion with respect to
the correct screw fittings.
Remove the blanking plugs and flange covers (colored plastic) and replace them
with pressure-resistant fittings or flanges.
fYou should observe the manufacturer’s installation instructions for the screw
fittings to ensure there is no external leakage. We recommend the use of
fittings with elastic seals.
fBefore installing, clean the connection lines to the hydraulic system, ensuring
they are free from dirt, scales, chippings, etc. Welded pipes must be blank on
the inside and flushed.
fDo not use cleaning rags/cotton waste for cleaning.
CAUTION!
WARNING!
WARNING!
Preparation
Cleaning the lines

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The hose assemblies should be installed such that
– Kinking and tensile load of the hose is avoided during operation,
– The hose is not twisted or turned,
– The outer layer of the hose does not rub off through abrasion or impact,
– The weight of the hose assembly does not cause inadmissible loading.
If a hose assembly becomes detached and there is a risk of whipping, it is
advisable to fit a hose safety catch. If the hose assemblies are equipped with
loosening-resistant fittings, no safety catch is required.
6.4 Connecting to the water supply
fThe fittings must be tightened according to manufacturer specifications!
fLay the lines to the water connections provided and connect them according
to the circuit diagram.
6.5 Installing the electrical system
Risk of injury when assembling under voltage!
If you fail to switch off the power supply before assembling the product, you may
suffer injury, destroy the product or damage system components.
fAlways switch off the power supply to the relevant system component before
assembling the product.
6.5.1 Earthing and potential equalization
Hydraulic power units from Bosch Rexroth are supplied with connection for the
external earthing system. Potential equalization within the hydraulic power unit
will only occur if the electrical wiring of the components is included in the scope
of delivery. If this is not the case, potential equalization must be carried out by the
machine manufacturer when wiring the hydraulic power unit to the machine.
The hydraulic power units must be earthed!
The earthing line and the lines for the potential equalization must have the
minimum cross-section as per VDE regulations and a yellow-green sheath
or labeling.
fBefore connecting the cables, you should earth the devices that are to be
connected and provide for potential equalization via a common equalizing bar.
Hose assemblies
CAUTION!

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6.5.2 Laying the power supply and control cables and connecting
the electricity supply
fThe electrical installation must be performed in accordance with the currently
applicable rules of electrical engineering.
fYou must ensure that the power supply is disconnected and also safeguarded
against being switched on unintentionally.
fYou should prevent this by e.g. using a warning sign to draw attention to
issues regarding working on the electrics.
fCarefully secure all cables to the electric motor with plastic cable clamps
against unintended loosening (swinging).
6.5.3 Installing the electrical control and monitoring equipment
Connect the control and monitoring equipment (switching devices, open-loop
or closed-loop equipment or frequency converters) according to the relevant
instructions, taking into account the appropriate safety precautions.
Penetrating dirt and liquids will cause faults!
Safe function of the hydraulic power unit/components is then no longer ensured.
fAlways ensure absolute cleanliness when working on the hydraulic power unit.
Damage to the surface from solvents and aggressive cleaning agents!
Aggressive detergents may damage the seals on the hydraulic power unit and
make them age faster.
fNever use solvents or aggressive detergents.
7 Technical data
Please refer to the product-specific documentation for the technical data of
the product.
8 Appendix
8.1 Address directory
Please refer to www.boschrexroth.com for addresses of foreign subsidiaries
CAUTION!
CAUTION!

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9 Glossary
Attachment points
Attachment points are fixtures in the form of lugs that are connected to the load
by means of welded or screw connections. They are used to lift or secure the load
during transport.
Attachment devices
Attachment devices are separate devices used to bridge the connection between
a crane and a load in order to lift the latter. Attachment devices are e.g. lifting
straps, belts or chains.
Component
Any part with a (partial) function in the sense of the technical overall system.
Components in the hydraulic system include e.g. valves, filters, cylinders,
hydraulic connection elements.
Floor conveyors
Floor conveyors are means of transport for the horizontal transport that are mostly
used within the company at ground level.
Line system
Any combination of lines (hoses, piping or bores) and hydraulic connection
elements allowing for the intended flow of the oil between tanks, pumps, valves,
accumulators, actuators, filters, etc.
Tank
The component in a hydraulic system that collects all the oil during operation and
standstill. It is not used for storing hydraulic energy.

Bosch Rexroth AG
Industrial Hydraulics
Zum Eisengießer 1
97816 Lohr am Main
Germany
Phone [phone]
[email protected]
www.boschrexroth.com
Printed in Germany
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