Control Blocks: For Mobile Applications

Control blocks
for mobile applications
Applies to the following types:

M1 MO
M4 RS
M6 SM
M7 SP
M8 SX Operating instructions Replaces: 03.2014
M9 RE 64025-B/10.2014 English
M1 M4 M6 M7
M8 M9 MO SP
SM SX RS
The data specified above only serve to
describe the product. No statements
concerning a certain condition or suitability
for a certain application can be derived from
our information. The 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 an example configuration.

The product supplied may therefore differ from
the photo shown.
The original operating instructions were

prepared in German.
Contents 3/52
Contents
1 About this documentation 5
1.1 Validity of the documentation 5
1.2 Required and amending documentation 5
1.3 Representation of information 7
1.3.1 Safety instructions 7
1.3.2 Symbols 8
1.3.3 Designations 8
1.3.4 Abbreviations 8
2 Safety instructions 9
2.1 General information on this chapter 9
2.2 Intended use 9
2.3 Improper use 10
2.4 Qualification of personnel 10
2.5 General safety instructions 10
2.6 Product-specific safety instructions 11
2.7 Personal protective equipment 13
3 General information on damage to property and damage to the product 14
4 Scope of delivery 16
5 About these products 17
5.1 Performance description 17
5.2 Product description 17
5.3 Product identification 17
6 Transport and storage 19
6.1 Transporting the control block 19
6.1.1 Transport by hand 19
6.1.2 Transport using lifting tools 19
6.2 Storing the control block 21
7 Assembly 23
7.1 Unpacking 23
7.2 Painting the control block 23
7.3 Installation conditions 24
7.4 Installation position 24
7.5 Assembling the control block 24
7.5.1 Required tools 24
7.5.2 Preparation 24
7.5.3 Dimensions 24
7.5.4 Fastening the control block 25
7.5.5 Completing the assembly 26
7.5.6 Connecting the control block mechanically 26
7.5.7 Connecting the control block hydraulically 27
7.5.8 Connecting the control block electrically 29
8 Commissioning 30
8.1 Before first commissioning 31
8.2 First commissioning 32
8.3 Re-commissioning after standstill 33
RE 64025-B/10.2014, control blocks, Bosch Rexroth AG

4/52
ContentsContents
9 Operation 34
9.1 Information on the use of control blocks at low temperatures 34
10 Maintenance and repair 36
10.1 Inspection 38
10.2 Maintenance 38
10.3 Repair 38
10.4 Spare parts 39
11 Disassembly and exchange 40
11.1 Necessary tools 40
11.2 Preparing disassembly 40
11.3 Disassembling the control block from the machine 40
11.4 Preparing the components for storage/further use 40
12 Disposal 41
13 Extension and modification 42
14 Troubleshooting 43
14.1 How to proceed for troubleshooting 43
14.2 Fault table 44
15 Technical data 46
16 Index 48
Bosch Rexroth AG, control blocks, RE 64025-B/10.2014

About this documentation 5/52
1 About this documentation
1.1 Validity of the documentation

This documentation applies to the following products:
•• M1 •• MO
•• M4 •• RS
•• M6 •• SM
•• M7 •• SP
•• M8 •• SX
•• M9
This documentation is aimed at the machine manufacturer.

This documentation contains important information on the safe and proper
transport, assembly and disassembly, commissioning, operation, maintenance and
simple troubleshooting of the product.
▶▶ You should read this documentation thoroughly and in particular
chapter 2 "Safety instructions" on page 9 and chapter 3 "General information
on damage to property and damage to the product" on page 14 before working
with the control block.
This documentation applies to all control blocks of the listed series irrespective of
their date of production until a new revision of this document is issued.
1.2 Required and amending documentation

▶▶ Do not commission the product until you have been provided with the
documentation marked with the book symbol relating to your Rexroth product
and you have understood and observed it.
Table 1: Required and amending documentation

Title Document number Document type
Open center control block MO-16, 22, 32 64354 Data sheet
Open center control block MO-40 64370 Data sheet
Open center control block MO-52 64373 Data sheet
Open center control block M1 64263 Data sheet
Open center control block SM 64122 Data sheet
Load-sensing control block M4-12 64276 Data sheet
Load-sensing control block SP-08 64139 Data sheet
LUDV control block M6-15 64321 Data sheet
LUDV control block RS12 64133 Data sheet

6/52 About this documentation
Table 1: Required and amending documentation

Title Document number Document type
LUDV control block SX 10 64132 Data sheet
Order confirmation Order confirmation
Contains the order-specific technical data of your control block.
Quotation drawing Quotation drawing
Contains the external dimensions, all connections and the hydraulic circuit
diagram of your control block.
Hydraulic fluids based on mineral oils and related hydrocarbons 90220 Data sheet
Describes the requirements on hydraulic fluids based on mineral
oil and related hydrocarbons for operation with Rexroth hydraulic
components and helps you to select a hydraulic fluid for your
Bosch Rexroth component.
Environmentally compatible hydraulic fluids 90221 Data sheet
Describes the requirements on environmentally compatible hydraulic fluids
for operation with Rexroth hydraulic components and helps you to select
a hydraulic fluid for your Bosch Rexroth component.
MTTFd reliability characteristics regarding the functional safety 90290 Data sheet
according to ISO 13849
MTTFd values for control blocks
Further information is available from Rexroth and at

www.boschrexroth.de/mobilhydraulik-katalog.

About this documentation 7/52
1.3 Representation of information

Consistent safety instructions, symbols, terms and abbreviations are used in this
documentation 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 included in chapter 2.6 "Product-
specific safety instructions" on page 11 and in chapter 3 "General information
on damage to property and damage to the product" on page 14 or whenever
a sequence of actions or instructions is explained which bears the risk of personal
injury or damage to property. The hazard avoidance measures described 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>
•• 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 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

Indicates a dangerous situation which will cause death or
DANGER severe personal injuries if not avoided.
Indicates a dangerous situation which may cause death or
WARNING severe personal injuries if not avoided.
Indicates a dangerous situation which may cause minor or
CAUTION medium personal injuries if not avoided.
Damage to property: The product or the environment could
NOTICE be damaged.

8/52 About this documentation
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. Numbered instruction:
2. The numbers indicate that the actions must be carried out one after
the other.
3.
1.3.3 Designations
The following designations are used in this documentation:
Table 4: Designations
Designation Meaning
Mono block Control block which is molded in one piece. Optionally, further directional
valves can be mounted to extend the functions.
Directional valve Control block element with 1 spool axis, in the following also referred to as
"control block disc".
Control spool Main spool
Actuation Type of control of the control spool
1.3.4 Abbreviations
The following abbreviations are used in this documentation:
Table 5: Abbreviations
Abbreviation Meaning
DB Pressure relief valve (Druckbegrenzungsventil)
DIN Deutsche Industrie Norm (German Industry Standard)
ISO International Organization for Standardization

Safety instructions 9/52
2 Safety instructions
2.1 General information on this chapter

The product has been manufactured according to the generally accepted codes of
practice. However, there is still the risk of personal injury and damage to property if
you do not observe this chapter and the safety instructions in this documentation.
▶▶ Read this documentation completely and thoroughly before working with
the product.
▶▶ 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 control block on
to third parties.
2.2 Intended use

Control blocks are hydraulic components and are therefore neither covered by
the scope of completely nor partly completed machinery in the sense of the EU
Machinery Directive 2006/42/EC. The component is exclusively intended to be
assembled together with other components to form partly completed or complete
machinery. The component may only be commissioned if it has been integrated
in the machine for which it is designed and if the safety of the overall system was
established according to the requirements of the Machinery Directive.
The control blocks specified in chapter 1.1 have been developed for the control of
different hydraulic actuators in mobile machines.
Any deviating use is only permitted after consultation with Bosch Rexroth.
The product can be used as safety-relevant part of a control system. It does,

however, not include any safety functions because they cannot be implemented
self-dependently by the product. If the product is used for the implementation
of safety functions, additional measures with regard to control and/or the safety-
related part of the control must be specified by the system manufacturer or system
planner. Further information is available in the standards for functional safety such
as ISO 13849, IEC 62061 or specific professional guidelines.
▶▶ Comply with the technical data, application and operating conditions and
performance limits according to data sheet and order confirmation. For
information on the permitted hydraulic fluids, see the respective data sheet.
The control block is not a piece of safety equipment.

Intended use includes having read and understood this documentation completely,
especially chapter 2 "Safety instructions" on page 9.

10/52 Safety instructions
2.3 Improper use

Any use deviating from the intended use is improper and thus not admissible.
The valve is not suitable for being operated in explosive environments.
Bosch Rexroth AG does not assume any liability for damage caused by improper use.
The user assumes all risks involved with improper use.
2.4 Qualification of personnel

The activities described in this documentation require basic knowledge of mechanics,
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. Experts are those who
can recognize potential dangers and apply the appropriate safety measures due to
their technical training, knowledge and experience, as well as their understanding
of the relevant provisions pertaining to the work to be undertaken. An expert must
observe the relevant specific professional rules and have the necessary hydraulic
expert knowledge.
Hydraulic expert knowledge means, amongst others:
•• Reading and understanding hydraulic schemes
•• Having knowledge of the function and interaction of hydraulic components
Bosch Rexroth offers measures supporting the training in specific fields. Please
find an overview of the training contents on the Internet at:
http://www.boschrexroth.de/didactic
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 who assemble, operate, disassemble or maintain Rexroth products must
not be under the influence of alcohol, drugs or pharmaceuticals that may affect
their ability to respond.
•• Only use original Rexroth accessories and spare parts.
•• Comply with the technical data and environmental conditions indicated in the
product documentation.
•• The installation or use of inappropriate products in safety-relevant applications
could result in uncontrolled operating conditions during operation. This may
cause injuries and/or damage to property. Therefore, only use a product for
safety-relevant applications if this use is expressly specified and permitted in the
documentation of the product, e.g. in explosion-protected areas 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
example a machine/system) in which the Rexroth products are to be installed
comply with the country-specific provisions, safety regulations and standards of
the application.

2.6 Product-specific safety instructions

The following safety instructions apply to chapters 6 to 14.
WARNING
Unintended pressure build-up/pressure reduction!
Danger to life, risk of injury, damage to property!
The control block may block in an undefined position due to internal contamination,
e.g. polluted hydraulic fluid, abrasion or residual dirt from system components.
As a result, the driven actuator is no longer under the operator’s control.
▶▶ Secure the machine against rolling (away) and unintended movements according
to the machine manufacturer's specifications.
▶▶ Comply with the specified cleanliness class for the hydraulic fluid according to
the data sheet.
Hydraulic fluid leaking through cracks in the housing, leaks between control
block and/or attachment parts due to the use of an inadmissible pressure
medium, adjustment work at seal lock nuts, cleaning with solvents and thus
destruction of seals!
Danger to life and risk of injury due to injection of a pressurized oil jet! Risk of
burning due to escaping oil!
▶▶ Access to the control blocks during operation must be limited in such a way
that hazards to persons caused by the bursting during operation is avoided by
suitable safeguards.
▶▶ Depressurize the control block and repair the leak.
Pressurized machine!
Danger to life, risk of injury, severe injury when working at machines that have not
been stopped! Damage to property!
▶▶ Secure the overall system according to the manufacturer's instructions.
▶▶ Make sure that the control block has been depressurized. For doing so, observe
the specifications of the machine manufacturer.
▶▶ Do not disconnect lines, connections or components as long as the control
block is under pressure.
▶▶ Observe the specifications of the machine manufacturer regarding
machine shut-down.
Danger due to suspended loads!

Danger to life, risk of injury, damage to property!
In case of improper transport, the control block may fall down and cause injuries
e.g. crush injuries or fractures and/or damage to the product.
▶▶ Make sure that the lifting capacity of the forklift and/or the lifting tool
is sufficient.
▶▶ Never step or reach below suspended loads.
▶▶ Provide for a stable position during transport.
▶▶ Use your personal protective equipment (e.g. safety goggles, protective gloves,
suitable working clothes, safety shoes).
▶▶ Use suitable lifting tools for the transport.
▶▶ Observe the prescribed position of lifting straps.
▶▶ Comply with the national laws and regulations regarding occupational health
and safety and transport.

12/52 Safety instructions
WARNING
Leaking oil mist!
Explosion hazard, risk of fire, allergic reactions, inhalation, environmental pollution!
▶▶ Depressurize the control block and repair the leak.
▶▶ Keep open fire and ignition sources away from the control block.
▶▶ If control blocks are positioned close to ignition sources or powerful heat
radiators, screening to ensure that potentially leaking hydraulic fluid cannot be
ignited and the hose lines are protected against early aging.
Electrical voltage!
Danger to life, risk of injury and damage to property due to electric shock!
▶▶ Always de-energize the mating connectors before assembling the product or
when connecting and disconnecting connectors.
▶▶ Secure the machine according to the manufacturer's instructions.
Incorrect energy supply!

Danger to life and risk of injury due to uncontrolled valve positions! These may
cause unexpected behavior of the control block.
▶▶ Always connect the earthing connection of the control block with the
appropriate earthing system of your installation.
▶▶ Only use a power supply unit with protective isolation. Always consider the
country-specific regulations.
CAUTION
Risk of injury due to sharp edges and rough surfaces!
When working at the control block and transporting it, there is a risk of injury, e.g.
due to sharp edges at the valve housing, at threads or at attachment parts.
▶▶ Wear safety shoes with steel toe caps.
▶▶ Wear protective gloves and suitable working clothes as protection against injuries.
Risk to limbs due to crushing and impact!

There is a risk of injury in the gap between the actuation element and the
valve housing.
▶▶ Keep your limbs away from the gap between the actuation element/hand lever
and the valve housing.
High noise development during operation!

Danger of hearing damage, deafness!
The noise emission of control blocks is e.g. dependent on operating pressure and
installation conditions. Under normal application conditions, the sound pressure
level may exceed 70 dBA.
▶▶ Always protect yourself by wearing ear protection when working close to
running control blocks.
Hot surfaces at the control block!

Risk of burning!
▶▶ Allow the control block to cool down sufficiently before touching it.
▶▶ Wear heat-resistant protective clothing, e.g. gloves.

CAUTION
Cold surfaces at the control block!
Sticking skin to and frostbites caused by contact with the cold valve housing!
▶▶ Wear personal protective clothing, e.g. cold protection gloves.
Improper laying of cables and lines!

Risk of stumbling and damage to property!
▶▶ Lay cables and lines in such a way that they cannot be damaged and no one can
trip over them.
Contact with hydraulic fluid!

Health hazard/impairment of health, e.g. eye injuries, skin lesions, poisoning due
to inhalation!
▶▶ Avoid contact with hydraulic fluids.
▶▶ When dealing with hydraulic fluids, you must imperatively observe the safety
instructions of the lubricant manufacturer.
▶▶ Use personal protective equipment (like e.g. safety goggles, protective gloves,
suitable working clothes, safety shoes).
▶▶ If hydraulic fluid comes into contact with the eyes or enters the bloodstream or
is swallowed nevertheless, consult a doctor immediately.
Escaped hydraulic fluid due to leakage!

Slip hazard!
▶▶ Pay attention to escaped hydraulic fluid on the ground around the machine.
▶▶ If hydraulic fluid has leaked, use an oil binding agent.
▶▶ Dispose of the hydraulic fluid in accordance with the applicable national
regulations in your country.
2.7 Personal protective equipment

The user of the control block is responsible for the personal protective equipment.
Observe the safety regulations and provisions in your country.
Bosch Rexroth recommends using the following personal protective equipment when
using the product:
•• Heat-resistant protective clothing, e.g. protective gloves for working at the
control block
•• Safety shoes, protective gloves, safety goggles, ear protection and suitable working
clothes for working at the control block

14/52 General information on damage to property and damage to the product
3 General information on damage to

property and damage to the product
The warranty only applies to the delivered configuration.
The claim to warranty expires in case of:
•• Incorrect assembly, commissioning and operation
•• Improper use
•• Removal of protection caps and lead seals (e.g. for pressure adjustments)
•• Alteration of the factory settings
•• Modifications and attachments
•• Opening the valve
•• Improper handling
•• Using third party spare parts
The following safety instructions apply to chapters 6 to 14.
NOTICE
Danger due to improper handling!
The product may be damaged!
▶▶ Do not apply any inadmissible mechanical, hydraulic or electrical loads to
the product.
▶▶ Never use the product as a handle or step.
▶▶ Do not transport the control block on sensitive attachment parts (e.g. actuation
elements, sensors, solenoids or valves).
▶▶ Put the control block carefully onto the contact surface in order not to damage
it and secure it against falling down.
▶▶ Do not place/put any objects on top of the product.
▶▶ Do not place/put the control block on the actuation elements.
▶▶ Avoid impacts against sensitive attachment parts (e.g. sensors, solenoids or
actuation elements).
▶▶ Avoid impacts against sealing surfaces (e.g. at the working connections).
▶▶ Do not remove the protective covers from the control block before connecting
the lines.
▶▶ Disconnect all electrical connector plugs prior to painting.
▶▶ Make sure that the electronic components (e.g. sensors) are not electrostatically
charged (e.g. during painting).
Control block falling down!

The surface coating may be damaged and attachment parts may come off or bend.
Impaired functionality.
▶▶ Use a suitable lifting, putting down and moving technique.
▶▶ Place the product on a clean, bearing surface.
Intrusion of fluids and foreign particles due to missing seals and caps!
Loss of the protection class and risk of short circuit!
▶▶ Before assembly, ensure that all seals and caps of the plug-in connections
are tight

General information on damage to property and damage to the product 15/52
NOTICE
Mixing hydraulic fluids!
▶▶ Drain all liquids from the control block prior to installation to avoid mixing with
the hydraulic fluid used for the machine.
▶▶ Any mixing of hydraulic fluids by different manufacturers and/or of different
types by the same manufacturer is generally not admissible.
Contamination of the hydraulic fluid!

The cleanliness of the hydraulic fluid has a considerable impact on the cleanliness
and life cycle of the hydraulic system as a whole. Early wear and malfunctions!
▶▶ It is imperative that the working environment at the site of installation is free of
dust and foreign substances in order to prevent foreign particles (e.g. welding
beads or metal chips) from getting into the hydraulic lines and causing
product wear or malfunctions. The control block must be protected from dirt
during installation.
▶▶ Only use clean connections, hydraulic lines and attachment parts (e.g.
measuring devices).
▶▶ No contamination must enter when closing the connections.
▶▶ Before commissioning, ensure that all hydraulic connections are tight and
that all seals and caps of the plug-in connections are correctly installed and
undamaged in order to prevent fluids and foreign particles from penetrating
the product.
▶▶ During filling, filter the hydraulic fluids using a suitable filter system in order to
minimize the solid particle contamination and water in the hydraulic system.
Improper cleaning!
▶▶ Cover all openings with appropriate safeguards in order to prevent cleaning
agents from penetrating the control block.
▶▶ Never use solvents or aggressive cleaning agents. Use water and mild cleaning
agents, if necessary, to clean the control block.
▶▶ Do not point high-pressure washers at sensitive components, e.g. rubber
components (bellows), electrical connections (solenoids, sensors) and
actuation elements.
▶▶ Use fiber-free cleaning cloths for cleaning.
Environmental pollution caused by incorrect disposal!

Careless disposal of the control block, the hydraulic fluid and the packaging
material may lead to environmental pollution!
▶▶ Dispose of the control block, the hydraulic fluid and the packaging in
accordance with the applicable national regulations in your country.
Leaking or spilt hydraulic fluid!

Environmental pollution and pollution of the ground water!
▶▶ When draining the hydraulic fluid, always put a collecting pan under
the control block.
▶▶ If hydraulic fluid is spilled, use an oil binding agent.
▶▶ Dispose of the hydraulic fluid in accordance with the applicable national

16/52 Scope of delivery
4 Scope of delivery
The scope of delivery includes:
•• Control block according to order confirmation
Upon delivery, the following parts are additionally mounted depending on the model:
•• Protective covers
•• Protective plugs/plug screws
•• Attachment point(s) for transport, e.g. ring bolt

About these products 17/52
5 About these products
5.1 Performance description

Please find technical data, operating conditions and limitations of use of the control
blocks in the data sheet and the order confirmation.
The assignment of the control blocks to the data sheets is available in
chapter 1.2 "Required and amending documentation" on page 5.
5.2 Product description

For the description of the set-up and function as well as instructions on the project
planning of the individual control blocks, refer to the data sheet.
The assignment of the control blocks to the data sheets is available in Table 1
"Required and amending documentation" on page 7.
5.3 Product identification

Use the name plate to identify the control block.
The details on the name plate apply to the control block in the condition as
supplied. If modifications have been carried out at the control block as compared
to the condition as supplied, the name plate information may possibly not be true
for the present control block.
▶▶ Take care not to damage the existing name plates.

▶▶ Compare the material number of the control block indicated on the name plate
with the details on the quotation drawing to make sure that the operating
instructions apply to the product available to you.
If in doubt, contact Bosch Rexroth.
1 2 1
MNR: R90xxxxxxx FD: 12W20 3 7

SN: XXXX 4
M4-G12345-20/5M4-12J_W2_MV01 5 MNR: R90xxxxxxx 2
123456789 6 123456789 6
Made in Germany 708A 7 Made in France
10 9 8 11 10 3 4
Fig. 1: Example name plate M4 Fig. 2: Example name plate SX
1 Word mark (manufacturer) 7 Area/works number

2 Material number of the control block 8 Installation stamp
3 Date of production 9 Test stamp
4 Serial number 10 Designation of origin
5 Material short text 11 DataMatrix code
6 Customer material number (optional)

18/52 About these products
Depending on the order, there might be deviations from the name plates shown
above. On customer-specific name plates, the Rexroth logo can be replaced by a
customer logo, for example.
Further labels on the product are intended for internal Bosch Rexroth
purposes only.
If the control block is supplied without name plate, the identification can be
found on the connection or end plate.

Transport and storage 19/52
6 Transport and storage

▶▶ Always comply with the required environmental conditions with regards to
transport and storage, see chapter 6.2 "Storing the control block" on page 21.
Failure to comply causes premature aging of components and reduces the

life cycle.
For unpacking instructions, see chapter 7.1 "Unpacking" on page 23.
6.1 Transporting the control block

Depending on the weight and transport duration, there are the following
transport possibilities:
•• Transport by hand
•• Transport using lifting tools (ring bolt or lifting strap)
The dimensions and weights vary according to the model. For the values applicable
to your control block, see the quotation drawing and the data sheet.
6.1.1 Transport by hand

Control blocks with a weight of up to 15 kg can be transported by hand for a short
time, if necessary.
Caution! Danger due to heavy loads!

When carrying control blocks, there is a risk of health hazards.
▶▶ Use a suitable lifting, putting down and moving technique.
▶▶ Use your personal protective equipment (like e.g. safety goggles, protective
gloves, suitable working clothes, safety shoes).
▶▶ Do not transport the control block using sensitive attachment parts (e.g. sensors
or valves).
▶▶ Put the control block carefully onto the contact surface in order not to damage it.
6.1.2 Transport using lifting tools

For the transport, the control block can be connected to a lifting tool using the
attachment points at the housing or using a lifting strap. Possible attachment
points are
•• mounting threads of the connection flanges
•• attached ring bolts.
▶▶ Ensure that the lifting tool is sufficiently dimensioned for the control block.
▶▶ Hang a chain or any other suitable lifting gear into the attachment points at the
housing of the control block.

20/52 Transport and storage
Transport using WARNING! Danger due to suspended loads!

a lifting strap During transport using a lifting strap, the control block may tilt out of the loop and
cause personal injuries.
▶▶ Use the broadest lifting strap possible.
▶▶ Make sure that the control block is properly secured with the lifting strap.
▶▶ You may only guide the control block by hand for fine positioning and in order to
avoid swinging.
▶▶ Never step or reach below suspended loads.
▶▶ Put the lifting strap around the control block in such a way that it does not run
over attachment parts (e.g. valves) and ensure that the control block is not
suspended at attachment parts.
Fig. 3: Transport using a lifting strap

Transport and storage 21/52
6.2 Storing the control block

Requirements •• The storage facilities must be free from corrosive substances, fumes and gases.
•• In order to avoid damage to seals, do not operate any ozone-generating devices in
the storage facilities, such as mercury vapor lamps, copiers, printers, high-voltage
devices, electric motors, electric radio sources and/or discharges.
•• The storage facilities must be dry and free from dust.
•• Optimum storage temperature: +5 °C to +20 °C.
•• Minimum storage temperature: –20 °C.
•• Maximum storage temperature: +40 °C.
•• UV protection: 100 %
Avoid high light irradiation (e.g. bright windows or direct neon light).
•• Relative air humidity (no condensation): Max. 65 %.
•• Store the control block in such a way that it is protected from shocks, do not stack it.
•• Do not store the control block on sensitive attachment parts, e.g. actuation
elements, sensors, solenoids or valves.
•• Do not remove any protective covers and protective plugs.
▶▶ Check the correct storage of the control block on a monthly basis. The maximum
admissible storage time is two years.
Following delivery As a standard, the control blocks are coated with a priming (single coat paint) or
protected against corrosion by electroplating at the factory.
Mineral oil is used for internal corrosion protection of closed valves. Surfaces of
the control block that are not coated or electroplated (e.g. flange surfaces) are not
protected against corrosion.
Delayed commissioning, long transport and storage times or the decommissioning of
Rexroth control blocks for a longer period of time may lead to corrosion. In order to
prevent this, additional corrosion protection measures have to be taken.
The claim to warranty expires in case of non-compliance with the requirements

and storage conditions or after expiry of the maximum storage time.
Recommended procedure following an extended storage time:

1. Check the complete control block for damage and corrosion prior to installation.
2. In a test run, check the control block for correct function and leak-tightness.
3. External seals of control blocks which have been stored for more than 12 months
must be checked for damage before assembly and must be replaced, if necessary.
4. If the storage time of two years is exceeded, outward facing seals have to
be exchanged.
After expiry of the maximum storage time, we recommend having the control
block checked by your competent Bosch Rexroth service.
For questions regarding repair and spare parts, contact your local Bosch Rexroth
service or the service department of the control block manufacturer's factory, see
chapter 10.4 "Spare parts" on page 39.

22/52 Transport and storage
Following disassembly If a dismounted control block is to be stored, it has to be preserved for the time of
storage to protect it against corrosion.
The following instructions only refer to control blocks that are operated with
a hydraulic fluid on mineral oil basis. Other hydraulic fluids require preservative
measures that are specifically designed for them. In this case consult the Bosch
Rexroth service, for the address see chapter 10.4 "Spare parts" on page 39.
Bosch Rexroth recommends the following procedure:

1. Clean the control block.
2. Drain the control block.
3. Close all connections air tightly.
4. Wet the unpainted flange-mounting surfaces and exterior seals of the control
block with mineral oil.
5. Protect sensitive attachment parts (e.g. actuation elements, sensors, solenoids or
valves) using suitable measures as in the condition as supplied.
6. Pack the control block with a suitable desiccant air-tightly in corrosion
protection film.
7. Store the control block in such a way that it is protected from shocks. For further
conditions, see section "Requirements" on page 21 in this chapter.
8. If required, send the control block to the Bosch Rexroth service for repair.

Assembly 23/52
7 Assembly
Prior to installation, make sure the following documents are at hand:
•• Quotation drawing (installation drawing) of the control block (available from your
contact at Bosch Rexroth)
•• Hydraulic circuit diagram of the control block (see the quotation drawing)
•• Hydraulic circuit diagram of the machine (available from the machine manufacturer)
•• Order confirmation (contains the order-specific technical data of your
control block)
•• Data sheet of the control block (contains the admissible technical data)
7.1 Unpacking
Caution! Danger due to falling parts!

If the packaging is opened improperly, parts may fall out and be damaged or even
cause injuries!
▶▶ Put the packaging on level ground with sufficient load carrying capacity.
▶▶ Only open the packaging from above or at the intended place.
1. Remove the control block packaging.

2. Check the control block for transport damage and completeness, see
chapter 4 "Scope of delivery" on page 16.
3. Dispose of the packaging in accordance with the currently applicable national
provisions in your country.
4. Return reusable packaging material to the sending Bosch Rexroth plant.
7.2 Painting the control block
CAUTION
Escape of aerosols during painting!
Risk of inhaling harmful substances.
▶▶ Wear inhalation protection and protective clothing during painting.
Complete the following steps if the control block is to be painted prior to

installation:
▶▶ Completely protect the hydraulic ports against paint application by screwing-in
plastic screw-in plugs beforehand.
▶▶ Protect the mounting threads against paint application by screwing-in bolts.
▶▶ Mask the flange surfaces of the control blocks as well as the connection and end
plates carefully before coating to prevent dirt or paint from entering.
▶▶ Avoid paint application to the contacts of the electrical connections and make
sure not to cause any damage to the connector.

24/52 Assembly
▶▶ Protect attachment parts (e.g. actuation elements, sensors, solenoids) against

paint application.
▶▶ Protect plastic and rubber parts against paint application.
▶▶ When removing the plastic screw-in plugs after painting, make sure that no paint
chips get into the control block.
▶▶ Protect name plates against paint application using a foil which can be removed
after coating.
7.3 Installation conditions

The installation position determines the installation and commissioning procedure
(e.g. bleeding of the control block).
▶▶ Mount the control block in such a way that the forces and torques to be expected
can be transmitted without risk. The machine manufacturer is responsible for the
design of the mounting elements and screw connections.
▶▶ Ensure that the control block is bled and filled with hydraulic fluid during
commissioning and operation. The control block must not drain hydraulically in
case of standstill.
▶▶ It is imperative that the working environment at the site of installation is free
of dust and foreign substances. The control block must be protected from dirt
during installation. Contamination of the hydraulic fluid may considerably impair
the function and life cycle of the control block.
7.4 Installation position

If not indicated otherwise in the technical documents, the control block can be
installed in any position.
7.5 Assembling the control block
7.5.1 Required tools

Installation can be carried out using standard tools. No special tools are required.
Also observe the instructions of the manufacturers of the other hydraulic
components when selecting the required tools.
7.5.2 Preparation
1. Compare the material number and the designation (type key) with the details in
the order confirmation.
If the material number of the control block does not match the number in the
order confirmation, contact the Bosch Rexroth service for clarification. For the
address, refer to chapter 10.4 "Spare parts" on page 39.
2. Drain the control block prior to installation to avoid mixing with the hydraulic
fluid used for the machine.
7.5.3 Dimensions
The quotation drawing contains the dimensions for all connections at the
control block.

Assembly 25/52
7.5.4 Fastening the control block

For mounting, the control block is provided with mounting bores which can be seen
in the quotation drawing and the data sheet. The required mounting hole image
(dimensions and tolerances) for the mounting bores on the machine can also be
found in the quotation drawing or on the data sheet. Select the tightening torques
according to the usual standard values for each bore size and bolt property class.
Excessive tightening torque might cause the control spool to jam. If this is the case,
reduce the mounting torque accordingly. Observe the adequate residual clamping
force of the screws.
1. Observe the contact surface requirements from the quotation drawing.

2. Check the levelness of the flange surface in the machine (tolerance: 0.5 mm)
3. Always fasten the control block at all mounting points provided. Depending on
the type of mounting, use screws and/or hexagon nuts with one of the property
classes listed in Table 6 according to EN ISO 4762 or EN ISO 4014.
4. Tighten the screws with the respective tightening torques specified in
the standard.
Bosch Rexroth recommends using a screw connection with the following parameters:
Table 6: Mounting screws
Series Dimension Property class Tightening Screw-in depth

torque [Nm] [mm]
M1-16 M8 8.8 / 10.9 27 / 40 1)
M1-25 M10 8.8 / 10.9 54 / 79 10

M1-32 M12 8.8 / 10.9 93 / 37 1)
M4-12 M10 8.8 / 10.9 41 / 60 12 … 15

M4-15 M10 8.8 / 10.9 54 / 79 10
M4-22 M16 8.8 / 10.9 230 / 338 1)
M6-15 M10 8.8 / 10.9 54 / 79 10

M6-22 M12 8.8 / 10.9 93 / 137 12
M7-20 M12 8.8 / 10.9 93 / 137 12
M7-22 M16 8.8 / 10.9 230 / 338 16
M8-16 M16 8.8 / 10.9 230 / 338 16
M8-18 M16 8.8 / 10.9 230 / 338 16
M8-22 M16 8.8 / 10.9 230 / 338 16
M8-25 M16 8.8 / 10.9 230 / 338 16
M8-32 M20 8.8 / 10.9 464 / 661 20
M8-35 M16 8.8 / 10.9 230 / 338 1)
M9-20 M16 8.8 / 10.9 230 / 338 16

M9-25 M16 8.8 / 10.9 230 / 338 16
MO-10 M10 8.8 / 10.9 54 / 79 1)
MO-16 M8 8.8 / 10.9 27 / 40 1)
MO-22 M10 8.8 / 10.9 54 / 79 1)
MO-32 M12 8.8 / 10.9 93 / 137 1)
MO-40 M16 8.8 / 10.9 230 / 338 1)
MO-52 M20 8.8 / 10.9 464 / 661 20

RS12 M8 8.8 / 10.9 27 / 40 12
RS14 M10 8.8 / 10.9 54 / 79 1)
RS15 M10 8.8 / 10.9 54 / 79 18

SM 12 M8 8.8 / 10.9 27 / 40 1)

26/52 Assembly
Series Dimension Property class Tightening Screw-in depth

torque [Nm] [mm]
SP-08 M8 8.8 / 10.9 25 / 30 10 … 141)
SX 10 M8 8.8 / 10.9 27 / 40 1)
SX 12 M10 8.8 / 10.9 54 / 79 1)
SX 14 M10 8.8 / 10.9 54 / 79 1)
1 Through hole in the housing; the screw-in depth depends on the nut thread material.
)
7.5.5 Completing the assembly

1. Remove transport aids which might have been attached.
Caution! Operation with protective plastic plugs!

Operating the control block with protective plugs may cause injuries or damage to
the control block.
▶▶ Prior to commissioning, remove all protective plugs and replace them by line
connections or suitable pressure-resistant metal plug screws.
2. Remove the transport protection.

The control block is delivered with protective covers and protective plugs, where
appropriate. These components are not pressure-resistant and therefore have to be
removed prior to connection. Use suitable tools to avoid damage to the sealing and
functional surfaces. If the sealing or functional surfaces are damaged, contact your
Bosch Rexroth service or the service department of the control block manufacturer.
Line connectors are equipped with protective plugs or plug screws that serve as
transport protection. All connections required for the function have to be
connected. Non-compliance may lead to mulfunctions or damage. Connections
that are not connected have to be closed with plug screws as the protective plugs
are not pressure-resistant.
7.5.6 Connecting the control block mechanically

Please see the quotation drawing for the connection of the actuation elements
incl. tolerances. Select the tightening torques according to the actuation elements.
The actuation must be free of transverse forces!
▶▶ Before commissioning, make sure that the tongue is in zero position (control
spool in central position).

Assembly 27/52
7.5.7 Connecting the control block hydraulically
CAUTION
Dangerous motion of the hydraulic actuators!
Risk of injury caused by incorrect pin assignment or mixed up cable connectors due
to unintended actuator movement!
▶▶ Make sure that all pipes and/or hoses are connected to the correct control block
port and do not mix them up in any case.
▶▶ After completion of the connections, check the correct assignment of the cable
connectors to each control block solenoid.
NOTICE
Damage caused by incorrect assembly!
During operation, hydraulic lines and hoses installed under mechanical stress
create additional mechanical forces. This reduces the life cycle of the control block
and the complete machine.
▶▶ Assemble lines and hoses without stress.
The machine manufacturer is responsible for the design of the lines. The control
block has to be connected to the remaining hydraulic system according to the
hydraulic circuit diagram of the machine manufacturer.
The connections and the mounting threads are designed for the peak pressure
indicated in the data sheet. The machine manufacturer has to make sure that the
connection elements and lines comply with the intended application conditions
(pressure, flow, hydraulic fluid, temperature) including the required safety factors.
Only connect hydraulic lines that match the control block connection (pressure
level, size, system of units).
Instructions on the Observe the following instructions regarding the installation of hydraulic lines.
installation of lines •• Lines and hoses have to be installed without preload so that there are no
additional mechanical forces during operation that reduce the life cycle of the
control block and possibly the entire machine.
•• If necessary, remove any resinification caused by incorrect storage.
•• Use suitable seals as sealants.
––Observe the compatibility of seals with the hydraulic fluid used.
––Use the provided seal at each hydraulic connection.
––Make sure that the connections are clean and intact.
•• Make sure that the connections and connection elements are air-tight.
•• Pressure lines
––Only use pipes, hoses and connection elements as pressure lines that are rated
for the operating pressure range indicated in the data sheet. They also have to be
pressure-resistant with respect to the external air pressure.
•• Tank line
––Always install tank lines in such a way that the control block is always filled with
hydraulic fluid and cannot drain hydraulically in case of an extended standstill.

28/52 Assembly
Risk of confusion with The control blocks are used in fields of application with metric and US system
threaded connections of units.
Both the system of units and the size of the threaded hole and the screw-in stud
(e.g. plug screw) must match.
Due to little visual differences, there is a risk of confusion. In this regard, observe
the specifications in the quotation drawing. The SI units usually apply, unless
stated otherwise.
Warning! Leaking or ejected screw-in studs!

If a screw-in stud whose system of units and size do not match the threaded hole is
pressurized, it may come loose and even be ejected with high speed from the hole.
This may cause serious injuries and damage to property. Hydraulic fluid may escape
from this leakage point.
▶▶ Use the drawings (quotation drawing) to check the required screw-in stud for
all fittings.
▶▶ Make sure that there is no confusion when installing fittings, mounting screws
and plug screws.
▶▶ Use a screw-in stud with the same system of units and the right size for the
respective threaded hole.
Connection overview For an overview of the line connections, see the respective data sheet and the
quotation drawing.
Tightening torques Observe the specifications in standards and/or the manufacturer's specifications for
the screw-in studs, fittings, armatures, plug screws, etc. used. In addition, keep in
mind that tightening torques may also depend on the admissible pressure and
temperature range and on the application conditions.
Procedure Connecting the control block to the hydraulic system:

1. Remove the protective plugs and/or plug screws from the connections that are to
be connected according to the hydraulic circuit diagram.
2. Make sure that the sealing surfaces of the hydraulic connections and functional
surfaces are not damaged.
3. Only use clean hydraulic lines or rinse them prior to installation.
4. Connect the lines according to the quotation drawing and the machine diagram.
Check if all connections are piped or closed with plug screws.
5. Correctly tighten the fittings (observe the tightening torques!). Mark all correctly
tightened fittings, e.g. with a permanent marker.
6. Check all pipes and hose lines and all combinations of connection pieces,
couplings or connection points with hoses or pipes for their operational safety.

Assembly 29/52
7.5.8 Connecting the control block electrically
NOTICE
Functional impairment caused by wrong plug-in connections!
Only the plug-in connections listed in the data sheet/quotation drawing may be
used for the electrical connection.
▶▶ Comply with the assembly instructions of the plug-in connection manufacturer.
▶▶ Before commissioning, check the power supply as to whether the voltage
complies with the details of the quotation drawing and whether the total
of the currents to be expected is less than or equal to the capacity of the
power supply.
▶▶ The plug-in connections may only be contacted when deenergized. The assembly
process must not be repeated more than 10 times.
The machine manufacturer is responsible for the design of the electric control.
Electrically controlled control blocks have to be connected according to the electric
circuit diagram of the machine.
Regarding control blocks with electric adjustment device and/or attached sensors,
observe the specifications in the data sheet and the quotation drawing, e.g.:
•• The admissible voltage range
•• The admissible current
•• The correct pin assignment
For details on the correct connection assignment, the connector, the protection
class and the matching mating connector, see the data sheet and the quotation
drawing. The mating connector is not included in the scope of delivery.
Procedure Connecting the control block to the machine electronics:

1. De-energize the plug-in connections of the control block.
2. Prior to connection, check that the connector and all its seals are intact.
3. Connect the control block to the electrical system (12 V or 24 V).
Changing the If required, change the position of the connector by turning the solenoid body (coil).
connector position This does not depend on the connector model.
Proceed as follows:
2
1. Loosen the mounting nut (1) of the solenoid using a suitable tool. For this
purpose, turn the mounting nut (1) by one turn in counterclockwise direction.
1
2. Turn the body of the solenoid (2) in the desired position.
3. Re-tighten the mounting nut with a tightening torque of 4+1 Nm.

30/52 Commissioning
8 Commissioning
WARNING
Danger due to working in the danger zone of a machine!
Danger to life, risk of injury or severe injury!
▶▶ Pay attention to potential sources of danger and remove them before
commissioning the control block.
▶▶ When commissioning, comply with the instructions of the
machine manufacturer.
CAUTION
Commissioning an incorrectly installed product!
Confusing the connections or cable connectors causes unexpected functions
and/or irreparable damage to the control block and thereby endangers persons
and equipment!
▶▶ Make sure that all electrical and hydraulic connections are either connected
correctly or closed.
▶▶ Prior to the functional test, check if the required piping was installed according
to the hydraulic circuit diagram.
▶▶ Check that the cable connectors are correctly assigned to the respective
electric components.
▶▶ Commission the product only if it is installed completely.
Risk of injury caused by entrapped air

Air entrapped in the control block might cause components to vibrate during
operation in such a way that they hit the end stops hard and are damaged.
Unexpected movements of the actuators may cause injuries.
▶▶ Before commissioning, make sure that entrapped air is completely removed
from the control block. This can e.g. be done by a small amount of hydraulic
fluid q ≤ 20 % qpump flowing through in all switching positions. If the control
block is not equipped with a self-bleeding function at the covers, it may be
necessary to bleed the covers by means of the bleed screw.
▶▶ In any case, observe the instructions on bleeding in the operating instructions
of the machine.
NOTICE
Product damage and impaired functionality resulting from a lack of hydraulic fluid!
Commissioning the control block without or too little hydraulic fluid will damage or
even destroy the control block immediately.
▶▶ When commissioning or re-commissioning a machine, you should ensure that the
housing area, as well as the suction and working lines of the control block are
filled with hydraulic fluid and that they remain filled during operation.

Commissioning 31/52
8.1 Before first commissioning

▶▶ Make sure that the interfaces of the machine as well as the installation conditions
allow for the safe operation of the Rexroth control block. In case of doubt, please
contact Bosch Rexroth.
▶▶ Check the operating instructions for the machine to find out in which machine
the Rexroth control block must be installed and carry out a visual inspection
to check whether commissioning of the hydraulics might result in uncontrolled
and dangerous motions. If necessary, also observe the hazard analysis/risk
assessment of the machine.
▶▶ Take respective precautions if risks are to be expected, e.g. make sure that the
cylinder piston rod can be extended without any risk.
▶▶ Secure the load to be lifted additionally with a lifting tool/load lifting device.
▶▶ Check whether the electrical control of the machine allows for manual switching
of the control block solenoids during commissioning. If manual switching is not
possible or only under difficult conditions, you must prepare an external control
for the internal functional test of the hydraulic system.
▶▶ Develop a sequence program for the commissioning process and file it in the
technical documents as annex to the operating instructions.
▶▶ Divide the functional circuit diagram in sub-circuits which can be commissioned
one after the other.
▶▶ Read the functional circuit diagram and clarify ambiguous facts
and representations.
▶▶ Determine in which spool position the control blocks must be switched and how
the control blocks must be adjusted.
▶▶ Apply important mandatory signs, prohibition signs, information signs and check
whether the meaning of these signs is explained in the operating instructions.
▶▶ Observe the following order for commissioning:
––Pump circuit
––Parts of the control: e.g. pressure cut-off and switch-over, free circulation,
pressure reduction, etc.
▶▶ Make sure that pipes and/or hoses are connected to all ports and/or that the
ports are closed with plug screws.
▶▶ Ensure that the cap nuts and flanges on pipe fittings and flanges are tightened
according to the standard.
▶▶ Switch pressure and flow control valves, pump controls, and sensors such as
pressure switches, position switches and thermostats to the switching positions
and settings specified in the sequence program.

32/52 Commissioning
8.2 First commissioning

For Bosch Rexroth, the first commissioning is the first examination and release of
the product.
We recommend accepting points 1 up to and including 7 for the series production of
the hydraulic system.
For all commissioning works on the control block observe the general safety
instructions and the intended use in chapter 2 "Safety instructions" on
page 9.
▶▶ Let the control block acclimatize itself for several hours before commissioning,
as otherwise water may condense in the housing.
▶▶ Make sure that all electrical and hydraulic connections are either used or closed.
Commission the control block only if it is completely installed.
▶▶ Avoid temperature shocks. There must not be temperature differences of more
than 20 °C between the control block and the hydraulic fluid. Otherwise, there is
a risk of jammed spools. At temperatures below –20 °C, the control block has to
be warmed up.
▶▶ Only use hydraulic fluid that complies with the following requirements:
For information on admissible hydraulic fluids, refer to the relevant data sheet of
the product, see Table 1 "Required and amending documentation" on page 5.
For first commissioning of the control block, proceed as follows:

1. Completely fill the control block and, if available, the pilot control circuit, with
admissible hydraulic fluid (see data sheet).
2. Ensure the hydraulic supply of the control block.
3. If available, ensure the power supply of the control block.
4. Check the electrical connections of the control block.
Electrical connections must be checked for their proper condition by or under the
guidance and supervision of a specialized electrician before first commissioning
or any re-commissioning.
Observe the operating instructions of the machine where the control block
is installed.

Commissioning 33/52
5. Bleeding the control block.

––Before the actual operation, you must switch the control block several times
under operating pressure in each direction of actuation and with reduced
velocity. This will expel any remaining air from the control block. Mechanical
damage due to inadmissibly high acceleration of the hydraulic fluid and the
control spool is thus avoided and the control block's life cycle is increased.
––If automatic bleeding of the cover is not sufficient, bleeding can also be
carried out by means of the bleed screws potentially available at the cover
(series specific).
Procedure:
Attention! When loosening the bleed screw, hydraulic fluid may leak!
▶Loosen
▶ the bleed screw of the cover by up to two rotations to ensure that the
air can escape through the thread and the seal of the bleed screw.
▶Switch
▶ the valve several times in order to completely bleed the cover.
▶Fastening
▶ the bleed screw considering the valid tightening torque.
––Also observe the instructions on bleeding in the operating instructions of
the machine.
Carry out a leak test.
Ensure that no hydraulic fluid leaks at the control block and at the connections
during operation. If hydraulic fluid leaks, see Table 8 "Fault table" on page 44.
6. Carry out a functional test.
The functional test must be made according to the specifications of the machine
manufacturer, see operating instructions of the machine. In any case: Slowly
increase the pressure and stop the functional test immediately in case of leakage!
7. Check the hydraulic fluid temperature of the control block after several hours
of continuous operation. Check whether the measured temperature lies within
the product-specific limits. If the temperature lies outside the determined limits,
the Bosch Rexroth warranty will forfeit.
8. Have a hydraulic fluid sample analytically tested for the required cleanliness class
after initial commissioning. Replace the hydraulic fluid if the required cleanliness
class is not achieved. If the hydraulic fluid is not tested in the laboratory after
initial commissioning, the following applies: Replace the hydraulic fluid.
8.3 Re-commissioning after standstill

Re-commissioning is necessary if the control block has been out of operation for a
period of more than 12 months.
▶▶ Carry out the re-commissioning as described in chapter 8.2 "First commissioning"
on page 32.
Also observe the instructions for (re-)commissioning after standstill in the

machine operating instructions.

34/52 Operation
9 Operation
The product is a component which does not require any settings or modifications
during operation. As a result, this chapter of the instructions does not contain any
information on adjustment options. Only use the product within the performance
range provided in the technical data. The machine manufacturer is responsible for
the correct project planning of the hydraulic system and its control.
▶▶ Avoid temperature shocks. There must not be temperature differences of more
than 20 °C between the control block and the hydraulic fluid. Otherwise, there is
a risk of jammed spools. With temperatures below –20 °C, the control block has
to be warmed up.
9.1 Information on the use of control blocks at low temperatures

Boundary conditions •• Minimum ambient temperature –40 °C
•• Warm-up phase with little load from –40 °C
•• Operation with load from –25 °C
General information •• For use under –25 °C, seals deviating from the standard are used. Differing limits
of use are specified in the Technical Customer Documents (TKU) of the control
block.
•• Avoid humidity in the environment of the control blocks as potential condensation
at the movement seals may lead to freezing of the control spools during standstill.
This may also lead to the destruction of the seal ring if the control spool is
actuated.
•• The viscosity limits specified in the control blocks data sheets must be complied
with over the entire operating period by selecting a suitable hydraulic fluid, both in
winter and in summer with warmer temperatures.
•• For boundary conditions, the following values apply:
νmin = 5 mm²/s
(shortly at a max. admissible temperature of θmax = 115 °C/90 °C)
Note that the max. hydraulic fluid temperature of 115 °C (90 °C for perbunan) must
not be exceeded locally, e.g. at the pressure reducing valve, either.
νmax = 2000 mm²/s
(shortly in case of cold start, n ≤ 1000 min-1, θmin = –40 °C)
•• Especially the start-up viscosity must be observed.

•• If new components are installed into a cold machine, they must be filled at higher
temperatures in advance to ensure sufficient lubrication in all areas.
•• Coordinate the measures for filters, cylinders, gears etc. with the manufacturers.

Operation 35/52
Information on •• Control units, amplifiers, sensors, encoders, solenoids

the electronics ––Minimum storage temperature –50 °C
––Installation and full function from –40 °C
•• Devices with displays (unless specified in more detail)
––Minimum storage temperature –20 °C
––Installation and full function from –20 °C
•• With switching and proportional solenoids, possible increases in the hysteresis
and/or extended switching times due to increasing operating medium viscosity
with decreasing temperature are to be expected.
Procedure 1. Heat up all components to at least –40 °C.

2. Start the drive motor.
3. Warm up the pump according to the specification (see data sheet 90300‑03‑B)
4. Warm-up phase of the open hydraulic system
––Pump starts up with Diesel motor and should be operated with idle speed of
the Diesel motor for at least 10 minutes in order to ensure self lubrication.
––The pump must be in pressure-reduced circulation (max. 50 bar and max. 50 %
delivery volume).
––Loading of the open circuit, e.g. by means of separate preload valve, generates
a circulation pressure of approx. 50 bar at the pump. Maintain this operating
state until –25 °C are reached in the system. The Diesel speed must not
be increased.
––Afterwards, operate all machine functions slowly and several times at minimum
load in order to heat up the entire machine as evenly as possible. In this
connection, the tank temperature is to be observed which will decrease again
due to the return flow of the cold hydraulic fluid.
5. Warm-up phase of the closed hydraulic system
––Set the pump to neutral position without flow.
––The pump starts up with Diesel motor and should be operated with idle speed
of the Diesel motor for at least 10 minutes.
––Afterwards, slowly swivel out the pump. All machine functions must be
operated slowly and several times without load until –25 °C are reached in the
entire machine.
6. Valves that are used at low temperature enable flushing from the pump to the
tank in order to sufficiently heat the control block.
7. The covers in hydraulically pilot operated valves are flushed with tank oil via the
flushing channels.
8. After completed pump warm-up, slowly operate all actuators without load in
order to exchange the cold oil contained in the actuators by warm oil.
9. The flushing should remain functional during operation in order to keep actuators
which are only operated occasionally at operating temperature.
10. Permanent flushing is necessary in all components in order to avoid temperature
shocks. The max. admissible temperature difference between operating medium
and the individual components is 20 °C.
11. Our control blocks may be loaded from a circuit temperature of ≥ –25 °C in
the machine.

36/52 Maintenance and repair
10 Maintenance and repair
CAUTION
Risks caused by reduced safety during maintenance works
Experience has shown that the number of accidents during maintenance is
higher than during normal operation. Therefore, we would ask you to observe the
following safety instructions in the interest of your safety.
▶▶ Regularly check the safety equipment – if any – for correct functionality.
▶▶ Complete all maintenance in due time, properly and completely and document it.
▶▶ Adequately secure the maintenance area before starting maintenance.
▶▶ Pay attention to cleanliness in order to avoid malfunctions caused by pollution.
Paint residues on sealing surfaces must be removed before assembly. Make
sure that paint residues do not enter control block openings as this may lead
to malfunctions.
▶▶ Operate the hydraulic product in maintenance mode with increased alertness as
it may possibly require disassembly of certain protective devices. Switch off the
hydraulic product and secure it against unintended re-activation.
▶▶ The user is not allowed to change the settings of safety valves. Re-adjustments
may only be carried out by authorized testing authorities.
▶▶ Wear protective goggles, protective gloves and safety boots.
Depressurize the hydraulic product and properly unload available pressure
accumulators, if applicable.
▶▶ Let system sections and pressure lines which can be opened cool down before
starting maintenance.
▶▶ Open slowly any segments that are still pressurized.
▶▶ Please observe that the hydraulic system might still be pressurized even after
it has been disconnected from the actual pressure supply if there are check
valves in the pressure lines above the pumps. Move all cylinders to the safe
end position.
▶▶ Lower all loads. Provide for an external safeguard if the load cannot be lowered.
Maintenance must not be carried out at lifted units without external safeguard.
▶▶ Switch off all pumps.
▶▶ Support vertical cylinders mechanically against sinking.
▶▶ Only new, structurally identical and tested components, spare parts and
lubricants in original equipment quality are admitted for replacement/use.
▶▶ Make sure that all protective devices and especially all protective functions
which could impair the safety-shutdown strategy are correctly installed and
checked for functionality before re-commissioning.
▶▶ After the completion of all work, remove all tools and devices used for
maintenance from the hydraulic product.
Personal injury caused by non-functional spare parts

Spare parts that do not meet the technical requirements specified by
Bosch Rexroth may cause personal injuries.
▶▶ Only use original Rexroth spare parts.

Maintenance and repair 37/52
NOTICE
Penetrating dirt and fluids will cause malfunctions!
Safe function of the control block is no longer ensured.
▶▶ Always ensure absolute cleanliness when working at the control block.
▶▶ Cover all openings with appropriate protective equipment in order to prevent
cleaning agents from penetrating the system.
▶▶ Ensure that all seals and caps of the plug-in connections are firmly attached so
that no humidity can penetrate the control block during cleaning.
▶▶ Dust accumulation on the control block has to be removed at regular intervals.
Damage to the surface from solvents and aggressive cleaning agents!

Aggressive cleaning agents may damage the seals of the control block and
accelerate ageing.
▶▶ Never use solvents or aggressive cleaning agents (cleaning agents on a
solvent base).
▶▶ Only clean the control block using a damp, lint-free cloth. Only use water and,
if necessary, a mild cleaning agent.
Damage to the hydraulic system and seals!

The water pressure of a high-pressure washer may damage the hydraulic system
and the seals of the control block. The water displaces the oil from the hydraulic
system and seals.
▶▶ Do not use high-pressure washers for cleaning.
Delayed inspections and maintenance works!

Damage to property!
▶▶ Perform the prescribed inspection and maintenance works at the control block
at the intervals specified in these instructions.
Also observe the instructions for maintenance and repair in the machine
operating instructions.

38/52 Maintenance and repair
10.1 Inspection
For reliable operation of the control block, Bosch Rexroth recommends checking
the control block on a regular basis and recording and archiving the following
operating conditions:
Table 7: Inspection plan
Works to be carried out at the control block Interval

Check the operating temperature weekly
Hydraulic fluid analysis: Viscosity, time deterioration annually or all 2000
and contamination operating hours
Check the control block for external leakage (visual inspection). daily
Check the control block for the development of strange noises. daily
Check the mounting elements for tight seat. monthly
All mounting elements have to be checked when the control block
is depressurized, de-energized and cool.
10.2 Maintenance
If used as intended, the control block is low-maintenance.
The life cycle of control block decisively depends on the quality of the applied
hydraulic fluid. We therefore recommend exchanging the hydraulic fluid at least
once per year or every 2000 operating hours (whichever occurs first) or to have it
analyzed for further usability by the hydraulic fluid manufacturer or a laboratory.
Observe the following general rule:

From a hydraulic fluid temperature of > 70 °C, the aging speed doubles with every
10 °C temperature increase.
For the maximum admissible degree of contamination of the hydraulic fluid,

see the data sheet in chapter "Technical data".
Also observe the information on the hydraulic fluid in the operating instructions
of the machine.
10.3 Repair
Bosch Rexroth offers a wide range of repair services for Rexroth control blocks.
The control block may only be repaired by Bosch Rexroth certified service centers or
by the machine manufacturer.
▶▶ Exclusively use Rexroth original spare parts to repair the Rexroth control blocks.
Otherwise, the functional safety of the control block is no longer ensured and you
lose your claim to warranty.
For questions regarding repair, contact your local Bosch Rexroth service
or the service department of the control block manufacturer's factory, see
chapter 10.4 "Spare parts" on page 39.
For repair works, the control block may only be disassembled to the extent
described in these operating instructions.

Maintenance and repair 39/52
10.4 Spare parts
CAUTION
Use of unsuitable spare parts!
Spare parts that do not meet the technical requirements specified by
Bosch Rexroth may cause personal injuries and damage to property.
▶▶ Exclusively use Rexroth original spare parts to repair the Rexroth control blocks.
Otherwise, the function of the control block is no longer ensured and you lose
your claim to warranty.
Spare parts lists are available from your local Bosch Rexroth representative.
Indicate the material and serial numbers of the control block as well as the material
numbers of the spare parts when ordering spare parts.
In case of questions regarding spare parts, please contact your local Bosch Rexroth
service or the service department of the control block manufacturer's factory.
Bosch Rexroth AG
Zum Eisengießer 1
97816 Lohr am Main, Germany
Phone: +49 (0) 9352 18-40 50 60
[email protected]
For the addresses of our sales and service network, see

www.boschrexroth.de/adressen.

40/52 Disassembly and exchange
11 Disassembly and exchange
11.1 Necessary tools

•• Tools suitable for the fastenings specified in the quotation drawing
•• Permanent marker for marking the control block plates
•• Clean collecting pan for collecting leaking hydraulic fluid
11.2 Preparing disassembly

1. Decommission the overall system as described in the machine
operating instructions.
––Depressurize and unload the hydraulic system as described by the
machine manufacturer.
––Ensure that the control block is depressurized and de-energized.
2. Secure the overall system according to the manufacturer's instructions.
11.3 Disassembling the control block from the machine
If the component to be exchanged (e.g. screw-in cartridge valve) is freely

accessible from the outside, the control block does not have to be disassembled
from the machine.
Proceed as follows to disassemble the control block:

1. Let the control block cool down so that it can be disassembled without risks.
2. Make sure that no hydraulic fluid can escape unintentionally from the system due
to the disassembly of the control block.
3. Place a clean collecting pan below the control block to collect any escaping
hydraulic fluid residues.
4. Disconnect the lines and collect any escaping hydraulic fluid residues in the
collecting pan.
5. Disassemble the control block according to the machine
manufacturer’s specifications.
6. Place the product on a clean, bearing surface.
7. Drain the control block completely.
8. Close all openings in order to prevent the deposition of dirt.
11.4 Preparing the components for storage/further use

▶▶ Proceed as described in chapter 6.2 "Storing the control block", section "After
disassembly" on page 22.

Disposal 41/52
12 Disposal
CAUTION
Spring preloaded components!
Risk of injury due to ejected components when the valve is disassembled into its
individual components!
▶▶ Slowly loosen screw-in parts and spring preloaded components and secure
them until the compression spring is unloaded.
Careless disposal of the control block, the hydraulic fluid and the packaging material
may lead to environmental pollution.
For the disposal of the control block, comply with the following instructions:
1. Drain the control block completely.
2. Dispose of the control block and the packaging material in accordance with the
applicable national regulations in your country.
3. Dispose of the hydraulic fluid in accordance with the currently applicable national
4. Disassemble the control block into its individual components in order to
recycle them.
5. Separate for example:
––Steel
––Aluminum
––Non-ferrous metal
––Electrical and electronic parts (solenoids, sensors, coils)
––Plastic
––Rubber (seals, bellows, pedal rubber)

42/52 Extension and modification
13 Extension and modification

Modifications as well as changes in settings at the control block are not admissible.
The Bosch Rexroth warranty applies only to the configuration supplied. Following
an extension or a modification, the claim to warranty expires.
Adjusting the settings causes the claim to warranty to expire. If you require the
settings to be changed, contact your local Bosch Rexroth service, for the address
see chapter 10.4 "Spare parts" on page 39.
Optional accessories For available accessories, see the respective data sheet.
Accessories are available from your Rexroth specialist dealer. For addresses of our
sales and service network, see www.boschrexroth.de/adressen.

Troubleshooting 43/52
14 Troubleshooting
Use Table 8 for troubleshooting. This table is not exhaustive.
In practice, there may be problems that are not included here.
14.1 How to proceed for troubleshooting

▶▶ Work systematically and in a targeted way.
▶▶ First, get a general idea of how your product works in conjunction with the
overall system.
▶▶ Try to find out whether the product has worked properly in conjunction with the
overall system before the error occurred.
▶▶ Try to determine any changes at the overall system into which the product
is integrated:
––Have the product’s operating conditions or its area of application
been changed?
––Was any maintenance work performed? Is there an inspection or
maintenance record?
––Have modifications (e.g. refittings) or repairs works been done on the overall
system (machine, electrics, control) or on the product?
––Has the hydraulic fluid been changed?
––Has the product or machine been used as intended?
––How did the fault become apparent?
▶▶ Try to get a clear idea of the cause of the error. If necessary, ask the actual
(machine) operator.
▶▶ Document all work done.
▶▶ If you could not remedy the occurred error, please contact one of the
addresses you find at http://www.boschrexroth.com/adressen
or in chapter 10.4 "Spare parts".

44/52 Troubleshooting
14.2 Fault table

The control block is not sensitive to faults if the specified application conditions are
met. This particularly applies to the quality of the hydraulic fluid and the maximum
admissible pressure values.
Table 8: Fault table
Fault Possible causes Remedy
Hydraulic fluid leaks at Control block is leaking Tighten the mounting screws applying the specified
the control block and/or the tightening torque.
control block plates Plug screws are leaking Tighten the plug screws applying the specified tightening
torque; replace copper seal rings, if necessary.
For O-ring seals:
Do not tighten up plug screw, replace seals and tighten
plug screw with specified tightening torque.
If leakage persists:
Check sealing surfaces/seal for damage.
Where appropriate, replace the plug screw.
Control block housing and/or control block Disassemble the control block and/or the control block
plate is leaking plate and replace by a new one.
Connections leading to the actuator (screw Check seals and replace the fittings, if necessary.
necks, fittings) are leaking Check tightening torques, see details of the
fitting manufacturer.
Valve housing at the secondary valve/plug Replace secondary valve/plug screw.
screw is leaking
Hydraulic fluid leaks Piping or hose lines damaged Replace piping or hose lines.
from the supply lines to
the control block The piping or hose lines are loose Tighten screwing and fittings according to the assembly
instructions applicable for fittings. All assembly
instructions are available from the machine manufacturer.
Hydraulic fluid escapes Seals in the flange surface are damaged Replace seals, see "Installation drawing".
between the control Deposition of dirt during assembly of Disassemble control block, clean flange surface.
block plates the control block
Control block housing leaking at the Replace control block plate.
flange surface
Tightening torque of the tie rods too low Check tightening torques, see "Technical data sheet".
Residual oil from assembly/test of Remove oil and dirt from the control block. Do not use
the control block any cleaning agents which are aggressive against plastic
or metal, change the properties of plastic, react with
metal or generate residues.
Working movement There is air in the hydraulic fluid Bleed the hydraulic system, see page 33.
not constant
Version: Tie rod screwed with too much/different Loosen tie rod nuts and tighten with specified
Mechanical actuation: tightening torque tightening torque.
The control spool cannot be Oil temperature too high and/or Check cooler function, oil supply and pump pressure in
controlled mechanically temperature difference between hydraulic neutral position.
fluid and control block too high, thus Avoid temperature shock, for related information see
blocking of control spool and control block "Technical data sheet".
as a result of different thermal expansion
Dirt or foreign matter deposited during the Try several times to switch the valve by actuating the
assembly of the connectors leading to the hand lever and/or the pilot control.
actuator jam the control spool Visually check the connections to the actuator, remove
foreign matter using a solenoid or tweezers. Replace
valve housing in case of jammed foreign matter.
The control spool does not The control spool jams See fault above "Control spool cannot be
reset or resets too slowly. controlled mechanically".
Control spool is retained due to the flow Reduce oil flow from the actuator to the tank.
force which is caused by too much oil flow

Troubleshooting 45/52
Table 8: Fault table

Fault Possible causes Remedy
Version: No solenoid current or solenoid current Check voltage supply and operating point Q/I, see
Electro-hydraulic actuation too low, wrong operating point (solenoid "Technical data sheet". Check plug-in connections.
Control spool shows no current not correctly adjusted to oil flow)
reaction or delayed reaction Pilot control valve and/or solenoid valve Replace pilot control valve and/or solenoid valve.
to electric control does not work
Undersupply (pump pressure too low). Undersupply (pump pressure too low). Provide minimum
Provide minimum pump pressure, pump pressure, see "Technical data sheet".
see "Technical data sheet".
Pilot oil supply jams Disassemble pilot oil supply and replace by a new one.
Pilot control valves are contaminated Replace pilot control valve.
Version: Undersupply (pump pressure too low) Provide minimum pump pressure, see "Technical
Hydraulic actuation data sheet".
No pilot pressure Check pilot oil supply
For valves in parallel Oil flows to the actuator with minimum Increase pump oil flow by applying higher speed or
operation: No pressure and/ pressure due to undersupply larger pump, and/or reduce actuator volume using a
or no oil flow at the actuator volume throttle.
with deflected control
spool, considerably delayed
pressure build-up
Neutral circulation pressure No load-sensing unloading
too high (only for M4, M6, M7, SP,SX)
Control spool not in neutral position For tongue: Check projection, see "Technical data sheet".
Pressure in the control covers too high (check control).
Return flow pressure too high Separate return flow from mutual return line, use
separate return line or increase line cross-section.
Inlet pressure compensator jams Replace inlet plate.
Motion at the actuator Control spool not in neutral position Pressure in the control covers too high (check control).
despite neutral position Secondary pressure relief valve is leaking Check set pressure at the secondary pressure relief valve.
and/or set too low
Leakage at control spool too large Leakage values see data sheet.
Install leakage-free lowering brake valve.
No detent function Return force in the actuating element too Disassemble and clean the detent.
high compared to the detent force (spring)
Detent unit worn out Replace the detent unit.
Detent release force The control spool jams See "Control spool cannot be deflected" under "Control
too high spool is jammed" at the top of this table.
Detent unit damaged Replace the detent unit.
Detent force too high Clean and grease detent unit. Replace detent unit if
malfunction cannot be removed.
Following faults due to contamination, it is – in addition to the repair – essential to

check the quality of the hydraulic fluid and to improve it, if necessary, by suitable
measures such as flushing, replacement or the additional installation of filters.

46/52 Technical data
15 Technical data
For the admissible technical data of the control blocks, see the respective data
sheet. The assignment of the control blocks to the data sheets is available in Table 1
"Required and amending documentation" on page 5.
The data sheets are available on the Internet at

www.boschrexroth.com/various/utilities/mediadirectory
For further information, refer to the online product catalog

Mobile hydraulics: www.boschrexroth.de/mobilhydraulik-katalog
The order-specific technical data of your control block are available in the
order confirmation.

Technical data 47/52

48/52 Index
16 Index
▶▶ A ▶▶ L
Abbreviations 8 lifting strap 20
Accessories 42 Lifting tool 19
Assembly 23
–– Completing 26 ▶▶ M
–– preparing 24 Maintenance 38
Modification 42
▶▶ B
Bleeding 33 ▶▶ N
Name plate 17
▶▶ C
Commissioning 30 ▶▶ O
–– first 32 Operation 34
Connecting
–– electrical 29 ▶▶ P
–– hydraulically 27 Performance description 17
Corrosion protection 21 Product description 17
▶▶ D ▶▶ Q
Designations 8 Qualification of personnel 10
Disassembly 40
–– implementing 40 ▶▶ R
–– preparing 40 Re-commissioning
Disposal 41 –– after standstill 33
Repair 38
▶▶ F Required documentation 5
Fault table 44
Functional test 33 ▶▶ S
Safety instructions 9
▶▶ H –– General 10
Hydraulic fluid 32 –– Product-specific 11
–– Disposal 41 –– Signal word 7
–– exchange 38 Scope of delivery 16
Settings 42
▶▶ I Solenoid position
Identification 17 –– change 29
Inspection 38 Spare parts 39
Installation conditions 24 Storage time 21
Installation position 24 Storing 21
Intended use 9 Symbols 8

Index 49/52
▶▶ T
Technical data 46
Tools 24, 40
Transport 19
–– by hand 19
–– using a lifting strap 20
–– using lifting tools 19
Troubleshooting 43
–– Fault table 44
▶▶ U
Unpacking 23
▶▶ W
Warranty 14, 21, 42
Weight 19

50/52 Index

Index 51/52

Bosch Rexroth AG
Mobile Applications
Zum Eisengießer 1
97816 Lohr am Main
Germany
Phone +49 9352 18-0
[email protected]
www.boschrexroth.com
For your local contact, please refer to:

www.boschrexroth.de/adressen
Subject to change without notice

Printed in Germany
RE 64025-B/10.2014

Control Blocks: For Mobile Applications

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RE 64025-B/10.2014, control blocks, Bosch Rexroth AG

Bosch Rexroth AG, control blocks, RE 64025-B/10.2014

1 About this documentation

1.1 Validity of the documentation

This documentation is aimed at the machine manufacturer.

1.2 Required and amending documentation

Table 1: Required and amending documentation

RE 64025-B/10.2014, control blocks, Bosch Rexroth AG

Table 1: Required and amending documentation

Further information is available from Rexroth and at

Bosch Rexroth AG, control blocks, RE 64025-B/10.2014

1.3 Representation of information

1.3.1 Safety instructions

Safety instructions are set out as follows:

•• Warning sign: Draws attention to the danger

Table 2: Risk classes according to ANSI Z535.6-2006

Warning sign, signal word Meaning

RE 64025-B/10.2014, control blocks, Bosch Rexroth AG

Table 3: Meaning of the symbols

▶▶ Individual, independent action

Bosch Rexroth AG, control blocks, RE 64025-B/10.2014

2.1 General information on this chapter

2.2 Intended use

The product can be used as safety-relevant part of a control system. It does,

The control block is not a piece of safety equipment.

RE 64025-B/10.2014, control blocks, Bosch Rexroth AG

2.3 Improper use

2.4 Qualification of personnel

2.5 General safety instructions

Bosch Rexroth AG, control blocks, RE 64025-B/10.2014

2.6 Product-specific safety instructions

Danger due to suspended loads!

RE 64025-B/10.2014, control blocks, Bosch Rexroth AG

Incorrect energy supply!

Risk to limbs due to crushing and impact!

High noise development during operation!

Hot surfaces at the control block!

Bosch Rexroth AG, control blocks, RE 64025-B/10.2014

Improper laying of cables and lines!

Contact with hydraulic fluid!

Escaped hydraulic fluid due to leakage!

2.7 Personal protective equipment

RE 64025-B/10.2014, control blocks, Bosch Rexroth AG

3 General information on damage to

The following safety instructions apply to chapters 6 to 14.

Control block falling down!

Bosch Rexroth AG, control blocks, RE 64025-B/10.2014

Contamination of the hydraulic fluid!

Environmental pollution caused by incorrect disposal!

Leaking or spilt hydraulic fluid!

RE 64025-B/10.2014, control blocks, Bosch Rexroth AG