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0% found this document useful (0 votes)
243 views326 pages

Tehnodel 22562640 PDF

Uploaded by

Wichain Rotchu
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

Product catalog

Industrial hydraulics
Part 7: Systems
1

Product catalog
Industrial hydraulics
Part 7: Systems

Product catalogs Industrial hydraulics of Bosch Rexroth at a glance:

Part 1: Pumps RE 00112-01

Part 2 Motors RE 00112-02

Part 3: Cylinders RE 00112-03

Part 4: On/off valves RE 00112-04

Part 5: Proportional servo valves RE 00112-05

Part 6: Electronics RE 00112-06

Part 7: Systems RE 00112-07

Part 8: Power units, Manifolds and plates, Accumulators RE 00112-08

Part 9: Filters RE 00112-09

Part 10: ATEX units for potentially explosive atmospheres RE 00112-10


For the latest product information from Bosch Rexroth, please visit our website:
[Link]/ics

RE 00112-07, Edition: 2013-08, Bosch Rexroth AG


2

Publisher Bosch Rexroth AG


Zum Eisengießer 1
97816 Lohr, Germany
Phone +49(0)9352/18-0
Fax +49(0)9352/18-40
info@[Link]
[Link]

Catalog No. Document no.: RE 00112-07


Material no.: R999000308
Edition: 2013-08
Replaces: RE 00112-04_2008-11

Reprints and translation, in whole or in part, only with the publisher´s prior consent.
Subject to revision.

Should you have queries with regard to the products in this catalog, please contact the
Rexroth sales partner in your vicinity.

[Link]/contact

Bosch Rexroth AG, RE 00112-07, Edition: 2013-08


3
Contents | Systems

Contents
General 5 1

Electro-hydraulic control 87 2

systems

Variable-speed pump 203 3

systems - Sytronix

Cooling lubricant systems 279 4

RE 00112-07, Edition: 2013-08, Bosch Rexroth AG


4

Bosch Rexroth AG, RE 00112-07, Edition: 2013-08


5
Contents | General | Systems

General
Designation Data sheet Page

Installation, commissioning and maintenance


1
General product information on hydraulic products 07008 7

Hydraulic fluids
Hydraulic fluids based on mineral oil and related hydrocarbons 90220 39
Environmentally acceptable hydraulic fluids 90221 55
Fire- resistant, water- free hydraulic fluids (HFDR/ HFDU) 90222 69

RE 00112-07, Edition: 2013-08, Bosch Rexroth AG


6

Bosch Rexroth AG, RE 00112-07, Edition: 2013-08


7

RE 07008/02.05 1/32
General product information on
hydraulic products

DE Ihre Sprache? – Siehe Rückseite!


EN Your language? – See back page!
FR Votre langue ? – Voir au dos !
IT La vostra lingua? – Vedi retro!
FI Kohdekielet? – Katso takankatta!
ES ¿Su idioma? – ¡Vea al dorso!
NL Uw taal? – Zie achterzijde!
SV Ditt sprak? – Se omslagets baksida!
PT O seu idioma? – Consulte a contracapa!
DA Dit sprog? – Se bagside!
EL Η γλώσσα σαρ; – Βλέπε πίσω πλευρά!
8
2/32 Bosch Rexroth AG Hydraulics General product information RE 07008

Contents Page
1 Important basic information 4
1.1 Conventions used in this product information 4
1.2 What you need to know about this product information 4
1.3 The contents of this product information 4

2 Scope of delivery and responsibilities 5


2.1 Scope of delivery and responsibilities of Bosch Rexroth 5
2.2 Responsibilities of the plant operator 5
2.3 Liability, guarantee, warranty 6
2.4 Copyright 6

3 Important basic safety instructions 7


3.1 What to do in an emergency 7
3.2 Safety labelling on the hydraulic product 7
3.3 Proper use 7
3.4 Requirements for personnel, duty of care 8
3.5 General ancillary dangers and protective measures
when operating hydraulic products 9

4 Technical data and ambient conditions 11


4.1 Information about pressure fluids 11
4.2 Ambient conditions 11

5 What you need to know about pressure fluids 13


5.1 How to handle pressure fluids safely 13
5.2 Functions and effectiveness 13
5.3 Viscosity 13
5.4 Leakage fluid 14
5.5 Topping up/refilling 14

6 Construction and mode of operation of a hydraulic system 15


6.1 Definitions of terms 15
6.2 Schematic 15
6.3 Safety concept 15

7 Moving hydraulic units/components 16

8 Storage and longer standstills 16


8.1 Hydraulic systems - subsequent bringing into use after storage 16
8.2 Seals, hoses and hose lines 17
9
RE 07008 General product information Hydraulics Bosch Rexroth AG 3/32

Contents Page
9 Assembly and bringing into first use 18
9.1 Safety advice for assembly and bringing into first use 18 1
9.2 Before bringing into first use 18
9.3 Bringing into first use, subsequent bringing into use 19

10 Operation 22

11 Trouble-shooting 22
11.1 What to do in the event of a fault 22
11.2 The basic approach to trouble-shooting 22
11.3 Trouble-shooting tables 23

12 Maintenance 24
12.1 Definitions of terms 24
12.2 Safety during maintenance tasks 24
12.3 Inspection and servicing 25
12.4 Service and storage lives of hose lines 28
12.5 Topping up the pressure fluid 29
12.6 Servicing pressure accumulators 29
12.7 Repair 29

13 General information about hydraulic pressure accumulators 30


13.1 General 30
13.2 Safety devices relating to hydraulic pressure accumulators 30

14 Hydraulic systems 31
14.1 Effects of leaks in the hydraulic system on the machine 31
10
4/32 Bosch Rexroth AG Hydraulics General product information RE 07008

1 Important basic information Observing the product information and Operating Instructions
¾ reduces downtimes and maintenance costs
¾ increases the service life of your hydraulic products.
1.1 Conventions used in this product
information
The Operating Instructions must be directly accessible to one
Cross-references are printed in italics. of the personnel at the hydraulic product and kept readily avail-
able at all times in a place known to the personnel.
The Operating Instructions must be read and understood and
all its provisions observed by those responsible and by the
DANGER operative personnel. We recommend that a record is made in
writing of the employees’ familiarisation with all the relevant
This symbol indicates a threat of danger which will result parts.
directly in death or very serious injury if not avoided.
The cross-references to directives, standards and regulations
contained in this product information refer to the versions cur-
rent at the time of writing of this product information, which can
WARNING be obtained from the title page of this product information.

This symbol indicates a threat of danger which may result


in death or very serious injury if not avoided. 1.3 The contents of this product information

In addition to this document, product information for Rexroth


hydraulic products normally includes Operating Instructions
CAUTION consisting of three parts:

This symbol indicates possible danger which may lead to ¾ Part I, the general Operating Instructions for the relevant
minor or serious injury and/or to material damage. class of products
¾ Part II, the Technical Datasheet

IMPORTANT ¾ Part III, the Product- and Application-specific Operating


Instructions.
This symbol indicates additional information.

If you do not have all three parts, please request the missing
1.2 What you need to know about this part from Bosch Rexroth. Only if all the information contained
product information in all parts of the three-part Operating Instructions is observed
can safe operation of Rexroth hydraulic products be ensured.
This product information applies to the following types of Specific cross-references are used to draw your attention to
hydraulic products: information that you can find in the Operating Instructions.
¾ Hydraulic components The Operating Instructions contain detailed information about
¾ Hydraulic power units the product, including

¾ Hydraulic systems. ¾ Information about the scope of delivery


¾ Safety instructions
This product information applies exclusively to hydraulic prod- ¾ Technical data and operating limits
ucts that are operated with mineral-oil-based pressure fluids, if
the Operating Instructions do not expressly permit the use of ¾ Information about bringing into (first) use and maintenance
other pressure fluids. ¾ Information about the mode of operation

IMPORTANT ¾ Layouts, drawings

As this product information for Rexroth hydraulic products ¾ Parts lists if appropriate
applies in a general sense, some of the content may not neces- ¾ Information about replacement parts and accessories.
sarily apply to the hydraulic product you have purchased.
However, only by strictly observing this product information
and the Operating Instructions can accidents be prevented
and problem-free operation of your Rexroth hydraulic product
be guaranteed.
11
RE 07008 General product information Hydraulics Bosch Rexroth AG 5/32

2 Scope of delivery and responsibilities Installation of Rexroth hydraulic products in a machine or sys-
tem may increase this value, and if so, the manufacturer of the
machine/system must document this.

2.1 Scope of delivery and responsibilities of At or above 85 dB(A), the plant operator must make suitable
Bosch Rexroth hearing protection available to the personnel.
1
Rexroth hydraulic products fulfil all safety requirements applica- 2.2.2 Special points concerning the installation of
ble to fluid power systems and their components.
certain products
IMPORTANT A Rexroth hydraulic product is intended above all for installa-
For the scope of delivery and the responsibilities of tion in machines, systems and power units as a part machine
Bosch Rexroth with respect to the product, please refer to the or a component for installation into another machine or system
Product-specific Operating Instructions. and is not a complete machine in the sense of the EU directive.
In addition to the Machinery Directive, still further directives
may apply, such as the Pressure Equipment Directive or the
Explosion Protection Directive.
2.2 Responsibilities of the plant operator A wide range of dangers can arise from the combined actions
of the hydraulic product and the machine or system in which
the hydraulic product is installed. Therefore you must always
CAUTION make sure that the hydraulic product is also suitable without
restriction for the proposed application at the installation loca-
If Rexroth hydraulic products are positioned in the vicinity tion. The interfaces with the overall machine and the operat-
of sources of ignition or strong radiators of heat, protec- ing conditions are also of the greatest importance. We recom-
tion must be put in place that would prevent any escaping mend that the results of the hazard analysis (risk assessment)
pressure fluid from igniting and the hose lines from aging of the overall machine are taken into account in the design of
prematurely. the hydraulic product.

Mineral-oil-based pressure fluid is hazardous to water and The functioning of the hydraulic product is also influenced by
flammable. It may only be used if the relevant safety data- the machine or system in which it is installed.
sheet from the manufacturer is available and all the mea- For this reason, you must also always observe the Operating
sures stipulated therein have been implemented. Instructions of the overall system in which your hydraulic prod-
If there is a risk of fluid leaking from the hydraulic prod- uct is installed. It is most important for you to also consider the
uct and contaminating water or the ground, the hydraulic possible use of the hydraulic product in a potentially explosive
product in question must be placed in a suitable collect- atmosphere (see 94/9/EC).
ing trough. In connection with this, the applicable statutory
regulations must be observed. IMPORTANT
You must also observe the EU directives for the use of work Bosch Rexroth points out that, at the time of their first intro-
equipment (Directive 89/391/EC) and the associated individ- duction on to the market, hydraulic products comply with the
ual directives, especially Directive 1999/92/EC for the protection requirements of all relevant EU directives and/or their imple-
from the danger arising from potentially explosive atmospheres mentation into national legislation in Germany. If the scope of
and their implementations in national legislation. The legisla- delivery is intended to be installed in a machine or system, then
tion contains minimum requirements with respect to the making the Machinery Directive applies as appropriate – including the
available by the employer of work equipment and for the use then currently applicable amendments – in that the scope of
of work equipment by employees at work, including the regu- delivery does not necessarily comply with the requirements
lations for operating equipment requiring supervision and the of the Machinery Directive because the scope of delivery is
obligation to produce explosion protection documentation. This intended for installation in a machine or because the scope of
involves, for example, dividing areas endangered by potentially delivery is intended for combination with other machines into a
explosive atmospheres into zones and specifying suitable work machine or a hydraulic system.
equipment and procedures for these areas. The bringing into use of the scope of delivery shall there-
fore not be permitted until the machine or system in which the
scope of delivery is to be installed or of which it represents a
2.2.1 Noise protection
component complies with the requirements of all relevant EU
directives.
The A-weighted equivalent continuous sound power level of
Rexroth hydraulic products can be obtained from the relevant Details of further responsibilities can be found in
Operating Instructions. If no values are documented then it can 3 Important basic safety instructions and in the Operating
be taken that the value is less than 70 dB(A). Instructions.
12
6/32 Bosch Rexroth AG Hydraulics General product information RE 07008

2.3 Liability, guarantee, warranty

Bosch Rexroth shall not be liable for damages that result from
non-compliance with or disregard of these and other parts of
the Operating Instructions.
Unauthorised tampering shall render the warranty null and void.
Bosch Rexroth shall only be liable if the scope of delivery was
shown to be defective. Bosch Rexroth shall not be liable if a
deficiency occurs that involves parts having been replaced by
the customer with equivalent but not identical parts as speci-
fied by the manufacturer.
Please refer to our general terms of supply or your contract for
details of the guarantee and manufacturer’s warranty.

2.4 Copyright

This product information may only be reproduced – electroni-


cally or mechanically, in whole or in part – with the express writ-
ten permission of Bosch Rexroth. It may likewise not be distrib-
uted, amended, transmitted, translated into another language
or employed or copied for other purposes or by other parties
without such consent.
13
RE 07008 General product information Hydraulics Bosch Rexroth AG 7/32

3 Important basic safety instructions IMPORTANT


The hydraulic product shall be operated exclusively with pres-
sure fluids complying with DIN 51524. Where other pressure
3.1 What to do in an emergency fluids are permitted, for example brake fluids for brake valves,
this is specially mentioned in the Operating Instructions.
In the event of an emergency, fault or other abnormal occur- 1
For details on proper use see 4 Technical data and ambient
rences:
conditions.
1. Switch off the hydraulic system.
The following information can be found in the Operating
2. Secure the main switch against being unintentionally Instructions:
switched on again.
¾ the proper use, specific to the hydraulic product
3. Secure the danger area so that no one can enter the dan-
¾ where applicable, the safety category in accordance with
ger area unknowingly or uncontrolled.
EN 954-1
4. Notify the relevant specialist personnel immediately.
¾ non-permitted and improper use.
5. In the event of fire, observe the provisions of the safety
datasheets issued by the manufacturer of the pressure
fluid and the fire precautions specifically applicable to
your place of work, which must be documented in the 3.3.1 Proper use, requirements before operation
plant operator’s operating manual.
¾ Rexroth hydraulic products may only be operated if they
are in perfect technical condition.

WARNING • In the event of disturbances in the power supply and/


or damage to the electrical equipment, switch off
immediately and secure the main switch against being
Fighting fires with materials other than those permitted switched on again without authorisation.
can lead to explosions and/or more rapid spread of the
fire! • Report and rectify all faults and damage indicated by
Danger to life from smoke inhalation! the system or discovered by other means.
¾ The connections, operating conditions and performance
data specified in the Operating Instructions must be
observed and never changed.
3.2 Safety labelling on the hydraulic product ¾ Rexroth hydraulic products shall not be converted or
otherwise modified without prior consultation with
IMPORTANT Bosch Rexroth.

¾ The meanings of the safety labelling on the Rexroth prod- ¾ The plant operator shall not modify the program code of
uct are explained in the Operating Instructions. programmable control systems.

¾ For a diagram of the nameplate and an explanation of the ¾ Dependencies and time factors shall not be modified with-
information on it please refer to the Operating Instructions. out prior consultation.
¾ The safety devices fitted by Rexroth must be present,
properly installed and in full working order – except when
this is impractical during setting up or maintenance work.
3.3 Proper use They shall not be relocated, bypassed or rendered ineffec-
tive.
Rexroth hydraulic products are designed and constructed for
the provision, transmission, control or regulation of energy and ¾ Safety components such as limit switches, valves and
signals using the flow of oil. other control components shall not be rendered inopera-
tive.
Unless otherwise agreed, the Rexroth hydraulic product satis-
fies at least safety category B in accordance with EN 954-1. ¾ Tamperproof lead seals installed by the manufacturer shall
not be removed or damaged except when this is neces-
If the hazard analysis/risk assessment of the overall machine sary in the course of maintenance tasks defined in the
in which the Rexroth hydraulic product is to be installed indi- Operating Instructions.
cates that a safety category higher than category B in accor-
dance with EN 954-1 is required for the Rexroth hydraulic ¾ The specified maintenance tasks in the Operating Instruc-
product, then a correspondingly higher rated hydraulic product tions shall be carried out at the intervals stated in the
can be supplied and installed only after special agreement with Operating Instructions.
Bosch Rexroth.
14
8/32 Bosch Rexroth AG Hydraulics General product information RE 07008

¾ Uncontrolled access by persons unfamiliar with the sys- Servicing personnel (who carry out filter and oil changes, for
tem to the immediate operating zone of Rexroth hydraulic example) shall fulfil the following requirements:
products is prohibited (even if the product in question has
¾ They have been instructed in the relevant activity.
been shut down).
¾ Specialist knowledge of hydraulics is not required to carry
¾ Rexroth hydraulic products must never be assembled,
out servicing work.
operated or maintained by persons under the influence of
alcohol, drugs or other medication which affect one’s abil-
ity to react. Repair personnel shall fulfil the following requirements:
¾ The personnel must be hydraulics experts, who have been
instructed and meet the definition given above,
3.4 Requirements for personnel, ¾ Repair personnel must be familiar with the function of the
duty of care hydraulic system as a whole, from subsystems to their
interaction with the function of the entire machine.
¾ Repair personnel must be able to read hydraulic circuit
3.4.1 Qualifications of specialist personnel diagrams, interpret individual functions from their symbols
and understand function diagrams.
A specialist person is someone who, using his specialist train-
ing, knowledge and experience as well as familiarity with the ¾ Repair personnel must possess knowledge of the function
relevant conditions, can and construction of hydraulic elements.

¾ safely carry out the tasks allocated to him and correctly


assess the scope and implications of his work
3.4.3 Requirements for electrical maintenance
¾ recognise possible dangers
personnel
¾ undertake the necessary measures to eliminate possible
accidents. All work on electrical equipment shall only be carried out by
an authorised, qualified electrician, or by instructed persons
under the guidance and supervision of a qualified electrician, in
accordance with the rules applicable to electrotechnical prod-
3.4.2 Requirements for hydraulics maintenance ucts.
personnel

In accordance with DIN 31051, maintenance comprises the


individual activities of inspection, servicing and repair. All
3.4.4 Minimum age
personnel involved in maintenance shall be familiar with and
observe all parts of the Operating Instructions and this product
Persons under the age of 18 who are currently receiving
information.
instruction or training or are working under supervision may not
Inspection personnel shall fulfil the following requirements: work on Rexroth hydraulic products.
¾ They have been instructed in the relevant activity. This does not apply to young persons of 16 or over if
¾ Specialist knowledge of hydraulics is not required for ¾ working on Rexroth hydraulic products is necessary in
purely inspection activities but the personnel must be order for them to accomplish a training objective
aware of the particular dangers associated with hydraulic
¾ their protection is guaranteed by the supervision of an
products.
experienced, competent person
¾ they are allowed to use only tools, work implements and
protective gear that preclude the risk of injury.
15
RE 07008 General product information Hydraulics Bosch Rexroth AG 9/32

3.4.5 Training 3.5.1 Dangers from pressure fluid

The plant operator using Bosch Rexroth hydraulic products


shall train his personnel regularly in the following subjects: CAUTION
¾ Observation and use of the Operating Instructions and
legal requirements Handling pressure fluid without protection is hazardous to
1
health.
¾ Proper operation of the Rexroth hydraulic product
Please observe the manufacturer’s safety instructions and the
¾ Observation of the instructions of safety officers and the safety datasheets for the pressure fluid that you are using.
plant operator’s operating manual
¾ What to do in an emergency. DANGER
IMPORTANT Serious damage to health or death may result if pressure fluid
Bosch Rexroth can provide you with training support in special- enters the blood stream or is swallowed. If this occurs, contact
ist areas. a doctor immediately!

An overview of the training can be found on the Internet at


[Link]
3.5.2 Malfunctions due to contamination of
pressure fluid
3.5 General ancillary dangers and Contamination of the pressure fluid can be caused by:
protective measures when operating
¾ Wear during operation of the machine/system (metallic
hydraulic products
and non-metallic abrasion)
¾ Leaks of the hydraulic product
DANGER ¾ Contaminants introduced during servicing/repair

In the interests of your safety, all safety instructions shall be ¾ The use of dirty (unfiltered) pressure fluid when the pres-
carefully observed, especially those in the Operating Instruc- sure fluid is changed.
tions.
In spite of the high intrinsic safety of Rexroth hydraulic prod- Contaminants lead to malfunctions, increased wear and shorter
ucts, the risk of personal injury or damage to the environment service life of the hydraulic product. This can have negative
cannot be excluded, even when the equipment is properly effects on the safety and reliability of the hydraulic product.
used. Therefore the maintenance tasks specified in the Operating
New, additional dangers may arise if the hydraulic product is Instructions shall be carried out at regular intervals and the
installed in another machine or installed with other machines utmost cleanliness is required during work on the hydraulic
in a system. This shall apply in particular to mechanical move- product.
ments generated by the hydraulic product.
Information on these additional dangers can be found in the CAUTION
overall operating manual of the supplier of the overall system in
which the hydraulic product is installed. When changing the pressure fluid, always use factory-fresh
pressure fluid and filter it before filling to remove any contami-
nants in the pressure fluid that it often contains from the pack-
aging container (drum). Flush out lines and hoses before instal-
lation.
The cleanliness class of a pressure fluid is specified in accor-
dance with ISO 4406. Detailed information can be obtained
from the relevant datasheet or the Operating Instructions.
16
10/32 Bosch Rexroth AG Hydraulics General product information RE 07008

In older datasheets, the cleanliness class is sometimes speci- 3.5.4 Product-specific ancillary dangers
fied in accordance with NAS 1638. The following table can
be used to convert this to an equivalent ISO 4406 cleanliness All product-specific ancillary dangers and precautions can be
class: found in the relevant Operating Instructions.
Comparison table for cleanliness classes
Earlier class to Current class to 3.5.5 Disposal
NAS 1638 ISO 4406 (c)
Class 7 Class 18/16/13 ¾ Take metal, cable and plastic ducts to a recycling materi-
Class 9 Class 20/18/15 als collection centre.
¾ Dispose of electronic components as electronic waste.
¾ Dispose of back-up batteries as special waste.
3.5.3 Electrical dangers
¾ Cleaning agents, operating fluids and other materials:
When working on electrical systems:
• De-energise the hydraulic system before beginning any CAUTION
maintenance work.
Please observe the disposal regulations specified in
• Cordon off the working area with red-white safety chain
the appropriate Safety Datasheets.
and warning signs.
• Lock the main switch, remove the key and keep it in a safe
place until the work is completed.
• Attach a warning sign to the main switch.
• Check that there is no voltage using a two-pole voltage
detector.
• Earth and short-circuit the point where you are working.
• Cover neighbouring live parts.
• Clear your workplace to prevent contact with live parts as
a result of tripping or slipping. Wear safety footwear.
• Always use electrically insulated tools.
• Disconnect plugs at sensors and valves – even those with
low voltages – after the system has been de-energised.

DANGER
Even after disconnection of the electrical supply
(main switch OFF) the following supply systems/danger
areas can still give rise to life-threatening voltages:
¾ Electrics, electronics, hydraulics (e.g. accumulators,
rechargeable batteries)
¾ Main switch
¾ Power supply cables
¾ Points identified with an electric shock warning sign.
17
RE 07008 General product information Hydraulics Bosch Rexroth AG 11/32

4 Technical data and ambient conditions 4.2 Ambient conditions

IMPORTANT
4.2.1 Use in potentially explosive atmospheres
The product-specific technical data, operating limits and ambi-
ent conditions for the operation of your Rexroth hydraulic prod-
1
uct can be found in the Operating Instructions. DANGER
This includes the following information:
Rexroth hydraulic products shall be used in potentially
¾ Minimum flow rate for adequate cooling explosive atmospheres only if they are designed for this
¾ Permissible maximum temperature of the coolant purpose and this is expressly stated in the Operating
Instructions.
¾ Performance data
¾ Type of control and regulation functions IMPORTANT
¾ Permissible pressures, flow rates Directive 1999/92/EC of the European Parliament and Coun-
cil dated 16 December 1999 concerning the minimum require-
¾ Connections. ments for improving the safety and health protection of work-
ers potentially at risk from explosive atmospheres governs
protection from danger from potentially explosive atmospheres.
Observe the requirements contained in the regulations for
4.1 Information about pressure fluids operating equipment requiring supervision and the obligation to
produce explosion protection documentation.
Unless otherwise indicated in the Operating Instructions, the This involves, for example, dividing areas endangered by poten-
following specification applies to the pressure fluid to be used: tially explosive atmospheres into zones and specifying suitable
¾ Mineral-oil-based pressure fluid complying with the work equipment and procedures for these areas.
requirements of DIN 51524. Observe the requirements of Directive 94/9/EC of the Euro-
¾ Operating temperature range 0 °C…+80 °C pean Parliament and Council dated 23 March 1994 on the
(in tank < 72 °C). approximation of laws of the member states concerning equip-
ment and protective systems intended for use in potentially
Any deviations from this can be found in the Operating Instruc- explosive atmospheres (ATEX Product Directive) and/or the
tions. corresponding national legislation by means of which the Direc-
tive was implemented in law in the EU member states. The
IMPORTANT directive contains requirements for the use of equipment and
protective systems in potentially explosive atmospheres.
Bosch Rexroth recommends a maximum operating tempera-
ture of 55 °C, because the rate of ageing of the pressure fluid
increases and the service life of the seals and hoses is reduced
at higher temperatures.
¾ Viscosity ranges:
see RE 07075 and RE 90220
¾ Max. permissible contamination class of the pressure fluid
in accordance with ISO 4406: see 3.5.2 Malfunctions
due to contamination of pressure fluid.
The maximum permissible cleanliness class can be found in the
Operating Instructions. The following types of pressure fluids
shall be used.

IMPORTANT
Rexroth hydraulic components are tested with test oil MZ45
manufactured by ESSO (class ISO VG 46 at 40 °C),
(Viscosity η = approx. 46 mm2/s).
18
12/32 Bosch Rexroth AG Hydraulics General product information RE 07008

4.2.2 Climatic operating conditions

Unless otherwise indicated in the Operating Instructions,


the permissible ambient temperature
¾ for control units: 0 °C…+50 °C
¾ for drive units with electric motors without heat exchang-
ers, surface-cooled by free air circulation:
0 °C…+30 °C
¾ for drive units with heat exchangers: < +40 °C.

Unless otherwise specified, Rexroth hydraulic products are


designed for use in temperate climate zones and in covered
areas (not in the open air) at relative air humidities of < 70 %
and at room temperatures of 22 °C.

IMPORTANT
For systems with oil-air heat exchangers:
Observe the information given in the circuit diagram in the
Operating Instructions.

In relation to the electronic equipment, the permissible ambient


conditions apply to installed and protected electrical connec-
tions of class IP 55.
¾ Ambient temperature +5 °C…+40 °C
assuming that the average air temperature over a 24 hour
period does not exceed +35 °C.
¾ Relative air humidity: 23…95 %, non-condensing.
¾ Altitude: up to 1000 m above national datum.

DANGER
Rexroth hydraulic products shall not be used in aeronau-
tical equipment, except where they have been specially
approved and appropriately labelled to this effect.
19
RE 07008 General product information Hydraulics Bosch Rexroth AG 13/32

5 What you need to know about IMPORTANT


pressure fluids Observe the following rules of thumb:
At pressure fluid temperatures >70 °C, the rate of ageing
doubles for each 10 °C.
5.1 How to handle pressure fluids safely
1
5.3 Viscosity
DANGER
Mineral-oil-based pressure fluid is hazardous to water and
5.3.1 Viscosity grades
flammable.
It may only be used if the relevant safety datasheet from The most important characteristic of a pressure fluid is its vis-
the manufacturer is present and all the measures stipu- cosity, i.e. stickiness. Viscosity range always plays a priority
lated therein have been implemented. role in the selection of a pressure fluid.
Viscosity is measured in the SI unit [mm2/s]. Many manufactur-
ers still provide their information in centiStoke [cSt], the equiv-
alent of [mm2/s].
5.2 Functions and effectiveness The viscosity grades (VG = viscosity grade) in accordance with
ISO 3448 relate to the viscosity at 40 °C. The viscosity grade
Due to the many tasks of pressure fluid, its selection, inspec- is appended to the type designation or the commercial name of
tion and maintenance are of vital importance for: the pressure fluid.
¾ proper functioning Example: A pressure fluid with a viscosity grade of ISO VG 46
has a viscosity of 46 mm2/s at 40 °C.
¾ operating safety
The relationship between medium temperature and viscosity for
¾ service life hydraulic oil (example)
¾ and the cost effectiveness of the hydraulic product.
Medium
Viscosity
temperature
The tasks of pressure fluid: 3 °C 800 mm2/s
¾ to transmit hydraulic energy from the pump to the hydrau- 8 °C 500 mm2/s
lic cylinder/motor 25 °C 100 mm2/s
60 °C 20 mm2/s
¾ to lubricate parts moving against one another
77 °C 12 mm2/s
¾ corrosion protection
¾ to remove contaminants Too high a viscosity leads to the formation of air and vapour
bubbles as a result of low pressure (cavitation). Too low a vis-
¾ to remove locally accumulated heat. cosity leads to increased leakage losses. Increased leakage
losses cause the pressure fluid to heat up more, leading in turn
to a further reduction in viscosity. The pressure fluid then loses
its ability to lubricate.
5.2.1 Reduced function due to ageing
Valves, pumps and hydraulic motors, in particular, require exact
The effectiveness of pressure fluid diminishes as it ages compliance with the defined viscosity ranges.
(undergoes chemical changes). Acids and resinous residues
For certain ambient and operating temperatures, not all the
form, which may cause valve spools to stick.
requirements can always be covered with the available ranges
The following factors accelerate the ageing process: of the viscosity grades.
¾ high temperatures In order to comply with all the requirements, high viscosity
pressure fluids with viscosity index improvers or a pressure
¾ oxygen in the pressure fluid fluid cooler/heater may be used.
¾ air humidity
¾ water
¾ metallic catalysers
¾ operating pressure
¾ contaminants.
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14/32 Bosch Rexroth AG Hydraulics General product information RE 07008

5.4 Leakage fluid

Clearances and play mean that some leakage fluid escapes


from all hydraulic products. Leakage fluid can be lead away
internally or externally, depending on the component. It can be
fed back into the tank or must be disposed of.

CAUTION
Make sure that the leakage fluid is fed back into the tank
in a proper manner.
Dispose of leakage fluid that is not fed back into the tank
properly, in compliance with the applicable environmental
protection regulations.

5.5 Topping up/refilling

CAUTION
When topping up/refilling your hydraulic system, make
sure that you use pressure fluid of the same sort and type
and from the same manufacturer.
If the fluid is heavily contaminated or prematurely aged,
then the system, including the tank must be cleaned and
flushed before refilling. New pressure fluid must always be
filtered in accordance with the required cleanliness class,
as it does not normally meet the required cleanliness class
in the as-supplied state.
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6 Construction and mode of operation


of a hydraulic system 9

6.1 Definitions of terms 8 1


Hydraulics (fluid technology)
7
Transmission, control and distribution of energy and signals
using a pressurised fluid medium. 6

Hydraulic system 5
Arrangement of interconnected components for transferring
and controlling hydraulic energy.
4

3
Component
2
A single unit (e.g. a valve, filter, cylinder, motor) that consists
of one or more parts and which is a functional constituent of a 1
hydraulic system.
1 Tank
Oil preparation
2 Filter
Drive
3 Pump Energy conversion
A component that converts the energy of the hydraulic fluid
into mechanical energy (e.g. motor, cylinder). 4 Pressure limiting valve
5 Directional valve
Energy control
6 Check valve
6.2 Schematic 7 Throttle valve

8 Hydraulic cylinder
In a system operated with hydraulic oil, first of all mechani- Energy conversion
cal energy is converted into hydraulic energy, transported and 9 Hydraulic motor
controlled in this form, to finally be converted once more into
mechanical work.
The hydraulic elements are arranged in accordance with these 6.3 Safety concept
functions. The following diagram shows a schematic represen-
tation of the elements of a complete hydraulic system. Hydraulic products contain sensors and actuators, the interac-
tion of which is particularly important with regard to the fulfil-
To demonstrate their operating principle, standardised symbols
ment of technical safety functions.
(ISO 1219) are used instead of sectional diagrams of the vari-
ous devices. Line connections are represented by simple lines, Individual hydraulic products form part of an overall safety con-
as can be seen in the example. cept.
Applications required to perform safety functions are designed
using special hydraulic components that satisfy the require-
ments of the relevant directives, such as the Pressure Equip-
ment Directive and other standards.
The manufacturer of the overall machine or system defines and
bears responsibility for the safety category to EN 954-1 to be
fulfilled.

IMPORTANT
A more detailed description of the safety concept and the spe-
cific safety components installed can be found in the Operating
Instructions and the Operating Instructions of the supplier of
the overall system in which the hydraulic product is installed.
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16/32 Bosch Rexroth AG Hydraulics General product information RE 07008

7 Moving hydraulic units/components IMPORTANT


The factory-applied corrosion protection is adequate provided
Hydraulic units or components may be moved by a fork-lift that
truck or a hoist, depending on their size and the local condi-
tions. ¾ no condensation or leakage water can enter the system
¾ long standstills are avoided.
IMPORTANT
Contact Bosch Rexroth if you are not clear about the conse-
For details see the Operating Instructions.
quences of long standstills on the state of the hydraulic prod-
uct.

CAUTION
Always ensure hydraulic products are empty of pressure 8.1.2 Storage times in relation to the ambient
fluid for transportation. conditions
Rexroth hydraulic products are delivered empty of pressure
fluid. However, products may contain oil residues left over from Delays in bringing into use, long shipping and storage times or
the final inspection at our factory. long periods of non-use can lead to rust formation in Rexroth
hydraulic products. Additional corrosion protection measures
must be implemented to prevent this.

IMPORTANT
8 Storage and longer standstills If all the openings on the hydraulic products are not sealed so
as to be air-tight, this will reduce the storage life of the hydrau-
lic product by nine months.
8.1 Hydraulic systems - subsequent bringing After the specified storage time has expired, in any event not
longer than 24 months, the corrosion protection must be
into use after storage
checked and further conservation measures applied if neces-
sary.
Corrosion, especially oxidation, can cause metal surfaces to
lose the standard of surface finish required for the hydraulic
system to function properly.
Rust and other metallic and non-metallic particles lead to abra-
sive wear (erosion), which detrimentally affects the functioning
of the hydraulic system.

CAUTION
If a hydraulic system is to be brought into use again fol-
lowing a long standstill, it must first be flushed clean.

8.1.1 Factory-applied corrosion protection

Rexroth hydraulic products are tested in accordance with


Class III using a hydraulic oil that has additional anti-corrosive
properties. The film of oil that remains in the product after the
test provides sufficient internal corrosion protection.
This factory lubrication ensures that valves do not stick during
subsequent use of the hydraulic product, and guarantees com-
patibility with seals and the pressure fluid to be used.
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8.2 Seals, hoses and hose lines

CAUTION
Seals: 1
Observe the requirements of ISO 2230 and/or DIN 7716
and the specific manufacturer’s data on seals.
Hoses and hose lines:
In the Federal Republic of Germany, please observe the
requirements of DIN 20066, ZH 1/74 Safety rules for
hydraulic hose lines and the specific manufacturer’s data
on hoses and hose lines.
In addition, the following conditions shall be observed:
¾ Seals, hoses and hose lines are stored in cool, dry and
dust-free conditions.
The hoses and hose lines can be enclosed in plastic foil to
ensure low-dust storage conditions. Ideal storage conditions
for hoses and hose lines are temperatures from +15 °C to
+25 °C and a relative humidity of below 65 %.
¾ Do not store elastomers below –10 °C. The ideal stor-
age conditions for seals are temperatures from +10 °C
to +20 °C and a relative humidity of between 65 % and
75 %.
¾ Store hoses and hose lines in the original packaging if
possible. Prevent the entry of air.
¾ Avoid direct sunlight and UV radiation and shield from
nearby sources of heat.
¾ Darkened storage locations are preferred.
¾ Do not use ozone-forming light sources or equipment
(e.g. fluorescent lamps, mercury-vapour lamps, copiers,
laser printers) or electrical spark-forming devices in the
vicinity of hoses and hose lines.
¾ Seals, hoses and hose lines must not come into contact
in particular with materials or vapours that could damage
them (e.g. acids, alkalis, solvents).
¾ Store seals, hoses and hose lines lying down and free
from tension. If the hoses and hose lines are coiled, take
care not to bend them to less than the smallest bending
radius specified by the manufacturer.
Maximum storage times
¾ NBR seals: 4 years
¾ FKM seals: 10 years
¾ Hoses: 4 years
¾ Hose lines: 2 years

For reasons of safety, seals, hoses/hose lines shall not be


used once these permissible storage times are reached or
exceeded. Permissible storage times could be considerably
reduced if the permissible storage conditions are not main-
tained. If you are not clear about the storage times and/or stor-
age conditions then you should not use the product.
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18/32 Bosch Rexroth AG Hydraulics General product information RE 07008

9 Assembly and bringing into first use Bringing into (first) use shall only be done by an instructed,
authorised hydraulics expert who has the required special-
ist knowledge.
IMPORTANT
Specialist hydraulics knowledge means, among other things,
Only the permissible pressure fluids given in the Operating that the person can read and fully understand hydraulics draw-
Instructions are to be used. Information on other pressure flu- ings. In particular, he must fully comprehend the range of func-
ids can be found in the Operating Instructions or are available tions of the integrated safety components as part of the overall
on request. safety concept.
Filling the pressure fluid tank must always take place through a
suitable filter unit. Experience has shown that even new pres-
sure fluid can often have more than the maximum permissible
level of contamination. 9.2 Before bringing into first use
All information specific to assembly and bringing into first use
can be found in the Operating Instructions. 1. Check the scope of delivery for transport damage.

Pay attention to cleanliness: 2. Check that the Operating Instructions for the Rexroth
hydraulic product are present and complete.
¾ Do not use cleaning wool or cloths containing fibres for Contact us if the Operating Instructions are not there or
cleaning. are incomplete.
Depending on the condition of the system or machine, 3. Assemble the hydraulic product.
cleaning with fibre-free cloths may be sufficient. Use suit-
able liquid cleaning agents to remove lubricants and other • Observe the Operating Instructions and this product
stronger contaminants. Make sure that cleaning agent information.
does not get into the hydraulic system. • Assemble the hydraulic components, so that they are
¾ Never use hemp and putty as sealants. mounted strain-free on even surfaces.
• Tighten the fastening bolts evenly using the specified
The functional or failure behaviour of identical hydraulic prod- tightening torque.
ucts may vary due to conditions specific to the machine or sys- 4. Ensure that the interfaces of the system/machine and the
tem in which the hydraulic product is installed (mass, speed, installation conditions provide for safe operation of the
electrical triggering at setpoint values, etc.), see also Section hydraulic product. If in doubt, consult the people responsi-
11 Trouble-shooting. ble for the overall system/functional machine.
5. Check the construction of the hydraulic product against
the circuit diagrams, lists of equipment and assem-
bly drawings. If there are any differences, draw this to
9.1 Safety advice for assembly and the attention of the people responsible. If important
bringing into first use documents are missing, they can be requested from
Bosch Rexroth. Only documents issued by the bodies
authorised to do so shall be used.
DANGER 6. Based on the Operating Instructions for the system or
machine in which the hydraulic product is installed, check
Hydraulic products are generally intended for installation whether bringing the hydraulic system into use could lead
in machines/systems or devices. to uncontrolled, dangerous movements. Where appropri-
The function of the hydraulic product must therefore ate, take into account the hazard analysis/risk assessment
always be seen in relation to the function of this machine for the system or machine.
– i.e. seemingly identical hydraulic products may demon- 7. Take the precautions appropriate to the anticipated dan-
strate different functional behaviours as a result of the gers, e.g.
function of the machine in which they are installed.
• Ensure that the cylinder piston rod can move out
For this reason, a hydraulic drive must not be brought into without danger.
use until it has been determined that the machine in which
it is installed conforms to EU standards. • Use a hoist or other lifting device to additionally
secure lifted loads.
Do not bring hydraulic drives into use until you have famil-
iarised yourself completely, firstly with the function of the
hydraulic product and hydraulic equipment and secondly
with the hydraulically powered machine functions, and
have clarified and dealt with any possible dangers.
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RE 07008 General product information Hydraulics Bosch Rexroth AG 19/32

8. As part of bringing into (first) use, check whether the elec- 9.3 Bringing into first use,
tric motors and valve solenoids can be switched manually subsequent bringing into use
using the electrical controls of the system/machine. If they
cannot be switched manually – or can but with difficulty
– you must provide a remote control (e.g. test boxes for
Rexroth proportional valves) for the internal function test of DANGER
the hydraulic system. 1
Before bringing into (first) use, have all pressure accumu-
IMPORTANT lators and safety systems checked by an expert or special-
ist in accordance with national regulations.
Starting up the hydraulics solely by means of emergency man-
ual operation is not recommended, as several valves at once 1. Clean the lock on the transport and storage container
cannot be switched as required in the correct sequence. before opening.

9. Draw up a sequential program for bringing into (first) use 2. Clean the hydraulic unit and all other component groups,
and store it with the technical documentation as an appen- so that no dirt can get into the hydraulic system during
dix to the Operating Instructions. bringing into (first) use.
For this you should consider the following: 3. Check the paint on the tank for integrity.
Hydraulic drives basically consist of the following func-
tional groups 4. Flush the connection lines to remove dirt, scale, chips etc.

¾ Pump circuit (generation of pressurised oil flow); 5. Pickle and flush welded pipes.
pump, electric motor, oil tank, filters, monitoring
devices, etc.
CAUTION
¾ Control system for at least one hydraulic consumer
(cylinder, motor); directional control valves, pressure Remove all residues of water and cleaning agents
and flow control valves, check valves before performing further work.
¾ Hydraulic consumers (cylinders, motors) with spe-
cially assigned valves, e.g. braking valve.
6. Clean the interior of the hydraulic components to get rid of
contaminants:
10. Divide the functional circuit diagram into separate mini-cir-
cuits that can each be started up in succession. • Clean the filler plug of the pressure fluid tank.

11. Read the functional circuit diagram and seek clarification • Remove dust and chips using an industrial vacuum
of any unclear text or diagrams. More information about cleaner, by rinsing parts or similar cleaning method.
the functioning of components, e.g. a pump regulator, is • Completely remove any oil residues left over from the
available in the Technical Datasheet. factory test.
12. Establish into which position valves are to be switched, or • Remove any gummed oil which may have formed due
how valves are to be set. to incorrect storage.
13. Put up any necessary directional, prohibitive or informative
signs and check whether the meaning of these signs are 7. Connect up all connection lines.
explained in the Operating Instructions.
14. Follow this sequence for bringing into (first) use IMPORTANT
¾ Pump circuit Observe the installation instructions from the manufacturer
of the connection components.
¾ Parts of control system:
e.g. pressure cut-off and switchover,
open centre, DANGER
pressure reduction etc.
Make sure that pipes and hoses are connected at all
¾ Cylinder and motor circuits:
ports or that the ports are sealed with screw plugs.
First move,
fill and bleed, 8. Carry out a special check to make sure that the union nuts
then finally optimise all settings. and flanges are correctly tightened at the pipe connec-
tions and flanges.
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20/32 Bosch Rexroth AG Hydraulics General product information RE 07008

IMPORTANT
CAUTION
Mark all the checked connections, e.g. with paint.
Make sure that all pipes and hoses and every combination of Use oil filler units (filter units) suitable for pres-
connection pieces, couplings or connection points with hoses sure fluids.
or pipes are checked for their operational safety by someone • Do not remove the filter strainers from filler necks or the
who has the appropriate knowledge and experience. filter element from filters before filling the pressure fluid
tank.
9. Connect the hydraulic consumers. Dimension the connec- 13. Fill the pressure fluid tank up to the upper mark on the
tion lines in accordance with the performance data in the inspection window. Observe the maximum fluid level, tak-
Circuit Diagram and the Operating Instructions. ing into consideration the volume in the connection lines
10. Install the electrical system for the drive and control sys- and hydraulic consumers.
tem: 14. Set the pressure and flow control valves, pump regula-
• Check the connected loads. tor, signalling elements such as pressure switches, limit
switches and temperature regulators to the settings and
• Connect coolant water if necessary. values defined in the sequential program (see 9.2 Before
bringing into first use).
• Check the direction of rotation of the pumps
(e.g. as indicated by attached arrow markings).
DANGER
11. Check the pressure fluid to ensure that no water has
entered it. Do not change the settings of valves with a safety
function, valves with a position switch or valves with
12. Before filling the pressure fluid tank, please observe the preset electronics.
following requirements:
• Set operating-pressure valves and flow control valves
¾ The pressure fluid must conform to the specification to the lowest possible values.
in the Operating Instructions.
• Set directional control valves to their basic setting.

CAUTION • Reduce the setpoint values of proportional valves to


minimum values.
Never fill new hydraulic products with used pressure • Do not remove the tamperproof lead seals. Damaged
fluid. or removed tamperproof lead seals indicate improper
use of the hydraulic product.
¾ The drums of pressure fluid must be sealed and clean
on the outside. 15. If applicable:
Fill the pressure accumulator to the specified gas pre-
charge pressure and then check the pressure, see Operat-
IMPORTANT ing Instructions.
If the pressure fluid has a high level of initial contamination 16. Fill the pump body:
(see 4 Technical data and ambient conditions): Use the leakage oil port to fill pump bodies that have this
feature, see Operating Instructions.
Use a filter unit to fill the pressure fluid tank. Ensure that the fil-
ter element is clean. 17. If applicable:
Open the cocks in the suction line.
IMPORTANT 18. Start the drive motors:
The fineness of the filter shall correspond to the cleanliness
• With electric motor in jogging mode, allow to start
class required by the overall system and if possible be even
briefly
finer.
The filter unit used shall fulfil the requirements for functional • Combustion engines in idle
safety and service life.
• Pay attention to the direction of rotation.
• If possible, fill the pressure fluid tank via a filling coupling,
using a return filter if possible.
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RE 07008 General product information Hydraulics Bosch Rexroth AG 21/32

19. Bleed the hydraulics (valve, pump, motor, line, cylinder). 23. After bringing the machine into first use, have a sample of
the pressure fluid analysed to ensure that it achieves the
IMPORTANT required cleanliness class. Change the pressure fluid if the
required cleanliness class is not achieved.
Details on bleeding can be found in the Operating Instruc- If the pressure fluid is not tested in the laboratory after
tions. bringing the machine into first use:
• Operate the hydraulic product at low pressure until it Change the pressure fluid. 1
is fully bled. 24. Replace the pressure fluid filter.
• Bleed the hydraulics lines to consumers or measuring 25. Document and file all set values.
points at the highest point, if possible.
• Operate the directional valves in jogging mode.
• Next, advance and retract all hydraulic consumers DANGER
several times.
26. To ensure the safety of persons and the system, after
• Increase the load slowly. Check the pressure fluid
bringing the machine into first use, perform the following
level in the pressure fluid tank. If necessary, top it up
tests using the defined maximum values:
with pressure fluid.
• Function test
Bleeding has been accomplished fully and correctly if the pres- • Pressure test.
sure fluid in the tank does not foam, if the hydraulic consumers
do not make any jerky movements and if no abnormal noises Prepare a record of the bringing into (first) use or accep-
can be heard. tance and have it signed by the plant operator. This record
is an important document and requires to be filed.
20. Set the valves and sensors and start up the machine:
• Set the switching operations of valves with a IMPORTANT
switching time adjustment/ramp in accordance with Information on how to perform the function test and pres-
the dynamic conditions, see Operating Instructions. sure test can be found in the Operating Instructions.
• Finely adjust and optimise the setting of proportional
valves without on-board electronics (OBE).

Manufacturing tolerances mean that valves and amplifiers have


to be adjusted in line with one another. Valves with in-built elec-
tronics (OBE, On Board Electronics) have the valve and ampli-
fiers adjusted in line with one another at the factory.
Amplifiers for valves without OBE are supplied from the fac-
tory with a basic setting. Depending on the type of valve and
amplifier, you may have to fine-tune the null point and sensitivity
before bringing the valve into use.

IMPORTANT
Details on fine-tuning can be found in the Operating Instruc-
tions.
21. Check the operating temperature after the machine has
been running continuously for several hours. Too high an
operating temperature indicates that there are faults that
need to be analysed and rectified.
22. Rectify any leakages, e.g. by relieving couplings from pres-
sure and then retightening.

IMPORTANT
Apart from moisture, which should not be sufficient to form one
drop, no measurable, unintentional leakage shall be found.
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22/32 Bosch Rexroth AG Hydraulics General product information RE 07008

10 Operation ¾ Is there a machine record book that may document similar


malfunctions in the past?

IMPORTANT
Please refer to the Operating Instructions for all information on 11.2.2 Recommended way of working when
how to operate the Rexroth hydraulic product.
trouble-shooting

Successful trouble-shooting for a hydraulic product requires


precise knowledge about the structure and method of opera-
11 Trouble-shooting tion of the individual components.
Where hydraulics are combined with electrics/electronics, in
particular, trouble-shooting is rendered more difficult and co-
operation between electricians and hydraulic specialists is
11.1 What to do in the event of a fault required.
• Even if you are under time pressure, proceed systemati-
cally and methodically.
DANGER Indiscriminate, hasty dismantling and readjustments may,
in the worst case, result in the original cause of failure
In the event of abnormal occurrences or malfunctions, stop being impossible to determine.
all work on the Rexroth hydraulic product immediately and
inform the responsible personnel. • Make sure that you gain an overview of the function of the
hydraulics in respect of the overall system in which the
IMPORTANT hydraulics are installed.

A table for product-specific trouble-shooting can be found in • Try to find out whether the hydraulics performed the
the Operating Instructions. required function in the overall system prior to the
occurrence of the fault.
If the responsible personnel are unable to rectify the problem
immediately: • Try to determine any modifications to the overall system in
which the hydraulics are installed:
• Switch off the main switch. If applicable, turn off any
combustion engines used as drive motors. ¾ Have the operating conditions or operating range of
the hydraulics been changed?
• Secure the main switch against being unintentionally
switched on again. ¾ Have modifications (e.g. retrofitted equipment)
or repairs been carried out on the overall system
• Inform the machine manufacturer. (machine/system, electrics, control system) or on the
hydraulics? If yes: What were they?
¾ Have the set values of the hydraulics been changed?
11.2 The basic approach to trouble-shooting ¾ Have the hydraulics recently undergone mainte-
nance?
The information in this section is intended to help you create
the ideal conditions for carrying out trouble-shooting as effi- ¾ Has the hydraulic product/machine been operated
ciently as possible. improperly?
¾ How does the malfunction manifest itself?

11.2.1 General conditions • Form a clear picture of the cause of the fault. Ask the
machine operators directly, if necessary.
¾ Is all the necessary technical documentation to hand? • Document any work undertaken, changed set values, etc.
¾ If no hydraulic circuit diagram is available: • Document any amendments/additional information that
Can a hydraulic circuit diagram be drawn using the struc- should be included in the Operating Instructions.
ture, signs and labelling of the equipment?
¾ Are there enough measuring points?
¾ Has the customer provided useful information about how
the malfunction manifests itself and about the functional
behaviour of the system/component prior to the malfunc-
tion?
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RE 07008 General product information Hydraulics Bosch Rexroth AG 23/32

11.2.3 Systematic trouble-shooting procedure 11.3 Trouble-shooting tables

¾ Is there an inspection and maintenance book which might


provide information about the trend of test parameters IMPORTANT
(e.g. temperature of hydraulic fluid, replacement intervals The causes of failure in hydraulic systems can be extremely
of filter elements, noises)? complex. Therefore, general rules for trouble-shooting can only
be laid down to a limited degree. 1
¾ Have there been any identical or similar failures in the
past? Please refer to the relevant Operating Instructions for product
• Make a note of causes of failures with a low specific information about trouble-shooting the Rexroth hydrau-
probability. Only investigate the failure causes you lic product.
have noted down if all failure causes with a high
probability have been proven to be inapplicable.
• Draw up a list of priorities of the most probable failure
causes.
• Verify these listed failure causes one after the other
(by means of theoretical conclusions, disassembly,
measurements or tests).
• Document the causes of failure you have discovered,
and note down how you discovered them.
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24/32 Bosch Rexroth AG Hydraulics General product information RE 07008

12 Maintenance Before undertaking any manual intervention in the Rexroth


hydraulic product:

12.1 Definitions of terms DANGER


The term Maintenance as defined in DIN 31051 encompasses Please refer to the Operating Instructions for all the neces-
all measures to maintain and restore the desired conditions sary information on depressurisation and on those parts of
and to determine and assess the actual condition of the techni- the Rexroth hydraulic product that are not depressurised
cal devices of a system . automatically.
These measures are divided into the following categories: • Advance all cylinders to their safe end position.
¾ Inspection (determining the actual condition) • Lower all loads.
¾ Servicing (maintaining the desired condition) • Switch off all pumps.
¾ Repair (restoring the desired condition). • Mechanically support vertical cylinders so that they
cannot drop. Never perform any maintenance work on
The above measures include:
raised units without external support.
¾ Adapting maintenance objectives to suit company objec-
• Relieve any accumulators of pressure in the proper
tives
manner.
¾ Determining appropriate maintenance strategies.
• Switch off the pressure supply and secure the
hydraulic product against being inadvertently switched
on again.
12.2 Safety during maintenance tasks • Ensure that only authorised personnel remain in the
work zone.
• Wear safety glasses, gloves and boots.
DANGER
• Allow pressure lines and sections of the system which
In the interests of safety, please observe all the following have to be opened to cool down before commencing
safety instructions carefully and at all times. maintenance work.

• Check safety devices regularly to see that they are • Open with care any segments that have to remain
working properly. under pressure.

• Perform all maintenance work properly, completely and


within the stipulated periods and make a record of the Since check valves are located in the pressure lines above the
work. pumps, the hydraulic system may still be under pressure even
after it has been disconnected from the actual pressure supply.
• Inform all personnel before commencing maintenance
work. Certain segments, such as servo cylinders, also continue to
remain under pressure because the proportional valves remain
• Generously cordon off the maintenance zone before in the closed position (all valves are illustrated in their basic
commencing work. position in the hydraulics diagram).
• Inform all persons of ongoing maintenance work by means Observe the following:
of the appropriate signs.
In particular, attach warning signs to the control cabinet, ¾ Only new, interchangeable and tested components,
main switch, actuators and points of access. replacement parts and lubricants in original-equipment
quality are approved for use/replacement.
If you have to switch off the hydraulic product, secure it against
being unintentionally switched on again as follows: ¾ For reasons of safety, the installation of used and/or
untested components is strictly prohibited and leads to
• Switch off all drives, disconnect the hydraulics from the loss of EU Conformity.
mains at the main switch.
• Depressurise the hydraulic product (relieve any pressure Exercise extreme vigilance when operating the hydraulic prod-
accumulators of pressure). uct in maintenance mode, which may in certain circumstances
• Secure the main switch against being unintentionally necessitate the temporary removal of certain safety devices.
switched on again.
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RE 07008 General product information Hydraulics Bosch Rexroth AG 25/32

Make sure that all safety devices are properly installed and work.
have undergone a function test before bringing the system
(back) into use. • Document and file details of any work undertaken,
changed set values, etc.
• Perform welding, burning or grinding work on the hydraulic
unit or its attachments only with the approval of local • Document and file details of any amendments/additional
safety authorities/fire brigade and with suitable protective information that should be included in the Operating
Instructions. 1
covering to prevent ingress of contaminants.
• When performing assembly work above your height, use • Modifications and additions could affect the validity of the
the steps and platforms provided by the plant operator. Do EU Conformity Declaration/Manufacturer’s Declaration.
not climb on any parts of the system. Always consult Bosch Rexroth about any proposed
modifications or additions.
• Remove all tools and materials needed for maintenance
from the hydraulic product.
• Always rectify any leakage from the hydraulic product
immediately.
• Always inform personnel before (re)starting the hydraulic
product.

12.3 Inspection and servicing

The objective of inspection and servicing is


¾ To maintain all system functions along with the initial
parameters of the system
¾ To ensure continual availability of the system
¾ To detect weak points
¾ To ensure that the system attains the required service life.

IMPORTANT
The following general specifications are based on use of the
hydraulic product in central Europe and under the usual operat-
ing conditions of commercial and industrial plants.
We strongly recommend the use of an inspection and servicing
book, in which all work specific to that site, and all inspection
and servicing intervals should be defined and documented.
An inspection and servicing book is also helpful in that
¾ It provides comparison values to aid with early detection of
malfunctions
¾ It allows warranty claims to be dealt with more easily.

CAUTION
Ensure cleanliness during all work.
• Please observe the requirements for pressure fluids
mentioned in Section 9 Assembly and bringing into first
use.
• Clean the external environment of couplings/joints and
devices before disassembly. Do not use cleaning wool or
cloths containing fibres for cleaning.
• Seal all openings using protective caps.
• Bleed the hydraulic product after each item of servicing
32
26/32 Bosch Rexroth AG Hydraulics General product information RE 07008

12.3.1 Inspection procedures and test equipment, 12.3.2 Location of testing and measuring points
general
IMPORTANT
The following are some of the typical inspection and testing
procedures that are regularly used in connection with hydraulic Please refer to the Operating Instructions for the installation
systems and components. location of filling level indicators, filling points, drainage points,
filters, testing points, strainers, solenoids, etc. that require reg-
IMPORTANT ular inspection and servicing.
Keep the indicated typical test equipment ready for this type of
work.
12.3.3 Inspection and servicing plan, hydraulic
Type of test Typical test Typical products, general
equipment testing activities
The graph illustrates the concept of wear/wear margin.
Pressure Pressure gauge Checking of The wear margin is a characteristic feature used to describe
measure- or sensor with the condition of the system for the purpose of maintenance.
• specified pressure
ment suitable measuring
range and connec- • opening pressure 5
tion pipe and con-
• pressure difference
nection coupling
before and after the Z0
object under test 100%

Visual – Checks for


inspection
• all components
securely seated 1
• damage
4
• wear 6
• leakage (formation of 0
oil droplets) t0 ts ti1 ti2
• presence of all 2
3
warning and
informative signs 1 Wear margin Z0
2 Time t
Touch – Checks for
inspection 3 Repair (corrective maintenance) time (ti2 – ti1)
• unusual local
vibrations 4 Damage threshold (damage time tS)
5 Desired condition after corrective maintenance
Temperature Temperature Checks for 6 Failure
inspection measuring
• unusual local
instrument
temperature zones
The reduction in the wear margin reflects wear. The curve rep-
resents one possible form of the wear profile during the period
Acoustic – Checks for
of use. It is determined during inspection and varies depend-
inspection
• changes in running ing, firstly, on the system itself (e.g. material selection, sur-
noise of the unit face treatment, quality) and secondly on external influences
or boundary conditions such as servicing levels, corrosive cir-
• changes in flow noise culating air and dust. Thirdly, it depends on how the system
• changes in operating is operated; whether with partial load or partially with excess
noise in the unit and load, whether it is subject to surge loads or steady load, etc.
valve control. Where hydraulic systems are concerned, the curve is also influ-
enced by the cleanliness class and degree of fouling of the
pressure fluid, the number of cycles and the ambient condi-
tions.
33
RE 07008 General product information Hydraulics Bosch Rexroth AG 27/32

All the factors mentioned above can exert an influence on the 12.3.5 Inspection and servicing plan: electrics and
curve but this need not necessarily adversely affect the quality control system
of its information, as wear always signifies the reduction in the
wear margin, which is understood to be the primary initial vari-
able before wear commences. IMPORTANT
Consequently, this means that a sudden change in the wear The product-specific inspection and servicing plan for electrics
1
margin must also count as wear, and that the element of time and control systems can be found in the Operating Instruc-
on its own is not of decisive importance for wear, but is of con- tions.
siderable interest in the assessment and evaluation of such
wear.
An increase in the wear margin to over 100 % above its base-
line may be achieved through corrective maintenance, if such 12.3.6 Lubrication points, lubricants, intervals
measures entail an improvement and this increase is estab-
lished as the new desired condition for future corrective main- IMPORTANT
tenance.
The details of the specified lubricants, lubrication points and
Certain system parts may be subject to a wear margin which associated lubrication cycles can be found in the Operating
diminishes in such a way that the time available for use is insuf- Instructions.
ficient for the requirements of the plant or operation. In this
case, investigations must be carried out to ascertain whether
the introduction of suitable technical measures might counter
this reduction in the wear margin to a satisfactory extent. The
time and expenditure required for such measures must natu-
12.3.7 Set values of valves, regulators and
rally be kept in reasonable proportion to the expected degree signalling elements
of success.
Pressure and flow control valves, pump regulators and signal-
If such conditions arise, we refer to these parts as weak points. ling elements such as pressure sensors, pressure switches,
Since their elimination may provide economic and safety limit switches and temperature regulators are given their opti-
advantages, weak points require to be rectified immediately. mum setting when the system is brought into first use.

IMPORTANT Check regularly whether all values are correctly set with the aid
of the hydraulics diagram and the documented values.
The inspection and servicing plan for your particular product
can be found in the Operating Instructions.
DANGER
The set values of valves with position switches shall only
12.3.4 Inspection and servicing plan, be calibrated or readjusted at the factory.
electrohydraulic systems The set values of safety valves shall not be altered by the
user. Any readjustment shall be performed by authorised
Electrohydraulic systems with proportional valves must be ser- testing bodies only.
viced in accordance with hydraulic requirements and strate-
Too low a pressure difference between the operating pres-
gies. However, technical control components must also be
sure and the opening pressure can lead to frequent opening
incorporated in these servicing cycles.
of safety valves. This leads to increased power losses and an
On this basis, an overall strategy for system servicing must be unacceptable increase in temperature of the pressure fluid. In
developed and documented. this event, select a lower operating pressure.

IMPORTANT
The appropriate component characteristics relevant to servic-
ing can be found in the Operating Instructions.
34
28/32 Bosch Rexroth AG Hydraulics General product information RE 07008

12.3.8 Replacement of pressure fluid filters and


ventilation filters CAUTION
In certain circumstances the contamination indicator does
not show a required filter replacement.
CAUTION
If the check function never indicates filter replacement and the
Unfiltered pressure fluid filters lead to increased wear of contamination indicator is functioning correctly, this may have
all the system’s hydraulic products and can cause func- the following causes:
tional failures with dangerous effects. Therefore, always ¾ Faulty filter
replace contaminated oil filters immediately.
¾ A bypass valve may have been installed and is not closing
Clogged ventilation filters result in inadequate cooling and correctly, e.g. due to the entry of dirt particles.
can therefore cause excessive heating up and malfunc-
tions of the hydraulic system. Therefore, always replace
contaminated ventilation filters immediately.
• Clogged filters must always be replaced immediately. 12.4 Service and storage lives of hose lines
Do not clean clogged filters.
• Allow the contents of the replaced oil filter to drip and IMPORTANT
fully drain. In terms of the service life of hydraulic hose lines in these
• Dispose of the filter in accordance with the applicable Operating Instructions, replacement and storage lives are mea-
regulations. sured from the date of manufacture of the hose line.
Even when properly stored and subjected to permissible loads,
Exact instructions on how to replace a filter can be found in the seals, hoses and hose lines undergo a natural ageing process.
Filter manufacturer’s instructions for use. The replacement and storage lives of seals, hoses and hose
lines are therefore limited (see 8.2 Seals, hoses and hose
lines).

12.3.9 Checking filters with a contamination indicator


DANGER
Filters with contamination indicators continuously measure the
degree of fouling. The dirt-retention capacity of the filter is uti- Hose lines must be replaced in accordance with the provi-
lized to the full. sions of the servicing plan, even if there are no detectable
technical defects in the hose line.
IMPORTANT Hoses that have already been used as part of a hose line
Check the contamination indicator when the pressure fluid is shall not be reused in a hose line.
warm (during or immediately after operation).
The first use may have changed the properties of the hose
If the ambient temperature is low or the pressure fluid is cold, material to such an extent that reuse of the hose repre-
its high viscosity may cause clogging to be indicated, although sents a very high risk.
the pressure fluid is in fact clean.
Procedure:
1. Wait until the hydraulic product has reached operating
temperature.
2. Press the indicator button (check function):
If the indicator button pops out again immediately, the filter
must be replaced by the end of the shift at the latest.

Due to the progressive loss in pressure as the filter becomes


increasingly contaminated, the indicator point has a certain
reserve capacity, i.e. generally sufficient for a work shift of 8 h.
If the filter is not replaced after 8 h, dirt may penetrate the sys-
tem, resulting in contamination of the hydraulic product.
35
RE 07008 General product information Hydraulics Bosch Rexroth AG 29/32

12.5 Topping up the pressure fluid 12.7 Repair

IMPORTANT IMPORTANT
Only pressure fluids specified in the Operating Instructions are Repair (corrective maintenance) is the restoring of the desired
to be used. condition.
1
When changing or topping up the pressure fluid, fill the pres- In addition, observe the special safety instructions in
sure fluid tank on the hydraulic product as follows: 12 Maintenance and the safety instructions in the Operating
Instructions.
1. Fill the pressure fluid tank using a special filling unit with
an integral filter (min. 10 μm).
2. Drop the system pressure right down by resetting the
pump. Set the pressure setting value on the pump pres- DANGER
sure control to minimum or zero pressure.
Ensure cleanliness during all work.
3. Fill and bleed the line system of the hydraulic product from
the unit to the cylinder. To do this actuate the cylinder in • Clean the external environment of couplings/joints and
both directions, see Operating Instructions. devices before disassembly. Do not use cleaning wool or
cloths containing fibres for cleaning.
4. Top up the pressure fluid volume to the specified quantity.
• Seal all openings using protective caps.
5. Raise the pump pressure to the system pressure.
• Bleed the hydraulic product after each item of repair work.
The hydraulic product is ready for operation.
• If appropriate, follow the procedure for bringing into first
6. Carry out a test run. use, see 9.3 Bringing into first use, subsequent bringing
7. Check the level of the fluid after the hydraulic product has into use.
warmed up to the operating temperature and adjust if nec- • Document any amendments/additional information that
essary. should be included in the Operating Instructions.

IMPORTANT
Check the contamination indicator when the pressure fluid is
warm (during or immediately after operation).
If the ambient temperature is low or the pressure fluid is cold,
its high viscosity may cause clogging to be apparently indi-
cated.

12.6 Servicing pressure accumulators

DANGER
Pressure accumulators are subject to the national legisla-
tion on safety requirements for pressure vessels applica-
ble in the place of installation.
Observe the Pressure Equipment Directive 97/23/EC.

IMPORTANT
The gas precharge pressure is measured with a testing and fill-
ing device.
Details of the procedure can be found in the Operating Instruc-
tions.
Inspection and servicing
• Carry out the tests required by law.
• Test and monitor the gas precharge pressure regularly.
36
30/32 Bosch Rexroth AG Hydraulics General product information RE 07008

12.7.1 General safety instructions for repair work


WARNING

DANGER Do not perform any welding, soldering or mechanical work


on accumulator vessels.
Repair work shall only be done by an authorised hydraulics Welding and soldering carry a risk of explosion!
expert who has the required specialist hydraulics knowl-
Mechanical tampering may cause the vessel to burst and
edge.
the operating permit will be withdrawn.
Specialist hydraulics knowledge means, among other things,
Do not charge hydrostatic accumulators with oxygen or air.
that the person can read and fully understand hydraulics draw-
Risk of explosion!
ings. In particular, he must fully comprehend the range of func-
tions of the integrated safety components. Depressurise the system before working on hydraulic
installations.
Components may only be dismantled for the purpose of repair
to the extent described in the Operating Instructions. Improper installation can lead to serious damage to per-
sons and property.
Never repair a defective safety valve. It must be completely
replaced.
Faulty parts may only be replaced by new, interchangeable,
tested components in original-equipment quality. Any devia- 13.2 Safety devices relating to
tions from this can be found in the Operating Instructions.
hydraulic pressure accumulators
Before each subsequent bringing into use after repair work, the
hydraulic product shall be accepted by a hydraulics expert. The equipping, installation and operation of hydrostatic accu-
The operator of the hydraulic product is required to check by mulators is regulated by the national implementation of the EU
means of a servicing record that the inspection and servicing Pressure Equipment Directive 97/23/EC and additionally in the
plan as been complied with. Federal Republic of Germany by the Technical Regulations for
Pressure Vessels (TRB). This legislation requires the following
Pressure vessels have to be pressure tested every 10 years safety equipment:
and the information recorded in accordance with the Pressure
Equipment Directive 97/23/EC or its implementation in national ¾ Device to protect against excessive pressure
legislation. (prototype-tested)
¾ Pressure relief device
¾ Pressure measuring device
¾ Test gauge connection
13 General information about
¾ Shut-off device
hydraulic pressure accumulators
¾ Optional: electromagnetically operated pressure relief
device
13.1 General ¾ Safety device to protect against overheating.

The regulations applicable at the place of installation concern-


ing hydraulic pressure accumulators (hydrostatic accumula- IMPORTANT
tors) must be observed before bringing into use and during
operation. See the Operating Instructions.

The plant operator bears sole responsibility for compliance with


the existing regulations.
Hydrostatic accumulators are subject to the national implemen-
tation of the EU Pressure Equipment Directive 97/23/EC.
Documents supplied with accumulators must be preserved
with care; they will be required during recurring inspections by
specialists.
The bringing into use of hydrostatic accumulators shall be car-
ried out by trained expert personnel only.
37
RE 07008 General product information Hydraulics Bosch Rexroth AG 31/32

14 Hydraulic systems 14.1 Effects of leaks in the hydraulic system


on the machine
Hydraulic systems are generally intended for installation in
machines or systems. In addition to the basic information about If pressure fluid escapes from the hydraulic system and comes
the installed components, the information contained in the into contact with hot surfaces on the machine, this can lead to
Operating Instructions made available for each hydraulic sys- the generation of life-threatening smoke, fire and/or other dan-
tem by Bosch Rexroth also applies to hydraulic systems. 1
gerous operating conditions.
By installing the hydraulic system in a machine or system, the These risks shall be determined by the machine manufacturer
interaction of the hydraulic system with the overall machine by means of a hazard analysis and if necessary provision made
may give rise to changes in the potential dangers. In particular for the appropriate safety devices.
the effect of hydraulic and electrical control of hydraulic drives
that create mechanical movement are to be considered.
This information shall be included in the hazard analysis/risk
assessment of the overall machine carried out by its supplier
and in the Operating Instructions of the overall machine. This
also applies to the specification of the interfaces between the
hydraulic system and the overall machine.
Hydraulic systems are subject to legislation including the Pres-
sure Equipment Directive and other relevant EU directives that
have been implemented in national legislation. Exact informa-
tion can be found in the EU Conformity Declaration or Manu-
facturer’s Declaration that is supplied with the hydraulic system
or the hydraulic product.

WARNING
Before installing a hydraulic system in a machine or mod-
ifying an existing hydraulic system in a machine, satisfy
yourself that
¾ the hydraulic system is suitable for its application in the
machine
¾ the ambient conditions in the machine are suitable and/or
permissible for the use of the hydraulic system
¾ other installed items on or in the machine cannot disturb
or endanger the functioning or the safe operation of the
hydraulic system.

If the overall machine is to be used in a potentially explosive


atmosphere, then it must be ensured that the hydraulic system
has been designed and is suitable for this use.
38
32/32 Bosch Rexroth AG Hydraulics General product information RE 07008

DE Bestellinformation für deutsche Produktinformation: RD 07008


EN Ordering Information for Product Information in English: RE 07008
FR Information de commande pour la notice française Informations générales sur les produits : RF 07008
IT Informazioni d’ordine per le informazioni tedesche sul prodotto: RI 07008
ES Información para el pedido de la información del producto en español: RS 07008
FI Tilaustiedot - suomenkieliset tuotetiedot: RSF 07008
NL Bestelinformatie voor Nederlandse productinformatie: RNL 07008
SV Beställningsnummer för svensk produktinformation: RSK 07008
PT Informação dos dados de encomenda para informação de produto alemã: RP 07008
DA Bestillingsinformationer vedr. dansk produktinformation: RDK 07008
EL Πληροφορίερ παραγγελίαρ για τιρ γερμανικέρ πληροφορίερ προϊϋντορ: RGR 07008

[Link]
→ Datenblatt-Suche/Datasheet search
→ Suche nach Datenblatt/Search by datasheet

07008

Bosch Rexroth AG © All rights reserved, Bosch Rexroth AG, including applications for intellec-
Hydraulics tual property rights. We reserve all power of disposal, rights of reproduction
Zum Eisengiesser 1 and issue.
97816 Lohr am Main, Germany
The data specified above only serve to describe the product.
Tel. + 49 (0) 93 52 / 18-0
No statements concerning a certain condition or suitability for a certain
Fax + 49 (0) 93 52 / 18-23 58
application can be derived from our information. The given information does
documentation@[Link]
not release the user from the obligation of own judgement and verification. It
[Link]
must be remembered that our products are subject to a natural process of
wear and aging.
39

RE 90220/05.12 1/16
Hydraulic fluids based on mineral Replaces: 05.10

oils and related hydrocarbons

Application notes and requirements for Rexroth hydraulic components

Hydraulic fluids

Hydraulic fluids based Environmentally Fire-resistant, Fire-resistant,


Title on mineral oils and acceptable hydraulic water-free water-containing
related hydrocarbons fluids hydraulic fluids hydraulic fluids

Standard DIN 51524 ISO 15380 ISO 12922 ISO 12922

RE 90223
Data sheets RE 90220 RE 90221 RE 90222
(in preparation)

HL
HEPG
HLP HFDR HFC
HEES partially saturated
HLPD HFDU (ester base) HFB
Classification HEES saturated
HVLP HFDU (glycol base) HFAE
HEPR
HLPD and more HFAS
HETG
and more
40
2/16 Bosch Rexroth AG Hydraulic fluids based on mineral oils RE 90220/05.12

Contents
1 Basic information .................................................................................................................................................................................................3
1.1 General instructions ...................................................................................................................................................................................3
1.2 Scope ...........................................................................................................................................................................................................3
1.3 Safety instructions .....................................................................................................................................................................................3
2 Solid particle contamination and cleanliness levels ....................................................................................................................................4
3 Selection of the hydraulic fluid ..........................................................................................................................................................................5
3.1 Selection criteria for the hydraulic fluid .................................................................................................................................................5
3.1.1 Viscosity .................................................................................................................................................................................................5
3.1.2 Viscosity-temperature behavior........................................................................................................................................................5
3.1.3 Wear protection capability ................................................................................................................................................................6
3.1.4 Material compatibility..........................................................................................................................................................................6
3.1.5 Aging resistance .................................................................................................................................................................................6
3.1.6 Air separation ability (ASA)...............................................................................................................................................................6
3.1.7 Demulsifying ability and water solubility .........................................................................................................................................6
3.1.8 Filterability .............................................................................................................................................................................................6
3.1.9 Corrosion protection ..........................................................................................................................................................................6
3.1.10 Additivation .........................................................................................................................................................................................7
3.2 Classification and fields of application ................................................................................................................................................7
4 Hydraulic fluids in operation ..............................................................................................................................................................................9
4.1 General .........................................................................................................................................................................................................9
4.2 Storage and handling ...............................................................................................................................................................................9
4.3 Filling of new systems...............................................................................................................................................................................9
4.4 Hydraulic fluid changeover ......................................................................................................................................................................9
4.5 Mixing and compatibility of different hydraulic fluids .........................................................................................................................9
4.6 Re-additivation............................................................................................................................................................................................9
4.7 Foaming behavior .......................................................................................................................................................................................9
4.8 Corrosion ...................................................................................................................................................................................................10
4.9 Air ................................................................................................................................................................................................................10
4.10 Water ........................................................................................................................................................................................................10
4.11 Fluid servicing, fluid analysis and filtration .......................................................................................................................................10
5 Disposal and environmental protection ........................................................................................................................................................11
6 Other hydraulic fluids based on mineral oil and related hydrocarbons .................................................................................................12
7 Glossary ...............................................................................................................................................................................................................15
41
RE 90220/05.12 Hydraulic fluids based on mineral oils Bosch Rexroth AG 3/16

1 Basic information
1.1 General instructions Notes:
In the market overview RE 90220-01, hydraulic fluid based on
The hydraulic fluid is the common element in any hydraulic mineral oil are described which, according to the information of
component and must be selected very carefully. Quality and the lubricant manufacturer, feature the respective parameters
cleanliness of the hydraulic fluid are decisive factors for the of the current requirements standard DIN 51524 and other
operational reliability, efficiency and service life of a system. parameters which are of relevance for suitability in connection 1
Hydraulic fluids must conform, be selected and used in with Rexroth components.
accordance with the generally acknowledged rules of technol- These specifications are not checked or monitored by Bosch
ogy and safety provisions. Reference is made to the country- Rexroth. The list in the market overview does not therefore
specific standards and directives (in Germany the directive of represent a recommendation on the part of Rexroth or approval
the Employer's Liability Insurance Association BGR 137). of the respective hydraulic fluid for use with Rexroth compo-
This data sheet includes recommendations and regulations nents and does not release the operator from his responsibility
concerning the selection, operation and disposal of hydraulic regarding selection of the hydraulic fluid.
fluids based on mineral oils and related hydrocarbons in the Bosch Rexroth will accept no liability for its components
application of Rexroth hydraulic components. for any damage resulting from failure to comply with the
The individual selection of hydraulic fluid or the choice of notes below.
classification are the responsibility of the operator.
It is the responsibility of the user to ensure that appropriate 1.3 Safety instructions
measures are taken for safety and health protection and to Hydraulic fluids can constitute a risk for persons and the
ensure compliance with statutory regulations. The recommen- environment. These risks are described in the hydraulic fluid
dations of the lubricant manufacturer and the specifications safety data sheets. The operator is to ensure that a current
given in the safety data sheet are to be observed when using safety data sheet for the hydraulic fluid used is available and
hydraulic fluid. that the measures stipulated therein are complied with.
This data sheet does not absolve the operator from verifying
the conformity and suitability of the respective hydraulic fluid
for his system. He is to ensure that the selected fluid meets the
minimum requirements of the relevant fluid standard during the
whole of the period of use.
Other regulations and legal provisions may also apply. The
operator is responsible for their observance, e.g. EU directive
2004/35/EG and their national implementations. In Germany
the Water Resources Act (WHG) is also to be observed.
We recommend that you maintain constant, close contact
with lubricant manufacturers to support you in the selection,
maintenance, care and analyses.
When disposing of used hydraulic fluids, apply the same care
as during use.

1.2 Scope
This data sheet must be observed when using hydraulic fluids
based on mineral oils and related hydrocarbons in Bosch
Rexroth hydraulic components.
Please note that the specifications of this data sheet may be
restricted further by the specifications given in the product
data sheets for the individual components.
The use of the individual hydraulic fluids in accordance with
the intended purpose can be found in the safety data sheets or
other product description documents of the lubricant manufac-
turers. In addition, each use is to be individually considered.
Rexroth hydraulic components may only be operated with
hydraulic fluids based on mineral oils and related hydrocarbons
according to DIN 51524 if specified in the respective compo-
nent data sheet or if Rexroth approval for use is furnished.
42
4/16 Bosch Rexroth AG Hydraulic fluids based on mineral oils RE 90220/05.12

2 Solid particle contamination and cleanliness levels


Solid particle contamination is the major reason for faults oc- Hydraulic fluids frequently fail to meet these cleanliness
curring in hydraulic systems. It may lead to a number of effects requirements on delivery. Careful filtering is therefore required
in the hydraulic system. Firstly, single large solid particles during operation and in particular, during filling in order to
may lead directly to a system malfunction, and secondly small ensure the required cleanliness levels. Your lubricant manu-
particles cause continuous elevated wear. facturer can tell you the cleanliness level of hydraulic fluids
as delivered. To maintain the required cleanliness level over
For hydraulic fluids, the cleanliness level is given as a three-
the operating period, you must use a reservoir breather filter.
digit numerical code in accordance with ISO 4406. This
If the environment is humid, take appropriate measures, such
numerical code denotes the number of particles present in
as a breather filter with air drying or permanent off-line water
a hydraulic fluid for a defined quantity. Moreover, foreign solid
separation.
matter is not to exceed a mass of 50 mg/kg (gravimetric
examination according to ISO 4405). Note: the specifications of the lubricant manufacturer relat-
ing to cleanliness levels are based on the time at which the
In general, compliance with a minimum cleanliness level of
container concerned is filled and not on the conditions during
20/18/15 in accordance with ISO 4406 or better is to be main-
transport and storage.
tained in operation. Special servo valves demand improved
cleanliness levels of at least 18/16/13. A reduction in cleanli- Further information about contamination with solid matter and
ness level by one level means half of the quantity of particles cleanliness levels can be found in brochure RE 08016.
and thus greater cleanliness. Lower numbers in cleanliness
levels should always be striven for and extend the service life
of hydraulic components. The component with the highest
cleanliness requirements determines the required cleanliness
of the overall system. Please also observe the specifications in
table 1: "Cleanliness levels according to ISO 4406" and in the
respective data sheets of the various hydraulic components.

Table 1: Cleanliness levels according to ISO 4406

Particles per 100 ml


Up to and Scale number
More than
including
8,000,000 16,000,000 24 20 / 18 / 15
4,000,000 8,000,000 23 > 4 μm > 6 μm > 14 μm
2,000,000 4,000,000 22
1,000,000 2,000,000 21
500,000 1,000,000 20
250,000 500,000 19
130,000 250,000 18
64000 130,000 17
32000 64000 16
16000 32000 15
8000 16000 14
4000 8000 13
2000 4000 12
1000 2000 11
500 1000 10
250 500 9
130 250 8
64 130 7
32 64 6
43
RE 90220/05.12 Hydraulic fluids based on mineral oils Bosch Rexroth AG 5/16

3 Selection of the hydraulic fluid


The use of hydraulic fluids based on mineral oils for Rexroth If the viscosity of a hydraulic fluid used is above the permitted
hydraulic components is based on compliance with the operating viscosity, this will result in increased hydraulic-me-
minimum requirements of DIN 51524. chanical losses. In return, there will be lower internal leakage
losses. If the pressure level is lower, lubrication gaps may not
be filled up, which can lead to increased wear. For hydraulic
3.1 Selection criteria for the hydraulic fluid pumps, the permitted suction pressure may not be reached, 1
The specified limit values for all components employed in the which may lead to cavitation damage.
hydraulic system, for example viscosity and cleanliness level,
If the viscosity of a hydraulic fluid is below the permitted
must be observed with the hydraulic fluid used, taking into
operating viscosity, increased leakage, wear, susceptibility to
account the specified operating conditions.
contamination and a shorter component life cycle will result.
Hydraulic fluid suitability depends, amongst others, on the
following factors: 3.1.2 Viscosity-temperature behavior
For hydraulic fluids, the viscosity temperature behavior (V-T
3.1.1 Viscosity
behavior) is of particular importance. Viscosity is characterized
Viscosity is a basic property of hydraulic fluids. The permissible in that it drops when the temperature increases and rises when
viscosity range of complete systems needs to be determined the temperature drops; see Fig. 1 "Viscosity temperature chart
taking account of the permissible viscosity of all components for HL, HLP, HLPD (VI 100)". The interrelation between viscos-
and it is to be observed for each individual component. ity and temperature is described by the viscosity index (VI).
The viscosity at operating temperature determines the The viscosity temperature diagram in Fig. 1 is extrapolated
response characteristics of closed control loops, stability and in the < 40 °C range. This idealized diagram is for reference
damping of systems, the efficiency factor and the degree of purposes only. Measured values can be obtained from your
wear. lubricant manufacturer and are to be preferred for design
purposes.
We recommend that the optimum operating viscosity range
of each component be kept within the permissible temperature
range. This usually requires either cooling or heating, or both.
The permissible viscosity range and the necessary cleanliness
level can be found in the product data sheet for the component
concerned.

Fig. 1: Viscosity-temperature chart for HL, HLP, HLPD (VI 100, double logarithmic representation)
40° 20° 0° 20° 40° 60° 80° 100°
1600
1000
600
400
VG 68
VG

VG 00
VG

VG
VG

VG
VG 6

1
15
15
10

32
22

200
0

100
Viscosity Q [mm2/s]

60

40

20

10

5
40° 25° 10° 0° 10° 30° 50° 70° 90° 115°
Temperature t [°C]
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3.1.3 Wear protection capability 3.1.6 Air separation ability (ASA)


Wear protection capability describes the property of hydraulic The air separation ability (ASA) describes the property of a
fluids to prevent or minimize wear within the components. hydraulic fluid to separate undissolved air. Hydraulic fluids
The wear protection capability is described in DIN 51524-2,-3 contain approx. 7 to 13 percent by volume of dissolved air
via test procedures "FZG gear test rig" (ISO 14635-1) and (with atmospheric pressure and 50 °C). Hydraulic fluids
"Mechanical test in the vane pump" (ISO 20763). From always contain dissolved air. During operation, dissolved air
ISO VG 32 DIN 51524-2,-3 prescribes a rating of at least may be transformed into undissolved air, leading to cavitation
10 (FZG test). At present, the FZG test cannot be applied damages. Fluid classification, fluid product, reservoir size and
to viscosity classes < ISO VG 32. design must be coordinated to take into account the dwell
time and ASA value of the hydraulic fluid. The air separation
3.1.4 Material compatibility capacity depends on the viscosity, temperature, basic fluid and
aging.
The hydraulic fluid must not negatively affect the materials
It cannot be improved by additives.
used in the components. Compatibility with coatings, seals,
hoses, metals and plastics is to be observed in particular. The According to DIN 51524 for instance, an ASA value d 10
fluid classifications specified in the respective component data minutes is required for viscosity class ISO VG 46,
sheets are tested by the manufacturer with regard to material 6 minutes are typical, lower values are preferable.
compatibility. Parts and components not supplied by us are to
be checked by the user. 3.1.7 Demulsifying ability and water solubility
The capacity of a hydraulic fluid to separate water at a defined
Table 2: Known material incompatibilities
temperature is known as the demulsifying ability. ISO 6614
Classification Incompatible with: defines the demulsifying properties of hydraulic fluids.
HLxx classifications with EPDM seals For larger systems with permanent monitoring, a demulsifying
Zinc- and ash/free fluid with good water separation capability (WSC) is recom-
with bronze-filled PTFE seals
hydraulic fluids mended. The water can be drained from the bottom of the
reservoir. In smaller systems (e.g. in mobile machines), whose
3.1.5 Aging resistance fluid is less closely monitored and where water contamination
The way a hydraulic fluid ages depends on the thermal, into the hydraulic fluid, for instance through air condensation,
chemical and mechanical stress to which it is subjected. Aging cannot be ruled out completely, an HLPD fluid is recom-
resistance can be greatly influenced by the chemical composi- mended.
tion of the hydraulic fluids. The demulsifying ability up to ISO-VG 100 is given at 54 °C,
High fluid temperatures (e.g. over 80 °C) result in a approxi- and at 82 °C for fluids with higher viscosity.
mate halving of the fluid service life for every 10 °C temperature Water emulsifying HLPD hydraulic fluids have no, or a very
increase and should therefore by avoided. The halving of the poor, demulsifying ability.
fluid service life results from the application of the Arrhenius
equation (see Glossary). 3.1.8 Filterability

Table 3: Reference values for temperature-dependent Filterability describes the ability of a hydraulic fluid to pass
aging of the hydraulic fluid through a filter, removing solid contaminants. The hydraulic
fluids used require a good filterability, not just when new, but
Reservoir temperature Fluid life cycle also during the whole of their service life. Depending on the
80 °C 100 % basic fluid used and the additives (VI enhancers) there are
90 °C 50 % great differences here.
100 °C 25 % The filterability is a basic prerequisite for cleanliness, servicing
and filtration of hydraulic fluids. Filterability is tested with the
new hydraulic fluid and after the addition of 0.2 % water. The
Hydraulic fluids based on mineral oils and related hydrocar-
underlying standard (ISO 13357-1/-2) stipulates that filterability
bons are tested with 20% water additive during testing of
must have no negative effects on the filters or the hydraulic
aging resistance according to ISO 4263-1.
fluid, see chapter 4 "Hydraulic fluids in operation".
The calculated fluid service life is derived from the results of
tests in which the long-term characteristics are simulated in 3.1.9 Corrosion protection
a short period of time by applying more arduous conditions
Hydraulic fluids should not just prevent corrosion formation
(condensed testing). This calculated fluid service life is not to
on steel components, they must also be compatible with
be equated to the fluid service life in real-life applications.
non-ferrous metals and alloys. Corrosion protection tests on
Table 3 is a practical indicator for hydraulic fluids with water different metals and metal alloys are described in DIN 51524.
content < 0.1%, cf. chapter 4.10. "Water". Hydraulic fluids that are not compatible with the materials
listed above must not be used, even if they are compliant with
ISO 51524.
Rexroth components are usually tested with HLP hydraulic
fluids or corrosion protection oils based on mineral oils before
they are delivered.
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3.1.10 Additivation
The properties described above can be modified with the
help of suitable additives. A general distinction is made for
fluids between heavy metal-free and heavy metal-containing
(generally zinc) additive systems. Both additive systems are 1
most often incompatible with each other. The mixing of these
fluids must be avoided even if the mixing ratio is very low. See
chapter 4, "Hydraulic fluids in operation”.
Increasing additivation generally leads to deteriorated air
separation ability (ASA) and water separation capability
(WSC) of the hydraulic fluid. According to the present state
of knowledge, all hydraulic fluids described in this document,
independently of the actual additivation, can be filtered using
all filter materials with all known filtration ratings t 1 μm without
filtering out effective additives at the same time.
Bosch Rexroth does not prescribe any specific additive system.

3.2 Classification and fields of application

Table 4: Classification and fields of application


Typical field of
Classification Features Notes
application
HL fluids Hydraulic fluids HL fluids can be HL fluids may be used only for components whose product data
according to predominantly only used in hydraulic sheet specifically allows HL fluids. For components which have
DIN 51524-1 with additives for systems that do not not been approved according to the product data sheet, please
VI = 100 oxidation and corro- pose any require- consult your Bosch Rexroth sales partner.
sion protection, but ments as to wear
Hydraulic fluids that only comply with the requirements of classes
no specific additives protection.
HL and HR in accordance with ISO 11158 without proving that
for wear protection in
DIN 51524-1 is also met may be used only with written approval
case of mixed friction
of Bosch Rexroth AG.
Observe restrictions as to pressure, rotation speed etc.
HLP fluids Hydraulic fluid with HLP fluids are suit- For information on approved components, please refer to the
according to corrosion, oxidation able for most fields respective product data sheet. For components which have not
DIN 51524-2 and verified wear of application and been approved according to the product data sheet, please
VI = 100 protection additives components provided consult your Bosch Rexroth sales partner.
the temperature and
For the viscosity classes VG10, VG15 and VG22, DIN 51524
viscosity provisions
defines no requirements as to wear protection (DIN 51354 part 2
are observed.
and DIN 51389 part 2). Beyond the requirements of DIN 51524
part 2, we require the same base oil type, identical refining
procedure, identical additivation and identical additivation level
across all viscosity classes.

Continued on page 8
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Table 4: Classification and fields of application (continued from page 7)


Typical field of
Classification Features Notes
application
HVLP fluids HLP hydraulic fluid HVLP fluids are used For information on approved components, please refer to the
according to with additional in systems operated respective product data sheet. For components which have not
DIN 51524-3 improved viscosity over a wide tempera- been approved according to the product data sheet, please
VI > 140 temperature behavior ture range. consult your Bosch Rexroth sales partner.
The same notes and restrictions as defined for HLP fluids apply
accordingly.
The effect on Rexroth components (e.g. compatibility with material
seals, wear resistance capacity) may differ when using related
hydrocarbons instead of mineral oils, cf. Table 6, line 8.
When using HVLP fluids, the viscosity may change on account of
the shear of the long-chain VI enhancers. The viscosity index, high
at the start, decreases during operation. This needs to be taken
into account when selecting the hydraulic fluid.
The only value at present that can be used to assess viscosity
changes in operation is the result of the test in accordance with
DIN 51350 part 6. Please note that there are practical applications
that create a much higher shear load on such fluids than can be
achieved by this test. Up to VI < 160, we recommend a maximum
permitted viscosity drop of 15 %, viscosity at 100 °C.
The viscosity limits given by Bosch Rexroth for its components
are to be observed for all operating conditions, even after the
hydraulic fluids have sheared.
HVLP fluids should be used only if required by the temperature
ranges of the application.
HLPD fluids HLP and HVLP HLPD and HVLPD For information on approved components, please refer to the
according to hydraulic fluid with fluids are used in respective product data sheet. For components which have not
DIN 51524-2, additional detergent systems where been approved according to the product data sheet, please
and or dispersant deposits as well consult your Bosch Rexroth sales partner.
HVLPD fluids in
additives as solid or liquid
accordance with Some of these fluids are able to absorb significant quantities of
contamination need
DIN 51524-3 water (> 0.1 %). This may have negative implications for the wear
to be kept temporarily
protection and the aging properties of the fluid.
suspended
The wetting ability of these fluids varies largely depending on the
product. Therefore it is not correct to say that they are generally all
very well able to prevent stick-slip.
In individual cases where higher water contamination is to be
expected (such as in steelworks or under humid conditions),
the use of HLPD/HVLPD fluids cannot be recommended as the
emulsified water does not settle in the reservoir but is evaporated
in heavily loaded positions. For such cases, we recommend using
HLP hydraulic fluids with particularly good demulsifying ability. The
water collected at the reservoir bottom is to be drained regularly.
If HLPD/HVLPD fluids are used, contamination does not settle. It
rather remains suspended and needs to be filtered out or removed
by appropriate draining systems. For this reason, the filter area
must be increased.
HLPD/HVLPD fluids may contain additives that in the long run
are incompatible with plastics, elastomers and non-ferrous metals.
Furthermore, these additives may lead to the premature clogging
of hydraulic filters. Therefore, test the filterability and the selection
of the filter material in consultation with the filter manufacturer.
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4 Hydraulic fluids in operation


4.1 General For information on changing over hydraulic fluids with different
classifications please refer to VDMA 24314, VDMA 24569 and
The properties of hydraulic fluids can change continually during ISO 15380 appendix A.
storage and operation.
Bosch Rexroth will not accept liability for any damage to its
Please note that the fluid standard DIN 51524 merely components resulting from inadequate hydraulic fluid change- 1
describes minimum requirements for hydraulic fluids in new overs!
condition at the time of filling into the bins. The operator of a
hydraulic system must ensure that the hydraulic fluid remains
in a utilizable condition throughout its entire period of use. 4.5 Mixing and compatibility of different
hydraulic fluids
Deviations from the characteristic values are to be clarified with
the lubricant manufacturer, the test labs or Bosch Rexroth. If hydraulic fluids from different manufacturers or different
types from the same manufacturer are mixed, gelling, silting
Please note the following aspects in operation. and deposits may occur. These, in turn, may cause foaming,
impaired air separation ability, malfunctions and damage to
4.2 Storage and handling the hydraulic system.

Hydraulic fluids must be stored correctly in accordance with If the fluid contains more than 2 % of another fluid then it is
the instructions of the lubricant manufacturer. Avoid exposing considered to be a mixture. Exceptions apply for water, see
the containers to lengthy periods of direct heat. Containers chapter 4.10 "Water".
are to be stored in such a way that the risk of any foreign liquid Mixing with other hydraulic fluids is not generally permitted.
or solid matter (e.g. water, foreign fluids or dust) ingression This also includes hydraulic fluids with the same classification
into the inside of the container can be ruled out. After taking and from the market overview RE 90220-01. If individual lubri-
hydraulic fluids from the containers, these are immediately to cant manufacturers advertise miscibility and/or compatibility,
be properly resealed. this is entirely the responsibility of the lubricant manufacturer.
Recommendation: Bosch Rexroth customarily tests all components with mineral
– Store containers in a dry, roofed place oil HLP before they are delivered.

– Store barrels on their sides Note: With connectible accessory units and mobile filtering
systems, there is a considerable risk of non-permitted mixing
– Clean reservoir systems and machine reservoirs regularly of the hydraulic fluids!
Rexroth will not accept liability for any damage to its compo-
4.3 Filling of new systems nents resulting from mixing hydraulic fluids!
Usually, the cleanliness levels of the hydraulic fluids as
delivered do not meet the requirements of our components. 4.6 Re-additivation
Hydraulic fluids must be filtered using an appropriate filter
system to minimize solid particle contamination and water in Additives added at a later point in time such as colors, wear
the system. reducers, VI enhancers or anti-foam additives, may negatively
affect the performance properties of the hydraulic fluid and
As early as possible during test operation, new systems should the compatibility with our components and therefore are not
be filled with the selected hydraulic fluid so as to reduce the permissible.
risk of accidentally mixing the fluids (see chapter 4.5 "Mixing
and compatibility of different hydraulic fluids"). Changing Rexroth will not accept liability for any damage to its compo-
the hydraulic medium at a later point represents significant nents resulting from re-additivation!
additional costs (see following chapter).
4.7 Foaming behavior
4.4 Hydraulic fluid changeover Foam is created by rising air bubbles at the surface of hydraulic
Changeovers, in particular between hydraulic fluids with fluids in the reservoir. Foam that develops should collapse as
heavy metal-free and heavy metal-containing (generally zinc) quickly as possible.
additives, frequently lead to malfunctions, see chapter 3.1.10 Common hydraulic fluids in accordance with DIN 51524 are
"Additivation". sufficiently inhibited against foam formation in new condi-
In the case of changeovers of the fluid in hydraulic systems, it tion. On account of aging and adsorption onto surfaces, the
is important to ensure compatibility of the new hydraulic fluid defoamer concentration may decrease over time, leading to a
with the remainder of the previous hydraulic fluid. We recom- stable foam.
mend obtaining a written performance guarantee from the Defoamers may be re-dosed only after consultation with the
manufacturer or supplier of the new hydraulic fluid. The quantity lubricant manufacturer and with his written approval.
of old fluid remaining should be minimized. Mixing hydraulic
fluids should be avoided, see following chapter. Defoamers may affect the air separation ability.
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4.8 Corrosion 4.11 Fluid servicing, fluid analysis and filtration


The hydraulic fluid is to guarantee sufficient corrosion protec- Air, water, operating temperature influences and solid matter
tion of components under all operating conditions, even in the contamination will change the performance characteristics of
event of impermissible water contamination. hydraulic fluids and cause them to age.
During storage and operation, hydraulic fluid based on mineral To preserve the usage properties and ensure a long service life
oils with anti-corrosion additives protect components against for hydraulic fluid and components, the monitoring of the fluid
water and "acidic" oil degradation products. condition and a filtration adapted to the application require-
ments (draining and degassing if required) are indispensable.
4.9 Air The effort is higher in the case of unfavorable usage conditions,
increased stress for the hydraulic system or high expectations
Under atmospheric conditions, the hydraulic fluid contains
as to availability and service life, see chapter 2 "Solid particle
dissolved air. In the negative pressure range, for instance in
contamination and cleanliness level".
the suction pipe of the pump or downstream of control edges,
this dissolved air may transform into undissolved air. The When commissioning a system, please note that the required
undissolved air content represents a risk of cavitation and of minimum cleanliness level can frequently be attained only by
the diesel effect. This results in material erosion of components flushing the system. Due to severe start-up contamination, it
and increased hydraulic fluid aging. may be possible that a fluid and/or filter replacement becomes
necessary after a short operating period (< 50 operating
With the correct measures, such as suction pipe and reservoir
hours).
design, and an appropriate hydraulic fluid, air intake and
separation can be positively influenced. The hydraulic fluid must be replaced in regular intervals and
tested by the lubricant manufacturer or recognized, accredited
See also chapter 3.1.7 "Air separation ability (ASA)”.
test labs. We recommend a reference analysis after com-
missioning.
4.10 Water The minimum data to be tested for analyses are:
Water contamination in hydraulic fluids can result from direct
– Viscosity at 40 °C and 100 °C
ingress or indirectly through condensation of water from the air
due to temperature variations. – Neutralization number NN (acid number AN)
Water in the hydraulic fluid may result in wear or direct failure – Water content (Karl-Fischer method)
of hydraulic components. Furthermore, a high water content in
– Particle measurement with evaluation according to ISO 4406
the hydraulic fluid negatively affects aging and filterability and
or mass of solid foreign substances with evaluation to
increases susceptibility to cavitation.
EN 12662
Undissolved water can be drained from the bottom of the
– Element analysis (RFA (EDX) / ICP, specify test method)
reservoir. Dissolved water can be removed only by using
appropriate measures. If the hydraulic system is used in humid – Comparison with new product or available trend analyses
conditions, preventive measures need to be taken, such as
– Assessment / evaluation for further use
an air dehumidifier at the reservoir vent. During operation, the
water content in all hydraulic fluids, determined according to – Also recommended: IR spectrum
the "Karl Fischer method" (see chapter 6 "Glossary") for all hy-
Compared to the pure unused hydraulic fluid, the changed
draulic fluids must constantly be kept below 0.1% (1000 ppm).
neutralization number NN (acid number AN) indicates how
To ensure a long service life of both hydraulic fluids and
many aging products are contained in the hydraulic fluid. This
components, Bosch Rexroth recommends that values below
value must be kept as low as possible. As soon as the trend
0.05% (500 ppm) are permanently maintained.
analysis notes a significant increase in the acid number, the
To ensure a long service life for the hydraulic fluids and the lubricant manufacturer should be contacted.
components, we recommend that values below 0.05 % (500
In case of warranty, liability or guarantee claims to Bosch
ppm) are permanently maintained. Detergent and or dispersant
Rexroth, service verification and/or the results of fluid analyses
hydraulic fluids (HLPD / HVLPD) are able to absorb (and keep
are to be provided.
suspended) more water. Prior to using these hydraulic fluids,
please contact the lubricant manufacturer.
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5 Disposal and environmental


protection
Hydraulic fluids based on mineral oil and related hydrocarbons
are hazardous for the environment. They are subject to a
special disposal obligation.
The respective lubricant manufacturers provide specifications 1
on environmentally acceptable handling and storage. Please
ensure that spilt or splashed fluids are absorbed with appropri-
ate adsorbents or by a technique that prevents it contaminating
water courses, the ground or sewerage systems.
It is also not permitted to mix fluids when disposing of hydraulic
fluids. Regulations governing the handing of used oils stipulate
that used oils are not to mixed with other products, e.g.
substances containing halogen. Non-compliance will increase
disposal costs. Comply with the national legal provisions
concerning the disposal of the corresponding hydraulic
fluid. Comply with the local safety data sheet of the lubricant
manufacturer for the country concerned.
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6 Other hydraulic fluids based on mineral oil and related hydrocarbons


Table 6: Other hydraulic fluids based on mineral oils and related hydrocarbons

Serial
Hydraulic fluids Features / Typical field of application / Notes
number
1 Hydraulic fluids with – Can be used without confirmation provided they are listed in the respective product
classification data sheet and are compliant with DIN 51524. Conformity with DIN 51524 must be
HL, HM, HV according verified in the technical data sheet of the fluid concerned. For classification see Table
to ISO 11158 4: "Hydraulic fluid classification”.
– Fluids only classified in accordance with ISO 11158 may be used only with prior
written approval of Bosch Rexroth AG.
2 Hydraulic fluids with – May not be used.
classification
HH, HR, HS, HG ac-
cording to ISO 11158
3 Hydraulic fluids with – DIN 51502 merely describes how fluids are classified / designated on a national
classification level.
HL, HLP, HLPD, HVLP,
– It contains no information on minimum requirements for hydraulic fluids.
HVLPD to DIN 51502
– Hydraulic fluids standardized according to DIN 51502 can be used without confirma-
tion provided they are listed in the respective product data sheet and are compliant
with DIN 51524. Conformity with DIN 51524 must be verified in the technical data
sheet of the fluid concerned. For classification see Table 4: "Hydraulic fluid clas-
sification”.
4 Hydraulic fluids with – ISO 6743-4 merely describes how fluids are classified / designated on an interna-
classification tional level. It contains no information on minimum requirements for hydraulic fluids.
HH, HL, HM, HR, HV,
– Hydraulic fluids standardized according to ISO 6743 -4 can be used without
HS, HG according to
confirmation provided they are listed in the respective product data sheet and are
ISO 6743-4
compliant with DIN 51524. Conformity with DIN 51524 must be verified in the techni-
cal data sheet of the fluid concerned. For classification see table 4: "Classification
and fields of application".
5 Lubricants and regulator – Turbine oils can be used after confirmation and with limited performance data.
fluids for turbines to
– They usually offer lower wear protection than mineral oil HLP. Classification of
DIN 51515-1 and -2
turbine oils to DIN 51515-1 comparable to HL, turbine oils to DIN 51515-2 compa-
rable to HLP.
– Particular attention must be paid to material compatibility!
6 Lube oils C, CL, CLP – Lube oils in acc. with DIN 51517 can be used after confirmation and with limited
in accordance with performance data. They are mostly higher-viscosity fluids with low wear protection.
DIN 51517 Classification: CL similar to HL fluids and CLP similar to HLP fluids.
– Particular attention must be paid to material compatibility, specifically with non-ferrous
metals!
7 Fluids to be used in – There are medical white oils and synthetic hydrocarbons (PAO).
pharmaceutical
– Can only be used after consultation and approval for use in the specific application,
and foodstuff industries,
even if they are compliant with DIN 51524.
in acc. with FDA /
USDA / NSF H1 – May be used only with FKM seals.
– Other fluids used in pharmaceutical and foodstuff industries may be used only after
confirmation.
– Attention is to be paid to material compatibility in accordance with the applicable food
law.
Caution! Fluids used in pharmaceutical and foodstuff industries should not be con-
fused with environmentally acceptable fluids!

Continued on page 13
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Table 6: Other hydraulic fluids based on mineral oils and related hydrocarbons
(continued from page 12)
Serial
Hydraulic fluids Features / Typical field of application / Notes
number
8 Hydraulic fluids of – Can only be used after consultation and approval for use in the specific application, 1
classes HVLP and even if they are compliant with DIN 51524.
HVLPD based on
– Lower pour point than HLP
related hydrocarbons
– Other wetting (polarity)
9 Automatic Transmission – ATF are operating fluids for automatic gearboxes in vehicles and machines. In special
Fluids (ATF) cases, ATFs are also used for certain synchronous gearboxes and hydraulic systems
comprising gearboxes.
– To be used only after confirmation!
– Some of these fluids have poor air separation abilities and modified wear properties.
– Check material compatibility and filterability!
10 Multi-purpose oil – Multi-purpose oils (industry) combine at least two requirements for a fluid,
(MFO) – Industry for instance metal machining and hydraulics.
– To be used only after confirmation!
– Please pay particular attention to air separation ability, modified wear properties and
the reduced material life cycle.
– Check material compatibility and filterability!
11 Multi-purpose oils – Multi-purpose oils combine requirements for wet brakes, gearboxes, motor oil
(MFO) – Mobil (STOU only) and hydraulics.
UTTO, STOU
– Fluids of the types:
– UTTO (= universal tractor transmission oil) and
– STOU (= Super Tractor super tractor universal oil)
– To be used only after confirmation!
– Please pay particular attention to shear stability, air separation ability and modified
wear properties.
– Check material compatibility and filterability!
12 Single-grade engine – To be used only after confirmation!
oils 10W, 20W, 30W
– Please pay particular attention to the air separation ability and filtering ability.
13 Multi-grade engine oils – To be used only after confirmation!
0Wx-30Wx
– Please pay particular attention to air separation ability, changes in wear protection
capability, viscosity changes during operation, material compatibility, dispersant and
detergent properties and filterability.
Caution! Multi-grade engine oils have been adapted to specific requirements in com-
bustion engines and are suitable for use in hydraulic systems only to a limited extent.
14 Hydraulic fluids for – To be used only after confirmation!
military applications to
– Please pay particular attention to air separation ability, changes in wear protection
MIL 13919 or H 540,
capability, viscosity changes during operation, material compatibility, water separa-
MIL 46170 or H 544,
tion capability and filterability.
MIL 5606 or H 515,
MIL 83282 or H 537, Caution! Hydraulic fluids for military applications do not meet the current requirements
MIL 87257 for high-quality hydraulic fluids and are suitable for use only to a limited degree.
15 Motor vehicle transmis- – Motor vehicle transmission oil can be used after confirmation and with limited
sion oils performance data.
– Pay particular attention to wear protection, material compatibility, specifically with
non-ferrous metals, as well as viscosity!
Continued on page 14
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Table 6: Other hydraulic fluids based on mineral oils and related hydrocarbons
(continued from page 13)
Serial
Hydraulic fluids Features / Typical field of application / Notes
number
16 Diesel, test diesel in – Diesel / test diesel has poorer wear protection capabilities and a very low viscosity
acc. with DIN 4113 (< 3 mm2/s).
– May be used only with FKM seals
– Please note their low flash point!
– To be used only after confirmation and with limited performance data!
17 Hydraulic fluids for roller – Hydraulic fluids for roller processes have lower wear protection capabilities than
processes mineral oil HLP and a lower viscosity
– Please note their low flash point!
– Hydraulic fluids for roller processes with limited performance data can be used only
after confirmation.
18 Fluids for power – Can only be used after consultation and approval for use in the specific application,
steering, even if they are compliant with DIN 51524.
hydro-pneumatic sus-
– Please note the low viscosity!
pension,
active chassis etc. – In most cases they have poor water separation capability
– Check the material compatibility!
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7 Glossary
Additivation Cavitation
Additives are chemical substances added to the basic fluids to Cavitation is the creation of cavities in fluids due to pressure
achieve or improve specific properties. reduction below the saturated vapour pressure and subse-
quent implosion when the pressure increases. When the
Aging
cavities implode, extremely high acceleration, temperatures
Hydraulic fluids age due to oxidation (see chapter 3.1.5 "Aging 1
and pressure may occur temporarily, which may damage the
resistance"). Liquid and solid contamination acts as a catalyzer
component surfaces.
for aging, meaning that it needs to be minimized as far as
possible by careful filtration. Neutralization number (NN)
The neutralization number (NN) or acid number (AN) specifies
API classification
the amount of caustic potash required to neutralize the acid
Classification of basic fluids by the American Petroleum
contained in one gram of fluid.
Institute (API) – the largest association representing the US oil
and gas industry. Pour point
The lowest temperature at which the fluid still just flows when
Arrhenius equation
cooled down under set conditions. The pour point is specified
The quantitative relation between reaction rate and temperature
in the lubricant manufacturers' technical data sheets as a
is described by an exponential function, the Arrhenius equation.
reference value for achieving this flow limit.
This function is usually visualized within the typical temperature
range of the hydraulic system. For a practical example, see RFA (wavelength dispersive x-ray fluorescence analysis)
chapter 3.1.5 "Aging resistance”. Is a procedure to determine nearly all elements in liquid and
solid samples with nearly any composition. This analysis
Related hydrocarbons
method is suitable for examining additives and contamination,
Related hydrocarbons are hydrocarbon compounds that are
delivering fast results.
not classified as API class 1, 2 or 5.
Shearing/shear loss
Basic fluids
Shearing of molecule chains during operation can change the
In general, a hydraulic fluid is made up of a basic fluid, or
viscosity of hydraulic fluids with long chain VI enhancers. The
base oil, and chemical substances, the so-called additives.
initially high viscosity index drops. This needs to be taken into
The proportion of basic fluid is generally greater than 90%.
account when selecting the hydraulic fluid.
Demulsifying
The only value at present that can be used to assess viscosity
Ability of a fluid to separate water contamination quickly;
changes in operation is the result of the test in accordance
achieved with careful selection of base oil and additives.
with DIN 51350 part -6. Please note that there are practical
Detergent applications that create a much higher shear load on such
Ability of certain additives to emulsify part of the water contami- hydraulic fluids than can be achieved by this test.
nation in the oil or to hold it in suspension until it has evapo-
Stick-slip effect (sliding)
rated with increasing temperature. Larger water quantities, in
Interaction between a resilient mass system involving friction
contrast (above approx. 2 %), are separated immediately.
(such as cylinder + oil column + load) and the pressure
Dispersant increase at very low sliding speeds. The static friction of the
Ability of certain additives to keep insoluble liquid and solid system is a decisive value here. The lower it is, the lower the
contamination in suspension in the fluid. speed that can still be maintained without sticking. Depend-
ing on the tribologic system, the stick-slip effect may lead to
Diesel effect
vibrations generated and sometimes also to significant noise
If hydraulic fluid that contains air bubbles is compressed
emission. In many cases, the effect can be attenuated by
quickly, the bubbles are heated to such a degree that a self-
replacing the lubricant.
ignition of the air-gas mix may occur. The resultant temperature
increase may lead to seal damage and increased aging of the Viscosity
hydraulic fluid. Viscosity is the measure of the internal friction of a fluid to
flow. It is defined as the property of a substance to flow under
Hydraulic fluids based on mineral oils
tension. Viscosity is the most important characteristic for
Hydraulic fluids based on mineral oils are made from petroleum
describing the load-bearing capacity of a hydraulic fluid.
(crude oil).
Kinematic viscosity is the ratio of the dynamic viscosity and the
ICP (atomic emission spectroscopy)
density of the fluid; the unit is mm²/s. Hydraulic fluids are clas-
The ICP procedure can be used to determine various wear
sified by their kinematic viscosity into ISO viscosity classes.
metals, contamination types and additives. Practically all
The reference temperature for this is 40 °C.
elements in the periodic system can be detected with this
method. Viscosity index (VI)
Refers to the viscosity temperature behavior of a fluid.
Karl Fischer method
The lower the change of viscosity in relation the temperature,
Method to determine the water content in fluids. Indirect
the higher the VI.
coulometric determination procedure in accordance with
DIN EN ISO 12937 in connection with DIN 51777-2. Only the
combination of both standards will assure adequately accurate
measured values.
54
16/16 Bosch Rexroth AG Hydraulic fluids based on mineral oils RE 90220/05.12

Bosch Rexroth AG © This document, as well as the data, specifications and other information
Hydraulics set forth in it, are the exclusive property of Bosch Rexroth AG. It may not be
Zum Eisengießer 1 reproduced or given to third parties without its consent.
97816 Lohr am Main, Germany No statements concerning the suitability of a hydraulic fluid for a specific purpose
Phone +49 (0) 93 52 / 18-0 can be derived from our information. The information given does not release the
Fax +49 (0) 93 52 / 18-23 58 user from the obligation of own judgment and verification.
documentation@[Link] It must be remembered that our products are subject to a natural process of
[Link] wear and aging.
Subject to change.
55

RE 90221/05.12 1/14
Environmentally acceptable Replaces: 05.10

hydraulic fluids

Application notes and requirements for Rexroth hydraulic components

Hydraulic fluids

Hydraulic fluids based Environmentally Fire-resistant, Fire-resistant,


Title on mineral oils and acceptable hydraulic water-free water-containing
related hydrocarbons fluids hydraulic fluids hydraulic fluids

Standard DIN 51524 ISO 15380 ISO 12922 ISO 12922

RE 90223
Data sheets RE 90220 RE 90221 RE 90222
(in preparation)

HL HEPG
HLP HEES partially satu- HFDR HFC
HLPD rated HFDU (ester base) HFB
Classification
HVLP HEES saturated HFDU (glycol base) HFAE
HLPD HEPR and more HFAS
and more HETG
56
2/14 Bosch Rexroth AG Environmentally acceptable hydraulic fluids RE 90221/05.12

Contents
1 Basic information .................................................................................................................................................................................................3
1.1 General instructions ...................................................................................................................................................................................3
1.2 Environmental compatibility .....................................................................................................................................................................3
1.3 Scope ...........................................................................................................................................................................................................3
1.4 Safety instructions .....................................................................................................................................................................................3
2 Solid particle contamination and cleanliness levels .....................................................................................................................................4
3 Selection of the hydraulic fluid ..........................................................................................................................................................................5
3.1 Selection criteria for the hydraulic fluid .................................................................................................................................................5
3.1.1 Viscosity .................................................................................................................................................................................................5
3.1.2 Viscosity-temperature behavior........................................................................................................................................................5
3.1.3 Wear protection capability ................................................................................................................................................................6
3.1.4 Material compatibility..........................................................................................................................................................................6
3.1.5 Aging resistance .................................................................................................................................................................................6
3.1.6 Biological degradation .......................................................................................................................................................................6
3.1.7 Air separation ability (ASA) ...............................................................................................................................................................7
3.1.8 Demulsifying ability and water solubility ........................................................................................................................................7
3.1.9 Filterability .............................................................................................................................................................................................7
3.1.10 Corrosion protection ........................................................................................................................................................................7
3.1.11 Additivation .........................................................................................................................................................................................7
3.2 Classification and fields of application ................................................................................................................................................8
4 Hydraulic fluids in operation ............................................................................................................................................................................10
4.1 General .......................................................................................................................................................................................................10
4.2 Storage and handling .............................................................................................................................................................................10
4.3 Filling of new systems.............................................................................................................................................................................10
4.4 Hydraulic fluid changeover ....................................................................................................................................................................10
4.5 Mixing and compatibility of different hydraulic fluids .......................................................................................................................10
4.6 Re-additivation..........................................................................................................................................................................................10
4.7 Foaming behavior .....................................................................................................................................................................................10
4.8 Corrosion ...................................................................................................................................................................................................11
4.9 Air ................................................................................................................................................................................................................11
4.10 Water ........................................................................................................................................................................................................11
4.11 Fluid servicing, fluid analysis and filtration .......................................................................................................................................11
5 Disposal and environmental protection ........................................................................................................................................................12
6 Glossary ...............................................................................................................................................................................................................13
57
RE 90221/05.12 Environmentally acceptable hydraulic fluids Bosch Rexroth AG 3/14

1 Basic information
1.1 General instructions – acute daphnia toxicity at least 100 mg/l
(according to ISO 5341)
The hydraulic fluid is the common element in any hydraulic
– acute bacteria toxicity at least 100 mg/l
component and must be selected very carefully. Quality and
(according to ISO 8192)
cleanliness of the hydraulic fluid are decisive factors for the
operational reliability, efficiency and service life of a system. The same amount of care should be taken when handling 1
environmentally acceptable hydraulic fluids as for mineral oils,
Hydraulic fluids must conform, be selected and used in
leakage from the hydraulic system should be avoided. Environ-
accordance with the generally acknowledged rules of technol-
mentally acceptable hydraulic fluids are designed so that in the
ogy and safety provisions. Reference is made to the country-
event of accidents and leakage,less permanent environmental
specific standards and directives (in Germany the directive of
damage is caused than by mineral oils, see also chapter 5
the Employer's Liability Insurance Association BGR 137).
"Disposal and environmental protection".
This data sheet includes recommendations and regulations
In comparison to mineral oil HLP/HVLP , the biological deg-
concerning the selection, operation and disposal of envi-
radation of environmentally acceptable hydraulic fluids may
ronmentally compatible hydraulic fluids in the application of
change fluid aging, see chapter 3.1.5 "Aging resistance", 3.1.6.
Rexroth hydraulic components.
"Biological degradation" and 4 "Hydraulic fluids in operation".
The individual selection of hydraulic fluid or the choice of
classification are the responsibility of the operator.
1.3 Scope
It is the responsibility of the user to ensure that appropriate
This data sheet must be applied when using environmentally
measures are taken for safety and health protection and to ensure
acceptable hydraulic fluids with Rexroth hydraulic components.
compliance with statutory regulations. The recommendations
The specifications of this data sheet may be further restricted
of the lubricant manufacturer and the specifications given in the
by the specification given in the data sheets for the individual
safety data sheet are to be observed when using hydraulic fluid.
components.
This data sheet does not absolve the operator from verifying
The use of the individual environmentally acceptable hydraulic
the conformity and suitability of the respective hydraulic fluid
fluids in accordance with the intended purpose can be found in
for his system. He is to ensure that the selected fluid meets the
the safety data sheets or other product description documents
minimum requirements of the relevant fluid standard during the
of the lubricant manufacturers. In addition, each use is to be
whole of the period of use.
individually considered.
Other regulations and legal provisions may also apply. The operator
Rexroth hydraulic components may only be operated with
is responsible for their observance, e.g. EU directive 2004/35/EG,
environmentally acceptable hydraulic fluids according to
2005/360/EG and their national implementation. In Germany the
ISO 15380 if specified in the respective component data
Water Resources Act (WHG) is also to be observed.
sheet or if a Rexroth approval for use is furnished.
We recommend that you maintain constant, close contact
The manufacturers of hydraulic systems must adjust their
with lubricant manufacturers to support you in the selection,
systems and operating instructions to the environmentally
maintenance, care and analyses.
acceptable hydraulic fluids.
When disposing of used hydraulic fluids, apply the same care
Notes:
as during use.
In the market overview RE 90221-01, environmentally accept-
Environmentally acceptable hydraulic fluids have been used able hydraulic fluids based on mineral oil are described which,
successfully for many years. In some countries, the use of envi- according to the information of the lubricant manufacturer,
ronmentally acceptable hydraulic fluids is already prescribed in feature the respective parameters of the current requirements
ecologically sensitive areas (e.g. forestry, locks, weirs). standard ISO 15380 and other parameters which are of rel-
evance for suitability in connection with Rexroth components.
Environmentally acceptable hydraulic fluids may only be used
in the pharmaceutical and food industry subject to required These specifications are not checked or monitored by Bosch
certification to FDA/USDA/NSF H1. Rexroth. The list in the market overview does not therefore
represent a recommendation on the part of Rexroth or approval
of the respective hydraulic fluid for use with Rexroth compo-
1.2 Environmental compatibility
nents and does not release the operator from his responsibility
There is no unambiguous legal definition for environmentally regarding selection of the hydraulic fluid.
acceptable hydraulic fluids as different testing procedures can
Bosch Rexroth will accept no liability for its components
be applied for biological degradation and toxicity.
for any damage resulting from failure to comply with the
According to ISO 15380 the definition of "environmentally notes below.
acceptable" is as follows: Humans, animals, plants, air and soil
must not be endangered. With regard to hydraulic fluids in an
unused condition in the bin this mainly means:
1.4 Safety instructions
– biological degradation at least 60 % Hydraulic fluids can constitute a risk for persons and the
(according to ISO 14593 or ISO 9439) environment. These risks are described in the hydraulic fluid
safety data sheets. The operator is to ensure that a current
– acute fish toxicity at least 100 mg/l
safety data sheet for the hydraulic fluid used is available and
(according to ISO 7346-2)
that the measures stipulated therein are complied with.
58
4/14 Bosch Rexroth AG Environmentally acceptable hydraulic fluids RE 90221/05.12

2 Solid particle contamination and cleanliness levels


Solid particle contamination is the major reason for faults oc- the operating period, you must use a reservoir breather filter.
curring in hydraulic systems. It may lead to a number of effects If the environment is humid, take appropriate measures, such
in the hydraulic system. Firstly, single large solid particles as a breather filter with air drying or permanent off-line water
may lead directly to a system malfunction, and secondly small separation.
particles cause continuous elevated wear.
Note: the specifications of the lubricant manufacturer relat-
For mineral oils, the cleanliness level of environmentally accept- ing to cleanliness levels are based on the time at which the
able hydraulic fluids is given as a three-digit numerical code in container concerned is filled and not on the conditions during
accordance with ISO 4406. This numerical code denotes the transport and storage.
number of particles present in a hydraulic fluid for a defined
Further information about contamination with solid matter and
quantity. Moreover, foreign solid matter is not to exceed a mass
cleanliness levels can be found in brochure RE 08016.
of 50 mg/kg (gravimetric examination according to ISO 4405).
In general, compliance with a minimum cleanliness level of
20/18/15 in accordance with ISO 4406 or better is to be main-
tained in operation. Special servo valves demand improved
cleanliness levels of at least 18/16/13. A reduction in cleanli-
ness level by one level means half of the quantity of particles
and thus greater cleanliness. Lower numbers in cleanliness
levels should always be striven for and extend the service life
of hydraulic components. The component with the highest
cleanliness requirements determines the required cleanliness
of the overall system. Please also observe the specifications in
table 1: "Cleanliness levels according to ISO 4406" and in the
respective data sheets of the various hydraulic components.
Hydraulic fluids frequently fail to meet these cleanliness
requirements on delivery. Careful filtering is therefore required
during operation and in particular, during filling in order to
ensure the required cleanliness levels. Your lubricant manu-
facturer can tell you the cleanliness level of hydraulic fluids
as delivered. To maintain the required cleanliness level over

Table 1: Cleanliness levels according to ISO 4406

Particles per 100 ml


Up to and Scale number
More than
including
8,000,000 16,000,000 24 20 / 18 / 15
4,000,000 8,000,000 23 > 4 μm > 6 μm > 14 μm
2,000,000 4,000,000 22
1,000,000 2,000,000 21
500,000 1,000,000 20
250,000 500,000 19
130,000 250,000 18
64000 130,000 17
32000 64000 16
16000 32000 15
8000 16000 14
4000 8000 13
2000 4000 12
1000 2000 11
500 1000 10
250 500 9
130 250 8
64 130 7
32 64 6
59
RE 90221/05.12 Environmentally acceptable hydraulic fluids Bosch Rexroth AG 5/14

3 Selection of the hydraulic fluid


Environmentally acceptable hydraulic fluids for Bosch Rexroth If the viscosity of a hydraulic fluid is below the permitted
hydraulic components are assessed on the basis of their fulfill- operating viscosity, increased leakage, wear, susceptibility to
ment of the minimum requirements of ISO 15380. contamination and a shorter life cycle will result.
Please ensure that the permissible temperature and viscosity
3.1 Selection criteria for the hydraulic fluid limits are observed for the respective components. This usually 1
requires either cooling or heating, or both.
The specified limit values for all components employed in the
hydraulic system, for example viscosity and cleanliness level,
3.1.2 Viscosity-temperature behavior
must be observed with the hydraulic fluid used, taking into
account the specified operating conditions. For hydraulic fluids, the viscosity temperature behavior (V-T
behavior) is of particular importance. Viscosity is characterized
Hydraulic fluid suitability depends, amongst others, on the
in that it drops when the temperature increases and rises when
following factors:
the temperature drops. The interrelation between viscosity and
temperature is described by the viscosity index (VI).
3.1.1 Viscosity
If exposed to the cold for several days, viscosity may rise sig-
Viscosity is a basic property of hydraulic fluids. The permissible
nificantly (HETG and HEES). After heating, the characteristic
viscosity range of complete systems needs to be determined
values as specified on the data sheet are restored. Please ask
taking account of the permissible viscosity of all components
your lubricant manufacturer for the " Flow capacity after 7 days
and it is to be observed for each individual component.
at low temperature" (ASTM D 2532) of fluid classifications
The viscosity at operating temperature determines the HETG and partially saturated HEES.
response characteristics of closed control loops, stability and
All known environmentally acceptable hydraulic fluids have
damping of systems, the efficiency factor and the degree of
better viscosity temperature behavior than mineral oil HLP and
wear.
generally feature greater shear stability than HVLP mineral
We recommend that the optimum operating viscosity range of oils. This should be taken into consideration when selecting
each component be kept within the permissible temperature hydraulic fluid for the required temperature range. A lower
range. This usually requires either cooling or heating, or both. viscosity level can frequently be used to save any drive power
The permissible viscosity range and the necessary cleanliness during a cold start and avoid viscosity being too low at higher
level can be found in the product data sheet for the component temperatures. The required viscosity and temperature limits
concerned. in the product data sheets are to be observed in all operating
conditions.
If the viscosity of a hydraulic fluid used is above the permitted
operating viscosity, this will result in increased hydraulic-me- Depending on the basic fluid types/classes, VI indices can be
chanical losses. In return, there will be lower internal leakage achieved of 140–220, see Fig. 1: "Examples: V-T diagrams in
losses. If the pressure level is lower, lubrication gaps may not comparison to HLP (reference values)" and Table 4: "Classifi-
be filled up, which can lead to increased wear. For hydraulic cation and fields of application of environmentally acceptable
pumps, the permitted suction pressure may not be reached, hydraulic fluids".
which may lead to cavitation damage.

Fig. 1: Examples V-T diagrams in comparison to HLP (reference values, double-logarithmic representation)

40q 20q 0q 20q 40q 60q 80q 100q


1600 Typical viscosity data [mm2/s]
1000
600 Temperature –20 °C 40 °C 100 °C
400
HEES partially saturated 1250 46 9
200
HEES saturated 2500 46 8
Viscosity Q [mm2/s]

100
60 HEPG 2500 46 10
40 HEPR 1400 46 10

20 For comparison HLP


4500 46 7
(see RE 90220)
HEPG
10 HEPR
HEES partially saturated
HEES saturated
5 HLP
40q 25q 10q 0q 10q 30q 50q 70q 90q 115q
Temperature t [°C]
Detailed V-T diagrams may be obtained from your lubricant manufacturer for their specific products.
60
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3.1.3 Wear protection capability 3.1.5 Aging resistance


Wear protection capability describes the property of hydraulic The way an environmentally acceptable hydraulic fluids ages
fluids to prevent or minimize wear within the components. The depends on the thermal, chemical and mechanical stress to
wear protection capability is described in ISO 15380 via test which it is subjected. The influence of water, air, temperature
procedures"FZG gear test rig" (ISO 14635-1) and "Mechani- and contamination may be significantly greater than for mineral
cal test in the vane pump" (ISO 20763). From ISO VG 32, oils HLP/HVLP. Aging resistance can be greatly influenced by
ISO 15380 prescribes a rating of at least 10 (FZG test). At the chemical composition of the hydraulic fluids .
present, the FZG test cannot be applied to viscosity classes
High fluid temperatures (e.g. over 80 °C) result in a approxi-
< ISO VG 32. The wear protection capability of environmen-
mate halving of the fluid service life for every 10 °C temperature
tally acceptable hydraulic fluids in relation to the two test
increase and should therefore by avoided. The halving of the
procedures is comparable to that of mineral oil HLP/HVLP.
fluid service life results from the application of the Arrhenius
equation (see Glossary).
3.1.4 Material compatibility
The hydraulic fluid must not negatively affect the materials Table 3: Reference values for temperature-dependent
used in the components. Compatibility with coatings, seals, aging of the hydraulic fluid
hoses, metals and plastics is to be observed in particular. The
Reservoir temperature Fluid life cycle
fluid classifications specified in the respective component data
sheets are tested by the manufacturer with regard to material 80 °C 100 %
compatibility. Parts and components not supplied by us are to 90 °C 50 %
be checked by the user. 100 °C 25 %
A modified aging test (without adding water) is prescribed for
Table 2: Known material incompatibilities
fluid classifications HETG and HEES. Hydraulic fluids with
Classification Incompatible with: HEPG and HEPR classification are subjected to the identical
HE... general One-component color coatings, lead, galva- test procedure as mineral oils (with 20 % water added). The
nized zinc coatings, some non-ferrous metals, calculated fluid service life is derived from the results of tests in
seals made of NBR. In some cases, the which the long-term characteristics are simulated in a short pe-
latter show major increases in volume when riod of time by applying more arduous conditions (condensed
impermissibly aged hydraulic fluids come testing). This calculated fluid service life is not to be equated to
into contact with the material. NBR is only the fluid service life in real-life applications.
permitted by prior consent, please observe Table 3 is a practical indicator for hydraulic fluids with water
the customary seal and tube replacement content < 0.1%, cf. chapter 4.10. "Water".
intervals. Do not use any hydrolysis/suscep-
tible polyurethane qualities. 3.1.6 Biological degradation
Note Environmentally acceptable hydraulic fluids are ones which
Please check seals and coatings of control degrade biologically much faster than mineral oils. Biologi-
cabinets, outer coatings of hydraulic compo- cal degradation is a biochemical transformation effected by
nents and accessories (connectors, cables, micro-organisms resulting in mineralization. For environmentally
control cabinets) for resistance to vapors acceptable hydraulic fluids that make reference to ISO 15380,
issuing from hydraulic fluids. biological degradation according to ISO 14593 or ISO 9439
HETG/HEES Zinc, some non-ferrous alloys with zinc must be verified. 60% minimum degradation is defined as limit
HEPG Steel/aluminum tribocontacts, paper filters, value. Proof of biological degradation is furnished for the new,
polymethylmethacrylate (PMMA), NBR unmixed, ready-formulated hydraulic fluids. Aged or mixed
hydraulic fluids are less able to degrade biologically. Biological
Note degradation outside the defined test procedure is subject to a
Check plastics for resistance variety of natural influences. The key factors are temperature,
The material incompatibilities mentioned here do not automati- humidity, contamination, fluid concentration, type and quantity
cally result in function problems. However the elements of the of micro-organisms. Environmentally acceptable hydraulic fluids
materials are found in the hydraulic fluids after use. The biologi- require no extended maintenance in comparison to mineral oils,
cal degradation of hydraulic fluids is negatively influenced. please observe chapter 4 "Hydraulic fluids in operation".
61
RE 90221/05.12 Environmentally acceptable hydraulic fluids Bosch Rexroth AG 7/14

3.1.7 Air separation ability (ASA) 3.1.10 Corrosion protection


The air separation ability (ASA) describes the property of a Hydraulic fluids should not just prevent corrosion formation
hydraulic fluid to separate undissolved air. Hydraulic fluids on steel components, they must also be compatible with
always contain dissolved air. During operation, dissolved air non-ferrous metals and alloys. Corrosion protection tests on
may be transformed into undissolved air, leading to cavitation different metals and metal alloys are described in ISO 15380. 1
damages. Fluid classification, fluid product, reservoir size and Hydraulic fluids that are not compatible with the materials listed
design must be coordinated to take into account the dwell above must not be used, even if they are compliant with
time and ASA value of the hydraulic fluid. The air separation ISO 15380.
capacity depends on the viscosity, temperature, basic fluid
Rexroth components are usually tested with HLP hydraulic
and aging. It cannot be improved by additives.
fluids or corrosion protection oils based on mineral oils before
According to ISO 15380, for instance, an ASA value d 10 minutes they are delivered.
is required for viscosity class ISO VG 46, 6 minutes are typical,
lower values are preferable. 3.1.11 Additivation
The properties described above can be modified with the help
3.1.8 Demulsifying ability and water solubility
of suitable additives. Environmentally acceptable hydraulic
The capacity of a hydraulic fluid to separate water at a defined fluids should never contain heavy metals. According to the
temperature is known as the demulsifying ability. ISO 6614 present state of knowledge, all hydraulic fluids, regardless of
defines the demulsifying properties of hydraulic fluids. additivation, can be filtered with all customary filter materials
in all known filtration ratings (t 0.8 μm), without filtering out
Fluids classified HETG, HEES and HEPR separate from
effective additives at the same time.
water. HETG and HEES hydraulic fluids have a different
water separation ability to mineral oil HLP/HVLP. At 20 °C, in Bosch Rexroth does not prescribe any specific additive system.
comparison to mineral oil HLP/HVLP, a multiple ( > factor 3)
of water can separate in the hydraulic fluid. Water solubility is
also more temperature-dependent than for mineral oils. With
regard to water solubility, HEPR hydraulic fluids behave like
HVLP hydraulic fluids (see RE 90220). In the majority of cases,
HEPG-classified fluids HEPG dissolve water completely , see
chapter "4.10 Water".

3.1.9 Filterability
Filterability describes the ability of a hydraulic fluid to pass
through a filter, removing solid contaminants. The hydraulic
fluids used require a good filterability, not just when new, but
also during the whole of their service life. Depending on the
different basic fluids (glycols, saturated and partially saturated
ester oils, hydrocrack oils, polyalpha olefins, triglycerides) and
additives (VI enhancers), there are great differences here.
The filterability is a basic prerequisite for cleanliness, servicing
and filtration of hydraulic fluids. Rexroth therefore requires
the same degree of filterability of environmentally acceptable
hydraulic fluids as for mineral oils HLP/HVLP to DIN 51524. As
ISO 15380 does not comment on the filterability of hydraulic
fluids, filterability comparable to that of mineral oils HLP/HVLP
must be requested of lubricant manufacturers.
Filterability is tested with the new hydraulic fluid and after the
addition of 0.2 % water. The underlying standard (ISO 13357-
1/-2) stipulates that filterability must have no negative effects
on the filters or the hydraulic fluid, see chapter 4 "Hydraulic
fluids in operation".
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3.2 Classification and fields of application


Table 4: Classification and fields of application
Typical field
Classification Features Notes
of application
HEPG Basic fluid, glycols Systems on exposed For information on approved components, please refer to the
according to water courses respective product data sheet. For components which have not
ISO 15380 (locks, weirs, been approved according to the product data sheet, please
dredgers) consult your Bosch Rexroth sales partner.
Density at
15 °C: typically – Very good viscosity/temperature characteristics, shear
> 0.97 kg/dm³ stability
VI: typical > 170 – Resistant to aging
– Incompatible with mineral oil (exceptions must be confirmed
by the lubricant manufacturer)
– Can be water-soluble
– Can be mixed with water
– Very good wear protection properties
– A higher implementation temperature with the same viscosity
in comparison to mineral oil is to be expected
– Due to the higher density in comparison to HLP, lower suc-
tion pressures are to be anticipated for pumps. Reduce the
maximum speed as required and optimize suction conditions.
– Classified as insignificantly water-endangering (water hazard
class WGK 1)
– Prior to commissioning, contact the lubricant manufacturer,
as the components are tested with mineral oil HLP/corrosion
protection oil.
HEES Basic fluid: Ester Suitable for most For information on approved components, please refer to the
based on renew-
partially saturated fields of application respective product data sheet. For components which have not
according to able raw materials, and components. been approved according to the product data sheet, please
ISO 15380 synthetic esters, consult your Bosch Rexroth sales partner.
mixtures of various
Density at – Preferred use of FKM seals. Please enquire for shaft seal
esters, mixtures with
15 °C: typically rings and implementation temperatures under –15 °C.
polyalphaolefines
0.90–0.93 kg/dm³
(< 30%) – In operation, a higher temperature in comparison to mineral
VI: typical > 160 oil HLP/HVLP is to be expected given identical design and
viscosity
Iodine count < 90
– Limit lower (depending on viscosity class) and upper imple-
mentation temperatures (maximum 80 °C due to aging)
– Good viscosity/temperature characteristics, shear stability.
– Good corrosion protection, if correspondingly additivized
– Mostly classed as insignificantly water-endangering (water
hazard class WGK 1), in some cases as not water-endangering
– High dirt dissolving capacity on fluid changeovers
– In unfavorable operating conditions (high water content,
high temperature), HEES on ester basis have a tendency to
hydrolysis. The acidic organic decomposition products can
chemically attack materials and components.

Continued on page 9
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RE 90221/05.12 Environmentally acceptable hydraulic fluids Bosch Rexroth AG 9/14

Table 4: Classification and fields of application (continued from page 8)


Typical field
Classification Features Notes
of application
HEES Basic fluid: Ester Suitable for most For information on approved components, please refer to the
saturated based on renew- fields of application respective product data sheet. For components which have not 1
according to ISO able raw materials, and components. been approved according to the product data sheet, please
15380 synthetic esters, Saturated HEES consult your Bosch Rexroth sales partner.
mixtures of various should be preferred
Density at – Preferred use of FKM seals. Please enquire for shaft seal
esters, mixtures with over partially
15 °C: typically rings and implementation temperatures under –15 °C.
polyalphaolefines saturated HEES
0.90–0.93 kg/dm³
(< 30%) and HETG for – In operation, a higher temperature in comparison to mineral
VI: components and oil HLP/HVLP is to be expected given identical design and
typical 140–160 systems exposed to viscosity
high stress levels.
Iodine count <15 – Good viscosity/temperature characteristics, shear stability
– Good corrosion protection, if correspondingly additivized
– Mostly classed as insignificantly water-endangering (water
hazard class WGK 1), in the case of low viscosity classes
(up to ISO VG 32) also classed as not water-endangering
– High dirt dissolving capacity on fluid changeovers
HEPR Basic fluid: Suitable for most For information on approved components, please refer to the
according to synthetically fields of application respective product data sheet. For components which have not
ISO 15380 manufactured hydro- and components. been approved according to the product data sheet, please
carbons (polyalpha HEPR should be consult your Bosch Rexroth sales partner.
Density at 15 °C:
olefins PAO) partly preferred over
typically 0.87 kg/ – Behaves similarly to HVLP- hydraulic fluids, individual prod-
mixed with esters ( partially saturated
dm³ ucts comply with ISO 15380 HEPR and DIN 51524-3 HVLP
< 30 %) HEES and HETG
VI : for components and – Preferred use of FKM seals. Please enquire for shaft seal
typical 140–160 systems exposed to rings and implementation temperatures under –15 °C.
high stress levels.
– Good viscosity-temperature behavior
– Classified as insignificantly water-endangering (water hazard
class WGK 1)
Note:
Note shear stability (see chapter 4.11 "Fluid servicing, fluid
analysis and filtration" and chapter 6 "Glossary")
HETG Basic fluid: Not recommended Practical requirements are frequently not fulfilled by hydraulic
according to vegetable oils and for Rexroth compo- fluids in this classification. Use only permissible after consulta-
ISO 15380 triglycerides nents! tion.
Density at 15 °C: – Viscosity is not stable over time
typically 0.90-0.93
– Very fast fluid aging, very hydrolysis-susceptible
kg/dm³
(please observe neutralization number)
VI: typical > 200
– Tendency to gumming, gelling and setting.
Iodine count > 90
– Limit the lower (depending on viscosity class) and upper
implementation temperatures (see chapter 3.1.5)
– Only limited material compatibility
– Filterability problems at water ingress
– High dirt dissolving capacity on fluid changeovers
– Mostly classed as not water-endangering
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4 Hydraulic fluids in operation


4.1 General manufacturer or supplier of the new hydraulic fluid. The quantity
of old fluid remaining should be minimized. Mixing hydraulic
The properties of hydraulic fluids can change continually during fluids should be avoided, see following chapter.
storage and operation.
For information on changing over hydraulic fluids with different
Please note that the fluid standard ISO 15380 merely classifications, please refer to VDMA 24314, VDMA 24569
describes minimum requirements for hydraulic fluids in new and ISO 15380 appendix A.
condition at the time of filling into the bins. The operator of
a hydraulic system must ensure that the hydraulic fluid remains Bosch Rexroth will not accept liability for any damage to its
in a utilizable condition throughout its entire period of use. components resulting from inadequate hydraulic fluid change-
overs!
Deviations from the characteristic values are to be clarified with
the lubricant manufacturer, the test labs or Bosch Rexroth.
4.5 Mixing and compatibility of different
Bosch Rexroth will accept no liability for damage to its compo- hydraulic fluids
nents within the framework of the applicable liability legislation
insofar as the latter is due to non-observance of the following If hydraulic fluids from different manufacturers or different
instructions. types from the same manufacturer are mixed, gelling, silting
and deposits may occur. These, in turn, may cause foaming,
Please note the following aspects in operation. impaired air separation ability, malfunctions and damage to the
hydraulic system.
4.2 Storage and handling If the fluid contains more than 2 % of another fluid then it is
Hydraulic fluids must be stored correctly in accordance with considered to be a mixture. Exceptions apply for water, see
the instructions of the lubricant manufacturer. Avoid exposing chapter 4.10 "Water".
the containers to lengthy periods of direct heat. Containers Mixing with other hydraulic fluids is not generally permitted.
are to be stored in such a way that the risk of any foreign liquid This also includes hydraulic fluids with the same classification
or solid matter (e.g. water, foreign fluids or dust) ingression and from the market overview RE 90221-01. If individual lubri-
into the inside of the container can be ruled out. After taking cant manufacturers advertise miscibility and/or compatibility,
hydraulic fluids from the containers, these are immediately to this is entirely the responsibility of the lubricant manufacturer.
be properly resealed.
Bosch Rexroth customarily tests all components with mineral
Recommendation: oil HLP before they are delivered.
– Store containers in a dry, roofed place Note: With connectible accessory units and mobile filtering
– Store barrels on their sides systems, there is a considerable risk of non-permitted mixing
of the hydraulic fluids!
– Clean reservoir systems and machine reservoirs regularly
Rexroth will not accept liability for any damage to its compo-
nents resulting from mixing hydraulic fluids!
4.3 Filling of new systems
Usually, the cleanliness levels of the hydraulic fluids as 4.6 Re-additivation
delivered do not meet the requirements of our components.
Hydraulic fluids must be filtered using an appropriate filter Additives added at a later point in time such as colors, wear
system to minimize solid particle contamination and water in reducers, VI enhancers or anti-foam additives, may negatively
the system. affect the performance properties of the hydraulic fluid and
the compatibility with our components and therefore are not
As early as possible during test operation, new systems should permissible.
be filled with the selected hydraulic fluid so as to reduce the
risk of accidentally mixing fluids (see chapter 4.5 "Mixing and Rexroth will not accept liability for any damage to its compo-
compatibility of different hydraulic fluids"). Changing the hy- nents resulting from re-additivation!
draulic medium at a later point represents significant additional
costs (see following chapter). 4.7 Foaming behavior
Foam is created by rising air bubbles at the surface of hydraulic
4.4 Hydraulic fluid changeover fluids in the reservoir. Foam that develops should collapse as
In particular with the changeover from mineral oils to environ- quickly as possible.
mentally acceptable hydraulic fluids, but also from one environ- Common hydraulic fluids in accordance with ISO 15380 are
mentally acceptable hydraulic fluids to another, there may be sufficiently inhibited against foam formation in new condi-
interference (e.g. incompatibility in the form of gelling, silting, tion. On account of aging and adsorption onto surfaces, the
stable foam or reduced filterability or filter blockage). defoamer concentration may decrease over time, leading to a
In the case of changeovers of the fluid in hydraulic systems, it stable foam.
is important to ensure compatibility of the new hydraulic fluid Defoamers may be re-dosed only after consultation with the
with the remains of the previous hydraulic fluid. Bosch Rexroth lubricant manufacturer and with his written approval.
recommends obtaining verification of compatibility from the
Defoamers may affect the air separation ability.
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RE 90221/05.12 Environmentally acceptable hydraulic fluids Bosch Rexroth AG 11/14

4.8 Corrosion 4.11 Fluid servicing, fluid analysis and filtration


The hydraulic fluid is to guarantee sufficient corrosion protec- Air, water, operating temperature influences and solid matter
tion of components under all operating conditions, even in the contamination will change the performance characteristics of
event of impermissible water contamination. hydraulic fluids and cause them to age.
Environmentally acceptable hydraulic fluids are tested for To preserve the usage properties and ensure a long service life 1
corrosion protection in the same way as mineral oil HLP/ for hydraulic fluid and components, the monitoring of the fluid
HVLP. When used in practice other corrosion mechanisms are condition and a filtration adapted to the application require-
revealed in detail and in individual cases, for the most part in ments (draining and degassing if required) are indispensable.
contact with non-ferrous and white alloys.
The effort is higher in the case of unfavorable usage conditions,
increased stress for the hydraulic system or high expectations
4.9 Air as to availability and service life, see chapter 2 "Solid particle
contamination and cleanliness levels".
Under atmospheric conditions the hydraulic fluid contains
dissolved air. In the negative pressure range, for instance in When commissioning a system, please note that the required
the suction pipe of the pump or downstream of control edges, minimum cleanliness level can frequently be attained only by
this dissolved air may transform into undissolved air. The flushing the system. Due to severe start-up contamination, it
undissolved air content represents a risk of cavitation and of may be possible that a fluid and/or filter replacement becomes
the diesel effect. This results in material erosion of components necessary after a short operating period (< 50 operating
and increased hydraulic fluid aging. hours).
With the correct measures, such as suction pipe and reservoir The hydraulic fluid must be replaced at regular intervals and
design, and an appropriate hydraulic fluid, air intake and tested by the lubricant manufacturer or recognized accredited
separation can be positively influenced. test labs. We recommend a reference analysis after com-
missioning.
See also chapter 3.1.7 "Air separation ability (ASA)”.
The minimum data to be tested for analyses are:
4.10 Water – Viscosity at 40 °C and 100 °C
Water contamination in hydraulic fluids can result from direct – Neutralization number NN (acid number AN)
ingress or indirectly through condensation of water from the air
– Water content (Karl-Fischer method)
due to temperature variations.
– Particle measurement with evaluation according to
HEPG dissolves water completely. This means that any water
ISO 4406 or mass of solid foreign substances with
that has ingressed into the system cannot be drained off in the
evaluation to EN 12662
sump of the reservoir.
– Element analysis (RFA (EDX) / ICP, specify test method)
In the case of hydraulic fluids classed HETG, HEES and
HEPR undissolved water can be drained off from the reservoir – Comparison with new product or available trend analyses
sump, the remaining water content is however too high to
– Assessment / evaluation for further use
ensure that the maximum permissible water limit values are
observed in the long term. – Also recommended: IR spectrum"
Water in the hydraulic fluid can result in wear or direct failure Differences in the maintenance and upkeep of environmentally
of hydraulic components. Furthermore, a high water content acceptable hydraulic fluids with the corresponding suitability
in the hydraulic fluid negatively affects aging and filterability characteristics (as required in market overview RE 90221-01)
and increases susceptibility to cavitation. During operation, in comparison to mineral oil HLP/HVLP are not necessary.
the water content in all hydraulic fluids, determined according Attention is however drawn to the note in chapter 1.3.
to the "Karl Fischer method" (see chapter 6 "Glossary") for all
After changing over hydraulic fluids it is recommended that
environmentally acceptable hydraulic fluids must constantly be
the filters be replaced again after 50 operating hours as fluid
kept below 0.1% (1000 ppm). To ensure a long service life of
aging products may have detached themselves ("self-cleaning
both hydraulic fluids and components, Bosch Rexroth recom-
effect").
mends that values below 0.05% (500 ppm) are permanently
maintained. Compared to the pure unused hydraulic fluid the changed
neutralization number NN (acid number AN) indicates how
Due to the higher water solubility (except for HEPR) in
many aging products are contained in the hydraulic fluid. This
comparison to mineral oil HLP/HVLP it is urgently advised
difference must be kept as low as possible. As soon as the
that precautions be taken when using environmentally accept-
trend analysis notes a significant increase in the values, the
able hydraulic fluids, such as a dehumidifier on the reservoir
lubricant manufacturer should be contacted.
ventilation.
A higher viscosity than that of new materials indicates that the
Water content has an affect particularly in the case of HETG
hydraulic fluid has aged. Evaluation by the test lab or lubricant
and partially saturated HEES in that it accelerates aging
manufacturers is however authoritative, whose recommenda-
(hydrolysis) of the hydraulic fluid and biological degradation,
tion should be urgently observed.
see chapter 4.11 "Fluid servicing, fluid analysis and filtration".
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5 Disposal and environmental


On systems where the possibility of water contamination
protection
cannot be completely ruled out (also condensation), it should
All environmentally acceptable hydraulic fluids, are like mineral
be ensured via the hydraulic system circuit that fluid aging
oil-based hydraulic fluids, subject to special disposal obliga-
products are not accumulating in individual areas of the
tions.
hydraulic system, but are being removed from the system in
a controlled manner via the filtration system. This should be The respective lubricant manufacturers provide specifications
ensured via suitable hydraulic circuits (e.g. flushing circuit) or on environmentally acceptable handling and storage. Please
system manufacturer's operating instructions/specifications. ensure that spilt or splashed fluids are absorbed with appropri-
ate adsorbents or by a technique that prevents it contaminating
In case of warranty, liability or guarantee claims to Bosch
water courses, the ground or sewerage systems.
Rexroth, service verification and/or the results of fluid analyses
are to be provided. It is also not permitted to mix fluids when disposing of hydraulic
fluids. Regulations governing the handing of used oils stipulate
that used oils are not to mixed with other products, e.g.
substances containing halogen. Non-compliance will increase
disposal costs. Comply with the national legal provisions
concerning the disposal of the corresponding hydraulic
fluid. Comply with the local safety data sheet of the lubricant
manufacturer for the country concerned.
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RE 90221/05.12 Environmentally acceptable hydraulic fluids Bosch Rexroth AG 13/14

6 Glossary
Additivation Iodine count
Additives are chemical substances added to the basic fluids The iodine count is a yardstick for the quantity of single and
to achieve or improve specific properties. multiple unsaturated bonds between C atoms in the basic fluid.
A low iodine count indicates that the hydraulic fluid contains
Aging
few unsaturated bonds and is thus considerably more resistant
Hydraulic fluids age due to oxidation (see chapter 3.1.5 "Aging 1
to aging than a hydraulic fluid with a high iodine count. A
resistance"). Liquid and solid contamination acts as a catalyzer
statement about the position at which these multiple bonds are
for aging, meaning that it needs to be minimized as far as
located and about how "stable" they are against influencing
possible by careful filtration. Please refer to Hydrolysis.
factors cannot be derived simply by stating the iodine count.
Arrhenius equation
Karl Fischer method
The quantitative relation between reaction rate and temperature
Method to determine the water content in fluids. Indirect
is described by an exponential function, the Arrhenius equation.
coulometric determination procedure in accordance with DIN
This function is usually visualized within the typical temperature
EN ISO 12937 in connection with DIN 51777-2. Only the
range of the hydraulic system. For a practical example, see
combination of both standards will assure adequately accurate
chapter 3.1.5 "Aging resistance”.
measured values. For hydraulic fluids based on glycol, DIN EN
Basic fluids ISO 12937 is to be applied in conjunction with DIN 51777-1.
In general, a hydraulic fluid is made up of a basic fluid, or base
Cavitation
oil, and chemical substances, the so-called additives. The
Cavitation is the creation of cavities in fluids due to pressure
proportion of basic fluid is generally greater than 90%.
reduction below the saturated vapour pressure and subse-
Diesel effect quent implosion when the pressure increases. When the
If hydraulic fluid that contains air bubbles is compressed cavities implode, extremely high acceleration, temperatures
quickly, the bubbles are heated to such a degree that a self- and pressure may occur temporarily, which may damage the
ignition of the air-gas mix may occur. The resultant temperature component surfaces.
increase may lead to seal damage and increased aging of the
Neutralization number (NN)
hydraulic fluid.
The neutralization number (NN) or acid number (AN) specifies
Saturated esters the amount of caustic potash required to neutralize the acid
Esters differ by the number of C atoms (chain length) and contained in one gram of fluid.
position of the bonds between the C atoms. Saturated esters
Pour point
do not have double/multiple bonds between C atoms and are
The lowest temperature at which the fluid still just flows when
therefore more resistant to aging than partially saturated esters.
cooled down under set conditions. The pour point is specified
Partially saturated esters in the lubricant manufacturers' technical data sheets as a
In contrast to saturated esters, partially saturated esters have reference value for achieving this flow limit.
double/multiple bonds between C atoms. Rexroth defines
RFA (wavelength dispersive x-ray fluorescence analysis)
partially saturated esters as unsaturated bonds and mixtures
Is a procedure to determine nearly all elements in liquid and
of esters with unsaturated and saturated bonds. Esters with
solid samples with nearly any composition. This analysis
unsaturated bonds are produced on the basis of renewable
method is suitable for examining additives and contamination,
raw materials.
delivering fast results.
Depending on their number and position, these unsaturated
Shearing/shear loss
bonds between the C atoms are instable. These bonds can
Shearing of molecule chains during operation can change the
detach themselves and form new bonds, thus changing the
viscosity of hydraulic fluids with long chain VI enhancers. The
properties of those liquids (an aging mechanism). One of the
initially high viscosity index drops. This needs to be taken into
underlying requirements for inclusion in the market overview
account when selecting the hydraulic fluid.
RE 90221-01 is an aging stability characteristic. Attention is
however drawn to the note in chapter 1.3. The only value at present that can be used to assess viscosity
changes in operation is the result of the test in accordance
Hydrolysis
with DIN 51350 part -6. Please note that there are practical
Hydrolysis is the splitting of a chemical bond through the
applications that create a much higher shear load on such
reaction with water under the influence of temperature.
hydraulic fluids than can be achieved by this test.
ICP (atomic emission spectroscopy)
Stick-slip
The ICP procedure can be used to determine various wear
Interaction between a resilient mass system involving friction
metals, contamination types and additives. Practically all
(such as cylinder + oil column + load) and the pressure
elements in the periodic system can be detected with this
increase at very low sliding speeds. The static friction of the
method..
system is a decisive value here. The lower it is, the lower the
speed that can still be maintained without sticking. Depend-
ing on the tribologic system, the stick-slip effect may lead to
vibrations generated and sometimes also to significant noise
emission. In many cases, the effect can be attenuated by
replacing the lubricant.
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Viscosity
Viscosity is the measure of the internal friction of a fluid to
flow. It is defined as the property of a substance to flow under
tension. Viscosity is the most important characteristic for
describing the load-bearing capacity of a hydraulic fluid.
Kinematic viscosity is the ratio of the dynamic viscosity and the
density of the fluid; the unit is mm²/s. Hydraulic fluids are clas-
sified by their kinematic viscosity into ISO viscosity classes.
The reference temperature for this is 40 °C.
Viscosity index (VI)
Refers to the viscosity temperature behavior of a fluid. The
lower the change of viscosity in relation the temperature, the
higher the VI.

Bosch Rexroth AG © This document, as well as the data, specifications and other information
Hydraulics set forth in it, are the exclusive property of Bosch Rexroth AG. It may not be
Zum Eisengießer 1 reproduced or given to third parties without its consent.
97816 Lohr am Main, Germany No statements concerning the suitability of a hydraulic fluid for a specific purpose
Phone +49 (0) 93 52 / 18-0 can be derived from our information. The information given does not release the
Fax +49 (0) 93 52 / 18-23 58 user from the obligation of own judgment and verification.
documentation@[Link] It must be remembered that our products are subject to a natural process of
[Link] wear and aging.
Subject to change.
69

RE 90222/05.12 1/16
Fire-resistant, water-free hydraulic
fluids (HFDR/HFDU)

Application notes and requirements for Rexroth hydraulic components

Hydraulic fluids

Hydraulic fluids based Environmentally Fire-resistant, Fire-resistant,


Title on mineral oils and acceptable hydraulic water-free water-containing
related hydrocarbons fluids hydraulic fluids hydraulic fluids

Standard DIN 51524 ISO 15380 ISO 12922 ISO 12922

RE 90223
Data sheets RE 90220 RE 90221 RE 90222
(in preparation)

HL
HEPG
HLP HFDR HFC
HEES partially saturated
HLPD HFDU (ester base) HFB
Classification HEES saturated
HVLP HFDU (glycol base) HFAE
HEPR
HLPD and more HFAS
HETG
and more
70
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Contents
1 Basic information .................................................................................................................................................................................................3
1.1 General instructions ...................................................................................................................................................................................3
1.2 Fire resistance ............................................................................................................................................................................................3
1.3 Scope ...........................................................................................................................................................................................................4
1.4 Safety instructions .....................................................................................................................................................................................4
2 Solid particle contamination and cleanliness levels .....................................................................................................................................5
3 Selection of the hydraulic fluid ..........................................................................................................................................................................6
3.1 Selection criteria for the hydraulic fluid .................................................................................................................................................6
3.1.1 Viscosity .................................................................................................................................................................................................6
3.1.2 Viscosity-temperature behavior........................................................................................................................................................7
3.1.3 Wear protection capability ................................................................................................................................................................7
3.1.4 Material compatibility..........................................................................................................................................................................7
3.1.5 Aging resistance .................................................................................................................................................................................7
3.1.6 Environmentally acceptable ..............................................................................................................................................................8
3.1.7 Air separation ability (ASA) ...............................................................................................................................................................8
3.1.8 Demulsifying ability and water solubility ........................................................................................................................................8
3.1.9 Filterability .............................................................................................................................................................................................8
3.1.10 Corrosion protection ........................................................................................................................................................................8
3.1.11 Additivation .........................................................................................................................................................................................8
3.2 Classification and fields of application ................................................................................................................................................9
4 Hydraulic fluids in operation ...........................................................................................................................................................................11
4.1 General .......................................................................................................................................................................................................11
4.2 Storage and handling .............................................................................................................................................................................11
4.3 Filling of new systems.............................................................................................................................................................................11
4.4 Hydraulic fluid changeover ....................................................................................................................................................................11
4.5 Mixing and compatibility of different hydraulic fluids .......................................................................................................................11
4.6 Re-additivation..........................................................................................................................................................................................11
4.7 Foaming behavior .....................................................................................................................................................................................11
4.8 Corrosion ...................................................................................................................................................................................................12
4.9 Air ................................................................................................................................................................................................................12
4.10 Water ........................................................................................................................................................................................................12
4.11 Fluid servicing, fluid analysis and filtration .......................................................................................................................................12
5 Disposal and environmental protection ........................................................................................................................................................13
6 Glossary ...............................................................................................................................................................................................................14
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RE 90222/05.12 Fire-resistant, water-free hydraulic fluids Bosch Rexroth AG 3/16

1 Basic information
1.1 General instructions 1.2 Fire resistance
The hydraulic fluid is the common element in any hydraulic There is no clear legal definition of fire-resistant hydraulic fluids.
component and must be selected very carefully. Quality and There are great differences regarding fire resistance. The
cleanliness of the hydraulic fluid are decisive factors for the selection is the sole responsibility of the system operator with
operational reliability, efficiency and service life of a system. respect to requirements (application, construction and design 1
of the system, hottest source in the system, necessary fire
Hydraulic fluids must conform, be selected and used in
protection).
accordance with the generally acknowledged rules of technol-
ogy and safety provisions. Reference is made to the country- Different test procedures are applied for evaluating fire
specific standards and directives (in Germany the directive of resistance.
the Employer's Liability Insurance Association BGR 137).
Fire resistance test procedure according to ISO 12922:
This data sheet includes recommendations and regulations
– Ignition properties of spray according to ISO 15029-1
concerning the selection, operation and disposal of fire-resis-
(Spray flame persistence – hollow-cone nozzle method)
tant, water-free hydraulic fluids in the application of Rexroth
hydraulic components. – Ignition properties of spray according to ISO 15029-2
(Stabilized flame heat release)
The individual selection of hydraulic fluid or the choice of
classification are the responsibility of the operator. – Wick flame persistence of fluids according to ISO 14935
(average flame persistence)
It is the responsibility of the user to ensure that appropriate
measures are taken for safety and health protection and to – Determination of the flammability characteristics of fluids
ensure compliance with statutory regulations. The recommen- in contact with hot surfaces, ignition process according to
dations of the lubricant manufacturer and the specifications ISO 20823 (ignition temperature, flame spread)
given in the safety data sheet are to be observed when using
In general, fire-resistant hydraulic fluids are distinguished
hydraulic fluid.
between water-containing fire-resistant and water-free
This data sheet does not absolve the operator from verifying fire-resistant hydraulic fluids. Water-containing fire-resistant
the conformity and suitability of the respective hydraulic fluid hydraulic fluids are described in RE 90223.
for his system. He is to ensure that the selected fluid meets the
Water-free, fire-resistant hydraulic fluid means hydraulic
minimum requirements of the relevant hydraulic fluid standard
fluids with a water-proportion of 0.1% by volume ("Karl Fischer
during the whole of the period of use.
method", see chapter 6 "Glossary"), measured at the time
The currently valid standard for fire-resistant hydraulic fluids is of filling in the transport container.
the ISO 12922. In addition, other, more detailed documents,
In Europe water-free, fire-resistant hydraulic fluids are not
guidelines, specifications and legislation may also be valid. The
approved for use in underground coal mining. The classification
operator is responsible for ensuring that such regulations are
HFDU is no longer included in the VDMA 24317: 2005.
observed, for example:
Note
– 7th Luxembourg Report: Luxembourg, April 1994, Doc.
In contrast to water-containing fluids, all water-free, fire-
No. 4746/10/91 EN "Requirements and tests applicable to
resistant hydraulic fluids have a flash point and a fire point.
fire-resistant hydraulic fluids for hydrostatic and hydrokinetic
Specific parameters for flash point and fire point can be found
power transmission and control"
in the technical and/or safety data sheet for the hydraulic fluid
– VDMA 24314 (1981-11): "Changing hydraulic fluids – guide- concerned.
lines"
Just as much care should be taken when working with fire-
– VDMA 24317 (2005-11): "Fire-resistant hydraulic fluids – resistant hydraulic fluids are with other hydraulic fluids,
minimum technical requirements" e.g. mineral oils. A leak from the hydraulic system must be
avoided. The best and most cost-effective protection against
– FM Approval Standard 6930 (2009-04): "Flammability
fire and explosion is to prevent leakage with meticulous
Classification of Industrial Fluids" (only available in English)
service, maintenance and care of the hydraulic system.
– DIN Technical Report CEN/TR 14489 (2006-01): "Selection
guidelines for protecting safety, health and the environment"
We recommend that you maintain constant, close contact
with lubricant manufacturers to support you in the selection,
maintenance, care and analyses.
When disposing of used hydraulic fluids, apply the same care
as during use.
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1.3 Scope 1.4 Safety instructions


This data sheet must be applied when using water-free, fire- Hydraulic fluids can constitute a risk for persons and the
resistant hydraulic fluids with Rexroth hydraulic components. environment. These risks are described in the hydraulic fluid
The specifications of this data sheet may be further restricted safety data sheets. The operator is to ensure that a current
by the specifications given in data sheets for the individual safety data sheet for the hydraulic fluid used is available and
components concerned. that the measures stipulated therein are complied with.
The use of the individual water-free, fire-resistant hydraulic
fluids in accordance with the intended purpose can be found in
the safety data sheets or other product description documents
of the lubricant manufacturers. In addition, each use is to be
individually considered.
Rexroth hydraulic components may only be operated with
water-free, fire-resistant hydraulic fluids according to
ISO 12922 if specified in the respective component data
sheet or if a Rexroth approval for use is furnished.
The manufacturers of hydraulic systems must adjust their sys-
tems and operating instructions to the water-free, fire-resistant
hydraulic fluids.
Bosch Rexroth will accept no liability for its components
for any damage resulting from failure to comply with the
notes below.
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RE 90222/05.12 Fire-resistant, water-free hydraulic fluids Bosch Rexroth AG 5/16

2 Solid particle contamination and cleanliness levels


Solid particle contamination is the major reason for faults oc- Hydraulic fluids frequently fail to meet these cleanliness
curring in hydraulic systems. It may lead to a number of effects requirements on delivery. Careful filtering is therefore required
in the hydraulic system. Firstly, single large solid particles during operation and in particular, during filling in order to
may lead directly to a system malfunction, and secondly small ensure the required cleanliness levels. Your lubricant manu-
particles cause continuous elevated wear. facturer can tell you the cleanliness level of hydraulic fluids
as delivered. To maintain the required cleanliness level over 1
For mineral oils, the cleanliness level of water-free, fire-resistant
the operating period, you must use a reservoir breather filter.
hydraulic fluids is given as a three-digit numerical code in
If the environment is humid, take appropriate measures, such
accordance with ISO 4406. This numerical code denotes the
as a breather filter with air drying or permanent off-line water
number of particles present in a hydraulic fluid for a defined
separation.
quantity. Moreover, foreign solid matter is not to exceed a mass
of 50 mg/kg (gravimetric examination according to ISO 4405). Note: the specifications of the lubricant manufacturer relat-
ing to cleanliness levels are based on the time at which the
In general, compliance with a minimum cleanliness level of
container concerned is filled and not on the conditions during
20/18/15 in accordance with ISO 4406 or better is to be main-
transport and storage.
tained in operation. Special servo valves demand improved
cleanliness levels of at least 18/16/13. A reduction in cleanli- Further information about contamination with solid matter
ness level by one level means half of the quantity of particles and cleanliness levels can be found in brochure RE 08016.
and thus greater cleanliness. Lower numbers in cleanliness
levels should always be striven for and extend the service life
of hydraulic components. The component with the highest
cleanliness requirements determines the required cleanliness
of the overall system. Please also observe the specifications in
table 1: "Cleanliness levels according to ISO 4406" and in the
respective data sheets of the various hydraulic components.

Table 1: Cleanliness levels according to ISO 4406

Particles per 100 ml


Up to and Scale number
More than
including
8,000,000 16,000,000 24 20 / 18 / 15
4,000,000 8,000,000 23 > 4 μm > 6 μm > 14 μm
2,000,000 4,000,000 22
1,000,000 2,000,000 21
500,000 1,000,000 20
250,000 500,000 19
130,000 250,000 18
64000 130,000 17
32000 64000 16
16000 32000 15
8000 16000 14
4000 8000 13
2000 4000 12
1000 2000 11
500 1000 10
250 500 9
130 250 8
64 130 7
32 64 6
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3 Selection of the hydraulic fluid


Water-free, fire-resistant hydraulic fluids for Bosch Rexroth We recommend that the optimum operating viscosity range of
hydraulic components are assessed on the basis of their fulfill- each component be kept within the permissible temperature
ment of the minimum requirements of ISO 12922. range. This usually requires either cooling or heating, or both.
The permissible viscosity range and the necessary cleanliness
level can be found in the product data sheet for the component
3.1 Selection criteria for the hydraulic fluid concerned.
The specified limit values for all components employed in the
If the viscosity of a hydraulic fluid used is above the permitted
hydraulic system, for example viscosity and cleanliness level,
operating viscosity, this will result in increased hydraulic-me-
must be observed with the hydraulic fluid used, taking into
chanical losses. In return, there will be lower internal leakage
account the specified operating conditions.
losses. If the pressure level is lower, lubrication gaps may not
Hydraulic fluid suitability depends, amongst others, on the be filled up, which can lead to increased wear. For hydraulic
following factors: pumps, the permitted suction pressure may not be reached,
which may lead to cavitation damage.
3.1.1 Viscosity
If the viscosity of a hydraulic fluid is below the permitted
Viscosity is a basic property of hydraulic fluids. The permissible operating viscosity, increased leakage, wear, susceptibility to
viscosity range of complete systems needs to be determined contamination and a shorter component life cycle will result.
taking account of the permissible viscosity of all components
Please ensure that the permissible temperature and viscosity
and it is to be observed for each individual component.
limits are observed for the respective components. This usually
The viscosity at operating temperature determines the response requires either cooling or heating, or both.
characteristics of closed control loops, stability and damping
of systems, the efficiency factor and the degree of wear.

Fig. 1: Examples V-T diagrams for water-free, fire-resistant hydraulic fluids in comparison to
HLP and HFC (reference values, double-logarithmic representation)

40q 20q 0q 20q 40q 60q 80q 100q


1600
1000
600
400
200
Viscosity Q [mm2/s]

100
60
40

20

HFC
10
HFDU
HLP46
5
40q 25q 10q 0q 10q 30q 50q 70q 90q 115q HFDR
Temperature t [°C]

Typical viscosity data [mm2/s] Detailed V-T diagrams may be obtained from your lubricant
manufacturer for their specific products. Descriptions of the
at temperature 0 °C 40 °C 100 °C individual classifications can be found in chapter 3.2 and in
HFDR 2500 43 5,3 Table 4.
HFDU (ester base) 330 46 9,2
HFDU (glycol base) 350 46 8,7
For comparison HLP
610 46 7
(see RE 90220)
For comparison HFC
280 46
(see RE 90223)
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3.1.2 Viscosity-temperature behavior Table 2: Known material incompatibilities


For hydraulic fluids, the viscosity temperature behavior (V-T Classification Incompatible with:
behavior) is of particular importance. Viscosity is characterized HFD in Seals, plastics and coatings of control cabi-
in that it drops when the temperature increases and rises when general nets, outer coatings of hydraulic components
the temperature drops. The interrelation between viscosity and and accessory components (connectors, 1
temperature is described by the viscosity index (VI). wiring harnesses, control cabinets) are to be
tested for stability.
For cold testing over a period of several days, the viscosity
of ester-based HFDU can increase greatly. After heating, Note: hydraulic fluid vapors can also lead to
the characteristic values as specified on the data sheet are incompatibility!
restored. Please ask your lubricant manufacturer for the "Flow HFDR Individual component color coating, lead, gal-
capacity after seven days at low temperature" (ASTM D 2532) vanic zinc-plating, in part non-ferrous metals
for the fluid classification ester-based HFDU . with zinc, tin and aluminum in a tribological
HFDU fluid based on ester and glycol have better viscosity/ system. Sealing elements made of NBR. In
temperature characteristics than mineral oil HLP (see Fig. 1). some cases, the latter show major increases
This should be taken into consideration when selecting in volume when impermissibly aged hydraulic
hydraulic fluid for the required temperature range. The viscosity fluids come into contact with the material. Do
and temperature limits required in the product data sheets are not use any hydrolysis/susceptible polyure-
to be observed in all operating conditions. thane qualities.

Note HFDU based Single-component color coatings, lead,


For ambient temperatures below 0 °C, fire-resistant, water- on ester galvanized zinc coatings, in part non-ferrous
containing hydraulic fluids of classification HFC are to be metals with zinc, tin, seals made of NBR. In
preferred because they observe the component-related some cases, the latter show major increases
viscosity ranges and because the have better pour points in volume when impermissibly aged hydraulic
(see RE 90223). fluids come into contact with the material. Do
not use any hydrolysis/susceptible polyure-
3.1.3 Wear protection capability thane qualities.
HFDU based Single-component color coatings, steel/alu-
Wear protection capability describes the property of hydraulic on glycol minum tribocontacts, paper filters, polymeth-
fluids to prevent or minimize wear within the components. The ylmethacrylate (PMMA). The compatibility of
wear protection capability is described in ISO 12922 via test NBR is to be examined for individual case.
procedures"FZG gear test rig" (ISO 14635-1) and "Mechani-
cal test in the vane pump" (ISO 20763). The wear protection
capability of water-free, fire-resistant hydraulic fluids in relation The material incompatibilities mentioned here do not automati-
to the two test procedures is comparable to that of mineral oil cally result in function problems. However the elements of
HLP/HVLP. the materials are found in the hydraulic fluids after use. The
material incompatibilities described here may lead to acceler-
3.1.4 Material compatibility ated aging of the hydraulic fluid and to reduced fire resistance.

The hydraulic fluid must not negatively affect the materials 3.1.5 Aging resistance
used in the components. Compatibility with coatings, seals,
hoses, metals and plastics is to be observed in particular. The The way a water-free, fire-resistant hydraulic fluid ages de-
fluid classifications specified in the respective component data pends on the thermal, chemical and mechanical stress to which
sheets are tested by the manufacturer with regard to material it is subjected. The influence of water, air, temperature and
compatibility. Parts and components not supplied by us are to contamination may be significantly greater than for mineral oils
be checked by the user. HLP/HVLP. Aging resistance can be greatly influenced by the
chemical composition of the hydraulic fluids.
High fluid temperatures (e.g. over 80 °C) result in a approxi-
mate halving of the fluid service life for every 10 °C temperature
increase and should therefore by avoided. The halving of the
fluid service life results from the application of the Arrhenius
equation (see Glossary).

Table 3: Reference values for temperature-dependent


aging of the hydraulic fluid
Reservoir temperature Fluid life cycle
80 °C 100 %
90 °C 50 %
100 °C 25 %
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A modified aging test (ISO 4263-3 or ASTM D943 – without 3.1.9 Filterability
the addition of water) is specified for fluid classification
Filterability describes the ability of a hydraulic fluid to pass
HFDU. Fluid classification HFDR is described with a special
through a filter, removing solid contaminants. The hydraulic
procedure with respect to oxidation stability (EN 14832) and
fluids used require a good filterability, not just when new, but
oxidation service life (ISO 4263-3). The calculated fluid service
also during the whole of their service life. This can differ greatly
life is derived from the results of tests in which the long-term
depending on the different basic fluids (glycols, esters) and
characteristics are simulated in a short period of time by
additives (VI enhancers, anti-fogging additives).
applying more arduous conditions (condensed testing). This
calculated fluid service life is not to be equated to the fluid The filterability is a basic prerequisite for cleanliness, servicing
service life in real-life applications. and filtration of hydraulic fluids. Rexroth therefore requires the
same degree of filterability of water-free, fire-resistant hydraulic
Table 3 is a practical indicator for hydraulic fluids with water
fluids as for mineral oils HLP/HVLP to DIN 51524.
content < 0.1%, cf. chapter 4.10. "Water".
As ISO 12922 does not comment on the filterability of hydrau-
lic fluids, filterability comparable to that of mineral oils HLP/
3.1.6 Environmentally acceptable
HVLP must be requested of lubricant manufacturers.
HFDU fluids based on ester and glycol are hydraulic fluids
Filterability is tested with the new hydraulic fluid and after the
which may also be classified as environmentally acceptable.
addition of 0.2 % water. The underlying standard (ISO 13357-
The main criteria for fire-resistant, water-free hydraulic fluids
1/-2) stipulates that filterability must have no negative effects
are the leak-free, technically problem-free use and the neces-
on the filters or the hydraulic fluid, see chapter 4 "Hydraulic
sary fire resistance. Environmentally acceptable is merely a
fluids in operation".
supplementary criterion. Notes on environmentally compatible
hydraulic fluids can be found in RE 90221.
3.1.10 Corrosion protection
3.1.7 Air separation ability (ASA) Hydraulic fluids should not just prevent corrosion formation
on steel components, they must also be compatible with
The air separation ability (ASA) describes the property of a
non-ferrous metals and alloys. Corrosion protection tests on
hydraulic fluid to separate undissolved air. Hydraulic fluids
different metals and metal alloys are described in ISO 12922.
always contain dissolved air. During operation, dissolved air
may be transformed into undissolved air, leading to cavitation Rexroth components are usually tested with HLP hydraulic
damages. Fluid classification, fluid product, reservoir size and fluids or corrosion protection oils based on mineral oils before
design must be coordinated to take into account the dwell they are delivered.
time and ASA value of the hydraulic fluid. The air separation
capacity depends on the viscosity, temperature, basic fluid and 3.1.11 Additivation
aging. It cannot be improved by additives.
The properties described above can be modified with the help
According to ISO 12922 for instance, an ASA value d 15 min- of suitable additives.
utes is required for viscosity class ISO VG 46, practical values Bosch Rexroth does not prescribe any specific additive
on delivery are < 10 minutes, lower values are preferable. system.

3.1.8 Demulsifying ability and water solubility


The capacity of a hydraulic fluid to separate water at a defined
temperature is known as the demulsifying ability. ISO 6614
defines the demulsifying properties of hydraulic fluids.
The fluid classifications HFDU based on ester and HFDR
separate water, but HFD hydraulic fluids have a different
water separation ability to mineral oil HLP/HVLP. At 20 °C, in
comparison to mineral oil HLP/HVLP, a multiple (> factor 3) of
water can separate in the hydraulic fluid. Water solubility is also
more temperature-dependent than for mineral oils. The fluid
classification HFDU based on glycol usually dissolves water
completely, see chapter "4.10 Water".
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3.2 Classification and fields of application


Table 4: Classification and fields of application
Typical field
Classification Features Notes
of application 1
HFDU Base fluid: Mobile systems with For information on approved components, please refer to the
(glycol-based) Glycols high thermal loading respective product data sheet. For components which have
according to ISO not been approved according to the product data sheet,
12922 please consult your Bosch Rexroth sales partner.
Density at 15 °C: – Very good viscosity/temperature characteristics, shear
typically stability
> 0.97 kg/dm³
– Resistant to aging
VI: typical > 170
– Can be water-soluble
– Can be mixed with water
The classification
– Very good wear protection properties
"HFDU" is no longer
listed in the current – A higher implementation temperature with the same viscos-
standard sheet ity in comparison to mineral oil is to be expected
VDMA 24317.
– Due to the higher density in comparison to HLP, lower
suction pressures are to be anticipated for pumps. Reduce
the maximum speed as required and optimize suction
conditions.
– Prior to commissioning, contact the lubricant manufacturer,
as the components are tested with mineral oil HLP/corro-
sion protection oil.
– Incompatible with mineral oil (exceptions must be con-
firmed by the lubricant manufacturer).
HFDU (ester-based) Base fluid: Suitable for most For information on approved components, please refer to the
according to Ester based on fields of application respective product data sheet. For components which have
ISO 12922 regenerative raw and components. not been approved according to the product data sheet,
materials, synthetic please consult your Bosch Rexroth sales partner.
Density at 15 °C:
ester and mixtures
typically 0.90-0.93 – Preferred use of FKM seals. Please enquire about shaft
of different esters
kg/dm³ seal rings and implementation temperatures under –15 °C.
Because of the fire
VI: typical > 160 – Note shear stability (see chapter 4.11 "Fluid servicing, fluid
resistance, HFDU
analysis and filtration" and chapter 6 "Glossary")
Iodine count < 90 hydraulic fluids
based on ester are – Fire resistance is not stable over time
usually partially
– In operation, a higher temperature in comparison to mineral
The classification saturated esters
oil HLP/HVLP is to be expected given identical design
"HFDU" is no longer
and viscosity. Please check ATEX approvals for hydraulic
listed in the current
components.
standard sheet
VDMA 24317. – Limit the lower (see chapter 3.1.2) and upper implementa-
tion temperatures (see chapter 3.1.5)
– Good viscosity-temperature behavior
– Usually classified as insignificantly water-endangering
(water hazard class WGK 1)
– High dirt dissolving capacity on fluid changeovers
– In unfavorable operating conditions (high water content,
high temperature), HFDU on ester basis have a tendency
to hydrolysis. The acidic organic decomposition products
can chemically attack materials and components.
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Typical field
Classification Features Notes
of application
HFDR Base fluid: phos- Turbine control For information on approved components, please refer to the
according to ISO phoric acid ester systems respective product data sheet. For components which have
12922 not been approved according to the product data sheet,
please consult your Bosch Rexroth sales partner.
Density at 15 °C:
typically 1.1 kg/dm³ – Classified as hazardous materials
(for transportation and storage)
VI : typical 140–160
– Hazardous working material
– Water-endangering (Water hazard class 2 – WGK2)
– Develops toxic vapors in case of fire
– Preferred use of FKM, and possibly PTFE seals. Please
enquire for shaft seal rings and implementation tempera-
tures under –15 °C.
– In operation, a higher temperature in comparison to mineral
oil HLP/HVLP is to be expected given identical design and
viscosity
– Phosphoric acid esters display a tendency to hydrolysis
when they come into contact with moisture. Under the
influence of water/moisture, they become unstable or form
highly aggressive, acidic components which could damage
the hydraulic fluid and component beyond repair.
– Poor viscosity/temperature characteristics
– Due to the higher density in comparison to HLP, lower
suction pressures are to be anticipated for pumps. Reduce
the maximum speed as required and optimize suction
conditions.
– In unfavorable operating conditions (high water content,
high temperature), HFDR have a tendency to hydrolysis.
The acidic inorganic decomposition products chemically
attack materials and components.
HFDU (continued) Based on triglycer- Not recommended Hydraulic fluids based on polyalphaolefines are not recom-
ides, mineral oils or for Rexroth compo- mended on account of their poor fire resistance. This clas-
related hydrocarbons nents! sification can usually be identified from: density < 0.89;
VI < 140 to 160
Hydraulic fluids based on triglycerides are not recommended
on account of their aging resistance. This classification can
usually be identified from: density > 0.92; VI > 190; iodine
count > 90
Consult your lubricant manufacturer or your Bosch Rexroth
sales partner if the classification of a hydraulic fluid is not
clear.
HFDS Based on haloge- Not approved for HFDS and HFDT have not been permitted to be manufac-
nated hydrocarbons Rexroth compo- tured or used since 1989 for environmental reasons.
HFDT
or mixtures with nents!
halogenated
hydrocarbons
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4 Hydraulic fluids in operation


4.1 General manufacturer or supplier of the new hydraulic fluid. The quantity
of old fluid remaining should be minimized. Mixing hydraulic
The properties of hydraulic fluids can change continually during fluids should be avoided, see following chapter.
storage and operation.
Information about changing to a hydraulic fluid of a different
Please note that the fluid standard ISO 12922 merely classification can be found, for example, in VDMA 24314 and 1
describes minimum requirements for hydraulic fluids in new in ISO 7745. In addition, the information given in chapter 3.1.4
condition at the time of filling into the bins. The operator of a "Material compatibility" is also to be observed.
hydraulic system must ensure that the hydraulic fluid remains
in a utilizable condition throughout its entire period of use. Bosch Rexroth will not accept liability for any damage to its com-
ponents resulting from inadequate hydraulic fluid changeovers!
Deviations from the characteristic values are to be clarified with
the lubricant manufacturer, the test labs or Bosch Rexroth.
4.5 Mixing and compatibility of different
Bosch Rexroth will accept no liability for damage to its compo- hydraulic fluids
nents within the framework of the applicable liability legislation
insofar as the latter is due to non-observance of the following If hydraulic fluids from different manufacturers or different
instructions. types from the same manufacturer are mixed, gelling, silting
and deposits may occur. These, in turn, may cause foaming,
Please note the following aspects in operation. impaired air separation ability, malfunctions and damage to the
hydraulic system.
4.2 Storage and handling If the fluid contains more than 2 % of another fluid then it is
Hydraulic fluids must be stored correctly in accordance with considered to be a mixture. Exceptions apply for water, see
the instructions of the lubricant manufacturer. Avoid exposing chapter 4.10 "Water".
the containers to lengthy periods of direct heat. Containers Mixing with other hydraulic fluids is not generally permitted.
are to be stored in such a way that the risk of any foreign liquid This includes hydraulic fluids with the same classification. If
or solid matter (e.g. water, foreign fluids or dust) ingression individual lubricant manufacturers advertise miscibility and/or
into the inside of the container can be ruled out. After taking compatibility, this is entirely the responsibility of the lubricant
hydraulic fluids from the containers, these are immediately to manufacturer.
be properly resealed.
Bosch Rexroth customarily tests all components with mineral
Recommendation: oil HLP before they are delivered.
– Store containers in a dry, roofed place Note: With connectible accessory units and mobile filtering
– Store barrels on their sides systems, there is a considerable risk of non-permitted mixing
of the hydraulic fluids!
– Clean reservoir systems and machine reservoirs regularly
Rexroth will not accept liability for any damage to its compo-
nents resulting from mixing hydraulic fluids!
4.3 Filling of new systems
Usually, the cleanliness levels of the hydraulic fluids as delivered 4.6 Re-additivation
do not meet the requirements of our components. Hydraulic fluids
must be filtered using an appropriate filter system to minimize solid Additives added at a later point in time such as colors, wear
particle contamination and water in the system. reducers, VI enhancers or anti-foam additives, may negatively
affect the performance properties of the hydraulic fluid and
As early as possible during test operation, new systems should the compatibility with our components and therefore are not
be filled with the selected hydraulic fluid so as to reduce the permissible.
risk of accidentally mixing fluids (see chapter 4.5 "Mixing and
compatibility of different hydraulic fluids"). Changing the hy- Rexroth will not accept liability for any damage to its compo-
draulic medium at a later point represents significant additional nents resulting from re-additivation!
costs (see following chapter).
4.7 Foaming behavior
4.4 Hydraulic fluid changeover Foam is created by rising air bubbles at the surface of hydraulic
Problems may be encountered in particular when changing fluids in the reservoir. Foam that develops should collapse as
over from water-containing, fire-resistant hydraulic fluid or quickly as possible.
mineral oils to water-free, fire-resistant hydraulic fluids (e.g. Common hydraulic fluids in accordance with ISO 12922 are
incompatibilities in the form of gelling, silting, stable foam, sufficiently inhibited against foam formation in new condi-
reduced filterability or filter blockage). This may also happen tion. On account of aging and adsorption onto surfaces, the
when changing products within the same classification. defoamer concentration may decrease over time, leading to a
In the case of changeovers of the fluid in hydraulic systems, it stable foam.
is important to ensure compatibility of the new hydraulic fluid Defoamers may be re-dosed only after consultation with the
with the remains of the previous hydraulic fluid. Bosch Rexroth lubricant manufacturer and with his written approval.
recommends obtaining verification of compatibility from the
Defoamers may affect the air separation ability.
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4.8 Corrosion Water content has an affect particularly in the case of HEDU
hydraulic fluid on ester basis and HFDR in that it accelerates
The hydraulic fluid is to guarantee sufficient corrosion protec- aging (hydrolysis) of the hydraulic fluid and biological degra-
tion of components under all operating conditions, even in the dation, see chapter 4.11 "Fluid servicing, fluid analysis and
event of impermissible water contamination. filtration".
Water-free, fire-resistant hydraulic fluids are tested for cor-
rosion protection in the same way as mineral oil HLP/HVLP. 4.11 Fluid servicing, fluid analysis and filtration
When used in practice other corrosion mechanisms are
revealed in detail and in individual cases, for the most part in Air, water, operating temperature influences and solid matter
contact with non-ferrous and white alloys. contamination will change the performance characteristics of
hydraulic fluids and cause them to age.

4.9 Air To preserve the usage properties and ensure a long service life
for hydraulic fluid and components, the monitoring of the fluid
Under atmospheric conditions the hydraulic fluid contains condition and a filtration adapted to the application require-
dissolved air. In the negative pressure range, for instance in ments (draining and degassing if required) are indispensable.
the suction pipe of the pump or downstream of control edges,
this dissolved air may transform into undissolved air. The The effort is higher in the case of unfavorable usage conditions,
undissolved air content represents a risk of cavitation and of increased stress for the hydraulic system or high expectations
the diesel effect. This results in material erosion of components as to availability and service life, see chapter 2 "Solid particle
and increased hydraulic fluid aging. contamination and cleanliness levels".

With the correct measures, such as suction pipe and reservoir When commissioning a system, please note that the required
design, and an appropriate hydraulic fluid, air intake and minimum cleanliness level can frequently be attained only by
separation can be positively influenced. flushing the system. Due to severe start-up contamination, it
may be possible that a fluid and/or filter replacement becomes
See also chapter 3.1.7 "Air separation ability (ASA)”. necessary after a short operating period (< 50 operating
hours).
4.10 Water The hydraulic fluid must be replaced at regular intervals and
Water contamination in hydraulic fluids can result from direct tested by the lubricant manufacturer or recognized accredited
ingress or indirectly through condensation of water from the air test labs. We recommend a reference analysis after com-
due to temperature variations. missioning.

HFDU hydraulic fluids on glycol basis are water-soluble or The minimum data to be tested for analyses are:
can be mixed with water. This means that any water that has – Viscosity at 40 °C and 100 °C
ingressed into the system cannot be drained off in the sump
of the reservoir. – Neutralization number NN (acid number AN)

In the case of HDFU hydraulic fluids on ester basis, undis- – Water content (Karl-Fischer method)
solved water can be drained off from the reservoir sump, the – Particle measurement with evaluation according to
remaining water content is however too high to ensure that the ISO 4406 or mass of solid foreign substances with
maximum permissible water limit values are observed in the evaluation to EN 12662
long term.
– Element analysis (RFA (EDX) / ICP, specify test method)
With the fluid classification HFDR, the greater density of the
ester means that the any water that has ingressed will be on – Comparison with new product or available trend analyses
the surface of the hydraulic fluid. This means that any water – Assessment / evaluation for further use
that has ingressed into the system cannot be drained off in the
sump of the reservoir. – Also recommended: IR spectrum

Water in the hydraulic fluid can result in wear or direct failure No differences are needed in the maintenance and care of
of hydraulic components. Furthermore, a high water content in water-free, fire-resistant hydraulic fluids with the appropriate
the hydraulic fluid negatively affects aging and filterability and suitability parameters compared to HLP/HVLP mineral oils.
increases susceptibility to cavitation. During operation, the water Attention is however drawn to the note in chapter 1.3.
content in all hydraulic fluids, determined according to the "Karl After changing over hydraulic fluids it is recommended that the
Fischer method" (see chapter 6 "Glossary") for all water-free, filters be replaced again after 50 operating hours as fluid aging
fire-resistant hydraulic fluids must constantly be kept below 0.1% products may have detached themselves ("self-cleaning effect").
(1000 ppm). To ensure a long service life of both hydraulic fluids
and components, Bosch Rexroth recommends that values below Compared to the pure unused hydraulic fluid the changed
0.05% (500 ppm) are permanently maintained. neutralization number NN (acid number AN) indicates how
many aging products are contained in the hydraulic fluid.
Due to the higher water solubility in comparison to mineral oil This difference must be kept as small as possible. The lubricant
HLP/HVLP it is urgently advised that precautions be taken manufacturer should be contacted as soon as the trend
when using water-free, fire-resistant hydraulic fluids, such as a analysis notes a significant increase in values.
dehumidifier on the reservoir ventilation.
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5 Disposal and environmental


A higher viscosity than that of new materials indicates that the
protection
hydraulic fluid has aged. Evaluation by the test lab or lubricant
All water-free, fire-resistant hydraulic fluids, are, like mineral oil-
manufacturers is however authoritative, whose recommenda-
based hydraulic fluids, subject to special disposal obligations.
tion should be urgently observed.
The respective lubricant manufacturers provide specifications
On systems where the possibility of water contamination 1
on environmentally acceptable handling and storage. Please
cannot be completely ruled out (also condensation), it should
ensure that spilt or splashed fluids are absorbed with appropri-
be ensured via the hydraulic system circuit that fluid aging
ate adsorbents or by a technique that prevents it contaminating
products are not accumulating in individual areas of the
water courses, the ground or sewerage systems.
hydraulic system, but are being removed from the system in
a controlled manner via the filtration system. This should be It is also not permitted to mix fluids when disposing of hydraulic
ensured via suitable hydraulic circuits (e.g. flushing circuit) or fluids. Regulations governing the handing of used oils stipulate
system manufacturer's operating instructions/specifications. that used oils are not to mixed with other products, e.g.
substances containing halogen. Non-compliance will increase
In case of warranty, liability or guarantee claims to Bosch
disposal costs. Comply with the national legal provisions
Rexroth, service verification and/or the results of fluid analyses
concerning the disposal of the corresponding hydraulic
are to be provided.
fluid. Comply with the local safety data sheet of the lubricant
manufacturer for the country concerned.
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6 Glossary
Additivation Karl Fischer method
Additives are chemical substances added to the basic fluids to Method to determine the water content in fluids. Indirect
achieve or improve specific properties. coulometric determination procedure in accordance with DIN
Aging EN ISO 12937 in connection with DIN 51777-2. Only the
Hydraulic fluids age due to oxidation (see chapter 3.1.5 "Aging combination of both standards will assure adequately accurate
resistance"). Liquid and solid contamination acts as a catalyzer measured values. For hydraulic fluids based on glycol, DIN EN
for aging, meaning that it needs to be minimized as far as ISO 12937 is to be applied in conjunction with DIN 51777-1.
possible by careful filtration. Please refer to Hydrolysis. Cavitation
Arrhenius equation Cavitation is the creation of cavities in fluids due to pressure
The quantitative relation between reaction rate and temperature reduction below the saturated vapour pressure and subse-
is described by an exponential function, the Arrhenius equation. quent implosion when the pressure increases. When the
This function is usually visualized within the typical temperature cavities implode, extremely high acceleration, temperatures
range of the hydraulic system. For a practical example, see and pressure may occur temporarily, which may damage the
chapter 3.1.5 "Aging resistance”. component surfaces.

Basic fluids Neutralization number (NN)


In general, a hydraulic fluid is made up of a basic fluid, The neutralization number (NN) or acid number (AN) specifies
or base oil, and chemical substances, the so-called additives. the amount of caustic potash required to neutralize the acid
The proportion of basic fluid is generally greater than 90%. contained in one gram of fluid.

Diesel effect Pour point


The lowest temperature at which the fluid still just flows when
If hydraulic fluid that contains air bubbles is compressed cooled down under set conditions. The pour point is specified
quickly, the bubbles are heated to such a degree that a self- in the lubricant manufacturers' technical data sheets as a
ignition of the air-gas mix may occur. The resultant temperature reference value for achieving this flow limit.
increase may lead to seal damage and increased aging of the
hydraulic fluid. RFA (wavelength dispersive x-ray fluorescence analysis)
Is a procedure to determine nearly all elements in liquid and
Partially saturated esters solid samples with nearly any composition. This analysis
In contrast to saturated esters, partially saturated esters have method is suitable for examining additives and contamination,
double/multiple bonds between C atoms. Rexroth defines delivering fast results.
partially saturated esters as unsaturated bonds and mixtures
of esters with unsaturated and saturated bonds. Esters with Shearing/shear loss
unsaturated bonds are produced on the basis of renewable Shearing of molecule chains during operation can change
raw materials. the viscosity of hydraulic fluids with long chain VI enhancers
and anti-fogging additives. The initially high viscosity index
Depending on their number and position, these unsaturated drops. This needs to be taken into account when selecting the
bonds between the C atoms are instable. These bonds can hydraulic fluid.
detach themselves and form new bonds, thus changing the
properties of those liquids (an aging mechanism). Attention The only value at present that can be used to assess viscosity
is however drawn to the note in chapter 1.3. changes in operation is the result of the test in accordance
with DIN 51350 part -6. Please note that there are practical
Hydrolysis applications that create a much higher shear load on such
Hydrolysis is the splitting of a chemical bond through the hydraulic fluids than can be achieved by this test.
reaction with water under the influence of temperature.
Viscosity
ICP (atomic emission spectroscopy) Viscosity is the measure of the internal friction of a fluid to
The ICP procedure can be used to determine various wear flow. It is defined as the property of a substance to flow under
metals, contamination types and additives. Practically all tension. Viscosity is the most important characteristic for
elements in the periodic system can be detected with this describing the load-bearing capacity of a hydraulic fluid.
method.
Kinematic viscosity is the ratio of the dynamic viscosity and the
Iodine count density of the fluid; the unit is mm²/s. Hydraulic fluids are clas-
The iodine count is a yardstick for the quantity of single and sified by their kinematic viscosity into ISO viscosity classes.
multiple unsaturated bonds between C atoms in the basic fluid. The reference temperature for this is 40 °C.
A low iodine count indicates that the hydraulic fluid contains
few unsaturated bonds and is thus considerably more resistant Viscosity index (VI)
to aging than a hydraulic fluid with a high iodine count. A Refers to the viscosity temperature behavior of a fluid. The
statement about the position at which these multiple bonds are lower the change of viscosity in relation the temperature, the
located and about how "stable" they are against influencing higher the VI.
factors cannot be derived simply by stating the iodine count.
83
RE 90222/05.12 Fire-resistant, water-free hydraulic fluids Bosch Rexroth AG 15/16

1
84
16/16 Bosch Rexroth AG Fire-resistant, water-free hydraulic fluids RE 90222/05.12

Bosch Rexroth AG © This document, as well as the data, specifications and other information
Hydraulics set forth in it, are the exclusive property of Bosch Rexroth AG. It may not be
Zum Eisengießer 1 reproduced or given to third parties without its consent.
97816 Lohr am Main, Germany The data specified above only serve to describe the product. No statements
Phone +49 (0) 93 52 / 18-0 concerning a certain condition or suitability for a certain application can be
Fax +49 (0) 93 52 / 18-23 58 derived from our information. The information given does not release the user
from the obligation of own judgment and verification.
documentation@[Link]
[Link] It must be remembered that our products are subject to a natural process of
wear and aging.
Subject to change.
85

Systems

Electro-hydraulic control systems


The Rexroth [Link]. is an electrohydraulic closed-loop
control system based on a variable displacement axial
piston pump, for controlling pressure, flow and
power without throttling losses in the power train.

Variable-speed pump systems - Sytronix


The variable-speed pump drive DFEn is based on the
proven pressure and flow control system [Link]. An elec-
trohydraulically controlled axial piston pump is controlled
by a variable-speed drive.

Cooling lubricant systems


Different designs ensure the filtration and cooling of oils
and emulsions used for the metal processing.

RE 00112-07, Edition: 2013-08, Bosch Rexroth AG


86
Systems

Bosch Rexroth AG, RE 00112-07, Edition: 2013-08


87
Contents | Electro-hydraulic control systems | Systems

Electro-hydraulic control systems


Component
Designation Type series Data sheet Page

Sytems
1
Pressure and flow control system, with axial piston variable displacement SYDFE1, SYDFEE, 2X 30030 89
pump A10VSO.../31, size 18 to 140 SYDFEC
Pressure and flow control system, with axial piston variable displacement SYDFE1, SYDFEE, 3X 30630 119
pump A10VSO.../32, size 71 to 180 SYDFEC
Pressure and flow control system, with axial piston variable displacement SYHDFEE, 1X 30035 147
pump A4VSO, size 125 to 355 SYHDFEC

Accessories
Pump pre-load valve for the SYDFE control system SYDZ 0001 1X 29255 175
3/3 proportional directional valves, direct operated, with electrical VT-DFP 2X 29016 179
position feedback as pilot valves for control systems SY(H)DFE.
External control electronics for the SYDFE1 control of the A10VSO VT 5041 3X 30242 193
axial piston pump
2

RE 00112-07, Edition: 2013-08, Bosch Rexroth AG


88

Bosch Rexroth AG, RE 00112-07, Edition: 2013-08


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193

External control electronics for the SYDFE1 


control of the A10VSO axial piston variable
displacement pump
RE 30242 
Edition: 2013-06
Type VT 5041 Replaces: 12.11

▶ Component series 3X
▶ Analog, Euro-card format
▶ Part of the SYDFE1 pressure and flow control system
(component series 1X, 2X and 3X) for the control of the
axial piston variable displacement pump A10VSO... with
SYDFE1 control via valve VT-DFP...2X

H7709

Features Contents

▶ Implementation of the electronic functions of the Features 1


SYDFE1 control; pressure and swivel angle control; Ordering codes 2
optional power limitation Functional description 3
▶ Pressure controller circuitry can be adjusted and Block diagram/pin assignment 4
switched to two existing hydraulic fluid volumes (actua- Technical data 6
tors plus lines) Electronic card: Display and adjustment elements 8
▶ Differential amplifier inputs Front plate: Display and adjustment elements,
▶ Controller for valve spool position measuring sockets 9
▶ Minimum value generator for pressure and swivel Dimensions 10
angle controller
▶ Self-timed output stage
▶ Pressure-dependent leakage compensation (can be
switched off)
▶ Reverse polarity protection for voltage supply
▶ Switchable actual pressure value input (current, volt-
age, range)
▶ 6 LED displays on the front plate for the operating state
▶ Display instrument on the front plate for actual swivel
angle value (optional)
▶ Power limitation with internal or external command
value presetting (optional)

Bosch Rexroth AG, RE 30242, edition: 2013-06


194
2/10 VT 5041 | Control electronics

Ordering codes

01 02 03 04
VT 5041 – 3X / – 0

01 External control electronics for the SYDFE1 control of the A10VSO axial piston variable displacement pump VT 5041

02 Component series 30 to 39 (30 to 39: Unchanged technical data and pin assignment) 3X

Additional functions
03 Without power limitation/without display instrument 1
Without power limitation/with display instrument 2
With power limitation/with display instrument 3

04 For IW9 swivel angle sensor (standard) 0

Preferred types
Material no. Type
R901236404 VT 5041-3X/1-0
R901263598 VT 5041-3X/2-0
R901196678 VT 5041-3X/3-0

Recommended accessories

Card holder:
▶ Open card holder VT 3002-1-2X/32D
(see data sheet 29928)
Power supply unit:
▶ Type VT-NE32-1X, see data sheet 29929
Compact power supply unit 115/230 VAC → 24 VDC
– Output 1 (60 W) for VT-5041 supply
– Output 2 (24 W) for the supply of pressure transduc-
ers; e.g. type HM 12 or HM 13, see data sheet 29933

Bosch Rexroth AG, RE 30242, edition: 2013-06


195
Control electronics | VT 5041 3/10

Functional description

The analog control electronics VT5041-3X/... is designed The control electronics is equipped with a fault message
as insertion card in euro format. It is provided with a com- output where a voltage of 0 V is applied in case of error
mand value input each for pressure and swivel angle [1] as (= low-active). At the same time, the "Err." LED flashes.
a standard (optional power limitation). The actual pressure Depending on the jumper J1 configuration, the valve out-
value is measured with a pressure transducer. The position put can be de-energized in case of an error message.
transducer at the pump measures the actual swivel angle Causes for error messages:
value. The measured actual values are processed in ampli- ▶ Defective internal voltage supply
fier [2] and [3] and compared with the provided command ▶ The actual pressure value is greater than the admissible
values. The minimum value generator [4] controls that only system pressure (socket 2: pact > 11.5 V)
controller [6] or [10] which is allocated to the requested ▶ No enable signal at port 26c
operating point is automatically activated. The output ▶ Cable break or range of the swivel angle
signal of the minimum value generator [4] becomes the return exceeded
command value for the valve control loop. ▶ Cable break or range of the valve spool return exceeded
The optionally available power limitation is automatically ▶ Cable break "pressure transducer" (for adjust-
activated by the provision of a suitable command value. ments 4...20 mA, 0.5...5 V and 1...10 V)
The power command value can be provided internally or ▶ Control error (control difference x controller amplifica-
externally. If necessary, it limits the swivel angle command tion) is greater than 4 V (40%) for more than 1 second 2
value by means of a minimum value generator [5]. The In case of error, the electronics can be configured so that
resulting swivel angle command value can be measured at the output stage is de-energized and the valve spool is
socket 7. pressed to its mechanical end position. This causes the
The actual valve value (position of the valve spool) is pump to swivel back. The error can only be acknowledged
measured with an inductive position transducer. An oscilla- by resetting the enable signal.
tor/demodulator switch [7] enhances the signal. The
control deviation is generated and processed in the con- [ ] = assignment to the block diagram on page 4 and 5
troller for the valve spool position [8]. The output signal of
the valve controller [8] forms the command value for the
self-timing power output stage [9] which controls the
proportional solenoid of the valve.

RE 30242, edition: 2013-06, Bosch Rexroth AG


196
4/10 VT 5041 | Control electronics

Block diagram/pin assignment


Pressure command
value
1
6c
[1]
pSOLL 0...10 V u
4c u
Reference

22c
Switch TD 0/+24 V Pressure controller
Actual pressure D1 [10]
pIST 0...5 V 0...10 V value S3.1-3 P
2
0.5... 5 V 1...10 V [3] Adjustment D2
0...20 mA 4...20 mA 8c S3.4-6
u
10c u
Reference
R1 p IST
R2
Pressure control
Pressure controller deactivated
18a deactivated
Master/slave 0/+24 V
> +11,5 V
J4
FE1-contr. 1) Leakage
Version VT5041-3X/1-0 or .../2-0 compensation
< - 0,5 V

3
14c
[1] Adjustment
SWSOLL ±10 V u + Active swivel angle
Swivel angle
16c u + command value
controller
Reference 7
Single pump/
[5] [6]
[1] combination
MIN P
18c 1
SWIST-Master or ±10 V u 2 J2
20c u
power limit Reference 3
0...+10 V 100 % 8
cw
+
R3
ccw + DIV SW MAX
p IST
0%
Power limit
Version VT5041-3X/3-0
Enable
F valve output stage
26c &
Enable 0/+24 V
30a
+UB
32a +15V Enable 1)
=
28a = 0V
0V -15V
Shield 26a

32c 9 10
System ground Ub 1)
–15 V 20a
22a
M0
24a
+15 V

Abbreviations for the signals For the function of the jumpers and switches on the elec-
pSOLL Pressure command value tronic card see page 8.
pIST Actual pressure value For the meaning of the measuring sockets, and display and
Switch TD Oil volume selection adjustment elements (potentiometer) on the front plate,
SWSOLL Swivel angle command value see page 9.
SWIST Actual swivel angle value
SWIST-Master Actual master swivel angle value
FE1 contr. Pressure controller disabled

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197
Control electronics | VT 5041 5/10

8a 1 3
22a
Actual valve value M0 Valve position
6 sensor 2)
[7]
= 2 4
4a
R6
Enable R7 6a
J8 = ON
valve output stage 26a
Command value of valve J8 = ON: Compatible with
5 [8] [9] VT 5041-2X
28c
p-control 1) u
P i 30c Proportional solenoid 2)

[4] (2)
Actual swivel angle value 14a
MIN 4 [2]
> +4 V = 10a 1 Swivel angle
< -4 V sensor IW9 2)
R8 12a 2( )
R9 26a
t = 1 sec

u 24c pIST 0...10 V 2


u
p-ist v-soll u 12c
SWIST ±10 V
u
-control 1)
16a
Swivel angle control enabled

&
18a Power limitation active

J9 Power Limiter 1) Version VT5041-3X/3-0


Collective error

1 F
Actual valve value v-ist
error J1 Compatible with
KB-TP VT 5041-2X: J1 = OFF
Primary
KB-TS
Secondary

1 ≥1 2a
Error message "= HIGH"
sw-ist
Actual swivel angle
value error KB-IW9
2c
+15 V US Error message "= LOW"
+15V <10 V

U1+U2 unsym Error 1)


-15V > 2VǮ Ǯ

Diagnostic LEDs on the printed circuit board


1) LED displays on the front plate (for meaning see page 9)
v-soll Persisting control deviation is too great
2) For further information with regard to the connection,
v-ist Actual valve value error - exceeding of range see operating instructions 30011-B
p-ist Actual pressure value error
sw-ist Actual swivel angle value error - exceeds range
KB-TP Valve position sensor cable break - primary
KB-TS Valve position sensor cable break - secondary
KB-IW9 Swivel angle position sensor cable break
+15 V US +15 V undervoltage (internal power supply unit)
unsym Internal voltage supply is asymmetric

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198
6/10 VT 5041 | Control electronics

Technical data (for applications outside these parameters, please consult us.)

Operating voltage UB 24 V DC + 40 –10% (21.6… 33.6 V)


Upper limit value uB(t)max 35 V
Lower limit value uB(t)min 21 V
Current consumption Irated (Imax) 0.6 A (1.25 A)
Analog command value inputs
Pressure pSOLL Ue 0…10 V; Re > 50 kΩ
Standard ±10 V; regenerative: 0…10 V;
Swivel angle SWSOLL Ue
Re > 50 kΩ
Power (p ∙ SW)max 0…10 V, Re > 50 kΩ
or Ue
SWIST-Master ±10 V, Re > 50 kΩ
Analog actual value inputs
Ue 0...5 V, 0...10 V; Re > 50 kΩ
Pressure pIST 0.5...5 V, 1...10 V; Re > 50 kΩ
Ie
0...20 mA, 4...20 mA; RB = 100 Ω
Enable input (PLC) Ue > 12 V
Analog outputs
Output stage
Solenoid current Imax 2.5 A; R20 = 2 Ω
Oscillator
Frequency f 5.4 kHz
Amplitude for IW9 (actual swivel angle value) Uss 1 V (port 12a /14a)
Amplitude for DM2 (actual valve value) Uss 3.6 V (port 8a)
Signal voltage outputs
Actual pressure value U 0…10 V
Actual swivel angle value U –10 V… +10 V ≙ –100%... +100%
Auxiliary voltages for external use U ±(15 V + 2% – 6%); Imax = 10 mA
Measuring sockets, function and number
Pressure command value (pSOLL) 1 U 0… 10 V ≙ 0… +100%; Ri = 2 kΩ
Actual pressure value (pIST) 2 U 0… 10 V ≙ 0… +100%; Ri = 2 kΩ
Swivel angle command value (SWSOLL) 3 U ±10 V ≙ ±100%; Ri = 2 kΩ
Actual swivel angle value (SWIST) 4 U ±10 V ≙ ±100%; Ri = 2 kΩ
Valve command value (x_vsoll) 5 U ±10 V ≙ ±100%; Ri = 2 kΩ
Actual valve value (x_vist) 6 U ±10 V ≙ ±100%; Ri = 2 kΩ
Active swivel angle command value 7 U ±10 V ≙ ±100%; Ri = 2 kΩ
Power limit (Pmax) 8 U 0… +10 V ≙ 0… +100%; Ri = 2 kΩ
Reference 9 and 10
Message outputs
Swivel angle control enabled U UB – 3 V (Imax = 20 mA)
Power limitation active U UB – 3 V (Imax = 20 mA)
Error messages
Low-active U UB – 3 V (Imax = 20 mA); error at U < 1V
High-active U UB – 3 V (Imax = 20 mA)
Type of sensor
Swivel angle
IW9 (inductive position transducer) Throttle circuit; ±4 mm; 3-conductor connection
Valve
DM2 (inductive position transducer) Transformer circuit; ±0.6 mm; 4-conductor connection

Bosch Rexroth AG, RE 30242, edition: 2013-06


199
Control electronics | VT 5041 7/10

Technical data (for applications outside these parameters, please consult us.)

Type of connection
Compatibility 32 pin male multipoint connector; DIN 41612; design D
Card dimensions Euro-card 100 x 160 mm; DIN 41494
Front plate dimensions
Height 3 HE (128.4 mm)
Conductor path side width 1 TE
Component side width
VT 5041-3X/1-0 5 TE
VT 5041-3X/2-0 and VT 5041-3X/3-0 7 TE
Operating temperature range ̛ 0… +50 °C
Storage temperature range ̛ –20… +70 °C
Weight
Electronic card without display m 0.19 kg
Electronic card with display m 0.21 kg

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200
8/10 VT 5041 | Control electronics

Electronic card: Display and adjustment elements

Leakage Jumpers Valve command Jumpers Diagnostic LEDs Regenerative Jumpers


compensation J6 J7 value monitoring J9 For a description, see page 5 operation J3 J5
Off OFF OFF On ON and the operating On ON OFF
instructions 30011-B
4% OFF ON Off * OFF Off OFF ON
6% ON OFF
10% ON ON
Function Jumpers
pin 18a ** J4
Pressure control
OFF
KB-IW9

unsym
KB-TB
KB-TS

on/off
sw-ist
v-soll

p-ist
v-ist

Master/slave
ON
on/off
OFF
US ** Only for versions without
+15V ON * (standard)
power limitation
Reference for posi-
(VT 5041-3X/1-0 und
tion transducer
VT 5041-3X/2-0)

Valve deactivation in Jumpers


OFF (standard) case of error J1
Reference for actual Active OFF *
pressure value (–)
Inactive ON

ON * Compatible with VT 5041-2X

OFF

Volume adjustment of pressure controller


Input switch TD Switch S3
Selection for Jumpers Pressure controller Switch S3 Jumpers = OFF .1 .2 .3
analog input at J2 p amplification .7 .8 J11 ≤ 5.0 l OFF OFF OFF
pin 18c Bridge 8.0 OFF OFF OFF 7.5 l OFF ON OFF
Actual master 4.8 OFF ON OFF 10.0 l ON ON OFF
1-2
swivel angle value
4.0 OFF OFF ON 15.0 l ON OFF ON
External power
2-3 3.0 OFF ON ON 20.0 l OFF ON ON
limitation
2.4 ON OFF ON 25.0 l ON ON ON
2.0 ON ON ON
Input switch TD = ON Switch S3
Actual pressure Jumpers .4 .5 .6
value amplification J10 12.5 l OFF OFF OFF
1-fold OFF 30.0 l OFF ON OFF
2-fold ON 45 l ON ON OFF
60 l ON OFF ON
Signal adjustment of Switch S2
actual pressure value 75 l OFF ON ON
.1 .2 .3 .4 .5 .6 .7 .8
90 l ON ON ON
V 0...10 V OFF OFF OFF OFF OFF OFF ON ON
E 1...10 V OFF OFF OFF OFF ON OFF OFF ON
Explanations:
D 0...5 V OFF OFF ON ON OFF OFF ON ON
ON = bridge closed
F 0.5...5 V OFF OFF ON ON ON OFF OFF ON
OFF = bridge open
B 0...20 mA ON ON OFF OFF OFF OFF ON ON
= factory setting
C 4...20 mA ON ON OFF OFF ON ON OFF OFF

For the meaning of the measuring sockets, and display and adjustment elements (potentiometer) on the front plate,
see page 9.

Bosch Rexroth AG, RE 30242, edition: 2013-06


201
Control electronics | VT 5041 9/10

Front plate: Display and adjustment elements, measuring sockets


VT 5041-3X/1-0 VT 5041-3X/2-0 VT 5041-3X/3-0

Ub p-control Ub p-control Ub p-control


En. -control En. -control En. -control
Err. FE1-contr. Err. FE1-contr. Err. Power Limiter

R1 R1 R1

50 100

50 100
R2 R2 R2
R3
R6 R6 R6
R8 R8 R8

100 50

100 50
R9 R9 R9
2

1 2 1 2 1 2
3 4 3 4 3 4
5 6 5 6 5 6
7 8 7 8 7 8

VT5041 VT5041 VT5041

LED displays Measuring sockets (Ri = 2 kΩ)


Ub (green) Supply voltage available 1 Pressure command value 0…+10 V
En. (green) Enable available 2 Actual pressure value 0…+10 V
Err. (red) Fault/collective error 3 Swivel angle command value ±10 V
p-control (yellow) Pressure control enabled 4 Actual swivel angle value ±10 V
-control (yellow) Swivel angle control enabled 5 Valve command value ±10 V
FE1 contr. (yellow) Pressure controller disabled 6 Actual valve value ±10 V
Power Limiter (yellow) Power limitation active 7 Active swivel angle command value ±10 V
8 Power limit 0…+10 V
Adjustment elements (potentiometer)
⊥ Reference for measured values
R1 Zero point of actual pressure value
⊥ Reference for measured values
R2 Actual pressure value amplification
R3 Setting of the power limit Display (measuring instrument)
R6 Zero point of actual valve value Display of actual swivel angle value in %
R8 Zero point of actual swivel angle value
R9 Amplification of actual swivel angle value

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202
10/10 VT 5041 | Control electronics

Dimensions (dimensions in mm)

VT 5041-3X/1-0 VT 5041-3X/3(2)-1

Ub p-control Ub p-control
En. -control En. -control
Err. FE1-contr. Err. Power Limiter

R1 R1
50 100

R2 R2
3HE (128,4)

R3
R6 R6

100
R8 R8

89
50

R9 R9
100

1 2 1 2
3 4 3 4
5 6 5 6
7 8 7 8

VT5041 VT5041

6TE (30,5) 8TE (40,6) 2


7 165
186

Bosch Rexroth AG © This document, as well as the data, specifications and other information set
Hydraulics forth in it, are the exclusive property of Bosch Rexroth AG. It may not be
Zum Eisengießer 1 reproduced or given to third parties without its consent.
97816 Lohr am Main, Germany The data specified above only serve to describe the product. No statements
Phone +49 (0) 93 52 / 18-0 concerning a certain condition or suitability for a certain application can be
documentation@[Link] derived from our information. The information given does not release the user
[Link] 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.

Bosch Rexroth AG, RE 30242, edition: 2013-06


203
Contents | Variable-speed pump systems - Sytronix | Systems

Variable-speed pump systems - Sytronix


Component
Designation Type series Data sheet Page

Variable-speed pressure and flow control system Sytronix DFEn 5000, with SYDFEn 2X 62240 205
1
axial piston variable displacement pump A10VSO.../31, size 18 to 140
Variable-speed pressure and flow control system Sytronix DFEn 5000, with SYHDFEn 1X 62242 231
axial piston variable displacement pump A4VSO, size 125 to 355
Variable-speed pressure and flow control system Sytronix DFEn 5000, with SYDFEn 3X 62241 257
axial piston variable displacement pump A10VSO.../32, size 71 to 180

RE 00112-07, Edition: 2013-08, Bosch Rexroth AG


204

Bosch Rexroth AG, RE 00112-07, Edition: 2013-08


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Contents | Cooling lubricant systems | Systems

Cooling lubricant systems


Component
Designation Type series Data sheet Page

Filter systems
1
Slotted screen separator SUK 50405 281
Vacuum bowl filter TUW 50404 285
Gravity band filter SPB 50401 289
Gravity band filter HSF 50403 293
Gravity band filter LSF 50409 297
Vacuum band filter StUF 50400 301
Vacuum slotted screen filter VSF 50406 305
Magnetic separator MGS 50407 309
Hydrocyclone extractor IZF 50411 311

Conveying systems
Slotted screen lamella drag-chain conveyor SLK 50408 313
Lamella drag-chain conveyor LKF 50410 317 2
Conveyor IKF, IBF, ISF 50402 321

RE 00112-07, Edition: 2013-08, Bosch Rexroth AG


280

Bosch Rexroth AG, RE 00112-07, Edition: 2013-08


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Document no.: RE 00112-07


Material no.: R999000308
Versions no.: 2013-08
Replaces: RE 00112-06_2008-11
© Bosch Rexroth AG 2013
Subject to revisions!

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