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Bosch Rexroth WS290 Operating Instructions Manual

Hydraulics training system
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Hydraulics training system WS290
Operating instructions
RE 00225-B/12.15
Replaces: 02.15
English

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Summary of Contents for Bosch Rexroth WS290

  • Page 1 RE 00225-B/12.15 Hydraulics training system WS290 Replaces: 02.15 English Operating instructions...
  • Page 2  This document, as well as the data, specifications and other information set forth in it, are the exclusive property of Bosch Rexroth AG. It may not be reproduced or given to third parties without its consent.

  • Page 3: Table Of Contents

    Hydraulics training system WS290 | RE 00225-B/12.15 Bosch Rexroth AG 3/104 Contents Contents About this documentation ................6     Validity of the documentation ............. 6     In these instructions, the following signs and symbols are used ..6  ...
  • Page 4 4/104 Bosch Rexroth AG Hydraulics training system WS290 | RE 00225-B/12.15 Contents 5.14 Load simulator, rotatable ..............41     Technical data and dimensions ..............43     Technical data .................. 43     6.1.1 Constant pressure training system WS290 ....... 43  ...
  • Page 5 Hydraulics training system WS290 | RE 00225-B/12.15 Bosch Rexroth AG 5/104 Contents 10.1.3 Load-sensing system ............78     10.2 Switch-off 78     10.3 Resetting the EMERGENCY OFF ............ 79     Help in case of faults ................. 80  ...

  • Page 6: About This Documentation

    6/104 Bosch Rexroth AG Hydraulics training system WS290 | RE 00225-B/2.15 About this documentation About this documentation Validity of the documentation This documentation describes the "Hydraulics training system WS290", formerly called and described as “DS4”. For simplicity, the term "WS290 training system" will be used over the further course of the operating instructions.

  • Page 7: Symbols

    Hydraulics training system WS290 | RE 00225-B/12.15 Bosch Rexroth AG 7/104 About this documentation Safety instructions are set out as follows: SIGNAL WORD Type and source of danger Consequences in case of non-compliance Hazard avoidance measures  <Enumeration>   Warning sign: Draws attention to the danger ...

  • Page 8: Abbreviations

    8/104 Bosch Rexroth AG Hydraulics training system WS290 | RE 00225-B/2.15 About this documentation 1.4.3 Abbreviations The following abbreviations are used in this documentation: Abbreviations Table 3: Abbreviation Meaning LS control block Load-sensing control block WS290 training system Hydraulics training system WS290...

  • Page 9: Safety Instructions

    For example, in explosion- protected areas or in safety-related control components (functional safety). Bosch Rexroth AG does not assume any liability for damage caused by improper use. The user assumes all risks involved with improper use.

  • Page 10: Qualification Of Personnel

    10/104 Bosch Rexroth AG Hydraulics training system WS290 | RE 00225-B/2.15 Safety instructions In particular, improper use of the product includes:  Using the WS290 training system in a non-professional way and playing with it during the practical exercises and outside the training sessions, ...

  • Page 11: Troubleshooting, Maintenance And Repair

    Hydraulics training system WS290 | RE 00225-B/12.15 Bosch Rexroth AG 11/104 Safety instructions 2.4.3 Troubleshooting, maintenance and repair Maintenance and repair works as well as fault finding and troubleshooting measures require special knowledge and must only be carried out by qualified experts! ...

  • Page 12: Product- And Technology-Dependent Safety Instructions

    Risk of serious injury in the subsequent operation! Assembly works and commissioning may only be performed by employees  of Bosch Rexroth. This also applies to the re-commissioning following repair works. Have maintenance work performed by specialist personnel only. ...
  • Page 13 Hydraulics training system WS290 | RE 00225-B/12.15 Bosch Rexroth AG 13/104 Safety instructions WARNING Leaking hydraulic fluid due to leakage of the drive module or incomplete or faulty components of the hydraulic system! Risk of burning! Risk of injury! Risk of fire! Switch the system off immediately (EMERGENCY OFF switch).

  • Page 14: Personal Protective Equipment

    14/104 Bosch Rexroth AG Hydraulics training system WS290 | RE 00225-B/2.15 Safety instructions WARNING Danger from falling objects! Risk of injury! Provide free slots at the rack with covers in order to prevent objects from  being put down. Personal protective equipment The personal protective equipment for users of the product consists of: ...

  • Page 15: Safety Equipment

    Hydraulics training system WS290 | RE 00225-B/12.15 Bosch Rexroth AG 15/104 Safety instructions Safety equipment To protect people, the training system is equipped with the following safety equipment:  EMERGENCY OFF pushbutton  Hydraulic pressure limitation with the constant pressure system ...

  • Page 16: Operator Workplaces

    16/104 Bosch Rexroth AG Hydraulics training system WS290 | RE 00225-B/2.15 General warnings of damage to property and damage to the product 2.10 Operator workplaces In order to be able to teach and learn the processes on the WS290 training...
  • Page 17 Hydraulics training system WS290 | RE 00225-B/12.15 Bosch Rexroth AG 17/104 General warnings of damage to property and damage to the product secure them against restarting. De-energize the system at the main switch. Incorrect setting of the pressure relief valves and the pressure switches of the...

  • Page 18: Scope Of Delivery

    18/104 Bosch Rexroth AG Hydraulics training system WS290 | RE 00225-B/2.15 Scope of delivery Scope of delivery The WS290 training system is supplied as a packed system ready for operation. The WS290 training system stands on a subplate and is firmly tensioned by means of plastic straps.

  • Page 19: Information On This Product

    Hydraulics training system WS290 | RE 00225-B/12.15 Bosch Rexroth AG 19/104 Information on this product Information on this product General The following sections of these operating instructions illustrate as an example a variant of the WS290 training system and its components.

  • Page 20: Product Description

    20/104 Bosch Rexroth AG Hydraulics training system WS290 | RE 00225-B/2.15 Information on this product Product description Fig. 3: Constant pressure system with 2 workplaces 1 Base frame with transport rollers 7 Oil pan 2 Grid with reinforcement and mounting frame;...

  • Page 21: Base Frame/Device Carrier

    Hydraulics training system WS290 | RE 00225-B/12.15 Bosch Rexroth AG 21/104 Information on this product Base frame/device carrier The base frame is the basis for all WS290 training systems and consists of a modular device carrier (1) with stable, lockable and maneuverable transport rollers (2) and two integrated oil pans (3).
  • Page 22 22/104 Bosch Rexroth AG Hydraulics training system WS290 | RE 00225-B/2.15 Information on this product Oil drip sheet The oil drip sheets are inserted into the oil-tight pans of the base frame. For the complete fitting, 4 units are necessary.
  • Page 23 Hydraulics training system WS290 | RE 00225-B/12.15 Bosch Rexroth AG 23/104 Information on this product Installation container The installation container is equipped with a front-side lock and easy running tracks and fixedly screwed to the base frame next to the hydraulic power unit.

  • Page 24: Hose Storage

    24/104 Bosch Rexroth AG Hydraulics training system WS290 | RE 00225-B/2.15 Information on this product Hose storage 5.4.1 Hose storage for 9 hoses Fig. 9: Hose storage for 9 hoses The hose storage is attached to the side frame of the base frame and is used to hold up to 9 hose lines.

  • Page 25: Racks

    Hydraulics training system WS290 | RE 00225-B/12.15 Bosch Rexroth AG 25/104 Information on this product Racks The 19" racks with a construction length of 210 LE and a construction height of 3HE or 2x3HE are intended for the installation of electronic components into 19 inch installation technology.

  • Page 26: Power Supply Unit

    26/104 Bosch Rexroth AG Hydraulics training system WS290 | RE 00225-B/2.15 Information on this product Power supply unit One or two power supply units with regulated short-circuit-proof 24 VDC output are integrated into the side frame of the base frame. They are connected to the control box socket by means of a connection cable.

  • Page 27: Control Box "Energy Supply" Assembly

    Hydraulics training system WS290 | RE 00225-B/12.15 Bosch Rexroth AG 27/104 Information on this product Control box "Energy supply" assembly The control box is fastened at the base frame. The control box comprises two fixedly cabled EMERGENCY OFF pushbuttons and one connection cable with connector.

  • Page 28: Hydraulic Power Unit With Single Pump

    28/104 Bosch Rexroth AG Hydraulics training system WS290 | RE 00225-B/2.15 Information on this product Hydraulic power unit with single pump 5.8.1 General The hydraulic power unit with single pump is used to supply one workplace. Fig. 16: Hydraulic circuit diagram HY power unit with single pump...

  • Page 29: Assemblies And Functions

    Hydraulics training system WS290 | RE 00225-B/12.15 Bosch Rexroth AG 29/104 Information on this product 5.8.2 Assemblies and functions 1.0 Oil tank The oil tank has a volume of 40 liters. Oil is filled in through a filling and breathing filter at the top of the oil tank.
  • Page 30 30/104 Bosch Rexroth AG Hydraulics training system WS290 | RE 00225-B/2.15 Information on this product Control box The voltage supply of the hydraulic power unit is effected via the control box at consisting of 5.0 the hydraulic power unit. The control box with protective motor switch is...

  • Page 31: Hydraulic Power Unit With Double Pump

    Hydraulics training system WS290 | RE 00225-B/12.15 Bosch Rexroth AG 31/104 Information on this product Hydraulic power unit with double pump 5.9.1 General The hydraulic power unit with double pump is used to supply two workplaces. Fig. 17: Hydraulic circuit diagram Hy power unit with double pump...

  • Page 32: Assemblies And Functions

    32/104 Bosch Rexroth AG Hydraulics training system WS290 | RE 00225-B/2.15 Information on this product Item Assembly Item Assembly Oil tank Return flow filter Oil level and temperature display Clogging indicator optical Filling and breathing filters 4.01 P/T manifold 4.02...
  • Page 33 Hydraulics training system WS290 | RE 00225-B/12.15 Bosch Rexroth AG 33/104 Information on this product 2. Motor-pump unit A three-phase current motor drives two vane pumps with zero stroke control 2.0 Three-phase current motor which suck in the hydraulic oil from the oil tank and generate the required system 2.1 Vane pump...

  • Page 34: Ls Hydraulic Power Unit With Double Pump

    34/104 Bosch Rexroth AG Hydraulics training system WS290 | RE 00225-B/2.15 Information on this product 5.10 LS hydraulic power unit with double pump 5.10.1 General The hydraulic power unit with double pump is used to supply two workplaces. Fig. 18: Hydraulic circuit diagram LS Hy power unit with double pump...

  • Page 35: Assemblies And Functions

    Hydraulics training system WS290 | RE 00225-B/12.15 Bosch Rexroth AG 35/104 Information on this product 5.10.2 Assemblies and functions 1.0 Oil tank The oil tank has a volume of 40 liters. Oil is filled in through a filling and breathing filter at the top of the oil tank.
  • Page 36 36/104 Bosch Rexroth AG Hydraulics training system WS290 | RE 00225-B/2.15 Information on this product 6.0 Measuring glass The measuring glass mounted at the base frame is directly connected to the oil tank by means of a return flow hose...

  • Page 37: P/T Distributor With Depressurized Circulation ("Circulation Circuit")

    Hydraulics training system WS290 | RE 00225-B/12.15 Bosch Rexroth AG 37/104 Information on this product 5.11 P/T distributor with depressurized circulation ("circulation circuit") The P/T distributor with "circulation circuit" is attached to the side frame of the base frame by means of an angle.

  • Page 38: Load-Sensing Control Block (Ls Control Block)

    38/104 Bosch Rexroth AG Hydraulics training system WS290 | RE 00225-B/2.15 Information on this product 5.12 Load-sensing control block (LS control block) The load-sensing control block is attached to the side frame of the base frame by means of an angle.

  • Page 39: Measuring Glass

    Hydraulics training system WS290 | RE 00225-B/12.15 Bosch Rexroth AG 39/104 Information on this product 5.13 Measuring glass The measuring glass contains 2.5 l and is equipped with scale, vent valve, overflow protection and ball valve. Fig. 22: Measuring glass The measuring glass is attached to the WS290 base frame by means of an assembly console.
  • Page 40 40/104 Bosch Rexroth AG Hydraulics training system WS290 | RE 00225-B/2.15 Information on this product Fig. 23: Measuring glass 1 Measuring glass with scale 5 Overflow line 2 Return line connection 6 Discharge line 3 Shut-off cock 7 Fastening console...

  • Page 41: Load Simulator, Rotatable

    Hydraulics training system WS290 | RE 00225-B/12.15 Bosch Rexroth AG 41/104 Information on this product 5.14 Load simulator, rotatable Attachment of the load simulator is intended at the side frame. It can be rotated by 180° and is equipped with a safety mechanism.
  • Page 42 42/104 Bosch Rexroth AG Hydraulics training system WS290 | RE 00225-B/2.15 Information on this product Fig. 25: WS290 load simulator, rotatable 1 Housing 7 Hydraulic cylinder 2 Window/protective cover 8 Hose couplings 3 Mounting flange for assembly at 9 Clamping console for sensors...

  • Page 43: Technical Data And Dimensions

    Hydraulics training system WS290 | RE 00225-B/12.15 Bosch Rexroth AG 43/104 Technical data and dimensions Technical data and dimensions Technical data 6.1.1 Constant pressure training system WS290 Table 6: Technical data for the WS290 training system Denomination Unit Value Total weight Approx.

  • Page 44: Ws290 Training System With Load-Sensing

    44/104 Bosch Rexroth AG Hydraulics training system WS290 | RE 00225-B/2.15 Technical data and dimensions 6.1.2 WS290 training system with load-sensing Table 7: Technical data for the WS290 training system with load-sensing Denomination Unit Value Total weight Approx. 270 to 415 *...

  • Page 45: Dimensions Of The Hydraulics Training System Ws290

    Hydraulics training system WS290 | RE 00225-B/12.15 Bosch Rexroth AG 45/104 Technical data and dimensions Dimensions of the hydraulics training system WS290 1240 ~200 ~800 1350 1810 S = center of gravity A = support point (forklift) Fig. 26: WS290 dimensions (in mm) and support points...

  • Page 46: Identification Of The Hydraulics Training System Ws290

    MATERIAL-NR. MATERIAL NO. MNR : R 961002399 TYPE TS -DS 4-1 /R G2U09V2A0E 07MO S O L2T2 SCHALTPLAN-NR. CIRCUIT NO. TANK-INHALT; CAPACITY GEWICHT; WEIGHT l; ltr. Bosch R exroth AG D-97816 Lohr 7161 Made in Germany Fig. 27: Name plate...

  • Page 47: Operating And Display Elements

    Hydraulics training system WS290 | RE 00225-B/12.15 Bosch Rexroth AG 47/104 Operating and display elements Operating and display elements EMERGENCY OFF pushbutton An EMERGENCY OFF pushbutton is attached on each operator side (above the control box) (see fig. 28/pos. 1).

  • Page 48: Operating Elements At The Control Box

    48/104 Bosch Rexroth AG Hydraulics training system WS290 | RE 00225-B/2.15 Operating and display elements Operating elements at the control box Fig. 28: Operating elements at the control box 1 EMERGENCY OFF pushbutton 5 Automatic circuit breakers for coded socket...

  • Page 49: Operating And Display Elements At The Hydraulic Power Unit

    Hydraulics training system WS290 | RE 00225-B/12.15 Bosch Rexroth AG 49/104 Operating and display elements 4./5. Automatic circuit breakers In case of excessive current consumption, the current supply to the sockets is interrupted; the switch is in "0" position.  "0" position = current supply interrupted ...

  • Page 50: P/T Distributor With Depressurized Circulation ("Circulation Circuit")

    50/104 Bosch Rexroth AG Hydraulics training system WS290 | RE 00225-B/2.15 Operating and display elements 1. On/Off switch The switch at the motor protection serves as operating switch for the hydraulic power unit and protects the electric motor against excessive current consumption.
  • Page 51 Hydraulics training system WS290 | RE 00225-B/12.15 Bosch Rexroth AG 51/104 Operating and display elements Hose couplings At the P/T distributor, there are in each case hose couplings for the connection of hose lines for diverse set-ups and functions (see fig. 31): ...

  • Page 52: Load-Sensing Control Block (Ls Control Block)

    52/104 Bosch Rexroth AG Hydraulics training system WS290 | RE 00225-B/2.15 Operating and display elements Load-sensing control block (LS control block) Fig. 32: LS control block with 3/2-way ball valve and LS pressure relief valve 1 Switching lever for rest/...
  • Page 53 Hydraulics training system WS290 | RE 00225-B/12.15 Bosch Rexroth AG 53/104 Operating and display elements WARNING Danger due to pressurized hose lines! Risk of serious injury! Before decoupling the hoses, always depressurize the hydraulic circuit (see  chapter 13.2.6 "Exchanging hydraulic hose lines").

  • Page 54: Measuring Glass

    54/104 Bosch Rexroth AG Hydraulics training system WS290 | RE 00225-B/2.15 Operating and display elements Measuring glass CAUTION Risk of breaking of the measuring glass due to pressurization! Risk of minor injury! Prevent the measuring glass from being loaded with pressure/back pressure.

  • Page 55: Power Supply Unit 24 V

    Hydraulics training system WS290 | RE 00225-B/12.15 Bosch Rexroth AG 55/104 Operating and display elements Power supply unit 24 V 24V= max 4,5A power 230V ~ 50 Hz 100VA Fig. 35: WS290 power supply unit 24 V 1 Mains socket 230 V 3 Connector sockets 24 V +/–...

  • Page 56: Load Simulator, Rotatable

    56/104 Bosch Rexroth AG Hydraulics training system WS290 | RE 00225-B/2.15 Operating and display elements Load simulator, rotatable Prerequisites To be used, the load simulator has to  stand vertically and at working height,  have bottom clearance of at least 80-100 mm, ...
  • Page 57 Hydraulics training system WS290 | RE 00225-B/12.15 Bosch Rexroth AG 57/104 Operating and display elements Fig. 37: WS290 load simulator locking mechanism 1 Locking pins 2 Clamping lever Handles Before swiveling, the load simulator is to be manually secured at the handle and during swiveling, it is to be guided at the handles.

  • Page 58: Transport And Storage

    58/104 Bosch Rexroth AG Hydraulics training system WS290 | RE 00225-B/2.15 Transport and storage Transport and storage Delivery and unpacking Required tool: Chisel, plate shears (steel straps), knife (for plastic straps). CAUTION Risk of tilting of the WS290 training system! The center of gravity is possibly not in the middle;...

  • Page 59: Transportation

    Hydraulics training system WS290 | RE 00225-B/12.15 Bosch Rexroth AG 59/104 Transport and storage Transportation 8.2.1 Transportation within a building General The WS290 training system may be moved at any time and set up at another location. During transportation, consider the following: Ensure that the doors and passages are sufficiently wide.

  • Page 60: Transportation Between Two Buildings

    60/104 Bosch Rexroth AG Hydraulics training system WS290 | RE 00225-B/2.15 Transport and storage 8.2.2 Transportation between two buildings General If the WS290 training system is to be transported from one building to another, the following is to be observed: Ensure that the doors and passages are sufficiently wide.

  • Page 61: Storage

    Hydraulics training system WS290 | RE 00225-B/12.15 Bosch Rexroth AG 61/104 Transport and storage Storage Table 8: Storage conditions Denomination Unit Value Installation surface of the WS290 training system See chapter 4 Condition of the installation surface Even Min. storage temperature °C...

  • Page 62: Set-Up, Installation And Commissioning

    62/104 Bosch Rexroth AG Hydraulics training system WS290 | RE 00225-B/2.15 Set-up, installation and commissioning Set-up, installation and commissioning Setting the WS290 training system up NOTICE Danger due to irregularities, variations, faults, defects during the set-up or the test! Risk of damage! Do not put the WS290 training system into operation and/or take it out of ...

  • Page 63: Checking The Hydraulic Supply

     13.2 "Maintenance schedule"). If you notice any deviations from the manufacturer's specifications, you have to consult the Bosch Rexroth service or an authorized mineral oil supplier. Prerequisites Prerequisites to be met for filling: Ensure that the hydraulic power unit is switched off and that the mains plug is ...
  • Page 64 64/104 Bosch Rexroth AG Hydraulics training system WS290 | RE 00225-B/2.15 Set-up, installation and commissioning Filling the hydraulic power unit Fig. 38: Filling the hydraulic power unit How the hydraulic power unit is filled: Clean the environment of the filler inlet.

  • Page 65: Electric Installation

    Hydraulics training system WS290 | RE 00225-B/12.15 Bosch Rexroth AG 65/104 Set-up, installation and commissioning Bleeding In order to bleed the system, the pump must displace medium in circulation for 10 minutes. After the circulation, the oil level is to be checked.

  • Page 66: Checking The Functions

    66/104 Bosch Rexroth AG Hydraulics training system WS290 | RE 00225-B/2.15 Set-up, installation and commissioning Check the correct and sufficient electrical fuse protection and consider an  increased current consumption upon motor start-up. Connect the mains plug at the connection cable of the control box to the ...

  • Page 67: Checking The Direction Of Rotation Of The Electric Motor/The Pump

    Hydraulics training system WS290 | RE 00225-B/12.15 Bosch Rexroth AG 67/104 Set-up, installation and commissioning 9.5.2 Checking the direction of rotation of the electric motor/the pump NOTICE Danger of malfunction of the hydraulic pump due to wrong direction of rotation of...
  • Page 68 68/104 Bosch Rexroth AG Hydraulics training system WS290 | RE 00225-B/2.15 Set-up, installation and commissioning Fig. 39: Measuring glass for test set-up Check the filling level of the hydraulic fluid and refill hydraulic fluid, Preparing the test:  if necessary.

  • Page 69: Testing The Hydraulic Fluid Condition

    NOTICE Danger of the hydraulic pump running dry! Damage to property! Stop the system immediately and check the possible causes.  In case of a defect, inform the Bosch Rexroth service.  Possible errors and measures Table 9: Possible causes...
  • Page 70 Stop the hydraulic power unit.  Prevent the further operation of the WS290 training system.  Inform the Bosch Rexroth service.  Completing the tests Restoring the initial condition: Bring the 3-way ball valve into "circulation operation" (= horizontal position;...

  • Page 71: Checking The Running Noise Of Motor And Pump(S)

    NOTICE Danger of the hydraulic pump running dry! Risk of damage! Stop the system immediately and check the possible causes.  In case of a defect, inform the Bosch Rexroth service.  9.5.6 Checking the operating pressure WARNING Danger of bursting of the hydraulic system or of attachment components with a setting of >...

  • Page 72: Pressure Test Of The Zero Stroke Control With A Constant Pressure System

    Risk of serious injury! Never change the sealed zero stroke control which has been fixedly set at  the factory. Any setting is only admissible by the Bosch Rexroth service.  Switch on the hydraulic pump at the "ON" switch. ...

  • Page 73: Pressure Test In Circulation Operation

    Interrupt the further operation and stop the hydraulic power unit.  Prevent the further operation of the WS290 training system.  Inform the Bosch Rexroth service.  2. Pressure too low The zero stroke control is too low if the displayed pressure lies below 45 bar.

  • Page 74: Standby Pressure Test At The Load-Sensing System

    The hydraulic power unit is not tight – Prevent the further operation of the WS290 training system.  Inform the Bosch Rexroth service.  3. Pressure ok The pressure is ok if the displayed pressure lies between 6 bar and 10 bar.

  • Page 75: Commissioning The Hydraulic Power Unit

    If the pressure is too high or too low, proceed as follows: Bring the lever into rest position (vertical position).  Operate the OFF switch and  Inform the Bosch Rexroth service.  Commissioning the hydraulic power unit 9.6.1 Prerequisites: ...
  • Page 76 76/104 Bosch Rexroth AG Hydraulics training system WS290 | RE 00225-B/2.15 Set-up, installation and commissioning 2. Load-sensing With the LS control block, the operating state is selected by means of a 3/2-way ball valve.  Position A = rest position (vertical position).

  • Page 77: Operation

    Hydraulics training system WS290 | RE 00225-B/12.15 Bosch Rexroth AG 77/104 Operation 10 Operation 10.1 Switch-on Any safety equipment must be functional and complete. 10.1.1 Proceed as follows to switch on the system: WARNING Danger due to leaking high-pressure hydraulic fluid and parts flying around or...

  • Page 78: Constant Pressure System

    78/104 Bosch Rexroth AG Hydraulics training system WS290 | RE 00225-B/2.15 Operation 10.1.2 Constant pressure system After switch-on, bring the switching lever of the ball valve into vertical operating position. The system pressure may max. be 50 bar. 10.1.3 Load-sensing system After switch-on, bring the switching lever of the ball valve into horizontal operating position.

  • Page 79: Resetting The Emergency Off

    Hydraulics training system WS290 | RE 00225-B/12.15 Bosch Rexroth AG 79/104 Operation 10.3 Resetting the EMERGENCY OFF All workplaces available at the WS290 training system have an own EMERGENCY OFF circuit. The operated EMERGENCY OFF circuit will remain functional until the...

  • Page 80: Help In Case Of Faults

    There is permanently foam Leakage in the suction Immediately stop the in the measuring glass. range hydraulic power unit Inform the Bosch Rexroth service If it is not possible to identify and remedy fault causes, please contact the responsible Bosch Rexroth service department.

  • Page 81: Maintenance And Control

    Hydraulics training system WS290 | RE 00225-B/12.15 Bosch Rexroth AG 81/104 Maintenance and control 12 Maintenance and control This chapter describes the maintenance and control works which may be performed on the WS290 training system by trained personnel. Maintenance and control works which may only be performed by specifically skilled and qualified personnel are described in chapter 13 "Maintenance works".

  • Page 82: Maintenance And Control Plan

    82/104 Bosch Rexroth AG Hydraulics training system WS290 | RE 00225-B/2.15 Maintenance and control 12.2 Maintenance and control plan WARNING Danger due to leaking high-pressure hydraulic fluid and parts flying around or falling down due to incompletely or incorrectly set-up exercise installations! Risk of minor or serious injury! Avoid free, uncoupled hose lines.
  • Page 83 Hydraulics training system WS290 | RE 00225-B/12.15 Bosch Rexroth AG 83/104 Maintenance and control When? What? Where? Comments Protective cover At the load Check for simulator. completeness/ Weekly damage Hose couplings Check the free Exchange them movement; immediately. couplings engage safely.

  • Page 84: Maintenance Works

    84/104 Bosch Rexroth AG Hydraulics training system WS290 | RE 00225-B/2.15 Maintenance works 13 Maintenance works 13.1 General information Insufficient maintenance leads to  faults,  possible failure and  high repair costs. If during operation or a test, irregularities, variations, faults or wear are identified, the following shall be observed in any case: Take the training system out of operation without any undue delay.

  • Page 85: Maintenance Schedule

    Fittings Check for externally visible Have them replaced immediately damage: in case of damage! Breaks on pressure gauges? Inform the Bosch Rexroth service. At protective screws? Hydraulic power unit Running smoothness of motor In case of irregularities: and pump: Inform the Bosch Rexroth service.
  • Page 86 86/104 Bosch Rexroth AG Hydraulics training system WS290 | RE 00225-B/2.15 Maintenance works When? What? Where? Comments Weekly Hydraulic hoses Check the compliance with Replace/exchange: replacement periods. 6 years after date of production at the latest Oil medium Check the compliance with Replace/exchange: replacement periods.

  • Page 87: Supplies, Auxiliary Materials, Tools And Measuring Devices

    When placing a spare part order, always indicate the device type and the  material number, year of construction and part designation. Contact the Bosch Rexroth service department. The address and the contact data can be found on the back of these operating instructions.

  • Page 88: Hydraulic Oil Maintenance

    An oil exchange is required if strong contamination is visible at the exiting hydraulic fluid or in case of oil sludge. In this case, inform the Bosch Rexroth service by all means. 13.2.4 Performing the oil exchange General Exchange the hydraulic fluid if ...
  • Page 89 Stop the system immediately.  In case of serious contamination of hydraulic fluid/filter, flush all hydraulic  components used (pointer in the red range). Use suitable flushing fluid.  If necessary, ask the Bosch Rexroth service or the hydraulic fluid suppliers. ...

  • Page 90: Exchanging The Filter Element

    90/104 Bosch Rexroth AG Hydraulics training system WS290 | RE 00225-B/2.15 Maintenance works 13.2.5 Exchanging the filter element General The filter element has to be renewed  every time the hydraulic fluid is exchanged,  if the clogging indicator is in the YELLOW or RED range.
  • Page 91 Hydraulics training system WS290 | RE 00225-B/12.15 Bosch Rexroth AG 91/104 Maintenance works Fig. 45: Removing the filter element Check the seal ring for damage (see fig. 46).  Fig. 46: Checking and replacing the seal ring If necessary, replace the seal ring if it is damaged or porous.

  • Page 92: Exchanging Hydraulic Hose Lines

    92/104 Bosch Rexroth AG Hydraulics training system WS290 | RE 00225-B/2.15 Maintenance works Refill oil, if necessary.  Carry out another test run.  13.2.6 Exchanging hydraulic hose lines Six years after the date of production, the hydraulic hose lines are to be exchanged in general.
  • Page 93 Hydraulics training system WS290 | RE 00225-B/12.15 Bosch Rexroth AG 93/104 Maintenance works Fig. 47: Bending radii of the hydraulic hose lines of at least 100 mm Re-connect the hydraulic power unit to the mains.  Operate the "Start" pushbutton at the control box.

  • Page 94: Disposal

    94/104 Bosch Rexroth AG Hydraulics training system WS290 | RE 00225-B/2.15 Disposal 14 Disposal The training system is composed of materials which are recyclable and may be reused. Specialized companies may recycle this training system in order to obtain recyclable material and to minimize the quantity of the materials to be disposed of.

  • Page 95: Hydraulic Oil Data Sheet

    Hydraulics training system WS290 | RE 00225-B/12.15 Bosch Rexroth AG 95/104 Hydraulic oil data sheet 15 Hydraulic oil data sheet...
  • Page 96 96/104 Bosch Rexroth AG Hydraulics training system WS290 | RE 00225-B/2.15 Hydraulic oil data sheet...
  • Page 97 Hydraulics training system WS290 | RE 00225-B/12.15 Bosch Rexroth AG 97/104 Hydraulic oil data sheet...
  • Page 98 98/104 Bosch Rexroth AG Hydraulics training system WS290 | RE 00225-B/2.15 Hydraulic oil data sheet...
  • Page 99 Hydraulics training system WS290 | RE 00225-B/12.15 Bosch Rexroth AG 99/104 Hydraulic oil data sheet...
  • Page 100 100/104 Bosch Rexroth AG Hydraulics training system WS290 | RE 00225-B/2.15 Hydraulic oil data sheet...
  • Page 101 Hydraulics training system WS290 | RE 00225-B/12.15 Bosch Rexroth AG 101/104 Hydraulic oil data sheet...

  • Page 102: Declaration Of Conformity

    102/104 Bosch Rexroth AG Hydraulics training system WS290 | RE 00225-B/2.15 Declaration of conformity 16 Declaration of conformity...
  • Page 103 Hydraulics training system WS290 | RE 00225-B/12.15 Bosch Rexroth AG 103/104 Declaration of conformity...
  • Page 104 Bosch Rexroth AG Drive & Control Academy Bahnhofplatz 2 D-97070 Würzburg, Germany Phone: 09352 18 1920 Fax: 09352 18 6882 trainingsystems@boschrexroth.de www.boschrexroth.com\academy Subject to modifications Printed in Germany RE 00225-B/12.2015 Mat. no. R961003776...

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