Manual Rexroth RE15215
Manual Rexroth RE15215
MCR
Series 30, 31, 32, 33 and 41
Contents
1 About this manual 5
1.1 Validity of the documentation 5
1.2 Required and supplementary documentation 5
1.3 Display of information 6
1.3.1 Safety instructions 6
1.3.2 Symbols 7
1.3.3 Designations 7
1.3.4 Abbreviations 7
2 Safety instructions 8
2.1 About this chapter 8
2.2 Intended use 8
2.3 Improper use 8
2.4 Personnel qualifications 9
2.5 General safety instructions 9
2.6 Product-specific safety instructions 11
2.7 Personal protective equipment 14
3 General instructions on damage to equipment and the product 15
4 Delivery contents 18
5 About this product 19
5.1 Performance description 19
5.2 Product description 19
5.2.1 Section of the radial piston motor 19
5.2.2 Functional description 20
5.3 Product identification 26
5.4 Product variants 27
6 Transport and storage 28
6.1 Transporting the radial piston motor 28
6.1.1 Transporting by hand 29
6.1.2 Transporting with lifting device 29
6.2 Storing the radial piston motor 31
7 Installation 32
7.1 Unpacking 32
7.2 Installation conditions 32
7.3 Installation position 33
7.3.1 Below-reservoir installation (standard) 33
7.3.2 Above-reservoir installation 34
7.4 Installing the radial piston motor 35
7.4.1 Preparation 35
7.4.2 Dimensions 35
7.4.3 General instructions 35
7.4.4 Connection to the output shaft 36
7.4.5 Assembly of the speed sensor 37
7.4.6 Completing installation 38
7.4.7 Hydraulically connecting the radial piston motor 39
7.5 Peforming flushing cycle 41
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Contents
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8 Commissioning 42
8.1 First commissioning 42
8.1.1 Filling the radial piston motor 43
8.1.2 Testing the hydraulic fluid supply 44
8.1.3 Performing functional test 45
8.2 Running-in phase 45
8.3 Recommissioning after standstill 46
8.4 Final checks 46
9 Operation 47
9.1 Manual brake release in case of emergency 48
10 Maintenance and repair 49
10.1 Cleaning and care 49
10.2 Inspection 50
10.3 Maintenance 51
10.4 Repair 52
10.5 Spare parts 52
11 Removal and replacement 53
11.1 Required tools 53
11.2 Preparing for removal 53
11.3 Removing the radial piston motor 53
11.4 Preparing the components for storage or further use 53
12 Disposal 54
13 Modification and adjustments 55
14 Troubleshooting 56
14.1 How to proceed for troubleshooting 56
14.2 Malfunction table 57
15 Technical data 61
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Mineral-oil based hydraulic fluid and related hydrocarbons 90220 Data sheet
Describes the requirements on a mineral-oil based hydraulic fluid and related
hydrocarbons for the operation with Rexroth hydraulic components, and assists
you in selecting a hydraulic fluid for your hydraulic system.
Environmentally acceptable hydraulic fluids 90221 Data sheet
Describes the requirements on an environmentally acceptable hydraulic fluid
for operation with Rexroth hydraulic components and assists you in selecting
a hydraulic fluid for your hydraulic system.
Bosch Rexroth Fluid Rating List for Rexroth hydraulic components 90245 Data sheet
(pumps and motors)
Contains the hydraulic fluids positively evaluated by Bosch Rexroth.
Instructions on the Use of Radial Piston Motors at Low Temperatures 90321 Data sheet
Contains additional information on the use of Rexroth radial piston motors at low
temperatures.
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6/64 About this manual
SIGNAL WORD
Type and source of danger!
Consequences in case of noncompliance
▶▶ Measure for danger prevention
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1.3.2 Symbols
The following symbols mark notes that are not safety-relevant but which increase
the understanding of the documentation.
Symbol Meaning
If this information is disregarded, the product can not be used and/or
operated to the optimum extent.
3.
1.3.3 Designations
This documentation uses the following designations:
Table 4: Designations
Designation Meaning
MCR Radial piston motor (multi-stroke)
MCR-F Radial piston motor for wheel drives
MCR-W Radial piston motor for heavy duty wheel drives
MCR-C Radial piston motor for compact drives
MCR-A Radial piston motor for frame integrated drives
MCR-S Radial piston motor for chain drives
MCR-T Radial piston motor for track drives
MCR-H Radial piston motor for integrated drives
MCR-R Radial piston motor for hydraulic drive assist
MCR-D / MCR-E Radial piston motor for industrial applications
Threaded plug Metal screw, pressure-resistant
Protective plug Made out of plastic, not pressure-resistant, only for transportation
1.3.4 Abbreviations
This documentation uses the following abbreviations:
Table 5: Abbreviations
Abbreviation Meaning
ATEX EU directive for explosion protection (Atmosphère explosible)
DIN Deutsche Industrie Norm (German Institute for Standardization)
ISO International Organization for Standardization
JIS Japan Industrial Standard
RE Rexroth document in the English language
VDI 2230 Directive for the systematic calculation of high duty bolted joints and joints
with one cylindrical bolt from the VDI (Verein Deutscher Ingenieure –
Association of German Engineers)
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2 Safety instructions
The radial piston motor is only intended for professional use and not for private use.
Intended use includes having read and understood the complete documentation,
especially the chapter 2 "Safety instructions" on page 8.
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•• Using the radial piston motor under water unless customer-specific approval has
been granted by Bosch Rexroth RM Engineering Department
•• Using the radial piston motor in explosive environments unless the component
or machine/system has been certified as compliant with the ATEX directive
2014/34/EU
•• Using the radial piston motor in an aggressive atmosphere
•• Using the radial piston motor in aircraft or space craft
Bosch Rexroth offers training support for special fields. You can find an overview
of the training contents on the internet at:
www.boschrexroth.com/training.
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WARNING
Motor external overload!
Danger to life or risk of injuries, motor failure resulting in major motor break up and
failure to support loads .
▶▶ To ensure the durability of the motor for the specific combination of external
loads a technical approval by Bosch Rexroth RM Engineering Department is
required for each application. Please contact your Bosch Rexoth sales partner.
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WARNING
System/machine under pressure
Danger to life or risk of injury, serious injuries when working on machines/systems
not secured! Risk of property damage.
▶▶ Switch off the relevant machine/system component and secure it against
reconnection according to instructions provided by the machine/system
manufacturer.
▶▶ Make sure that all relevant components of the hydraulic system are
depressurized. Follow the instructions given by the machine/system
manufacturer.
▶▶ Note that the hydraulic system may still may be under pressure even after the
pressure supply itself has been disconnected.
▶▶ Do not disconnect any line connections, ports and components as long as the
hydraulic system is under pressure.
Electrical voltage!
Danger to life or risk of injury due to electric shock or damage to equipment!
▶▶ Always set up the relevant part of the machine/system so that it is free of
electrical voltage before you install the product or when connecting and
disconnecting plugs. Protect the machine/system against being energized.
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WARNING
Motor with dynamic and/or parking brake may not provide sufficient brake
torque!
Danger to life or risk of injuries, due to improper use of brakes/worn brakes!
▶▶ Avoid any contamination of braking surfaces particularly with lubricants.
▶▶ Ensure any fluids/lubricants used in any part of the motor comply with the
specification in the data sheet.
▶▶ Make sure the brake components are not worn, check brake torque on a regular
basis (see chapter 10).
▶▶ Do not use the parking brake as a dynamic brake, ensure the brake is fully
released during operation using the specified brake release pressure.
▶▶ Make sure the orientation of the motor is according to the installation drawing.
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CAUTION
High noise development in operation!
Danger of hearing damage, deafness!
The noise emission of radial piston motors depends on speed, operating pressure
and installation conditions. The sound pressure level may rise to significant levels
during normal application conditions.
▶▶ Always wear hearing protection when in the vicinity of the operating radial
piston motor.
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NOTICE
Danger from improper handling!
Product can be damaged!
▶▶ Do not expose the product to an impermissible mechanical load.
▶▶ Never use the product as a handle or step.
▶▶ Do not place/lay any objects on the product.
▶▶ Do not strike the drive shaft of the radial piston motor.
▶▶ Do not set/place the radial piston motor on the fittings.
▶▶ Do not strike fittings (e.g. sensors or valves).
▶▶ Do not strike sealing surfaces (e.g. service line ports).
▶▶ Leave the protective covers on the radial piston motor until shortly before the
lines are connected.
▶▶ Disconnect all electrical connectors before performing electro-welding
or painting operations.
▶▶ Make sure that the electronics are not electro-statically charged
(e.g. for painting operations).
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16/64 General instructions on damage to equipment and the product
NOTICE
Contamination of the hydraulic fluid!
The cleanliness of the hydraulic fluid has a considerable impact on the service
life of the radial piston motor. Contamination of the hydraulic fluid could cause
premature wear and malfunctions!
▶▶ Make sure that the working environment at the installation site is free of dust
and foreign substances in order to prevent contaminants, such as welding beads
or metal cuttings, from getting into the hydraulic lines and causing product
wear or malfunctions. The radial piston motor must be installed in a clean
environment.
▶▶ Use only clean connections, hydraulic lines and attachments.
▶▶ Only remove blanking plugs immediately prior to making connections .
▶▶ Before commissioning, make sure that all hydraulic connections are tight and
that all of the connection seals and plugs are installed correctly to ensure that
they are leakproof and fluids and contaminants are prevented from penetrating
the product.
▶▶ Use a suitable filter system to filter hydraulic fluid during filling to minimize
contamination entering in the hydraulic system.
Improper cleaning!
Product can be damaged!
▶▶ Plug all openings with the appropriate protective equipment in order to prevent
detergents from entering the radial piston motor.
▶▶ Never use solvents or aggressive detergents. Use only water and, if necessary,
a mild detergent to clean the radial piston motor.
▶▶ Do not point the power washer at sensitive components, e.g. shaft seal,
electrical connections and components.
▶▶ Use lint-free cloths for cleaning.
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NOTICE
Escaping or spilling hydraulic fluid!
Environmental pollution and contamination of the ground water!
▶▶ Always place a drip tray under the radial piston motor when filling and draining
the hydraulic fluid.
▶▶ Use an oil binding agent if hydraulic fluid is spilled.
▶▶ Observe the information in the safety data sheet for the hydraulic fluid and
the specifications provided by the maschin/system manufacturer.
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4 Delivery contents
B
A L
A
L B
X B
Z A
Z
Z
F L
F
The following ports are protected with protective plug/threaded plug and protective
covers.
•• Standard
––main ports A and B
––drain port L
•• Where applicable
––brake port Z
––2-speed port X
––filler port F (metal plug)
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8 3 2
9
1
4 7
5
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L
3
1 2 D D 7 E
A radial piston motor consists of a two part housing (1, 2), rotary group (3, 4),
cam (5), output shaft (6) and flow distributor (7).
It converts hydrostatic energy into mechanical energy.
Hydraulic fluid is directed from the motor inlet port in the rear case (2) via the
flow distributor (7) through galleries to the cylinder block (4). Pressure increases
in the cylinder bore which forces the radially arranged pistons (3) outwards. This
radial force acts via the rollers (8) against the profile on the cam ring (5) to create a
rotary torque. This torque is transferred to the output shaft (6) via the splines in the
cylinder block (4).
If the torque exceeds the shaft load, the cylinder block turns, causing the pistons to
stroke (working stroke). Once the end of a stroke is reached the piston is returned
to its bore by the reaction force at the cam (return stroke) and the fluid is fed to the
motor outlet port in the rear case.
The output torque is produced by the force resulting from the pressure and piston
surface. It increases with the pressure difference between the high- and low-
pressure side.
The output speed depends on the displacement and is proportional to the inward
flow.
The number of working and return strokes corresponds to the number of lobes on
the cam multiplied by the number of pistons.
Working Return
stroke stroke
Feed Return
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Flow paths The cylinder chambers (E) are connected to ports A and B via the axial bores and
the annular passages (D).
Bearings Tapered roller bearings capable of transmitting high axial and radial forces are fitted
as standard, except on Hydrobase motors (half motor without front case).
Freewheeling In certain applications there may be a requirement to freewheel the motor. This may
be achieved by connecting ports A and B to zero pressure and simultaneously
applying a pressure of 2 bar to the housing through port L. In this condition, the
pistons are forced into the cylinder block which forces the rollers to lose contact
with the cam thus allowing free rotation of the shaft.
Two speed operation (2W) In mobile applications where vehicles are required to operate at high speed with low
motor loads, the motor can be switched to a low-torque and high-speed mode. This
is achieved by operating an integrated valve which directs hydraulic fluid to only one
half of the motor while continuously re-circulating the fluid in the other half. This
"reduced displacement" mode reduces the flow required for a given speed and gives
the potential for cost and efficiency improvements. The motor maximum speed
remains unchanged.
Rexroth has developed a special spool valve to allow smooth switching to reduced
displacement whilst on the move. This is known as "soft-shift" and is a standard
feature of 2W motors. The spool valve requires either an additional sequence valve or
electro-proportional control to operate in "soft-shift" mode.
L X B A
15 bar
12 bar
Flushing valve In a closed circuit, the same hydraulic fluid continuously flows between the pump
and the motor which could lead to overheating of the hydraulic fluid.
The function of the flushing valve is to replace a proportion of the hydraulic fluid in
the closed circuit with that from the reservoir. When the hydraulic motor is operated
under load, either in the clockwise or anti-clockwise direction, the flushing valve
opens and takes a fixed flow of fluid through an orifice from the low pressure side
of the circuit. This flow is then fed to the motor housing and back to the reservoir
normally via a cooler. In order to charge the low pressure side of the circuit, cool
fluid is drawn from the reservoir by the boost pump and is fed to the pump inlet
through the check valve. Thus the flushing valve ensures a continuous renewal and
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22/64 About this product
cooling of the hydraulic fluid. The flushing feature incorporates a relief valve which
is used to maintain a minimum boost pressure and operates at a standard setting of
14 bar.
Different orifice sizes may be used to select varying flows of flushing fluid between
1.6 to 14 l/min (based on a boost/charge pressure of 25 bar). For all available
options refer to flushing information sheet 15225-01.
A (B)
B (A)
Parking brake NOTICE! Danger from improper use of the parking brake!
(multi-disc brake) Product can be damaged!
▶▶ The parking brake is designed solely for static use and should not be applied
whilst the motor is rotating.
2 9
12
16
15
14
10
13
11
Fig. 7: Parking brake section
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When fluid is fed via the brake port Z into the annular area (9), the pressure on the
underside of the piston rises, opposing the spring force.
If sufficient pressure is applied, the piston moves to the right, removing the
compression on the disc pack and allowing the motor to turn freely.
When the pressure is removed the spring forces the piston back to the left and once
again compresses the disc pack.
Thus, the brake is fail-safe.
Parking brake NOTICE! Danger from improper use of the parking brake!
(multi-disc brake) MCR-T Product can be damaged!
▶▶ The parking brake is designed solely for static use and should not be applied
whilst the motor is rotating.
9 12 10
11
16
The brake is mounted by the way of the front case (2) and drive shaft (16).
A disc pack (11), with alternate discs splined to the drive shaft and front case, is
compressed by the force of a disc spring (10) acting through a piston (12). The
friction between the discs generates a holding torque.
When fluid is fed via the brake port Z into the annular area (9), the pressure on the
underside of the piston rises, opposing the spring force.
If sufficient pressure is applied, the piston moves to the right, removing the
compression on the disc pack and allowing the motor to turn freely.
When the pressure is removed the spring forces the piston back to the left and once
again compresses the disc pack.
Thus, the brake is fail-safe.
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Parking brake NOTICE! Danger from improper use of the parking brake!
(form brake) MCR-S Product can be damaged!
▶▶ The parking brake is designed solely for static use and should not be applied
whilst the motor is rotating.
▶▶ Over time, wear may occur to the brake teeth. Brake holding capacity should be
confirmed on a regular basis.
9 1 Z
11
13
10
4
12
The form brake consists of a toothed brake piston (10) which is housed within
the motor’s front case (1). The brake piston is prevented from rotating by dowel
pins (12). The cylinder block (4) which is splined onto the motor’s shaft (6) has
teeth formed on its forward face (13) which engage with the teeth on the brake
piston and prevent rotation of the shaft. This engagement is maintained by an
annular arrangement of springs (11). To release the brake, hydraulic pressure is
applied to the brake piston chamber (9) via the port (Z) to compress the springs and
disengage the teeth.
Dynamic brake
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Speed sensor
15 14
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9 2
8
7
3
4
6 5
Additionally the motor serial number (3) along with the manufacture date (6) is
stamped on either the front case, rear case or the end cover of the radial piston
motor.
The cam part number along with the displacement is stamped on the cam.
These numbers are normally located in line with the main work ports.
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Examples are:
For full details please refer to the motor code in the relevant data sheet.
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Dimensions and weights The weight specification may vary depending on the motor type and configuration.
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▶▶ Do not lift the radial piston motor by using sensitive attachment parts (e.g.
sensors cables or valves).
▶▶ Carefully lower the radial piston motor onto the seating to prevent it from being
damaged.
WARNING! Care should be taken when transporting H and R (hydro base) type
motors as internal components may not be secure and could fall from the motor!
Transport with eye bolt For some motor types the drive shafts can be used to transport the radial piston
motor.
▶▶ This requires the use of an eye bolt of the correct thread size and load rating (the
thread size is stated on the installation drawing for the particular motor).
▶▶ The eye bolt should be screwed fully into the female thread in the end of the drive
shaft, the motor may then be hoisted as indicated in Fig. 14 below.
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Transport with hook Some motors have a mounting flange which can be used to transport the radial
piston motor.
▶▶ Insert the hook into one of the mounting holes of the flange, the motor may then
be lifted as indicated in Fig. 15.
▶▶ During lifting operations the motor must be manually supported to ensure it
cannot slip from the hook.
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After delivery The radial piston motors are provided ex-works with corrosion protection packaging.
The radial piston motor can be stored for a maximum of 2 years after which it should
be returned to Bosch Rexroth RM Service Department at Glenrothes for inspection,
seal replacement and functional test
The maximum cumulative storage time (from original manufacture date) for a radial
piston motor is 6 years after which it should be scrapped.
After removal If a removed radial piston motor is to be stored, it must be preserved against
corrosion for the duration of storage.
The following instructions only refer to radial piston motors which are operated
with a mineral-oil based hydraulic fluid. Other hydraulic fluids require
preservation methods that are specifically designed for them. In such cases,
consult your local contact person; you can find their contact information at
www.boschrexroth.com/addresses
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7 Installation
Prior to installation, the following documents must be available at hand:
•• Data sheet of the radial piston motor (contains the permissible values of technical
data)
•• Installation drawing for radial piston motor (can be obtained from your responsible
contact person at Bosch Rexroth)
•• Hydraulic schematic for the radial piston motor (included in the installation
drawing)
•• Hydraulic schematic for the machine/system (available from the machine/system
manufacturer)
•• Order confirmation (contains the order-related technical data for your radial piston
motor)
7.1 Unpacking
The radial piston motor is delivered in a corrosion protection film made of
polyethylene material (PE).
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1 2
L1 L1
L F
F L
3 4
L1 L1
F
L F
L Drain port
F Filler port
L1 Air bleeding
Note: L1 is part of the external piping
The oil filling of the case should always take place via the filler port F and the air
bleeding via port L1 in the drain line.
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5 6
L1
F
L
0.5 bar
F L
7 8
L1 F
L F
L1
L
0.5 bar
L Drain port
F Filler port
L1 Air bleeding
Note: L1 is part of the external piping
The oil filling of the case should always take place via the filler port F and the air
bleeding via port L1 in the drain line.
Where a check valve is fitted to the drain line, it should be sized to ensure the
motor’s case pressure limit is not exceeded at start-up.
Note: when the pistons are pushed out of the cylinder block at start-up, this
displaces oil from the motor case, momentarily delivering full pump flow to the drain
line.
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7.4.1 Preparation
1. Check the delivery contents for completeness and transport damage.
If the part number on the motor identification label (chapter 5.4) does not
correspond to the order confirmation, contact your local contact person for
clarification. You can find their contact information at
www.boschrexroth.com/addresses
B A
Port B Port A
View motor from shaft with ports uppermost and pressurising port B:
L Counter-clockwise
R Clockwise
7.4.2 Dimensions
The installation drawing specifies the dimensions of the mountings and ports of the
radial piston motor.
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36/64 Installation
•• All connections should be made with reference to the installation drawing and data
sheet and must all be completed prior to motor operation.
•• Oil cleanliness is vital to obtaining long service life, therefore well maintained
filtration is essential.
•• Care must be taken to ensure excessive forces are not generated by eccentric
mounting of the radial piston motor to a load. A suitable flexible coupling should be
used if this loading cannot be avoided.
Where wheel studs and nuts are supplied, the nuts must be tightened to the
following torque values:
The shaft connection to the wheel must use all mounting holes or wheel studs
specified on the drive shaft.
Spline Protect the spline from frictional corrosion by application of a suitable lubricant.
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Where wheel studs and nuts are supplied, the nuts must be tightened to the torque
values as per Table 7 "Wheel nut tightening torques" on page 36.
The shaft connection to the sprocket must use all mounting holes or wheel studs
specified on the drive shaft.
Protect the sprocket on the drive shaft from frictional corrosion by providing
adequate lubrication.
Bearing and shaft assembly The installation drawings for the MCR-H and MCR-R specifies all relevant data such
(with hydrobase motors as spline connection, bearing loads and sealing arrangements.
MCR-H and MCR-R)
7.4.5 Assembly of the speed sensor
Where a radial piston motor is supplied "speed sensor prepared" (P0 in the motor
code) a sensor may be fitted as follows:
1. Remove blanking plate from speed sensor port.
2. Remove plastic shipping cover from sensor nose.
3. Apply a suitable thread locking adhesive to the two M6 screws. Use just enough
to cover the threads and remove any excess.
4. Insert the sensor into the port and seat o-ring by pressing down firmly on the
centre of the sensor.
5. Tighten the two M6 screws, drawing down each side evenly.
6. Tighten to a final torque of 10 Nm.
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Installation 39/64
B
A L
A
L B
X B
Z A
Z
Z
F L
F
Ports intended for connecting lines are sealed from contamination by protective
covers or threaded plugs. All ports required for the motor’s function must be
connected. If a port is not connected, it must be plugged with a threaded metal
fitting of sufficient capacity to withstand system pressure.
Observe the following notes when routing the boost, pressure, drain and control
lines:
•• Lines and hoses must be installed without any mechanical pre-tension to ensure
additional motor loads are not created during operation.
•• Ensure correct sealing materials are used appropriate for the fluid type and
operating conditions.
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•• Pressure/boost line
––For the pressure/boost lines, use only pipes, hoses and connecting elements
rated for the operating pressure range specified in data sheet
•• Drain line
––The drain line should be routed to ensure that the motor’s case remains filled
with hydraulic fluid (reference chapter 7.3).
––The case pressure must not exceed the limit specified in the motor’s data sheet
under any operating conditions.
––The drain line connection to the reservoir must be below the minimum fluid level
under all conditions (see chapter 7.3 "Installation position" on page 33).
Port specifications Please refer to the data sheet and installation drawing with regards to port sizes,
peak pressure etc.
Tightening torques The following tightening torques apply:
•• Ports on the radial piston motor:
The maximum permissible tightening torques are maximum values to prevent
damage to the threaded holes. These must not be exceeded. For values, please
refer to the following table.
•• Fittings:
Observe the machine manufacturer’s instruction regarding tightening torques for
the fittings used.
•• Mounting screws:
As every application is different, the required grade and torque for the mounting
screws must be determined on an individual basis. For correct values, observe the
installation instructions of the machine manufacturer.
•• Filler Plugs:
For the metal filler plug supplied with the radial piston motor, the tightening torque
stated in the below table applies.
•• Wheel nuts:
Where wheel studs and nuts are supplied, the nuts must be tightened to the torque
values as per Table 7 "Wheel nut tightening torques" on page 36.
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Above torque values are calculated based on the minimum thread engagements
quoted.
They represent the maximum values that can be applied without damaging the motor
housing. However, the actual tightening torque for the fittings must come from the
specification of the machine manufacturer.
Shorter thread engagement lengths result in a lower permissible tightening
torque, but higher thread engagement lengths do not result in a higher permissible
tightening torque.
If higher thread engagement lengths are used, check the available thread depths in
the housing to ensure that the fitting can be screwed fully home.
For the filler plug, the nominal setting on the torque wrench must be within ± 2 Nm.
The flushing cycle must be performed with an additional flushing unit. Follow the
instructions of the flushing unit‘s manufacturer for the exact procedure during the
flushing cycle.
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8 Commissioning
WARNING
Danger while working in the danger zone of a machine/system!
Danger to life, risk of injury or serious injuries!
▶▶ Pay attention to and rectify potential danger sources before operating the radial
piston motor.
▶▶ Nobody may stand in the danger zone of the machine/system.
▶▶ The emergency stop button for the machine/system must be within the
operator’s reach.
▶▶ Always follow the instructions of the machine/system manufacturer during
commissioning.
CAUTION
Commissioning of an incorrectly installed product!
Risk of injury and damage to equipment!
▶▶ Make sure that all electrical and hydraulic ports are connected or plugged.
▶▶ Only commission a completely installed fault-free product with original
accessories from Bosch Rexroth.
Lubricants such as petroleum jelly may be used to retain seals during production
assembly of radial-piston motors. Traces of lubricant may appear during
running-in of the motor, adjacent to sealing interfaces. This is normal and does
not indicate leakage where no recurring drip is observed.
During all work for commissioning the radial piston motor, observe the general
safety instructions and intended use detailed in chapter 2 "Safety instructions" on
page 8.
▶▶ Connect pressure gauges to the functional and drain lines of the radial piston
motor to record operating and case pressures during commissioning.
▶▶ During the commissioning process, monitor the temperature of the hydraulic fluid
in the reservoir to ensure that it remains within the permissible viscosity limits.
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CAUTION
Risk of impaired brake performance!
For braked motors ensure that the fluid does not contain any friction modifying
additives (e.g. anti-stick slip additives), as they may cause a significant reduction in
brake torque.
▶▶ When using fluids other than mineral oil, brake torque needs to be checked on a
case-by-case basis.
▶▶ Ensure that the correct additive is present where specified on installation
drawing (dynamic disc brake). This is necessary to prevent brake noise.
▶▶ The drum and caliper disc brake can be configured to operate with either
mineral oil or brake fluid. Ensure the correct seals have been specified for the
intended fluid otherwise damage and leakage will occur.
▶▶ If in doubt please contact Bosch Rexroth RM Engineering Department in
Glenrothes (contact details see chapter 10.5 "Spare parts" on page 52).
Professional filling and air bleeding is necessary to prevent damage to the radial
piston motor and to maintain correct function. The radial piston motor must not be
operated while it is being filled.
Usually, the cleanliness level of commercial hydraulic fluids is insufficient for our
components. These hydraulic fluids must be filtered using an appropriate filter
system to minimize solid particle contamination and water in the system.
Bosch Rexroth evaluates hydraulic fluids on the basis of the Fluid Rating
according to data sheet 90235. For hydraulic fluids which have been positively
evaluated in the Fluid Rating, please refer to data sheet 90245 “Bosch Rexroth
fluid rating list for Rexroth hydraulic components (pumps and motors)”. The
hydraulic fluid should be selected so that the operating viscosity in the operating
temperature range is within the optimum range.
To ensure the functional reliability of the radial piston motor, cleanliness level
20/18/15
according to at least ISO 4406 is necessary for the hydraulic fluid. You can find
details on the permissible and optimal viscosities
and admissible temperatures in data sheet.
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2. Fill the radial piston motor via the filler port F. See section 7.3 "Installation
position" on page 33. Motors fitted with internal flushing will automatically fill
at initial operation. The hydraulic lines of the system must also be filled.
3. The air bleeding should be done via the port L1 in the drain line. See section
7.3 "Installation position" on page 33.
4. On completion of the filling operation, ensure that all ports are reconnected and
plugs refitted.
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WARNING
Incorrectly connected radial piston motor!
Incorrectly connected ports will lead to malfunctions (e.g. reverse instead of
forward) and will present serious danger to persons and equipment!
▶▶ Before the functional test, check that all piping and hoses have been correctly
installed and connected in accordance with the system or machine hydraulic
schematic.
Once you have tested the hydraulic fluid supply, you must perform a functional test
on the machine/system. The functional test should be performed according to the
instructions of the machine/system manufacturer.
The radial piston motor is tested for functional capability and performance before
delivery to ensure it meets the specification of the technical data sheet. To achieve
the required performance during commissioning it must be ensured that the radial
piston motor is installed properly in the machine/system.
▶▶ For braked motors, check brake hold and function are sufficient to meet the
requirements of the system or machines.
NOTICE
Damage to equipment by incorrect viscosity!
Increased hydraulic fluid temperature may reduce the fluid viscosity to an
unacceptable level resulting in damage to the motor (see data sheet)!
▶▶ Monitor the operating temperature during the running-in phase, e.g. by
measuring the case drain temperature.
▶▶ Reduce the loading (pressure, rpm) of the radial piston motor if unacceptable
operating temperatures occur.
▶▶ If operating temperatures remain too high then the cooling capacity of the
system must be improved.
The bearings and sliding surfaces are subject to a running-in phase. The increased
friction at the start of the running-in phase results in increased heat development
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which decreases with increasing operating hours. The motor efficiency continues to
increase until the end of the running-in phase.
During the running-in period (minimum 24 hours) the motor should not be run
unloaded (shaft not connected to load) at greater than 100 rpm.
(e.g. The motors on a wheeled machine should not be run if the machine is jacked
off the ground.)
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9 Operation
The MCR motor is not designed with any end user adjustable settings.
For this reason, this chapter of the manual does not contain any information on
adjustment options. Only use the product within the performance range provided
in the technical data. The machine or system manufacturer is responsible for the
proper layout of the hydraulic system and its control.
Confirm at regular intervals:
▶▶ Operating speeds, pressures and temperature and fluid viscosity are within
current data sheet recommendations (see also section 8.4 "Final checks" on
page 46).
▶▶ Fluid cleanliness within data sheet limits.
▶▶ Motor is still securely mounted, running at normal sound level and free from
external leakage.
▶▶ Fluid is changed per the machine manufacturer’s recommendation.
▶▶ Where applicable, check bearing lubrication is still effective.
For higher loading or speed conditions, case flushing may be added to obtain a
temperature reduction. Flush using both motor drain ports L and F. Before any
changes in operating requirements or conditions are considered please contact
Bosch Rexroth RM Engineering Department in Glenrothes (contact details see
chapter 10.5 "Spare parts" on page 52).
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Mechanical brake release should only be used in the event of hydraulic failure.
Ensure mechanical release is disengaged after use to maintain fail-safe operation
of the brake.
2 9
12
16
15
14
10
13
11
In case of hydraulic system failure, the brake may be manually released by removing
the plug (14) and inserting a puller into the tapped hole in the brake piston (15).
Motor type Screw size Minimum screw length Approx. release torque
MCR3 M12 30 mm 60 Nm
MCR5 M16 30 mm 120 Nm
MCR10 M16 40 mm 160 Nm
MCR15 M20 45 mm 230 Nm
MCR20 M20 50 mm 340 Nm
Alternatively, if the plug is not present or a suitable puller is not available, the brake
may be released by loosening the end cover screws (13). Ensure the screws are
retightened in a diametrically opposed manner and to the torque values specified in
Table 10.
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NOTICE
Inspection and maintenance work carried out too late!
Damage to equipment!
▶▶ Carry out the specified inspection and maintenance work at the intervals
described in this manual.
NOTICE
Damage to seals and electrical system by high pressure cleaning apparatus!
The water jet of a power washer may damage the seals and electrical system of the
radial piston motor!
▶▶ Do not point the power washer at sensitive components, e.g. shaft seal,
electrical connections and the brake end cover.
For cleaning and care of the radial piston motor, observe the following:
▶▶ Check whether all seals and fittings on the connections are securely seated
to ensure that no moisture can penetrate into the radial piston motor during
cleaning.
▶▶ Use only water and, if necessary, a mild detergent to clean the radial piston
motor. Never use solvents or aggressive detergents.
▶▶ Remove coarse external dirt and keep sensitive and important components, such
as solenoids, valves, indicators and sensors, clean.
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10.2 Inspection
In order to ensure long and reliable operation of the radial piston motor, Bosch
Rexroth recommends regular monitoring of the hydraulic system and radial piston
motor. The inspection schedule in Table 11 should be followed and the results
documented and archived:
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10.3 Maintenance
The radial piston motor is low maintenance when used properly.
The service life of the radial piston motor is heavily dependent on the quality of the
hydraulic fluid. For this reason, we recommend changing the hydraulic fluid at least
once per year or every 2000 operating hours (which ever occurs first) or having
it analyzed by the hydraulic fluid manufacturer or a laboratory to determine its
suitability for further use.
The service life of the radial piston motor is limited by the service life of the bearings
fitted. You can ask your local contact person about service life. You can find their
contact information at
www.boschrexroth.com/addresses
A life calculation must, in all cases, be carried out prior to installation of a radial
piston motor on a new machine.
Based on these details, a maintenance period is to be determined by the system
manufacturer for the replacement of the bearings and included in the maintenance
schedule of the hydraulic system.
Where a drum brake is fitted, the thickness of the brake shoe linings has to be
checked by sight control through the wear checking hole at regular intervals,
depending on the use of the vehicle, but at least twice a year.
When the remaining lining thickness is small, these intervals have to be shortened
correspondingly in order to avoid greater damage to the brake and drum.
Remaining thickness must be minimum 2.0 mm at the thinnest point of the lining.
Where a caliper disc brake is fitted pads should be examined at least twice a
year and replaced when the lining thickness is reduced to 2 mm. An optional pad
thickness indicator is available which can be used to operate a warning when the
pad thickness reaches this limit.
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10.4 Repair
Bosch Rexroth offers a comprehensive range of services for the repair of Rexroth
radial piston motors.
Repairs to Rexroth radial piston motors should only be carried out by authorized and
qualified staff at service centers certified by Bosch Rexroth.
▶▶ Only original spare parts supplied by Bosch Rexroth should be used to repair
Rexroth radial piston motors. Failure to do so will invalidate the warranty and may
result in unsatisfactory performance and component failure.
In the event of questions regarding repairs, contact your responsible Bosch Rexroth
Service partner or the service department of the manufacture‘s plant for the radial
piston motor, see chapter 10.5 "Spare parts" on page 52.
CAUTION
Use of unsuitable spare parts!
Spare parts that do not meet the technical requirements specified by Bosch
Rexroth may cause personal injury or property damage!
▶▶ Only original spare parts supplied by Bosch Rexroth should be used to repair
Rexroth radial piston motors. Failure to do so may result in unsatisfactory
performance and possible component failure.
The spare parts lists for radial piston motors are order specific. When ordering spare
parts, quote the material and serial number of the radial piston motor as well as the
material numbers of the spare parts.
Address all questions regarding spare parts to your responsible Bosch Rexroth
Service partner or the service department of the manufacturer‘s plant for the radial
piston motor.
For general inquiries, please contact your local contact person. You can find their
contact information at
www.boschrexroth.com/addresses
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Removal and replacement 53/64
This chapter is not applicable to MCR-R type motors. For MCR-R refer to the
appropriate installation drawing and procedure.
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12 Disposal
Incorrect disposal of the radial piston motor, hydraulic fluid or packaging material
could lead to pollution of the environment.
Observe the following points when disposing of the radial piston motor:
1. Completely drain the radial piston motor of hydraulic fluid.
2. Dispose of the radial piston motor packaging material in accordance with the
national regulations in your country.
3. Dispose of the hydraulic fluid according to the national regulations of your
country. Reference should also be made to the applicable safety data sheet for
the hydraulic fluid.
4. Dismantle the radial piston motor into its individual parts and properly recycle
these parts.
5. Separate the parts into:
––Cast parts
––Steel
––Aluminum
––Non-ferrous metal
––Electronic waste
––Plastic
––Seals
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The Bosch Rexroth warranty only applies for the delivered configuration. Any
unauthorised modifications or adjustments carried out to the radial piston motor
will invalidate the product warranty.
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14 Troubleshooting
Table 12 contains a list of potential issues that may affect the radial piston motor.
This list should not be considered comprehensive and is for guidance only. Where
motor disassembly is suggested, advice should be requested from the Bosch Rexroth
RM Service Department in Glenrothes prior to any action taking place.
Only authorized personnel may perform troubleshooting inside a safety area
designated by the machine manufacturer.
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Unusual noise Output speed too high, causing cavitation and/or Check motor speed versus machine specification.
pistons to lift off cam. If too high, reset pump, and/or engine speed.
Charge pressure too low, causing cavitation and/ Check charge pressure versus machine
or pistons to lift off cam. specification. If necessary, adjust, repair or
replace charge pump (closed circuit) or other
source of charge pressure (open circuit).
High case pressure causing pistons to lift off Check case pressure versus machine
cam, or 2-speed spool (where fitted) to remain specification. If too high, check drain line for
partially shifted. blockages.
Low 2-speed shift pressure causing partial Check 2-speed shift pressure versus machine
shifting of 2-speed spool (where fitted). specification. If too low, adjust, repair or replace
pressure source.
2-speed spool (where fitted) jammed in a partially Check 2-speed spool and replace spool and/or
shifted position. motor housing as necessary.
Motor mounting screws are loose, causing motor Check motor mounting screws are correctly
to rattle against frame. tightened per machine manufacturer’s
specifications.
Improper fixing of wheel or load to motor output Check wheel or load is attached per machine
shaft. manufacturer’s specifications, and is correctly
aligned.
Improper fixing of hydraulic lines causing rattling Check installation of lines per machine
against machine frame. manufacturer’s specifications.
Internal damage to radial piston motor. Strip down and inspect motor. Replace defective
parts or complete motor as necessary.
Air intake. Completely bleed hydraulic system. Check
tightness of all connections.
Brake release pressure too low, causing brake Check brake release pressure versus machine
(where fitted) not to be fully released. manufacturer’s specification and adjust, repair or
replace pressure source as necessary.
High pressure fluctuations Internal damage to radial piston motor. Strip down and inspect radial piston motor.
Replace defective parts or complete motor as
necessary.
Out-of-balance or fluctuating load. Check load and attachment of load per machine
manufacturer’s specifications, and adjust as
necessary.
Blocked or incorrectly sized supply or return line. Check main lines to motor A and B ports for
blockages, and that they are correctly sized per
machine manufacturer’s specifications.
High speed fluctuations Internal damage to motor, causing leakage Blank off flushing (if fitted) and check motor case
variation. drain leakage for pulsations, while rotating motor
at low speed, under load. If necessary, strip down
and inspect motor, paying particular attention to
piston rings. Replace defective parts or complete
motor as necessary.
Faulty pump or pump controller. Check pump and pump controller versus machine
manufacturer’s specifications and adjust, repair
or replace as necessary.
Fluctuating signal from speed sensor (where Check output from speed sensor on oscilloscope
fitted and used in closed-loop speed control (should give correct number of pulses per motor
system). revolution per specification). Replace sensor or
target disc as necessary.
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Expected output torque or Insufficient pressure generated by pump. Apply full load to motor(s) and check maximum
tractive effort not achieved pressure per machine manufacturer’s
specification. If too low, block A and B lines and
check maximum pressure at blocked lines. If
pressure is still too low, adjust, repair or replace
pump, pump control or system pressure relief
valves as necessary.
High leakage in motor does not allow full pressure Apply full load to motor(s) and check maximum
to be generated. pressure per machine manufacturer’s
specification. If too low, block A and B lines and
check maximum pressure at blocked lines. If
pressure is now correct, strip down and inspect
motor. Replace defective parts or complete motor
as necessary.
Motor not fully run in. Continue to run motor (under load) for
24 – 48 hours to achieve maximum efficiency.
A continuing increase in output torque may be
noticed over this period.
High 2-speed shift pressure causing partial or full Check 2-speed pressure when not shifted versus
shifting of 2-speed spool (where fitted) when not machine specification. If too high, adjust, repair
intended. or replace control valve and check for blocked
lines as necessary.
2-speed spool (where fitted) jammed in a partially Strip 2-speed valve and check all components,
or fully shifted position. including bore in motor housing. Remove any
contamination and replace components or motor
housing as necessary.
Brake release pressure too low, causing brake Check brake release pressure versus machine
(where fitted) not to be fully released. manufacturer’s specification and adjust, repair or
replace pressure source as necessary. If pressure
source OK, strip down brake, check and replace
brake seal as necessary.
Internal damage to motor. Apply full load to motor(s) and check maximum
pressure per machine manufacturer’s
specification. If pressure is correct, and none
of other above faults are apparent, strip down
and inspect motor. Replace defective parts or
complete motor as necessary.
Expected output speed not Insufficient flow generated by pump. Check engine/prime mover speed and pump flow.
achieved Adjust, repair or replace engine/prime mover or
pump as necessary.
High leakage in motor. Strip down and inspect motor. Replace defective
parts or complete motor as necessary.
Low 2-speed shift pressure causing partial or Check 2-speed pressure when shifted versus
non-shifting of 2-speed spool (where fitted). machine specification. If too low, adjust, repair
or replace external control valve for 2-speed
actuation and check for blocked lines as
necessary.
2-speed spool (where fitted) jammed in a partially Strip 2-speed valve and check all components,
or non-shifted position. including bore in motor housing. Remove any
contamination and replace components or motor
housing as necessary.
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Motor does not rotate Expected motor torque achieved and load Check system pressure. If pressure has risen to
exceeds motor torque. relief valve setting, reduce load on motor.
Expected motor torque not achieved and load See Problem/Symptom "Expected output torque
exceeds motor torque. or tractive effort not achieved".
No oil being supplied to motor. Check engine/prime mover speed, pump flow and
operation of control valve (if fitted). Adjust, repair
or replace engine/prime mover, pump or valve as
necessary.
Brake not released. See Problem/Symptom "Brake does not release".
Motor rotates in wrong Oil supply connections to motor incorrectly Connect oil supply correctly.
direction connected.
Hydraulic fluid temperature Excessive inlet temperature at motor. Check cooling system and external flushing valve,
too high if fitted.
Malfunction of pressure control valves (e.g. high- Check appropriate components and repair or
pressure relief valve, pressure controller). replace if necessary.
Output speed too high. Check motor speed versus machine specification.
If too high, reset pump, and/or engine speed.
Motor case drain pressure too high, causing Check case pressure versus machine
integrated flushing valve (where fitted) to close. specification. If too high, check drain line for
blockages.
Pump charge pressure below opening pressure of Check charge pressure versus machine
integrated flushing valve (where fitted). specification. Reset charge pressure, and check/
repair charge pump as necessary.
Malfunction of integrated flushing valve (where Apply a differential pressure of > 10 bar across
fitted). motor, and check case drain flow versus machine
manufacturer’s specification. If insufficient flow
is present, check flushing poppet for blocked
orifice. If poppet OK, remove flushing spool and
springs, and inspect parts including bore in motor
housing. Clean and/or replace parts as required.
External leakage External seals (e.g. shaft/cam/brake seal) Check oil cleanliness and motor pressure, confirm
damaged. drain line is unblocked and case drain pressure
is within machine manufacturer’s specification.
Strip down motor and inspect suspected leaking
seals. If shaft seal is damaged, check bearings.
Replace parts as necessary.
Loose bolts. Ensure all bolts are tightened to correct torque
setting per Service Manual or motor assembly
drawing.
Loose fittings. Ensure all fittings are tightened to correct torque
setting per manufacturer’s specification.
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Insufficient brake torque Excessive pressure in brake release chamber Check brake pressure in engaged state per
(disc brake). machine manufacturer’s specification. If too high,
check control valve and drain lines to reservoir,
and repair/replace, or remove blockage, as
necessary.
Motor case drain pressure too high, causing Check case pressure versus machine
partial release of brake (disc brake). specification. If too high, check drain line for
blockages.
Worn brake linings, discs or teeth (MCR-S). Replace brake shoes or brake discs as necessary.
In case of wear on parking brake (disc or form
brake), investigate cause, as brake should not be
used dynamically and should not wear.
Anti-stick/slip additive in hydraulic fluid (disc Drain and flush system and refill with hydraulic
brake). fluid without additive. Strip and thoroughly clean
all motor components, replacing all brake discs.
Insufficient brake actuation pressure (dynamic Check pressure versus machine specification
brake). and check pressure source. Repair or replace
components as required.
Drum brake not run in. Carry out drum brake run-in procedure per motor
data sheet.
Brake does not release Brake release pressure too low (disc or form Check brake release pressure versus machine
brake). manufacturer’s specification and adjust, repair or
replace pressure source as necessary. If pressure
source OK, strip down brake and check and
replace brake seal as necessary.
Brake piston or seals damaged (disc or form Replace brake piston or seals as required.
brake).
Brake plates seized (disc brake). Strip and inspect brake, replacing parts as
required. If seized, investigate cause of seizure,
as parking brake should not be used dynamically.
Incorrect function of 2-speed 2-speed control pressures incorrect. Check shifted and non-shifted control pressures
control (where fitted) versus machine specification. Check, and repair
or replace control components as necessary.
Integrated 2-speed valve damaged. Strip 2-speed valve and check all components,
including bore in motor housing. Remove any
contamination and replace components or motor
housing as necessary.
Motor case drain pressure too high, causing Check case pressure versus machine
partial or non-shifting of 2-speed valve. specification. If too high, check drain line for
blockages.
Incorrect signal from speed Speed sensor or target disc damaged. Check output from speed sensor on oscilloscope
sensor (where fitted) (should give correct number of pulses per motor
revolution per specification). Replace sensor or
target disc as necessary.
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15 Technical data
The technical data of the radial piston motors can be found in the relevant data sheet
as listed in Table 1 “Required and supplementary documentation” on page 5.
Further information can be found in the online product catalog Mobile Hydraulics:
www.boschrexroth.com/radial-piston-motors
The order-related technical data of your radial piston motor can be found in the
order confirmation.
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Bosch Rexroth Limited
Viewfield Industrial Estate
Glenrothes, Fife
Scotland, KY6 2RD
United Kingdom
Phone +44 1592 631 777
www.boschrexroth.com
Subject to change
Printed in Germany
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