Training System DS4

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Hydraulic Training System

Components and Teachware

Type DS4

RE 00843/02.07

Replaces: 2.05

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Hydraulics Bosch Rexroth AG RE 00843/02.07 DS4 3/64

Page

System presentation 4 Workstations 6-34 Typical variants 6-8 Custom configuration 0-3 Component carriers 32 Workstation accessories 33-34 Component sets 35-67 On/off hydraulics, in accordance with BiBB 36-43

Proportional technology 44-49

Hydraulic closed-loop control axes 50-5

Measuring technology 52-6

Mobile hydraulics 62-63

Troubleshooting on hydraulic systems 64-67 • • • • • • • • • •

Page

Components 69-26 Valves 70-89 Energy converters 90-9 Hydraulic accessories 92-03 Electrics 04-4 Measuring instruments 5-22 Mobile hydraulics 23-26 Section models 27-3 Pumps 28 Valves 29-3 Teachware 33-48 Exercise manuals 34-35 Training manuals 36-40 Software 4-45 Sets of foils 46-47 Working material 48 • • • • • • • • • • • • •

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The hydraulic training system for basic and advanced training was developed to meet the increasing requirements of fluid power technology.

The basic training system basically consists of a component car-rier with stable, steerable castors with integrated hydraulic pow-er unit, an electrical switch box, a tool containpow-er, a measuring glass, and a P/T distributor.

The unit can optionally be fitted with up to 2 grid frames for hy-draulic components, or with up to 2 grooved panels for pneu-matic components, or with one grid frame and one grooved panel each.

The exercises are set up on grid frames or grooved panels and then connected by hoses. Quick-action couplings of the hydraulic hoses allow the training exercises to be carried out swiftly and safely.

A load simulator and numerous component sets are optional-ly available and turn the basic training system into a complete, custom system for basic and advanced training in line with practical needs, which guarantees your training success.

Hydraulic training system – system presentation

Features

– Training system for basic and advanced training in line with practical needs

– Suitable for holding training courses according to the rec-ommendations by BiBB (Bundesinstitut for Berufsbildung Berlin/Federal Institute for Vocational Training, Berlin) – Rugged and stable design

– Low operating noise

– Movable thanks to stable, steerable castors – Modular structure for a wide variety of variants

– Use of size 6 standard components of Rexroth's industrial valve product range

– Clearly arranged and carefully thought-out design – Great selection of component sets

• On/off hydraulics • Troubleshooting • Electrical components

• Beginner's sets for hydraulics and electrohydraulics • Proportional hydraulics

• Mobile hydraulics • Linear axes

– Concept across technologies, suitable for • Hydraulics and pneumatics

– With detailed and clearly structured trainee's and instruc-tor's training manual, with 2 exercises and solutions

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Hydraulics Bosch Rexroth AG

RE 00843/02.07 DS4 /64

Table of contents: Workstations

Page

Typical variants 6-8 DS4 training system with workstation 6 DS4 training system, can be extended to 2 workstations 7 DS4 training system with 2 workstations 8

Custom configuration 0-3 Configuration of the workstation according to own needs 0

Order example

Type code 2-3

Base frame 4

Frame 5

Central grooved plate 5

Mounting frame 5

Grid 6

Grooved panel 6

Base sets 7-20

Hydraulic power unit with single pump 7 Hydraulic power unit with double pump 8

Integrated container 8

Hoses 9

Oil drip trays 9

Mounting kit for power unit 20

Mounting kit for integrated container 20

Hydraulics connection block 2

P/T distributor 2 • • • • • • • • – – • – – • – – – – – – – • –

Page

Racks 22

Single-sided (one row, two rows) 22 Double-sided (one row, two rows) 22

Power supply 23-26

Power supply unit 24

Switch box 25-26

Measuring glass 27

measuring glass 27

Hose tray 28

Load simulator 29

Table grid, writing surface 30

Type of hose coupling 3

Component carrier 32

With one grid 32

With two grids 32

Accessories 33-34

Wheel-mounted container 33

Anti-skid mat 33

Assortment of drawer dividers 33

Monitor arm 34 Info panel 34 Rag holder 34 • – – • – – • – • • • • • • • • • • • •

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1

11

10

9

8

7

6

2

3

4 DS4 training system with 1 workstation

1 Base frame with castors 2 x grid frame

3 Oil drip tray, writing surface 4 Integrated container  Oil drip tray

6 Hydraulic power unit with single pump 230 V/50 Hz, .5 kW 7 Switch box 230 V/50 Hz with residual current protective

de-vice (RCD)

8 x P/T distributor with “circulation circuit“ 9 x power supply unit 24 V (on one side) 10 x measuring glass

11 x assembly carrier 20TE, x3 HE

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13

12

11

10

9

8

2

4

6

3

7

RE 00843/02.07 DS4 7/64

DS4 training system, can be extended to 2 workstations

1 Base frame with castors 2 x grid frame

3 x load simulator mounted; swivelling 4 x oil drip tray, writing surface  Integrated container

6 Oil pan

7 Hydraulic power unit with double pump 230 V/50 Hz, .5 kW

8 Switch box 230 V/50 Hz

9 x P/T distributor with “circulation circuit“ 10 x hose tray, small

11 2x power supply unit 24 V (both sides) 12 x measuring glass

13 x assembly carrier 20TE, x3 HE

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1

13

12

11

10

8

2

4

6

3

7

9 DS4 training system with 2 workstations

Workstations / typical variants

1 Base frame with castors 2 2x grid frame

3 Hose tray, large

4 2x oil drip tray, writing surface (both sides)  Integrated container

6 Oil pan

7 Hydraulic power unit with double pump 400 V/50 Hz, 2.2 kW

8 Switch box 400 V/50 Hz with residual current protective

de-vice

9 2x P/T distributor

10 x load simulator mounted; swivelling 11 2x power supply unit 24 V (both sides) 12 2x measuring glass

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RE 00843/02.07 DS4 9/64

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9

14

7

9 8 a

6 8 b

11 1 + 2

3

4

10 12 a

12 b

a

b

c

Configure the workstation according to your needs

Workstations / custom configuration

1 + 2 Training system – base frame 3 Frame

4 Grid

 a Base kit / container  b Base kit / power unit  c Base kit / oil pan

6 Hydraulic connection block 7 Rack

8 a Energy supply / power supply unit 8 b Energy supply / switch box

9 Measuring glass 10 Hose tray 11 Load simulator 12 a Writing surface 12 b Table grid

14 Equipment of electrical assembly

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RE 00843/02.07 DS4 11/64

Order example:

Workstations / custom configuration

2 3 4 5 6 7 8 9 0 2 3 4

TS–DS4 1X R G2 U07 V1 A0 E02 M1 S0 L… T1 W

Equipment of electrical assembly Coupling, leak-free Table grid / writing surface Load simulator Hose tray Measuring glass Energy supply Racks Hydraulic connection block Base kit Grid Frame Series identification Product division / product group

Fields: Details in the fields:

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Type code

Component carrier for hydraulic training workstation:

Workstations / custom configuration

2 3 4 5 6 7

TS–DS4 1X

Product division - product range

Training system base frame DS4 = TS-DS4

Series

Series code = 1X

Frame

Central grooved panel = N

Mounting frame = R

Grid

Without grid, without grooved panel = G0

Grid on one side = G1

Grooved panel on one side = N1

Grid on two sides = G2

Grooved panel on two sides = N2

side grid, side grooved panel = GN

Base kit

Without base kit = U00

Oil pan = U01

Hydraulic power unit 230 V/50 Hz, .5 kW, pump, oil pan, hose kit 000, complete = U02

Hydraulic power unit 230 V/50 Hz, .5 kW, 2 pumps, oil pan, hose kit 630/000, complete = U03

Hydraulic power unit 400 V/50 Hz, 2.2 kW, pump, oil pan, hose kit 000, complete = U04

Hydraulic power unit 400 V/50 Hz, 2.2 kW, 2 pumps, oil pan, hose kit 630/000, complete = U0

Hydraulic power unit 230 V/50 Hz, .5 kW, pump, oil pan, container, hose kit 000, complete = U06

Hydraulic power unit 230 V/50 Hz, .5 kW, 2 pumps, oil pan, container, hose kit 630/000, complete = U07

Hydraulic power unit 400 V/50 Hz, 2.2 kW, pump, oil pan, container, hose kit 000, complete = U08

Hydraulic power unit 400 V/50 Hz, 2.2 kW, 2 pumps, oil pan, container, hose kit 630/000, complete = U09

oil pan 737 x 725 mm, container = U10

oil pan 326 x 725 mm, 2 containers = U11

Hydraulic connection block

Without connection block = V0

P/T distributor with circulation function = V3

2 P/T distributor with circulation function = V4

Rack

Without assembly carrier = A0

Rack 20TE, x3HE, on one side = A1

Rack 20TE, 2x3HE, on one side = A2

Rack 20TE, x3HE, on two sides (2x R9600067) = A3

Rack 20TE, 2x3HE, on two sides (2x R9600066) = A4

Rack 20TE, x3HE (R9600067) + 2x3HE (2x R9600066) = A

Fields: Details in the fields:

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8 9 0 2 3 4 5

*

Further details in clear text

Equipment of electrical assembly Yxx = Specification of electrical assemblies in the assembly carriers

Type of coupling No code = Techno-Chemie couplings

W = Walther coupling, leak-free

Table grid / writing surface T0 = Without table grid / without writing surface

T1 = Table grid for one side

T2 = Table grid for two sides

T3 = Writing surfaces for one side

T4 = Writing surfaces for two sides

T = Table grid for one side / writing surfaces for one side

Load simulator L0 = Without load simulator

L3 = load simulator, mounted, swivelling

L4 = 2 load simulators, mounted, swivelling

Hose tray

S0 = Without hose tray

S1 = hose tray, can be mounted to the side (cannot be combined with load simulator on one side)

S2 = 2 hose trays, can be mounted to the side (cannot be combined with load simulator on one side)

S3 = hose tray, large, can be mounted to the side (cannot be combined with load simulator on one side)

Measuring glass M0 = Without measuring glass

M1 = measuring glass with shut-off valve

M2 = 2 measuring glasses with shut-off valve

Power supply – (switch box with 2x emergency stop) E00 = Without switch box, without power supply unit

E01 = Without switch box, with power supply unit 24 VDC, 4.5 A, 5 V/50 Hz (for pneumatics only)

E02 = Without switch box, with power supply unit 24 VDC, 4.5 A, 230 V/50 Hz (for pneumatics only)

E03 = With switch box 5 V/50 Hz, with power supply unit 24 VDC, 4.5 A, 5 V/50 Hz

E04 = With switch box 5 V/50 Hz, with 2 power supply units 24 VDC, 4.5 A, 5 V/50 Hz

E09 = With switch box 5 V/50 Hz with RCD, with power supply unit 24 VDC, 4.5 A, 5 V/50 Hz

E10 = With switch box 5 V/50 Hz with RCD, with 2 power supply units 24 VDC, 4.5 A, 5 V/50 Hz

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Workstations / custom configuration

Type code designation

Variant consisting of:

R9 6 00 0 60 B ase frame Material no. for the sub-group of the

variant

TS-DS4-X x –

Base frame

Individual parts of the variant in type code “Field 1“ and “Field 2“

Base frame TS-DS4-1X

Material no. R961000160

Basis for all DS4 workstations. 2 oil-tight pans are fitted to the frame.

Dimensions mm W 350 x D 790 x H 850

Weight kg 67

Castors 4 pcs; steerable

Max. load-carrying capacity 2500 N

Paint coating Pan; light grey RAL 7035 Side panels, blue RAL 500

Material Aluminium profiles

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Workstations / custom configuration

Frame

Invididual parts in type code “Field 3“

Central grooved panel

Can be used on the DS4 instead of mounting frame for pneu-matic training.

Grids can nevertheless be used.

Dimensions mm W 30 x H 700 x D 30

Weight kg 24.3

Material Aluminium profile

R9 6 0022 6 C entral grooved panel R9 6 00 0226 Mounting frame Material no. for the sub-group of the variant N • R9600026 R • R96000226 Mounting frame Material no. R961000226

For mounting 2 grids or grooved panels or a combination of a grid and a grooved panel.

Weight kg 5.7

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Grid

Individual parts in type code “Field 4“

Grid

Reinforced grid for hydraulic components with 50 mm grid pattern

Weight kg .75

Material Steel, aluminium profile

Grid mm 50 x 50

W ithout grid W ithout grooved panel R9 6 00 02 0 Grid R9 6 00 0 69 Grooved panel Material no. for the sub-group of the variant G0 • • – G x R9600020 N x R9600069 G2 2x • R9600020 N2 2x • R9600069 GN x x – Grooved panel Material no. R961000169

With mounting pins

Weight kg 24

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Base kits

Individual parts of the variants in type code “Field “

Hydraulic power unit with single pump

For the supply of one workstation

Weight kg 75

Paint coating Blue RAL 500

Pressure bar 50 Oil tank l 40 Flow l/min 8 Voltage VAC 230 Frequency Hz 50 Power kW .5 Material no. R901133999 Dimensions mm W 540 x H 650 x D 440 Weight kg 87.5

Pressure bar 50 Oil tank l 40 Flow l/min 8 Voltage VAC 400 Frequency Hz 50 Power kW 2.2

Workstations / custom configuration

W ithout base R9 0 33 99 9

Power unit with single pump 40

0 V AC R9 0 340 00

Power unit with dou

-ble pump 40 0 V AC R9 0 340 0

Single power unit AC 23

0 V

R9

0

340

02

Double power unit AC 23

0 V R9 6 00 03 2

Mounting kit for power unit R9

6 00 0 54 Oil pan 326 x 7 25 mm R9 6 00 0 55 Oil pan 737 x 7 25 mm R9 6 00 0 56 Oil pan 48 x 7 25 mm R9 6 00 028 8 Integrated cont ainer R9 6 00 083 5

Mounting kit for in

-tegrated cont ainer R9 6 0024 74 Hose 630 mm long R9 6 0024 75

Hose 000 mm long Material no

.

for subgroup of the variant

U00 • – U0 • R9600056 U02 • • • 2x • R9600072 U03 • • • 2x • 2x • R9600079 U04 • • • 2x • R9600078 U05 • • • 2x • 2x • R9600077 U06 • • • • • 2x • R9600076 U07 • • • • • 2x • 2x • R9600074 U08 • • • • • 2x • R9600075 U09 • • • • • 2x • 2x • R9600073 U0 • • • R9600063 U • 2x • 2x • R9600062

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Base kits

Individual parts of the variants in type code “Field “ Hydraulic power unit with double pump

For the supply of two workstations

Weight kg 95

Pressure bar 50 Oil tank l 40 Flow l/min 8 Voltage VAC 230 Frequency Hz 50 Power kW .5 Material no. R901134000 Dimensions mm W 540 x H 650 x D 625 Weight kg 07.5

Pressure bar 50 Oil tank l 40 Flow l/min 8 Voltage VAC 400 Frequency Hz 50 Power kW 2.2

Workstations / custom configuration

Integrated container

Lock at the front, easy running tracks, with mounting kit Dimensions mm W 4 x H 70 x D 725

Weight kg 82

Material Sheet steel, powder-coated

Drawers mm 4 x 00 high

x 50 high Load carrying

ca-pacity per drawer

N 500

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Oil pan

For base DS4, with mounting kit

Dimensions mm L 737 x W 725 x H 30

Weight kg .2

Material Powder-coated sheet steel

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Base kits

Workstations / custom configuration

Hose

NW 08, pressure range 00 bar Didactic designation VSK.N-W

Weight kg 0.64

Length mm 630

Oil pan

Weight kg 6.5

Hose

NW 08, pressure range 00 bar Didactic designation VSL.N-W

Weight kg 0.74

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Base kits

Workstations / custom configuration

Mounting kit for power unit

Weight kg 0.950

Mounting kit for integrated container

Weight kg .9

Oil pan

Weight kg 5.

Mounting kit for oil pan

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RE 00843/02.07 DS4 21/64

Hydraulic connection block

Individual parts of the variants in type code “Field 6“

P/T distributor with circulation function

For DS4, can be mounted to the side panels by means of brackets

Weight kg 4.

Steel

Workstations / custom configuration

W ithout connection bloc k R9 6 00256 7 P /T distributor with circulation Material no. for the sub-group of the

variant

V0 • –

V3 • R96000435

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Workstations / custom configuration

W ithout rac k R9 6 00 0 67 Rac k 2 0TE ; 3H E R9 6 00 0 66 Rac k 2 0TE ; 2 x 3H E Material no. for the sub-group of the variant A0 • – A • R9600067 A2 • R9600066 A3 2x • R9600065 A4 2x • R9600064 A5 • • –

Racks

Rack, one row

20TE; 3HE for DS4

Weight kg 7.9

Sheet steel, powder-coated

Rack, two rows

20TE; 3HE for DS4

Weight kg .6

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Workstations / custom configuration

W

ithout switc

h box

W

ithout power sup

-ply unit 82 70 03 740 P

ower supply unit

5 V A C / 50 Hz R9 6 00 0 70

Power supply unit 230 V

A C / 50 Hz 82 70 084 Switc h box 5 V A C / 50 Hz without R D C 82 70 084 2 Switc h box 23 0 V A C / 50 Hz without R C D R9 6 00 028 9 Switc h box 40 0 V A C / 50 Hz without R C D On request Switc h box 5 V A C / 50 Hz with R C D R9 6 00 09 83 Switc h box 23 0 V A C / 50 Hz with R C D R9 6 00 09 62 Switc h box 40 0 V A C / 50 Hz with R C D Material no.

for the sub-group of the variant E00 • – E0 • 827003740 E02 • R9600070 E03 • • 82700840 E04 2x • • 827008402 E05 • • 827008403 E06 2x • • 827008404 E07 • • 827008405 E08 2x • • 827008406 E09 • • – E0 2x • • – E • • – E2 2x • • – E3 • • – E4 2x • • –

Power supply

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Power supply unit

Material no. 1827003740

For DS3 and DS4; regulated output; short-circuit-proof; ON/OFF switch; two 4-mm safety socket pairs +/- without connection cable

Weight kg 2.23

Material Sheet steel

Colour Blue RAL 500

Output voltage VDC 2 x 24 Input voltage VAC 5

Frequency Hz 60

Current max. A 4.5

Power supply unit

For DS3 and DS4; regulated output; short-circuit-proof; ON/OFF switch; two 4-mm safety socket pairs +/- with connection cable

Weight kg 2.43

Colour Blue RAL 500

Output voltage VDC 2 x 24 Input voltage VAC 5

Frequency Hz 60

Current max. A 4.5

Workstations / custom configuration

Power supply

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Switch box

Material no. 1827008411

With 2 x emergency stop; keyed socket; 2 socket outlets with earthing contact and fuses – without residual-current-operated circuit breaker

Weight kg 6.5

Output voltage VAC 3 x 5 Input voltage VAC 5

Frequency Hz 50

Current max. A 6

Workstations / custom configuration

Power supply

Switch box

Material no. on request

With 2 x emergency stop; keyed socket; 2 socket outlets with earthing contact and fuses – with residual-current-oper-ated circuit breaker

Weight kg 6.5

Frequency Hz 50

Current max. A 6

Switch box

Material no. 1827008412

Weight kg 6.5

Frequency Hz 50

Current max. A 6

Switch box

With 2 x emergency stop; keyed socket; 2 socket outlets with earthing contact and fuses – with residual-current-operat-ed circuit breaker

Weight kg 6.5

Frequency Hz 50

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Switch box

Weight kg 6.5

Output voltage VAC 2 x 230; x 400 Input voltage VAC 400

Frequency Hz 50

Current max. A 6

Workstations / custom configuration

Power supply

Switch box

With 2 x emergency stop; keyed socket; 2 socket outlets with earthing contact and fuses – with residual-current-opera-ted circuit breaker

Weight kg 6.5

Output voltage VAC 2 x 230; x 400 Input voltage VAC 400

Frequency Hz 50

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Measuring glass

With scale, bleed valve, overflow protection and ball valve Dimensions mm W 60 x H 700 x D 200

Weight kg 6.5

Capacity l 2.5

Material Acrylic glass

Aluminium profile Steel tube

PVC hose with nylon lining Length 3 m

Workstations / custom configuration

Measuring glass

Individual parts of the variant in type code “Field 9“

W ithout measuring glass R9 6 002564 Measuring glass Material no. for the sub-group of the

variant

M0 • –

M • R90000066

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Workstations / custom configuration

Hose tray

W ithout hose tray R9 6 00 0 88 Hose tray , 9-fold R9 6 002634 Hose tray , 50-fold Material no. for the sub-group of the variant S0 • – S • R9600088 S2 2x • R9600088 S3 • Hose tray Material no. R961000188

For a maximum of 9 hoses

(cannot be combined with load simulator on one side) Dimensions mm W 230 x H 40 x D 240

Weight kg 2.54

Steel

Hose tray, large

With oil pan for depositing small items.

Provided for mounting to the side panel. Sufficient for 50 hoses (cannot be combined with load simulator on one side) Dimensions mm W 700 x H 72 x D 320

Weight kg 4.5

Sheet steel, powder-coated

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Workstations / custom configuration

Load simulator

W ithout load simulator R9 6 00 0 87 Load simulator , swivelling Material no. for the sub-group of the

variant

L0 • –

L3 • R9600087

L4 2x • R9600087

Load simulator, swivelling

With anti-rotation safety mechanism, provided for mounting to the lateral panel.

Incl. 2 hose lines with angled connection, 2 m long, and mounting panel for proximity switch

Weight kg 3.5

Moved mass kg 5

Cylinder Diameter 25 / 6

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Workstations / custom configuration

Table grid / writing surface

W

ithout t

able grid

W

ithout writing sur

-face R9 6 00 0 92 Table grid 82 70 03 70 5 W riting surface Material no. for the sub-group of the variant T0 • – T 2x • R9600092 T2 4x • R9600092 T3 • 827003705 T4 2x • 827003705 T5 2x • • – Table grid Material no. R961000192

For DS4 oil pans, (4 off are required to equip the system completely)

Weight kg 2.6

Packaging unit

Writing surface

Material no. 182700370

For insertion into the pans of the DS4 component carrier Dimensions mm W 275 x H 25 x D 360

Weight kg 0.35

Colour White

Material PMMA

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Workstations / custom configuration

Type of hose coupling

Identification in type code “Field 13“

Leak-free couplings

Material no. for the sub-group of the

variant

-W • –

Type of rack equipment

Identification in type code “Field 14“

82 70 084 5 B IB B -G S hydraulics El . components 82 70 084 3 B IB B -G S hydraulics A-H , el

. components Material no.

for the sub-group of the variant Y02 2x • – Y04 x • x • – Y3 2x • – Y8 –

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Workstations / component carriers

Component carrier with one grid

For mounting hydraulic components

Weight kg 35

Powder-coated sheet steel

Castors 4 off; steerable

Load carrying capacity max: 2500 N

Paint coating Side panels, blue RAL 500

Component carriers with two grids

For mounting hydraulic components

Weight kg 42

Powder-coated sheet steel

Castors 4 off; steerable

Load carrying capacity max: 2500 N

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Workstations / accessories

Wheel-mounted container

Lock at the front, easy running tracks

Weight kg 84

Material Sheet steel, powder-coated

Drawers mm 4 x 00 high

x 50 high Load carrying

ca-pacity per drawer

500 N

Colour Light grey RAL 7035

Recommended accessories for wheel-mounted container: Anti-skid mat Material no. R96100068 Dimensions mm W 405 x H 00 x D 720 Weight kg 0.2 Material Neoprene Packaging unit 5

Assortment of drawer dividers

00 mm high

Weight kg 0.94

Packaging unit 4

Assortment of drawer dividers

50 mm high

Weight kg .39

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Workstations / accessories

Articulating monitor arm

Material no. 182700372

With keyboard and mouse holder

Weight kg 0

Load carrying

ca-pacity N 250

Sheet steel

Colour Light grey

Info panel

Material no. 1827003721

The position can be ajdusted by means of two joints incl. mounting kit

Weight kg 4.

Format DIN A4

Steel

Rag holder

Material no. 1827003722

Handy deposit for cleaning rags. Can also be used for cable routing Dimensions mm W 38 x H 60 x D 35 Weight kg 0.036 Colour Black Material Plastic Packaging unit 2

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RE 00843/02.07 DS4 3/64

Table of contents: Component sets

Page

On/off hydraulics according to BiBB 36-43

For manually operated valves 36-37

For electrically operated valves 38-39 Electrical components for experiments A-H 40 For additional experiments Z-Z3 4 Electrical components for experiments Z-Z3 42 Electrical components for experiments A-H and Z-Z3 43

Proportional technology 44-49 Analogue control for directional valve 44-45 Analogue control for flow control valve 46-47 Analogue control for pressure relief valve 48-49

Hydraulic closed-loop control axes 0-5

Axis control with Hy-Control 50-5

• • • • • • • • • •

Page

Measuring technology 52-6 Measuring technology 2042, minimal 52-53 Measuring technology 2042, standard 54-55 Measuring technology 3050, minimal for PC 56-57 Measuring technology 3050, ISDS standard for PC 58-59 Measuring technology 5050, standard for PC 60-6

Mobile hydraulics 62-63

Basic principles 62-63

Troubleshooting on hydraulic systems 64-67 With manually operated directional valves 64-65 With electrically operated directional valves 66-67 • • • • • • • •

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Component sets / on/off hydraulics – manual, according to BiBB

BiBB hydraulic component set A - H, for manually operated valves

This component set is used to impart the basic principles of hydraulics.

Training objectives

• Drive power unit / pump • Cylinders / hydraulic motors • Directional valves

• Pressure control valves • Flow control valves • Hydraulic accumulators • Basic circuits

• Commissioning

The set includes exclusively industrial components. All valves comply with the industrial standard for size 6.

For carrying out the exercises, all the required hoses and 4 pressure gauges for indicating the pressure are included in the scope of supply.

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Component sets / on/off hydraulics – manual, according to BiBB

Set consisting of:

Item Qty Material no. Designation Page

9 R96002474 Hose line 630 mm 9, 97

2 5 R96002475 Hose line 000 mm 9, 97

3 4 R96002476 Hose line 000 mm with minimess connection 99

4 4 R9600275 Pressure gauge, diameter 63, 0-00 bar incl. MSK 95

5 R9600249 Ball valve AB 2-20/G/4-500 86

6 R96002503 Diaphragm-type hydraulic accumulator with shut-off block for grid 92

7 3 R96002485 Distributor 94

8 2 R96002520 Pressure relief valve DBDH6GX/00 77

9 R96002544 Direct operated pressure reducing valve DR6DP- 5X/75YM 77

0 R96002545 Pilot operated pressure relief valve DB6K-4X/50YV 78

R96002539 Throttle valve DV06--X/V 83

2 R96002495 Throttle check valve DRV06--X/V 83

3 R96002546 2-way flow control valve 2FRM6B36-3X/0QRV 84

4 R9600253 Check valve, pilot operated SV 6 PB-6X/ 89

5 R96002489 Check valve S6A.X 87

6 R96002522 Check valve S6A3.X 88

7 2 R96002552 4/2 directional valve 4WMM6C5X 70

8 R96002550 4/3 directional valve 4WMM6G5X 70

9 R9600255 4/3 directional valve 4WMM6E5X/F 7

20 R96002505 Gear motor 9

Recommended accessories:

R96002893 BiBB additional experiments 4

R96003494 Single-rod cylinder, stroke = 200 mm 90

R90006256 Stopwatch, digital, quartz 03

R90000439 Filling and testing device 03

R90006520 Tachometer visual/mechanical 03

Teachware:

Training manuals

* BiBB Hydraulics - Basic Principles, Trainer‘s Manual 34

* BiBB Hydraulics - Basic Principles, Trainee‘s Manual 34

* BiBB Hydraulics - Basic Principles, Project Exercises, Trainer‘s Manual 34 * BiBB Hydraulics - Basic Principles , Project Exercises, Trainee‘s Manual 34 Supplementary literature

* The Hydraulic Trainer, Volume , Basic Principles 36

* The Hydraulic Trainer, Volume 5, Fluid Power Technology A-Z 38

* Hydraulics in theory and practice 39

Supplementary training media

* Hydraulic Trainer CBT Version 4.0 4

* Web Tr@iner Hydraulics - Basic Principles 42

(38)

Component sets / on/off hydraulics – electrical, according to BiBB

BiBB hydraulic component set A - H, for electrically operated valves

This component set is used for imparting basic knowledge in the field of electrohydraulics

• Drive power unit / pump • Cylinders / hydraulic motors

• Electrically controlled directional valves • Pressure control valves / pressure switches • Flow control valves

• Hydraulic accumulators • Basic circuits / relay circuits • Commissioning and troubleshooting

The set includes exclusively industrial components. All valves comply with the industrial standard for size 6.

For carrying out the exercises, all the required hoses and 4 pressure gauges for indicating the pressure are included in the scope of supply.

(39)

RE 00843/02.07 DS4 39/64

Component sets / on/off hydraulics – electrical, according to BiBB

9 R96002474 Hose line 630 mm 9, 97

2 5 R96002475 Hose line 000 mm 9, 97

4 4 R9600275 Pressure gauge, diameter 63, 0 - 00 bar incl. MSK 95

5 R9600249 Ball valve AB 2-20/G/4-500 86

6 R96002503 Diaphragm-type hydraulic accumulator with shut-off block for grid 92

7 3 R96002485 Distributor 94

8 2 R96002520 Pressure relief valve DBDH6GX/00 77

9 R96002544 Direct operated pressure reducing valve DR6DP- 5X/75YM 77

0 R96002545 Pilot operated pressure relief valve DB6K-4X/50YV 78

R96003488 Pressure switch 80

2 R96002495 Throttle check valve DRV06--X/V 83

3 R96002539 Throttle valve DV06--X/V 83

4 R96002546 2-way flow control valve 2FRM6B36-3X/0QRV 84

5 R9600253 Check valve, pilot operated SV 6 PB-6X/ 89

6 R96002489 Check valve S6A.X 87

8 2 R96002547 4/2 directional valve 4WE6C6X/EG24N9K4 73

9 R96002548 4/3 directional valve 4WE6G6X/EG24N9K4 73

20 R96002549 4/3 directional valve 4WE6E6X/EG24N9K4 74

2 R96002505 Gear motor 9

22 R900846807 Cable set HPF-E

23 2 R900846808 Cable set HPF-E2

R96002893 BiBB additional experiments 4

82700844 Electrical components BiBB Z -Z3 9“ 42

827008420 Electrical components BiBB Z -Z3 boxes

R90006256 Stopwatch, digital, quartz 03

R90000439 Filling and testing device 03

R90006520 Tachometer visual/mechanical 03

Teachware:

Training manuals

* BiBB Hydraulics - Basic Principles, Trainer‘s Manual 34

* BiBB Hydraulics - Basic Principles, Trainee‘s Manual 34

* BiBB Hydraulics - Basic Principles, Project Exercises, Trainer‘s Manual 34 * BiBB Hydraulics - Basic Principles, Project Exercises, Trainee‘s Manual 34 Supplementary literature

* The Hydraulic Trainer, Volume 5, Fluid Power Technology A - Z 38

* Web Tr@iner Hydraulics - Basic Principles 42

* Web Tr@iner Electrohydraulics 43

(40)

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3

2

6 Component sets / on/off hydraulics – electrical, according to BiBB

Electrical components for BiBB hydraulic component set A - H

Material no. 1827008413

Electrical components for controlling electrically operated valves A - H to BiBB as 9" version for installation in racks

Weight kg 5.23

R90079908 Operating module, 4 push-buttons / 2 switches BPS 7.4 04

2 R900897345 Operating module, distributor BPS 3. 04

3 R900897337 Operating module, relay BRS .2 04

4 5 827008408 Blind plate 3HE/2TE 09

5 2 R9600306 Proximity switch, inductive 4

(41)

RE 00843/02.07 DS4 41/64

R96002489 Check valve S6A.X 87

3 R96003488 Pressure switch incl. cable 80

4 R96002553 Pilot operated pressure relief valve 8

5 R96002485 Distributor 94

6 R96002554 4/3 directional valve 4WE6J6X/EG24N9K4 74

7 R900846807 Solenoid cable with LED, form A, black plug

8 2 R900846808 Solenoid cable with LED, form A, grey plug

82700844 BiBB electrical components Z - Z3 9“ 42

827008420 BiBB electrical components Z -Z3 boxes Supplementary literature

* Web Tr@iner Electrohydraulics 43

* The teachware in various languages can be found on the given pages

Component sets / on/off hydraulics – electrical, according to BiBB

BiBB hydraulic component set for additional experiments Z1 - Z3

Hydraulic components for 3 further experiments in ac-cordance with BiBB, based on the BiBB component set R96002887

This kit includes industrial components of size 6 and all the re-quired connection cables.

(42)

1

2

3

4 Component sets / on/off hydraulics – electrical, according to BiBB

Electrical components for BiBB hydraulic component set for additional experiments Z1 - Z3

Material no. 1827008414

Electrical components for controlling electrically operated valves Z - Z3 according to BiBB in 9“ variant,

for installation into racks

Weight kg 2.6

R90089734 Operating module, signal output BPS 8. 04

2 R900897337 Operating module, relay BRS .2 04

3 R900897346 Operating module, time relay BRS 2. 05

(43)

1

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2

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7

RE 00843/02.07 DS4 43/64

R900897345 Operating module, dstributor BPS 3. 04

2 R90079908 Operating module, 4 push-buttons / 2 switches BPS 7.4 04

3 2 R900897337 Operating module, relay BRS .2 04

4 R90089734 Operating module, signal output BPS 8. 04

5 827008408 Partial front panel 3HE/2TE 09

6 R900897346 Operating module, time relay BRS 2. 05

7 3 R9600306 Proximity switch, inductive 4

8 R90002502 Measurement cable set (large) 2

Component sets / for on/off hydraulics – electrical, according to BiBB

Electrical components for BiBB hydraulic component set

Material no. 182700841

Electrical components for controlling electrohydraulics (exten-ded set A - H and Z - Z3) in 9“ variant; complete 20 TE

(44)

4

2

6

1

3

7 Component sets / proportional technology

Component set, 4/3 proportional directional valve 4WREE6, load simulation valve, command value module

For analogue controlling of the proportional directional valve, based on BiBB component set R96002887

• Proportional valve technology

• Component technology (valve / amplifier) • Proportionality

• Cylinder control • Positioning

(45)

RE 00843/02.07 DS4 4/64

Component sets / proportional technology

R96003533 4/3 proportional directional valve 4WREE with integrated electronics and load simulation valve

75

2 R9600007 Operating module BPS 20.0 for command value generation 06

3 R9600630 Operating module BPS 2.0, adapter from 4 mm sockets to 7-pin connection plug 06

4 R9007665 Operating module BPS 6. 05

5 R9600957 Operating module BPS 5.2 with potentiometer +/- 0 Volt output 05

6 R96003550 7-pin cable for the connection of integrated electronics 3

7 R900826555 Cable set (command value measurement)

R96003495 Single-rod cylinder, 400 mm stroke 90

Teachware:

Training manuals

* Control Technology with Proportional Hydraulics, Trainer‘s Manual 34 * Control Technology with Proportional Hydraulics, Trainee‘s Manual 34 Supplementary literature

* The Hydraulic Trainer, Volume 2, Proportional and Servo-valve Technology 37 * The Hydraulic Trainer, Volume 5, Fluid Power Technology A - Z 38 Supplementary training media

* Web Tr@iner Proportional and Closed-loop Control Technology 44

* OHP foils Proportional Hydraulics 47

(46)

3

6

4

1 Component sets / proportional technology

Component set proportional technology

For analogue controlling of proportional flow control valve type 2FRE6B-2X/0QK4RV, based on

BiBB component set R96002887

• Cylinder control • Positioning

Weight kg 7.0

(47)

RE 00843/02.07 DS4 47/64

R96002557 Proportional flow control valve 2FRE6B-2X/0QK4RV 85

3 R90084480 Position transducer cable for proportional flow control valve (analogue control) 2

4 R900846809 Solenoid cable without LED, form A, grey plug

6 R90057058 Proportional amplifier VT-VRPA 08

R9007665 Operating module, command and actual value display BPS 6. in 9“ 05

R900843486 Precision pressure gauge 0 - 00 bar 95

Teachware:

Training manuals

* Proportional Hydraulics, Trainer‘s Manual 34

* Proportional Hydraulics, Trainee‘s Manual 34

Supplementary literature

(48)

2

4

1

3 Component sets / proportional technology

Component set proportional technology

For the analogue control of proportional pressure relief valve DBE6-X/50G24NK4M,

based on BiBB component set R96002887

Weight kg 7.5

(49)

RE 00843/02.07 DS4 49/64

R96002555 Proportional pressure relief valve DBE6-X/50G24NK4M 8

2 R900846809 Solenoid cable without LED, form A, grey plug

4 R900033823 Proportional amplifier VT-VSPA 08

R9007665 Operating module, command and actual value display, BPS 6. in 9“ 05

R900843486 Precision pressure gauge 0 - 00 bar 95

Teachware:

Training manuals

* Proportional Hydraulics, Trainer‘s Manual 34

* Proportional Hydraulics, Trainee‘s Manual 34

(50)

Component sets / hydraulic closed-loop control axes

Component set linear axis – HY-Control – with analogue amplifier

Component set HY-Control is a complete training system, in-cluding two-language training manual on CD-ROM.

A load can be steplessly simulated by means of a pressure re-lief valve on the passive cylinder.

• High-response valve technology

• Component technology (valve / amplifier) • Closed-loop position control

• Command value ramps • Zero point matching • Dynamic response • Commissioning

Weight kg 83

(51)

RE 00843/02.07 DS4 1/64

R90078458 Linear axis, analogue position measuring system 2 827003492 Controller module AVPC, box, SI

3 827008069 Operating module BPS 6./B with electro-box 49TE

4 R96002509 High-response valve size 6 OBE 76

5 827003336 Valve cable with Hirschmann plug CA 6 LS and valve plug-in connector 6 R9600256 Re-feed tank for HY-Control

7 3 R9600275 Pressure gauge, diameter 63, 0 - 00 bar incl. MSK 95

8 R96002486 Pressure relief valve DBDH6GX/00 for HY-Control

0 3 R96002475 Hose line 000 mm 9, 97

R9600259 Distributor for HY-Control 89

2 R96002796 CD HY-Control training manual de/en

Teachware:

(52)

6

1

3

4

Component set measuring technology 2042, minimal

The inexpensive entry into the electrical measurement of phys-ical variables such as pressure and speed.

All the required connection cables and the transport case are included.

Set up BiBB exercises (pump characteristic curves, regenera-tive circuit, etc.) and utilize an industrial measuring instrument instead of mechanical pressure gauges.

The data acquired via the connection cable can also be read out on a PC.

For this, you optionally require:

Software Material no. R9600939

Connection cable Material no. R9600947

Weight kg 4.6

(53)

RE 00843/02.07 DS4 3/64

Component sets / measuring technology

R90075448 Speed sensor (output 4 - 20 mA) 8

2 R900868620 Pressure transducer 0 - 200 bar / output 0 - 20 mA 8

3 R9600938 Multihandy 2042 5

4 R90020004 Plastic case 22

5 R90020002 Plug-in power supply unit, 230 VAC 22

6 R900063746 Measurement cable 2

In order to measure/display differential pressure in parallel, you require additionally

R900868620 Pressure transducer 0 - 200 bar / output 0 - 20 mA 8

R900063746 Measurement cable 2

Teachware:

(54)

8

4

7

6

1

3

9

2

Component set Measuring technology 2042, standard

Measure all relevant physical variables such as pressure, flow, temperature and speed in your hydraulic exercise set-up. All the required connection cables and the transport case are included.

Carry out BiBB exercises (pump characteristic curve, regen-erative circuit etc.) and utilize an industrial measuring instru-ment instead of mechanical pressure gauges.

The data acquired via the connection cable can also be read out on a PC.

For this, you optionally require:

Software Material no. R9600939

Connection cable Material no. R9600947

Weight kg 4.6

(55)

RE 00843/02.07 DS4 /64

Component sets / measuring technology

R96002536 Gear flow sensor 0.2 - 30 l/min 9

2 R900704454 F/I converter 20

3 R900868620 Pressure transducer 0 - 200 bar / output 0 - 20 mA 8

4 R90075448 Speed sensor (output 4 - 20 mA) 8

5 R9600938 Multihandy 2042 5

6 R90020004 Plastic case 22

8 2 R900063746 Measurement cable 2

9 R90023937 Temperature sensor 9

In order to measure/display differential pressure in parallel, you require additionally

R900868620 Pressure transducer 0 - 200 bar / output 0 - 20 mA 8

Teachware:

(56)

6

3

7

4

1

2

Component set measuring technology 300, minimal for PC

Measure physical variables such as pressure and speed using the industrial measuring device Multihandy 3050.

Carry out BiBB exercises (pump characteristic curve, regen-erative circuit etc.) and utilize sensors with frequency and ana-logue signals.

Thanks to ISDS (Intelligent Sensor Detection System), no cal-ibration required.

All the required connection cables, transport case, evaluation software HYDROcomsys / Win32 and the USB connection cable are included.

Weight kg 8.4

(57)

RE 00843/02.07 DS4 7/64

Component sets / measuring technology

R900892375 Speed sensor 8

2 R90073895 Pressure transducer 0 - 200 bar / output 0 - 20 mA with ISDS 8

3 R90073996 Multihandy 3050 incl. software HydroCOMsys/WIN 5

4 R90073394 Test case 22

5 R90020002 Plug-in power supply unit, 230VAC 22

6 R900733207 Measurement cable (ISDS) 2

7 R90077898 USB cable for Multihandy 3050/5050 L = .5 m 2

R90073895 Pressure transducer 0 - 200 bar / output 0 - 20 mA with ISDS 8

R900733207 Measurement cable (ISDS) 2

Teachware:

(58)

Component set Measuring technology 300 ISDS, stand-ard for PC

Measure all relevant variables such as pressure, flow, temper-ature and speed in your hydraulic exercise set-up using the industrial measuring device Multihandy 3050.

Carry out BiBB exercises (pump characteristic curve, regen-erative circuit etc.) and utilize sensors with frequency and analogue signals.

Thanks to ISDS (Intelligent Sensor Detection System), no calibration required.

All the required connection cables, transport case, evaluation software HYDROcomsys / Win32 and the USB connecting cable are included.

Weight kg .

(59)

RE 00843/02.07 DS4 9/64

Component sets / measuring technology

R96002508 Gear flow sensor 0.2 - 30 l/min with ISDS 9

2 R900892375 Speed sensor 8

5 R90073394 Test case 22

7 R900749653 Temperature sensor with ISDS 9

8 3 R900733207 Measurement cable (ISDS) 2

Teachware:

(60)

8

1

6

7

2

4

3

9

Component set measuring technology 00, standard for PC

The high-end measuring device for the most demanding use in complex circuits.

Utilize up to six measurement inputs for your complete hydrau-lic exercise set-up.

Carry out BiBB exercises (pump characteristic curve, regen-erative circuit etc.) and utilize sensors with frequency and ana-logue signals.

Thanks to ISDS (Intelligent Sensor Detection System), no cal-ibration required.

All the required connection cables, transport case, evaluation software HYDROcomsys / Win32 and the USB connecting cable are included.

Weight kg .5

(61)

RE 00843/02.07 DS4 61/64

R96002508 Gear flow sensor 0.2 - 30 l/min with ISDS 9

2 R900892375 Speed sensor 8

4 R900749653 Temperature sensor with ISDS 9

7 R90073394 Test case 22

8 3 R900733207 Measurement cable (ISDS) 2

Teachware:

* The Hydraulic Trainer, Volume , Basic principles 36

(62)

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Component set mobile hydraulics, basic principles

With manually operated mobile control blocks.

The component set includes standard mobile control blocks and is a unique training system on the market.

It was designed for, among others, the following professions: • Construction machine mechanics

• Construction machine operators • Agricultural machine mechanics.

It is used for illustrating the differences between industrial hy-draulics and mobile hyhy-draulics.

The types of actuation are • mechanical

• electrical

• electrohydraulic, proportional or switched

The actuating travel can be read off from scales. This allows recording of a flow characteristic curve in dependence upon the load.

Weight kg 36.5

(63)

RE 00843/02.07 DS4 63/64

R96002532 Mobile control block SM2 ( hand lever valve) 23

2 R96002533 Mobile control block SM2 (2 hand lever valves) 24

3 R9600253 Mobile control block SM2 ( x hand lever / x hydraulic) 25

4 R9600254 Pilot control device 26

Teachware:

Training manuals

* Mobile Hydraulics, Trainer‘s Manual 34

* Mobile Hydraulics, Trainee‘s Manual 34

* Hydrostatic drives with control of the secondary unit 38

* Hydraulics in mobile machinery 40

(64)

Component sets / troubleshooting on hydraulic systems

Hydraulic component set, troubleshotting

With manually operated directional valve.

This component set is based on the contents of BiBB exercises and deals in detail with the subject area of commissioning and troubleshooting.

It comprises valves with integrated defects that are to be installed in circuits. "Troubleshooting" provides assistance in imparting knowledge of and competence in systematic troubleshooting on hydraulic systems in a target-oriented manner.

Trainee's and Instructor's Manual included.

(65)

RE 00843/02.07 DS4 6/64

R9000545 Troubleshooting HP3/4/6 Trainer‘s and Trainee‘s Manual - de 35

2 R96002520** Pressure relief valve DBDH6GX/00 77

3 R96002545** Pilot operated pressure relief valve DB6K-4X/50YV 79

4 R9600247** Check valve S6A.X with hose 630 mm 87

5 R96002550** 4/3 directional valve 4WMM6G5X 70

6 Storage box

Teachware:

* The Hydraulic Trainer, Volume , Basic principles 36

* Web Tr@iner Hydraulics - basic principles 42

* The teachware in various languages can be found on the given pages ** Components are manipulated and identified by a “B“ on the nameplate

(66)

Hydraulic component set, troubleshooting

With electrically operated directional valve.

This component set is based on the contents of BiBB exercises and deals in detail with the subject area of commissioning and troubleshooting.

It comprises valves with integrated defects that are to be installed in circuits. "Troubleshooting" provides assistance in imparting knowledge of and competence in systematic troubleshooting on hydraulic systems in a target-oriented manner.

Trainee's and Instructor's Manual included.

Weight kg 2

Training System DS4

Hydraulic Training System

Components and Teachware

Type DS4

RE 00843/02.07

Replaces: 2.05

Table of contents

Contents

Page

Contents

Page

Hydraulic training system – system presentation

Features

Table of contents: Workstations

Contents

Page

Contents

Page

1

11

10

9

8

7

6

2

3

4



DS4 training system with 1 workstation

1

13

12

11

10

9

8

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4



6

3

7

DS4 training system, can be extended to 2 workstations

1

13

12

11

10

8

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4



6

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7

9

DS4 training system with 2 workstations

Workstations / typical variants

9

14

7

9

8 a

6

8 b

11

1 + 2

3

4

10

12 a

12 b

 a

 b

 c

Configure the workstation according to your needs

Workstations / custom configuration

Order example:

Workstations / custom configuration

Replaces: 2.05

a

b

c