Operation Power Brake Valve

Hydraulic power brake valves
for mobile applications
Applies to the following types:

LT 05 LT 10
LT 06 LT 12
LT 07 LT 13
LT 08 LT 17 Operating instructions Replaces: –.–
LT 09 LT 31 RE 66200-B/04.2013 English
LT 05 LT 06 LT 07 LT 08
LT 09 LT 10 LT 12 LT 13
LT 17 LT 31
The data specified above only serve to describe
the product. No statements concerning a
certain condition or suitability for a certain
application can be derived from our informa-
tion. The information given does not release
the user from the obligation of own judgment
and verification. It must be remembered that
our products are subject to a natural process of
wear and aging.
© This document, as well as the data, specifica-

tions and other information set forth in it, are
the exclusive property of Bosch Rexroth AG. It
may not be reproduced or given to third parties
without its consent.
The cover shows an example configuration. The

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

pared in German.
Contents 3/52
Contents
1 About this documentation 5
1.1 Validity of the documentation 5
1.2 Required and amending documentation 6
1.3 Representation of information 7
1.3.1 Safety instructions 7
1.3.2 Symbols 8
1.3.3 Designations 8
2 Safety instructions 9
2.1 General information on this chapter 9
2.2 Intended use 9
2.3 Improper use 9
2.4 Qualification of personnel 10
2.5 General safety instructions 10
2.6 Product-specific safety instructions 11
2.7 Personal protective equipment 13
3 General information on damage to property and damage to the product 14
4 Scope of delivery 17
5 About these products 17
5.1 Performance description 17
5.2 Product description 17
5.2.1 Power brake valves with modular design 18
5.2.2 Power brake valves with compact design 20
5.3 Product identification 21
6 Transport and storage 22
6.1 Transporting a power brake valve 22
6.2 Storing a power brake valve 22
7 Assembly 24
7.1 Unpacking 24
7.2 Painting the power brake valve 24
7.3 Installation conditions 25
7.4 Installation position 25
7.5 Installing the power brake valve 26
7.5.1 Required tools 26
7.5.2 Preparation 26
7.5.3 Dimensions 26
7.5.4 Fastening the power brake valve 26
7.5.5 Completing installation 27
7.5.6 Mechanically connecting the power brake valve 28
7.5.7 Hydraulically connecting the power brake valve 28
7.5.8 Electrically connecting the power brake valve 31
8 Commissioning 32
8.1 First commissioning 33
8.2 Re-commissioning after standstill 34
RE 66200-B/04.2013, LT, Bosch Rexroth AG

4/52
ContentsContents
9 Operation 35
10 Maintenance and repair 36
10.1 Inspection 36
10.2 Maintenance 37
10.3 Repair 37
10.4 Spare parts 38
11 Disassembly and replacement 39
11.1 Required tools 39
11.2 Preparing for disassembly 39
11.3 Disassembling the product 39
11.4 Preparing the components for storage/further use 39
12 Disposal 40
13 Extension and modification 41
14 Troubleshooting 42
14.1 How to proceed for troubleshooting 42
14.2 Fault table 43
14.3 Suggestion for measuring points 46
15 Technical data 48
16 Alphabetical index 49
Bosch Rexroth AG, LT, RE 66200-B/04.2013

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

This documentation applies to the following products:
•• LT 05
•• LT 06
•• LT 07
•• LT 08
•• LT 09
•• LT 10
•• LT 12
•• LT 13
•• LT 17
•• LT 31
This documentation is aimed at the machine manufacturer.

This documentation contains important information on the safe and appropriate
transport, assembly, and disassembly, commissioning, operation, maintenance and
simple troubleshooting of the product.
▶▶ Read this documentation carefully, and in particular chapter 2 "Safety instruc-
tions" on page 9 and chapter 3 "General information on damage to prop-
erty and damage to the product" on page 14, before working with the power
brake valve.
This documentation applies to all hydraulic power brake valves of the listed series ir-
respective of their manufacturing date until a new version of this document is issued.

6/52 About this documentation
1.2 Required and amending documentation

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

Title Document number Document type
1 circuit power brake valve LT 05 series 3X 66143 Data sheet
1 circuit power brake valve LT 05 series 3X 66143-E Spare parts list
Accumulator charging valve LT 06 series 3X 66191 Data sheet
2 circuit power brake valve LT 07 series 2X 66146 Data sheet
2 circuit power brake valve LT 07 series 2X 66146-E Spare parts list
Hand brake valve LT 08 series 2X 66148 Data sheet
Hand brake valve LT 08 series 2X 66148-E Spare parts list
Relay valve LT 09 series 2X 66153 Data sheet
Relay valve LT 09 series 2X 66153-E Spare parts list
Steering brake valve LT 10 series 2X 66154 Data sheet
1 circuit power brake valve with compact design LT 12 series 3X 66218 Data sheet
1 circuit power brake valve with compact design LT 12 series 3X 66218-E Spare parts list
Inching power brake valve LT 31 series 1X 66227 Data sheet
Inching power brake valve LT 31 series 1X 66227-E Spare parts list
Order confirmation Order confirmation
Contains the order-specific technical data of your power brake valve.
Quotation drawing (installation drawing) Quotation drawing
Contains the external dimensions, all connections and the hydraulic circuit dia-
gram of your power brake valve.
Hydraulic fluids based on mineral oils and related hydrocarbons 90220 Data sheet
Describes the requirements on mineral oil-based hydraulic fluids and related
hydrocarbons for operation with Rexroth hydraulic components and helps you to
select a hydraulic fluid for your Bosch Rexroth component.
Environmentally compatible hydraulic fluids 90221 Data sheet
Describes the requirements on environmentally compatible hydraulic fluids for
operation with Rexroth hydraulic components and helps you to select a hydraulic
fluid for your Bosch Rexroth component.
MTTFd reliability characteristics regarding the functional safety according 90291 Data sheet
to ISO 13849
MTTFd values for power brake valves
Further information is available from Rexroth and at

www.boschrexroth.de/mobilhydraulik-katalog.

About this documentation 7/52
1.3 Representation of information

Consistent safety instructions, symbols, terms and abbreviations are used in this
documentation so that you can quickly and safely work with your product. For a bet-
ter understanding, they are explained in the following sections.
1.3.1 Safety instructions

In this documentation, safety instructions are contained in chapter 2.6 "Product-
specific safety instructions" on page 11 and in chapter 3 "General information on
damage to property and damage to the product" on page 14 and wherever se-
quences of actions or instructions are explained which bear the danger of personal
injury or damage to property. The measures described for preventing these hazards
must be observed.
Safety instructions are set out as follows:
Signal word
Type and source of danger!
Consequences in case of non-compliance
▶▶ Hazard avoidance measures
▶▶ <Enumeration>
•• Warning sign: Draws attention to the danger

•• Signal word: Identifies the degree of danger
•• Type and source of danger: Indicates the type and source of danger
•• Consequences: Describes the consequences in case of non-compliance
•• Precaution: Specifies how the danger can be prevented
Table 2: Risk classes according to ANSI Z535.6-2006
Warning sign, signal word Meaning

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

8/52 About this documentation
1.3.2 Symbols
The following symbols indicate notices which are not safety-relevant but increase the
comprehensibility of the documentation.
Table 3: Meaning of the symbols
Symbol Meaning
If this information is not observed, the product cannot be used and/or
operated optimally.
▶▶ Individual, independent action

1. Numbered instruction:
2. The numbers indicate that the steps must be carried out one after
the other.
3.
1.3.3 Designations
The following designations are used in this documentation:
Table 4: Designations
Designation Meaning
SBS Service brake system
PBS Parking brake system
ABS Auxiliary brake system

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

The product has been manufactured according to the generally accepted codes of
practice. However, there is still the risk of personal injury and damage to property if
you do not observe this chapter and the safety instructions in this documentation.
▶▶ Read this documentation completely and thoroughly before working with
the product.
▶▶ Keep this documentation in a location where it is accessible to all users at
all times.
▶▶ Always include the required documentation when you pass the power brake valve
on to third parties.
2.2 Intended use

Power brake valves are hydraulic components and are therefore neither covered by
the scope of machinery nor partly completed machinery pursuant to the EC machin-
ery directive 2006/42/EC. The component is exclusively intended to be assembled
together with other components to form partly completed or complete machinery.
The component may only be commissioned if it has been integrated in the machine
for which it is designed.
The product is designed to be used in power brake systems in mobile machines.
Any deviating use is only permitted after consultation with Bosch Rexroth.
▶▶ Comply with the technical data, application and operating conditions and perfor-
mance limits according to data sheet and order confirmation. For information on
the permitted hydraulic fluids, see the respective data sheet.
The power brake valve is no safety equipment.

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

Any use deviating from the intended use is improper and thus not admissible.
Bosch Rexroth AG does not assume any liability for damage caused by improper use.

10/52 Safety instructions
2.4 Qualification of personnel

The activities described in this documentation require basic knowledge of mechan-
ics, electrics and hydraulics as well as knowledge of the appropriate technical terms.
In order to ensure safe use, these activities may only be carried out by a correspond-
ing expert or an instructed person under the direction and supervision of an expert.
Experts are those who can recognize potential hazards and apply the appropriate
safety measures due to their professional training, knowledge and experience, as
well as their understanding of the relevant conditions pertaining to the work to be
undertaken. An expert must observe the relevant specific professional rules and have
the necessary hydraulic expert knowledge.
Hydraulic expert knowledge means, amongst others:
•• Reading and understanding hydraulic schemes,
•• Having knowledge of the function and interaction of hydraulic components.
Bosch Rexroth offers measures supporting the training in specific fields. Please
find an overview of the training contents on the internet at:
http://www.boschrexroth.de/didactic
2.5 General safety instructions

•• Observe the valid regulations on accident prevention and for environmental protection.
•• Observe the safety regulations and provisions of the country where the product is
implemented/used.
•• Exclusively use Rexroth products in technically perfect condition.
•• Observe all notices on the product.
•• Persons who assemble, operate, disassemble or maintain Rexroth products must
not be under the influence of alcohol, drugs or pharmaceuticals that may affect
their ability to respond.
•• Only use genuine Rexroth accessories and spare parts.
•• Comply with the technical data and environmental conditions indicated in the prod-
uct documentation.

2.6 Product-specific safety instructions

Observe the applicable national and international directives, provisions and laws
regarding the design and safe operation of power brake systems that are equipped
with a power brake valve.
All legal regulations require that a vehicle is roadworthy in all operating states.
Furthermore, the braking system has to be state-of-the-art.
Braking systems have to be accepted by the competent authority pursuant to the
applicable national and international provisions.
The vehicle manufacturer is responsible for this.
The following safety instructions apply to chapters 6 to 14.
WARNING
Danger due to an unintended pressure build-up/pressure reduction!
Danger to life, risk of injury, damage to property!
The power brake may block in an undefined position due to internal pollution, e.g.
polluted hydraulic fluid, abrasion dust or residual dirt from system components. As
a result, the driven actuator is no longer under the operator’s control.
▶▶ Secure the machine against rolling (away) and unintended movements according
to the machine manufacturer's specifications.
▶▶ Comply with the specified cleanliness class for the hydraulic fluid according to
the data sheet.
Pressurized machine!
Danger to life, risk of injury, severe injury when working at systems that have not
been stopped! Damage to property!
▶▶ Safeguard the overall system according to the manufacturer's instructions.
▶▶ Make sure that the power brake valve is depressurized. To do so, observe the
specifications of the machine manufacturer.
▶▶ Do not disconnect lines, connections or components as long as the power brake
valve is under pressure.
▶▶ Observe the specifications of the machine manufacturer regarding ma-
chine shut-down.
Leaking oil mist!

Explosion hazard, risk of fire, allergic reactions, inhalation, environmental pollution!
▶▶ Depressurize the power brake valve and repair the leak.
▶▶ Keep open fire and sources of ignition away from the power brake valve.
Electrical voltage!
Danger to life, risk of injury and damage to property due to electric shock!
▶▶ Always switch off power supply to the mating connectors before assembling the
product or when connecting and disconnecting connectors.
▶▶ Safeguard the machine according to the manufacturer's instructions.

12/52 Safety instructions
WARNING
Incorrect energy supply!
Danger to life and risk of injury due to uncontrolled valve positions! These may
cause unexpected behavior of the power brake valve.
▶▶ Secure the power brake valve against unintended electrical and mechanical actuation.
▶▶ Always comply with the country-specific regulations.
CAUTION
Risk of injury due to sharp edges and rough surfaces!
When working at the power brake valve and transporting it, there is a risk of injury,
e.g. due to sharp edges at the valve housing, at threads, at the pedal or at attachments.
▶▶ Wear safety boots with steel caps.
▶▶ Wear protective gloves and suitable work clothes as protection against cuts.
Danger due to heavy loads!

When carrying power brake valves, there is a risk of health hazards.
▶▶ Use a suitable lifting, putting down and moving technique.
▶▶ Use your personal protective equipment (e.g. safety goggles, protective gloves,
suitable working clothes, safety shoes).
Risk to limbs due to crushing and impact!

There is a risk of injury in the gap between the actuation element and the
valve housing.
▶▶ Keep your limbs away from the gap between the actuation element/pedal/hand
lever and the valve housing.
The power brake valve has hot surfaces!

Risk of burning!
▶▶ Allow the power brake valve to cool down sufficiently before touching it.
▶▶ Wear heat-resistant protective clothing, e.g. gloves.
Contact with hydraulic fluid!

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

CAUTION
Escaping hydraulic fluid due to leakage!
Risk of burning and risk of injury due to escaping oil!
▶▶ Depressurize the power brake valve and repair the leak.
Escaped hydraulic fluid due to leakage!

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

The user of the power brake valve is responsible for the personal protective equip-
ment. Observe the safety regulations and provisions in your country.
Bosch Rexroth recommends using personal protective equipment for users of the
product consisting of:
•• Heat-resistant protective clothing, e.g. protective gloves for working at the power
brake valve.
•• Safety shoes, protective gloves, protective goggles and suitable work clothes for
working at the power brake valve.
▶▶ Wear heat-resistant protective clothing, e.g. protective gloves, when touching

a power brake valve that has heated up.
▶▶ When handling hydraulic fluids, wear protective gloves, safety goggles and suit-
able work clothes.

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

erty and damage to the product
The following safety instructions apply to chapters 6 to 14.
NOTICE
Danger due to improper handling!
The product may be damaged!
▶▶ Do not apply any inadmissible mechanical, hydraulic or electrical loads to
the product.
▶▶ Never use the product as a handle or step.
▶▶ Do not transport the power brake valve using sensitive attachments (e.g. actua-
tion elements, sensors, solenoids, or valves).
▶▶ Carefully place the power brake valve on the surface so that it is not damaged
and secure it against falling.
▶▶ Do not place any objects on top of the product.
▶▶ Do not place the power brake valve on actuation elements.
▶▶ Avoid impacts against sensitive attachments (e.g. sensors, solenoids, or actua-
tion elements).
▶▶ Avoid impacts against sensitive sealing surfaces (e.g. at the operating ports).
▶▶ Leave the protective covers on the power brake valve until shortly before con-
necting the lines.
▶▶ Disconnect all electrical connector plugs prior to painting.
▶▶ Make sure that the electronic components (e.g. sensors) are not charged elec-
trostatically (e.g. due to painting).
If the power brake valve falls down

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

General information on damage to property and damage to the product 15/52
NOTICE
Contamination of the hydraulic fluid!
The cleanliness of the hydraulic fluid has a considerable impact on the cleanliness
and service life of the hydraulic system as a whole. Contamination of the hydraulic
fluid can cause premature wear and malfunctions.
▶▶ It is imperative that the working environment at the site of installation is free of
dust and foreign substances in order to prevent foreign particles (e.g. welding
beads or metal chips) from getting into the hydraulic lines and causing product
wear or malfunctions. The power brake valve must be protected from dirt dur-
ing installation.
▶▶ Only use clean connections, hydraulic lines and attachments (e.g. measuring devices).
▶▶ No pollutants must enter when closing the connections.
▶▶ Ensure before commissioning that all hydraulic connections are tight and that all
the seals and caps of the plug-in connections are installed correctly and undam-
aged in order to prevent fluids and foreign particles from penetrating the product.
Improper cleaning!
The product may be damaged!
▶▶ Cover all openings with appropriate safeguards in order to prevent cleaning
agents from penetrating the power brake valve.
▶▶ Never use solvents or aggressive cleaning agents. Only clean the power brake
valve with water and a mild cleaning agent, if necessary.
▶▶ Do not point high-pressure washers at sensitive components, e.g. rubber compo-
nents (bellows), electrical connections (solenoids, sensors) and actuation elements.
▶▶ Use fiber-free cleaning cloths for cleaning.
Environmental pollution caused by incorrect disposal!

Careless disposal of the power brake valve, the hydraulic fluid and the packaging
material can pollute the environment.
▶▶ Dispose of the power brake valve, the hydraulic fluid and the packaging in accor-
dance with the applicable national regulations in your country.
Leaking or spilt hydraulic fluid!

Environmental pollution and pollution of the ground water!
▶▶ When draining the hydraulic fluid, always put a collecting pan under the power
brake valve.
▶▶ If hydraulic fluid is spilled, use an oil binding agent.
▶▶ Dispose of the hydraulic fluid in accordance with the applicable national regula-
tions in your country.

16/52 General information on damage to property and damage to the product
The warranty only applies to the delivered configuration.

The claim to warranty expires in case of:
•• Incorrect assembly, commissioning and operation
•• Improper use
•• Removal of protection caps and lead seals (e.g. for pressure adjustments)
•• Alteration of the factory settings
•• Modifications and attachments
•• Opening the valve
•• Improper handling
•• Using third party spare parts

Scope of delivery 17/52
4 Scope of delivery
The scope of delivery includes:
•• Power brake valve according to the order confirmation
Upon delivery, the following parts are additionally mounted depending on the model:
•• Protective covers
•• Protective plugs/plug screws
5 About these products
5.1 Performance description

Heavy construction, agriculture and forestry machinery as well as municipal vehicles,
vehicles for material handling and special vehicles require braking systems with
a high level of operational safety with low operating forces, in particular if they are
used in difficult terrain. These vehicles require servo-assisted or power brake sys-
tems to comply with the statutory braking action.
Please find technical data, operating conditions and limitations of use of the power
brake valves in the data sheet and the order confirmation.
Regarding which power brake valves are covered in which data sheets, see chap-
ter 1.2 "Required and amending documentation" on page 6.
5.2 Product description
There are power brake valves with modular and compact design.
For the description of the set-up and function as well as instructions on the adjust-
ment and installation of the individual power brake valves, see the data sheet.
Regarding which power brake valves are covered in which data sheets, see Table 1
"Required and amending documentation" on page 6.

18/52 About these products
5.2.1 Power brake valves with modular design
1 circuit brake valve LT 05 Accumulator charging valve LT 06 2 circuit brake valve LT 07 Hand brake valve LT 08
Relay valve LT 09 Steering brake valve LT 10 Inching brake valve LT 31

Fig. 1: Components with modular design
For brake pedal versions, see the respective data sheet.
6 6
9 9
13 13
11 11
2 4 2
5 10 3 5 14
10
6
8 6
1 15 14 4
1 15
7 14
12
12
Fig. 2: Schematic illustration of an example application: Fig. 3: Schematic illustration of an example application:
1 circuit power brake system 2 circuit power brake system
1 Pump 5 Inverted shuttle valve 8 1 circuit power brake 12 SBS pressure switch
2 Accumulator charging 6 Hydraulic accumulator valve LT 05 13 PBS spring-loaded
valve LT 06 7 2 circuit power brake 9 Hand brake valve LT 08 accumulator cylinder
3 Check valve valve LT 07 10 Brake pedal 14 Brake cylinder (wheel)
4 Pressure switch, 11 PBS pressure switch 15 Downstream actuators
accumulator pressure

About these products 19/52
Optional accessories •• Pressure switch

•• Hydraulic accumulator
•• Inverted shuttle valve
•• Check valve
Accumulator charging The hydraulic accumulators (6) are supplied with a higher priority than other actua-
process tors by the accumulator charging valve LT 06 (2), which is directly downstream of the
pump (1). This happens as soon as the accumulator pressure falls below a limit value.
When the set charging pressure for the hydraulic accumulators is reached, the accu-
mulator charging valve LT 06 applies the entire pump delivery volume to the down-
stream actuators (15).
The two service brake circuits are separated by an inverted shuttle valve (5). There-
fore, if one brake circuit fails, the other remains operational. The charging state of
the hydraulic accumulators has to be monitored by pressure switches (4) so that the
driver is warned by a visual signal if the energy supply fails, e.g. motor stop.
Operation of the service If the service brake is actuated, the 2 circuit power brake valve LT 07 (7) regulates
brake system (SBS) the pressure in the brake cylinders (14) in proportion to the actuating force and
actuating path of the pedal (10). The vehicle is decelerated by the wheel brakes.
When the braking process is completed, the hydraulic fluid flows back into the tank.
If one of the brake circuits fails, the other one remains operational due to the me-
chanical contact of the two control spools in the 2 circuit power brake valve LT 07 and
the circuit separation of the two hydraulic accumulators. The actuating force remains
unchanged. The brake light of the vehicle is controlled via the pressure switch (12).
Operation of the parking If the vehicle is in in parking position, the wheel brake is operated with the force of
brake system (PBS) the highly pre-tensioned spring of the spring-loaded accumulator cylinder (13). If the
hand brake valve LT 08 (9) is actuated in the "release" position, hydraulic fluid flows
into the spring-loaded accumulator cylinder and opens the parking brake. The
pressure switch (11) indicates if pressure is built up or reduced. The check valve (3)
prevents unintended pressure reduction in the PBS pressure supply.
The mechanical hand brake valve LT 08 (9) regulates the pressure sensitively.
Therefore, the "auxiliary brake" function is also fulfilled.
Auxiliary brake system The auxiliary brake system has to be designed according to the legal regulations.
(ABS)

20/52 About these products
5.2.2 Power brake valves with compact design

Power brake valves with compact design combine all required functions in one
valve housing.
1 circuit brake valve LT 12 2 circuit brake valve LT 13 2 circuit brake valve LT 17

Fig. 4: Components with compact design
4 4 4
2 S2 S3 S1
BR3
5
BR2
BR1
6
8 P T
P N
1 10
7
Fig. 5: Schematic illustration of an example application: 2 circuit power brake system
1 Pump 4 Hydraulic accumulator 8 Brake cylinder (wheel)

2 2 circuit power brake 5 PBS pressure switch 9 PBS spring-loaded
valve LT 13 6 SBS pressure switch accumulator cylinder
3 Brake pedal 7 Pressure switch, accu- 10 Downstream actuators
mulator pressure

About these products 21/52
5.3 Product identification

Use the name plate to identify the power brake valve.
The details on the name plate apply to the power brake valve in the condition as
supplied. If the power brake valve was modified as compared to the condition as
supplied, the details on the name plate may possibly not be true for the present
power brake valve.
▶▶ Take care not to damage the existing name plates.

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

SN: XXXX 4
LT13H3X/P100EXXXCB18AG24NK4/02M 5
123456789 6
Made in Germany 708A 7
10 9 8
Fig. 6: Name plate LT (example)
1 Word mark (manufacturer) 6 Customer material number (optional)

2 Material number of the power 7 Area/works number
brake valve 8 Installation stamp
3 Date of manufacture 9 Test stamp
4 Serial number 10 Designation of origin
5 Material short text
Depending on the order, there might be deviations from the name plates shown
above. On customer-specific name plates, it is possible to replace the Rexroth
logo with the customer logo, for example.

22/52 Transport and storage
6 Transport and storage

▶▶ Always comply with the required environmental conditions with regards to trans-
port and storage, see chapter 6.2 "Storing a power brake valve" on page 22.
Failure to comply causes premature aging of components and reduces the

service life.
For unpacking instructions, see chapter 7.1 "Unpacking" on page 24.
6.1 Transporting a power brake valve

The power brake valve may be transported by hand for a short time.
The dimensions and weight vary according to the model. For the values applicable to
your power brake valve, see the quotation drawing and the data sheet.
6.2 Storing a power brake valve

Requirements •• The storage facilities must be free from corrosive substances, fumes and gases.
•• In order to avoid damage to seals, do not operate any ozone-generating devices in
the storage facilities, such as mercury vapor lamps, copiers, printers, high-voltage
devices, electric motors, electric radio sources and/or discharges.
•• The storage facilities must be dry and free from dust.
•• Optimum storage temperature: +5 °C to +20 °C
•• Minimum storage temperature: –25 °C
•• Maximum storage temperature: +60 °C
•• UV protection: 100%
Avoid high light irradiation (e.g. bright windows or direct neon light).
•• Relative air humidity (no condensation): Max. 65%
•• Store the power brake valve in such a way that it is protected from shocks, do not
stack it.
•• Do not store the power brake valve on sensitive attachment parts, e.g. actuation
elements, sensors, solenoids or valves.
•• Do not remove any protective covers and protective plugs.
▶▶ Check the correct storage of the power brake valves on a monthly basis.
Following delivery As a standard, the power brake valves are coated with a priming (single coat paint)
or protected against corrosion by electroplating at the factory.
Mineral oil is used for internal corrosion protection of closed valves. Surfaces of the
power brake valve that are not coated or electroplated (e.g. flange surfaces) are not
protected against corrosion.
Delayed commissioning, long transport and storage periods or decommissioning
for an extended period of time may lead to the formation of rust on Rexroth power
brake valves. In order to prevent this, take additional corrosion protection measures.

Transport and storage 23/52
Recommended procedure following an extended storage time:

1. Check the complete power brake valve for damages and corrosion prior to installation.
2. In a test run, check the power brake valve for correct operation and tightness.
The claim to warranty expires if the requirements and storage conditions are not
complied with.
Following an extended storage period, we recommend having the power brake
valve checked by your local Bosch Rexroth service.
For questions regarding repair and spare parts, contact your local Bosch Rexroth ser-
vice or the service department of the power brake valve manufacturer, see chap-
ter 10.4 "Spare parts" on page 38.
Following disassembly If a dismounted power brake valve is to be stored, it has to be preserved for the time
of storage to protect it against corrosion.
The following instructions only refer to power brake valves that are operated with
a mineral oil-based hydraulic fluid. Other hydraulic fluids require preservative
measures that are specifically designed for them. In this case, consult the Bosch
Rexroth service. For the address, see chapter 10.4 "Spare parts" on page 38.
Bosch Rexroth recommends the following procedure:

1. Clean the power brake valve.
2. Drain the power brake valve.
3. Close all connections air tightly.
4. Wet the unpainted flange-mounting surfaces and exterior seals of the power
brake valve with mineral oil.
5. Protect sensitive attachments (e.g. actuation elements, sensors, solenoids or
valves) using suitable measures as in the condition as supplied.
6. Pack the power brake valve with a suitable desiccant air-tightly in corrosion pro-
tection film.
7. Store the power brake valve in such a way that it is protected from shocks. For
further conditions, see section "Requirements" on page 22 in this chapter.
8. If required, send the power brake valve to the Bosch Rexroth service for repair.

24/52 Assembly
7 Assembly
Prior to assembly, make sure the following documents are at hand:
•• Quotation drawing (installation drawing) of the power brake valve (available from
your contact at Bosch Rexroth)
•• Hydraulic circuit diagram of the power brake valve (see the quotation drawing)
•• Hydraulic circuit diagram of the machine (available from the machine manufacturer)
•• Order confirmation (contains the order-specific technical data of your power
brake valve)
•• Data sheet of the power brake valve (contains the admissible technical data)
7.1 Unpacking
Caution! Danger due to falling parts!

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

2. Check the power brake valve for transport damages and completeness, see chap-
ter 4 "Scope of delivery" on page 17.
3. Dispose of the packaging in accordance with the currently applicable national
regulations in your country.
4. Return reusable packagings to the sending Bosch Rexroth factory.
7.2 Painting the power brake valve
CAUTION
Escape of aerosols during painting!
Risk of inhaling harmful substances.
▶▶ Wear inhalation protection and protective clothing during painting.
Complete the following steps if the power brake valve is to be painted prior to installation:
▶▶ Completely protect the hydraulic ports against paint application by screwing-in
plastic threaded plugs beforehand.
▶▶ Protect the mounting threads against paint application by screwing-in bolts.
▶▶ Avoid paint being applied to the contacts of the electrical connections and make
sure not to cause any damage to the connector.
▶▶ Protect attachments (e.g. actuation elements, sensors, solenoids) against
paint application.

Assembly 25/52
▶▶ Protect plastic and rubber parts (e.g. shaft seal ring, bellows, pedal rubber)
against paint application.
▶▶ Protect name plates against the application of paint using a foil which can be
removed after coating.
▶▶ When removing the plastic threaded plugs after coating, make sure that no paint
chips enter the power brake valve.
7.3 Installation conditions

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

The positioning and adjustment of the power brake valve in the machine has to
comply with the applicable provisions on ergonomics and occupational safety. The
power brake valve has to be freely accessible and it must be possible to actuate it
completely in order to ensure full functionality.
Observe the installation position according to the specification. In this context,
observe the specifications in the data sheet and in the quotation drawing. If not indi-
cated otherwise in the technical documents, the power brake valves can be installed
in any position.

26/52 Assembly
7.5 Installing the power brake valve
7.5.1 Required tools

Installation can be carried out using standard tools. No special tools are required.
Also observe the instructions of the manufacturers of the other hydraulic compo-
nents when selecting the required tools.
7.5.2 Preparation
1. Compare the material number and the designation (type key) with the details in
the order confirmation.
If the material number of the power brake valve does not match the number in
the order confirmation, contact the Bosch Rexroth service, for the address see
chapter 10.4 "Spare parts" on page 38.
2. Drain the power brake valve prior to installation to avoid mixing with the hydraulic
fluid of the machine.
7.5.3 Dimensions
The quotation drawing contains the dimensions for all connections of the power
brake valve.
7.5.4 Fastening the power brake valve

For fastening, the power brake valve is provided with mounting bores which can be
seen in the quotation drawing and the data sheet. The required mounting hole image
(dimensions and tolerances) for the mounting bores on the machine can also be
found in the quotation drawing or on the data sheet. Select the tightening torques
according to the usual standard values for each bore size and bolt property class.
Too much tightening torque might cause the valve spool to jam. If this is the case,
reduce the mounting torque accordingly. Observe the adequate residual clamping
force of the screws. Regarding the design of the screw connections and the mount-
ing elements, observe the material specifications in Table 5.
Table 5: Material specifications
Component Material Material abbreviation/no.

Valve housing Cast steel GG-30 / EN-GJL-300
Brake pedal base plate for Aluminum alloy GK-AlSi9Cu3
LT 05, LT 07, LT 17, LT 19, LT 20, LT 31
Mounting flange (clamping ring) for Steel S235JR (St37) / 1.0037
LT 07, LT 31 without pedal
Hydraulic actuation for Steel 11SMn30 / 1.0715
LT 07, LT 09, LT 12, LT 13

Assembly 27/52
1. Observe the contact surface requirements from the quotation drawing.

2. Always fasten the power brake valve at all mounting points provided. Depending
on the type of mounting, use screws and/or hexagon nuts with one of the prop-
erty classes listed in Table 6 according to EN ISO 4762 or EN ISO 4014.
Bosch Rexroth recommends using a screw connection with the following parameters:
Table 6: Mounting screws and nuts
Series Dimension Property class

LT 05 M8 8.8 / 10.9
LT 06 M6 8.8 / 10.9
LT 07 M8 8.8 / 10.9
LT 08 M8 8.8 / 10.9
LT 09 M8 8.8 / 10.9
LT 10 M8 8.8 / 10.9
LT 12 M8 8.8 / 10.9
LT 13 M8 8.8 / 10.9
LT 17 M8 8.8 / 10.9
LT 31 M8 8.8 / 10.9
7.5.5 Completing installation
Caution! Operation with protective plastic plugs!

Operating the power brake valve with protective plugs may cause injuries or damage
to the power brake valve.
▶▶ Prior to commissioning, remove all protective plugs and replace them by line con-
nections or suitable pressure-resistant, metal plug screws.
▶▶ Remove the transport protection.

The power brake valve is delivered with protective covers and protective plugs,
where appropriate. They are not pressure-resistant and therefore have to be re-
moved prior to connection. Use suitable tools to avoid damage to the sealing and
functional surfaces. If the sealing or functional surfaces are damaged, contact
your Bosch Rexroth service or the service department of the manufacturer of the
power brake valve.
Connections intended to connect lines are equipped with protective plugs or plug
screws that serve as transport protection. All connections required for operation
have to be connected. Non-compliance may cause malfunctions or damages. If
a connection is not connected, it has to be closed with a plug screw as the
protective plugs are not pressure-resistant.

28/52 Assembly
7.5.6 Mechanically connecting the power brake valve

For the assembly instructions regarding the connection of the mechanical actuation
elements, see the data sheet.
7.5.7 Hydraulically connecting the power brake valve
NOTICE
Damage caused by incorrect assembly!
During operation, hydraulic lines and hoses installed under mechanical stress cre-
ate additional mechanical forces, which reduces the service life of the power brake
valve and the complete machine.
▶▶ Assemble lines and hoses without mechanical stress.
The machine manufacturer is responsible for the design of the lines. The power
brake valve has to be connected to the remaining hydraulic system according to the
hydraulic circuit diagram of the machine manufacturer.
The connections and the mounting threads are designed for the peak pressure indi-
cated in the data sheet. The machine manufacturer has to make sure that the con-
nection elements and lines comply with the intended application conditions (pres-
sure, flow, hydraulic fluid, temperature) including the required safety factors.
Select the cross-sections of the hydraulic transmission elements (pipes, hoses) in
such a way that the pressure drop between the hydraulic accumulator and the brake
cylinder remains low with low temperatures and the function of the power brake
valve remains intact.
Only connect hydraulic lines that match the power brake valve connection
(pressure level, size, system of units).

Assembly 29/52
Instructions on the installa- Observe the following instructions regarding the installation of hydraulic lines.
tion of lines •• Lines and hoses have to be installed without preload so that there are no addi-
tional mechanical forces that reduce the service life of the power brake valve and
possibly the entire machine.
•• Remove any resinifications caused by incorrect storage.
•• Use suitable seals as sealants.
––Observe the compatibility of seals with the hydraulic fluid used.
––Use the provided seal at each hydraulic connection.
––Make sure that the connections are clean and intact.
•• Make sure that the connections and connection elements are air-tight.
•• Pressure lines
––Use only pipes, hoses and connection elements as pressure lines that are rated
for the operating pressure range indicated in the data sheet. They also have to be
pressure-resistant with respect to the external air pressure.
•• Tank line
––Always install tank lines in such a way that the power brake valve is always
filled with hydraulic fluid and cannot drain hydraulically in case of an extend-
ed standstill.
––The tank pressure must not exceed the application pressure of the brake.
Risk of confusion with The power brake valves are used in applications with metric and US systems of units.
threaded connections Both the system of units and the size of the threaded hole and the screw-in stud
(e.g. plug screw) have to match.
Due to little visual differences, there is a risk of confusion. In this regard, observe the
specifications in the quotation drawing. The SI units usually apply, unless stated otherwise.
Warning! Leaking or ejected screw-in studs!

If a screw-in stud whose system of units and size do not match the threaded hole is
pressurized, it may come loose and even be ejected with high speed from the hole.
This may cause serious injuries and damage to property. Hydraulic fluid may escape
from this leakage point.
▶▶ Use the drawings (quotation drawing) to check the required screw-in stud for
all fittings.
▶▶ Make sure that there is no confusion when installing armatures, mounting screws
and plug screws.
▶▶ Use a screw-in stud with the same system of units and the right size for the re-
spective threaded hole.

30/52 Assembly
Connection overview For an overview of the line connections, see the respective data sheet and the
quotation drawing.
Tightening torques Observe the specifications in standards and/or the manufacturer's specifications for
the screw-in studs, fittings, armatures, plug screws, etc. used. Adapt the tightening
torques to the material of the power brake valve component (see Table 5 "Material
specifications" on page 26).
In addition, keep in mind that tightening torques may also depend on the admissible
pressure and temperature range and on the application conditions.
Procedure Connecting the power brake valve to the hydraulic system:

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

Assembly 31/52
7.5.8 Electrically connecting the power brake valve
NOTICE
Functional impairment caused by wrong plug-in connections!
Only the plug-in connections listed in the data sheet/quotation drawing may be
used for the electrical connection.
▶▶ Comply with the assembly instructions of the plug-in connection manufacturer.
▶▶ Before commissioning, check the power supply as to whether the voltage com-
plies with the details of the quotation drawing and whether the total of the cur-
rents to be expected is less than or equal to the capacity of the power supply.
▶▶ The plug-in connections may only be contacted when deenergized. The installa-
tion process must not be repeated more than 10 times.
The machine manufacturer is responsible for the design of the electric control.
Electrically controlled power brake valves have to be connected according to the
electric circuit diagram of the machine.
Regarding power brake valves with electric adjustment device and/or attachment
sensors, observe the specifications in the data sheet and the quotation drawing, e.g.:
•• The admissible voltage range
•• The admissible current
•• The correct pin assignment
For details on the correct connection assignment, the connector, the protection
class, and the matching mating connector, see the data sheet and the quotation
drawing. The mating connector is not included in the scope of delivery.
1. De-energize the plug-in connections of the power brake valve.
2. Connect the power brake valve to the electrical system (12 V or 24 V). Prior to
connection, check that the connector and all its seals are intact.
Changing the connec- If required, change the position of the connector by turning the solenoid body (coil).
tor position This does not depend on the connector model.
Proceed as follows:
2
1. Loosen the mounting nut (1) of the solenoid using a suitable tool. For this pur-
pose, turn the mounting nut (1) by one turn in counterclockwise direction.
1
2. Turn the body of the solenoid (2) to the desired position.
3. Re-tighten the mounting nut. Tightening torque of the mounting nut: 4+1 Nm.

32/52 Commissioning
8 Commissioning
WARNING
Danger due to working in the danger zone of a machine!
Danger to life, risk of injury or severe injury!
▶▶ Pay attention to potential sources of danger of danger and remove them before
commissioning the power brake valve.
▶▶ When commissioning, comply with the instructions of the machine manufacturer.
CAUTION
Commissioning an incorrectly installed product!
Confusing the connections or cable connectors causes unexpected functions and/
or irreparable damage to the power brake valve and thereby endangers persons
and equipment.
▶▶ Make sure that all electrical and hydraulic connections are either connected cor-
rectly or closed.
▶▶ Prior to the functional test, check if the required piping was installed according
to the hydraulic circuit diagram.
▶▶ Check that the cable connectors are correctly assigned to the respective elec-
tric components.
▶▶ Commission the product only if it is installed completely.
Risk of injury due to enclosed air

Air enclosed in the power brake valve might cause components to vibrate during
operation so that they hit the end stops hard and are damaged. Unexpected move-
ments of the actuators may cause injuries.
▶▶ Prior to commissioning, make sure that any enclosed air is completely removed
from the power brake valve.
▶▶ Always observe the instructions on bleeding in the operating instructions of
the machine.
Impaired functionality due to low inlet pressure

If the inlet pressure is too low while commissioning the power brake valve, the built
up brake pressure is too low or it is built up too slowly.
▶▶ When commissioning or re-commissioning a machine, make sure that the power
brake valve is supplied with the required inlet pressure. This information is also
contained in the data sheet.

Commissioning 33/52
NOTICE
Impaired functionality resulting from a lack of pressure fluid
If the power brake valve is commissioned without or with too little hydraulic fluid,
the built up brake pressure is too low or it is built up too slowly.
▶▶ When commissioning or re-commissioning a machine, make sure that the power
brake valve is filled with hydraulic fluid and remains filled during operation. To
do so, observe the specifications of the machine manufacturer.
8.1 First commissioning
For all commissioning work on the power brake valve observe the general safety
instructions and the intended use in chapter 2 "Safety instructions" on page 9.
▶▶ Let the power brake valve acclimate itself for several hours before commissioning,
as otherwise water may condense in the housing.
▶▶ Make sure that all electrical and hydraulic connections are either used or covered.
Commission the power brake valve only if it is installed completely.
▶▶ Avoid temperature shocks. There may be no temperature differences of more
than 20 °C between the power brake valve and the pressure fluid. Otherwise,
there is a risk of jammed spools. With temperatures below –20 °C the power
brake valve has to be warmed up.
▶▶ Only use a hydraulic fluid that complies with the following requirements:
For information on minimum requirements for hydraulic fluids, see Table 1 "Re-
quired and amending documentation" on page 6.
Proceed as follows for the first commissioning of the power brake valve:
1. Ensure the hydraulic supply of the power brake valve.
2. Ensure the power supply of the power brake valve.
3. Check the electrical connections of the power brake valve.
Electrical connections must be checked for their proper condition by or under the
guidance and supervision of a specialized electrician before first commissioning
or any recommissioning.
Observe the operating instructions of the machine where the power brake valve
is installed.

34/52 Commissioning
4. Bleeding the power brake valve.

Prior to operation, slowly actuate the power brake valve several times in all direc-
tions of actuation under operating pressure. This expels any remaining air from
the power brake valve. Mechanical damage due to inadmissibly high acceleration
of the hydraulic fluid and the valve spool is thereby avoided and the service life of
the power brake valve is increased.
Also observe the instructions on bleeding in the operating instructions of the machine.
5. Leakage testing.
Check that no hydraulic fluid leaks at the power brake valve and at the connec-
tions during operation.
6. Functional testing.
The functional test must be made according to the specifications of the machine
manufacturer, see operating instructions of the machine.
In any case: Slowly increase pressure; stop the functional test immediately in case
of leakage!
7. Commission the power brake valve.
8. Check the operating temperature of the power brake valve after several hours
of continuous operation. Too high operating temperatures indicate errors which
must be analyzed and removed.
8.2 Re-commissioning after standstill

▶▶ Carry out re-commissioning as described in chapter 8.1 "First commissioning" on
page 33.
Also observe the instructions for (re-)commissioning after standstill in the

machine operating instructions.

Operation 35/52
9 Operation
WARNING
Impaired mechanical operation due to contamination or objects!
Danger to life, risk of injury, damage to property!
The power brake may block in an undefined position or its movability may be im-
paired due to external contamination or objects. As a result, the driven actuator is
no longer under the operator’s control.
▶▶ With power brake valves with mechanical operation, the movability and accessi-
bility of the operating elements (e.g. pedal, hand lever) always has to be en-
sured and must not be impaired or blocked due to contamination or objects.
▶▶ It must always be possible to set the power brake valve to the intended end
position and back to the initial position.
No adjustments or modifications to the product are required during operation. As

a result, this chapter of the instructions does not contain any information on adjust-
ment options. Only use the product within the performance range provided in the
technical data. The machine manufacturer is responsible for the correct project plan-
ning of the hydraulic system and its control.

36/52 Maintenance and repair
10 Maintenance and repair
NOTICE
Delayed inspections and maintenance works!
Damage to property!
▶▶ Perform the prescribed inspections and maintenance works at the power brake
valve at the intervals specified in these instructions.
Also observe the instructions for maintenance and repair in the machine operat-
ing instructions.
10.1 Inspection
For reliable operation of the power brake valve, Bosch Rexroth recommends checking
it on a regular basis and recording and archiving the following operating conditions:
Table 7: Inspection plan
Work to be carried out at the power brake valve Interval

Check the operating temperature. Weekly
Hydraulic fluid analysis: Viscosity, time deterioration and contamination Annually or every 2000
operating hours
Check the power brake valve for external leakage (visual inspection). Daily
Check the power brake valve for strange noises. Daily
Check the mounting elements for tight fit. Monthly
All mounting elements have to be checked when the power brake valve
is depressurized, deenergized and cool.

Maintenance and repair 37/52
10.2 Maintenance
If used as intended, the power brake valve is low-maintenance.
The service life of the power brake valve decisively depends on the hydraulic fluid
quality. We therefore recommend exchanging the hydraulic fluid at least once a year
or every 2000 operating hours or to have it analyzed for further usability by the hy-
draulic fluid manufacturer or a laboratory.
Observe the following general rule:

From a hydraulic fluid temperature of >70 °C, the aging speed doubles with
every 10 °C temperature increase.
For the maximum admissible degree of contamination of the hydraulic fluid, see
the data sheet in chapter "Technical data".
Also observe the information on the hydraulic fluid in the operating instructions
of the machine.
10.3 Repair
Bosch Rexroth offers a wide range of repair services for the Rexroth power
brake valves.
The power brake valve may only be repaired by Bosch Rexroth certified service cen-
ters or by the machine manufacturer.
For questions regarding repair, contact your local Bosch Rexroth service or the
service department of the power brake valve manufacturer, see chapter 10.4 "Spare
parts" on page 38.

38/52 Maintenance and repair
10.4 Spare parts
CAUTION
Use of unsuitable spare parts!
Spare parts that do not meet the technical requirements specified by
Bosch Rexroth may cause personal injuries and damage to property.
▶▶ Exclusively use Rexroth original spare parts to repair the Rexroth power brake
valves. Otherwise, the function of the power brake valve is no longer ensured
and you lose your claim to warranty.
Regarding which power brake valves are covered in which spare parts list, see Table 1
"Required and amending documentation" on page 6.
Indicate the material and serial numbers of the power brake valve as well as the ma-
terial numbers of the spare parts when ordering spare parts.
In case of questions regarding spare parts, please contact your local Bosch Rexroth ser-
vice or the service department of the power brake valve manufacturer.
Bosch Rexroth AG
Zum Eisengießer 1
97816 Lohr am Main, Germany
Phone +49 (0) 93 52-18-0
[email protected]
For the addresses of our foreign subsidiaries, see

www.boschrexroth.de/adressen.

Disassembly and replacement 39/52
11 Disassembly and replacement
CAUTION
Stored energy in the hydraulic accumulators!
Danger to life, risk of injury, severe injury when working on pressurized machines!
▶▶ After decommissioning the overall system, the hydraulic accumulators may still
be pressurized. Ensure that the power brake valve is depressurized and deen-
ergized. In this regard, also observe the specifications in the operating instruc-
tions of the machine.
11.1 Required tools

Disassembly can be carried out with standard tools. No special tools are required.
11.2 Preparing for disassembly

1. Decommission the overall system as described in the machine operating instructions.
––Depressurize and unload the hydraulic system as described by the ma-
chine manufacturer.
––Ensure that the power brake valve is depressurized and deenergized.
2. Secure the overall system according to the manufacturer's instructions.
11.3 Disassembling the product

Proceed as follows to disassemble the power brake valve:
1. Let the power brake valve cool down until it can be disassembled without risks.
2. Make sure that no hydraulic fluid can escape unintentionally from the system due
to the disassembly of the power brake valve.
3. Place a clean collecting pan below the power brake valve to collect any escaping
residual hydraulic fluid.
4. Disconnect the lines and collect any escaping residual hydraulic fluid in the col-
lecting pan.
5. Remove the power brake valve according to the manufacturer's instructions.
6. Place the product on a clean, bearing surface.
7. Completely drain the power brake valve.
8. Close all openings.
11.4 Preparing the components for storage/further use

▶▶ Proceed as described in chapter 6.2 "Storing a power brake valve", section "Fol-
lowing disassembly" on page 23.

40/52 Disposal
12 Disposal
CAUTION
Spring preloaded components!
Risk of injury due to ejected components when the valve is disassembled into its
individual components!
▶▶ Slowly unscrew screwed-in parts and hold them in place.
Careless disposal of the power brake valve, the hydraulic fluid and the packaging
material may pollute the environment.
For the disposal of the power brake valve, comply with the following instructions:
1. Completely drain the power brake valve.
2. Dispose of the power brake valve and the packaging material in accordance with
the applicable national regulations in your country.
3. Dispose of the hydraulic fluid in accordance with the currently applicable national
regulations in your country.
4. Disassemble the power brake valve into its individual components in order to
recycle them.
5. Separate for example:
––Steel
––Aluminum
––Non-ferrous metal
––Electrical and electronic parts (solenoids, sensors, coils)
––Plastic
––Rubber (seals, bellows, pedal rubber)

Extension and modification 41/52
13 Extension and modification

Modifications to the power brake valve are not admissible. This includes changing
the set screws.
The Bosch Rexroth warranty applies only to the configuration supplied. Following
an extension or a modification, the claim to warranty expires.
Adjusting the set screws causes the claim to warranty to expire. If you require the
settings to be adjusted, contact your local Bosch Rexroth service. For the ad-
dress, see chapter 10.4 "Spare parts" on page 38.
Optional accessories For available accessories, see the respective data sheet.
Accessories are available from your Rexroth specialist dealer. For addresses of our
foreign subsidiaries, see www.boschrexroth.de/adressen.

42/52 Troubleshooting
14 Troubleshooting
Use Table 8 for troubleshooting. This table is not exhaustive.
In practice, there may be problems that are not included here.
14.1 How to proceed for troubleshooting

▶▶ Work systematically and in a targeted way.
▶▶ First get a general idea of how your product works in conjunction with the over-
all system.
▶▶ Try to find out whether the product has worked properly in conjunction with the
overall system before the error occurred.
▶▶ Try to determine any changes of the overall system into which the product is integrated:
––Were the product's operating conditions or its area of application changed?
––Was any maintenance work performed? Is there an inspection or mainte-
nance record?
––Were modifications (e.g. refittings) or repair works done on the overall system
(machine, electrics, control) or on the product?
––Was the hydraulic fluid changed?
––Was the product or machine used as intended?
––How did the fault become apparent?
▶▶ Try to get a clear idea of the cause of the error. If necessary, ask the actual (ma-
chine) operator.
▶▶ Document all work done.
▶▶ For support, see: www.boschrexroth.de/adressen.

Troubleshooting 43/52
14.2 Fault table

The power brake valve is not sensitive to faults if the specified operating conditions
are met, particularly the quality of the hydraulic fluid and the maximum admissible
pressure values.
Table 8: Fault table - power brake valve in general
Fault Possible causes Remedy
Hydraulic fluid leaks from the power The plug screws and/or reducing Carefully tighten the plug screws until they
brake valve pieces leak fit tightly.
If leakage persists:
Check the sealing surfaces/seals for damages
and dirt.
If required, disassemble the power brake valve
and replace it by a new one.
The brake valve housing leaks Disassemble the power brake valve and re-
place it by a new one.
The line connections (fittings) leak Check seals and replace the fittings, if neces-
sary. Check the tightening torque, see infor-
mation of the fitting manufacturer.
Disassemble the power brake valve and re-
Screw-in cartridge valve leaks Tighten the screw-in cartridge valve applying
the prescribed torque.
and dirt.
If required, replace the screw-in cartridge
valve or disassemble the power brake valve
and replace it by a new one.
The bleed screw leaks Tighten the bleed screw applying the pre-
scribed torque.
and dirt.
If required, replace the bleed screw or disas-
semble the power brake valve and replace it
by a new one.
The actuation leaks Carefully tighten until it fits tightly.
The control spool cannot be con- The hydraulic fluid temperature is too Take external measures to ensure the hydrau-
trolled mechanically high and/or the temperature difference lic fluid temperature.
between the hydraulic fluid and the valve Avoid a temperature shock.
housing is too high, this causes the spool
valve and valve housing to block as a re-
sult of different thermal expansion
Dirt or foreign matter that entered dur- Rinse the power brake valve.
ing installation or connection jam the Make sure the hydraulic fluid is clean.
control spool If the fault persists:
The control spool does not reset or resets The control spool jams See "The control spool cannot be con-
too slowly trolled mechanically".

Table 8: Fault table - power brake valve in general

The temperature at the power brake valve The ambient temperature is too high System-related; remedy by means of exter-
is too high nal measure.
The hydraulic fluid temperature is Decrease the hydraulic fluid temperature.
too high
The flow is too large Reduce the flow.
Not functional or malfunctioning The power brake valve is Correct the hydraulic connections.
connected incorrectly
An electric component is Correct the electrical connections.
connected incorrectly
No pressure supply Ensure the hydraulic fluid supply.
There is dirt or foreign matter in the Make sure the hydraulic fluid is clean.
power brake valve or system
No energy supply Ensure the energy supply.
An actuating element does not function Check the actuation element.
or is incorrectly mounted
The following system error descriptions and remedies serve only for additional
support.
Table 9: Fault table - hydraulic system

Hydraulic fluid leaks from the lines lead- The piping or hose assemblies are damaged Replace piping or hose assemblies.
ing to the power brake valve The piping or hose assemblies are loose Tighten the fittings applying the pre-
scribed tightening torque according to
the applicable assembly instructions of
the manufacturer.
The accumulator charging valve does not The control spool is blocked by dirt Replace the accumulator charging valve
switch off There are flow and pressure fluctuations at Measure the speed, flow and pressure at
port P, the flow of the pump is insufficient measuring point P01, see chapter 14.3.
Internal leakage at the downstream compo- Deactivate the downstream components
nents after ports S1 and S2 and/or internal one after another and localize the damaged
leakage at port X (LS port) is too high part. Replace the defective component.
The accumulator charging valve is of- The accumulator capacity is too low or the Check the accumulator, check the proj-
ten activated accumulator is defective ect planning.
The displacement of the brake cylinders is too Check the design, increase the accumulator
large compared to the accumulator capacity capacity, if required.
The hydraulic function is impaired There is air in the hydraulic fluid and Bleed the hydraulic system, see page 34.
the system
Unusual noise There is air in the hydraulic fluid Avoid aeration. Bleed the hydraulic system,
see page 34.
Change the tank array.
Flow noise The line cross-sections are too small with Increase the nominal width of the hydraulic
high flow lines and avoid narrow curves and small
bending radiuses.
Vibrations Pressure fluctuations in the system Bleed the hydraulic system, see page 34.
There is dirt or foreign matter in the system Make sure the hydraulic fluid is clean.

Table 9: Fault table - hydraulic system

The brake pressure builds up too The accumulator capacity is too low or the Check the accumulator, check the proj-
slowly or the required brake pressure is accumulator is defective ect planning.
not reached The displacement of the brake cylinders is too Check the design, increase the accumulator
large compared to the accumulator capacity capacity, if required.
The hydraulic lines are too long and/or the Take measurements at measuring
cross-section is too small points P06, P07, P08 and P09 and replace
the hydraulic lines, if required.
The pedal actuation is impaired Check the pedal movement and restore free
pedal actuation.
The control spool jams See "The control spool cannot be con-
trolled mechanically".
The hydraulic fluid temperature is too low, Comply with the correct viscosity range,
viscosity is too high see data sheet.
The brake pressure decreases too slowly, The hydraulic lines are too long and/or the Take measurements at measuring
brake pressure remains cross-section is too small points P06, P07, P08 and P09 and replace
the hydraulic lines, if required.
The pedal actuation is impaired Check the pedal movement and restore free
pedal actuation.
The control spool jams See "The control spool cannot be con-
trolled mechanically".
The number of required decelerations is The accumulator capacity is too low Check the accumulator, check the proj-
not reached The accumulator is too small or defective ect planning.
The brake gets hot, drags, cannot be com- The return flow from the brake cylinder to Take a measurement at measuring point P10.
pletely released the tank is impaired, the tank pressure is
too high
The pedal does not return to the initial position Check the mechanical system and the area
around the pedal.
The accumulator warning light The pressure switch is defective or cho- Check the pressure switch.
keeps iluminating sen incorrectly
The accumulator capacity is too low Check the accumulator, check the proj-
The accumulator is too small or defective ect planning.
The spring-loaded accumulator parking The parking brake valve (hand brake valve) Take a measurement at measuring
brake cannot be released generates no pressure on the spring-loaded point P13 and compare it to the specifica-
accumulator parking brake tions of the brake manufacturer.
The accumulator for the parking brake is Check the accumulator, check the proj-
too small or defective ect planning.
The electric actuation of the PBS is insuf- Check the power supply, check the plug-in
ficient, the power supply is interrupted or connections for contact and tight fit. Re-
the coil is defective place the coil, if required.
Following faults due to contamination, it is - in addition to the repair - essential to

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

14.3 Suggestion for measuring points
6 P18
P11
8
12
P16
10
P12 P13
P02 P03
2 P08A 13
3 5
9
N
S
P P08B
6 P06 P10
4
P01 1 14
P14 7
P09A 13
P04
11
P17
P09B
P15 P05 P07
Fig. 7: Schematic illustration of an example application with modular design with suggestions
for measurement points
1 Pump 6 Hydraulic accumulator 10 PBS pressure switch

2 Accumulator charging valve LT 06 7 2 circuit power brake 11 SBS pressure switch
3 Check valve valve LT 07 12 PBS spring-loaded accumulator cylinder
4 Pressure switch, accumulator pressure 8 Hand brake valve LT 08 13 Brake cylinder (wheel)
5 Inverted shuttle valve 9 Brake pedal 14 Downstream actuators
Table 10: Measuring point for modular design
No. Measuring point Connection

P01 Accumulator charging valve P
P02 Accumulator charging valve N
P03 Accumulator charging valve S
P04 Brake valve SP1
P05 Brake valve SP2
P06 Brake valve BR1
P07 Brake valve BR2
P08 Brake cylinder, 1st circuit, front axle
P09 Brake cylinder, 2nd circuit, rear axle
P10 Brake valve T
P11 Hand brake valve S
P12 Hand brake valve B
P13 PBS spring-loaded accumulator cylinder
P14 Accumulator pressure switch, no. 4
P15 SBS pressure switch, no. 12
P16 PBS pressure switch, no. 11
P17 Pump speed
P18 Hand brake valve T

9 P13
3
P12
4 4 4
P05 P11 P04
2 P16
S2 S3 BR3 S1
P15 5
BR2
BR1
6
8 T
P09 P07
P N
1 10
7
P08 P01 P14 P02 P10 P06
P17
Fig. 8: Schematic illustration of an example application with compact design with suggestions
for measurement points
1 Pump 4 Hydraulic accumulator 8 Brake cylinder (wheel)

2 2 circuit power brake 5 PBS pressure switch 9 PBS spring-loaded accumu-
valve LT 13 6 SBS pressure switch lator cylinder
3 Brake pedal 7 Pressure switch, accumula- 10 Downstream actuators
tor pressure
Table 11: Measuring points for compact design
No. Measuring point Connection

P01 Brake valve P
P02 Brake valve N
P03 –
P04 Brake valve S1
P05 Brake valve S2
P06 Brake valve BR1
P07 Brake valve BR2
P08 Brake cylinder, 1st circuit, front axle
P09 Brake cylinder, 2nd circuit, rear axle
P10 Brake valve T
P11 Brake valve S3
P12 Brake valve BR3
P13 PBS spring-loaded accumulator cylinder
P14 Accumulator pressure switch, no. 7
P15 SBS pressure switch, no. 6
P16 PBS pressure switch, no. 5
P17 Pump speed

48/52 Technical data
15 Technical data
For the admissible technical data of the power brake valves, see the respective data
sheet. Regarding which power brake valves are covered in which data sheets, see
Table 1 "Required and amending documentation" on page 6.
The data sheets are available on the Internet at

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

Mobile hydraulics: www.boschrexroth.de/mobilhydraulik-katalog
The order-specific technical data of your power brake valve are available in the or-
der confirmation.

Alphabetical index 49/52
16 Alphabetical index
▶▶ A ▶▶ O
Accessories 41 Operation 35
▶▶ B ▶▶ P
Bleeding Power brake valve
–– Hydraulic system 34 –– Disassembling 39
–– Extension and modification 41
▶▶ C –– Fastening 26
Commissioning 32 –– Installing 26
–– First commissioning 33 –– Painting 24
Connecting –– Storing 22
–– electrically 31 –– Transporting 22
–– hydraulically 28
Corrosion protection 22 ▶▶ Q
Qualification of personnel 10
▶▶ D
Disassembly 39 ▶▶ R
–– Disassembling 39 Re-commissioning
–– Preparing 39 –– After standstill 34
Disposal 40 Required documentation 6
▶▶ E ▶▶ S
External leakage 36 Safety instructions
–– General 10
▶▶ H –– Product-specific 11
Hydraulic fluid 33 –– Signal word 7
–– Disposal 40 Scope of delivery 17
Solenoid position
▶▶ I –– Changing 31
Identification 21 Spare parts 38
Inspection and maintenance 21 Storage 22
–– Inspection 21 Symbols 8
–– Maintenance 21
–– Repair 21 ▶▶ T
Installation conditions 25 Technical data 48
Intended use 9 Tools 26, 39
Transport 22
▶▶ M Troubleshooting 42
Maintenance and repair 36 –– Fault table 43
–– Maintenance 37
–– Repair 37 ▶▶ U
Unpacking 24
▶▶ N
Name plate 21 ▶▶ W
Warranty 16, 23, 41

50/52 Alphabetical index

51/52

Bosch Rexroth AG
Mobile Applications
Zum Eisengießer 1
97816 Lohr am Main
Germany
Phone: +49 93 52 18-0
[email protected]
www.boschrexroth.com
Your local contact person can be found at:

www.boschrexroth.com/addresses
Subject to change without notice

Printed in Germany
RE 66200-B/04.2013

Operation Power Brake Valve

Uploaded by

Document Informationclick to expand document informationOperation Power Brake Valve maybe app Brake valve for PW150ES-6K

Document Informationclick to expand document information

Copyright:

Available Formats

Operation Power Brake Valve

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Operation Power Brake Valve

Uploaded by

Copyright:

Available Formats

Hydraulic power brake valves

for mobile applications

Applies to the following types:

© This document, as well as the data, specifica-

The cover shows an example configuration. The

The original operating instructions were pre-

RE 66200-B/04.2013, LT, Bosch Rexroth AG

Bosch Rexroth AG, LT, RE 66200-B/04.2013

1 About this documentation

1.1 Validity of the documentation

This documentation is aimed at the machine manufacturer.

RE 66200-B/04.2013, LT, Bosch Rexroth AG

1.2 Required and amending documentation

Table 1: Required and amending documentation

Further information is available from Rexroth and at

Bosch Rexroth AG, LT, RE 66200-B/04.2013

1.3 Representation of information

1.3.1 Safety instructions

Safety instructions are set out as follows:

•• Warning sign: Draws attention to the danger

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

Warning sign, signal word Meaning

RE 66200-B/04.2013, LT, Bosch Rexroth AG

Table 3: Meaning of the symbols

▶▶ Individual, independent action

Bosch Rexroth AG, LT, RE 66200-B/04.2013

2.1 General information on this chapter

2.2 Intended use

The power brake valve is no safety equipment.

2.3 Improper use

RE 66200-B/04.2013, LT, Bosch Rexroth AG

2.4 Qualification of personnel

2.5 General safety instructions

Bosch Rexroth AG, LT, RE 66200-B/04.2013

2.6 Product-specific safety instructions

The following safety instructions apply to chapters 6 to 14.

Leaking oil mist!

RE 66200-B/04.2013, LT, Bosch Rexroth AG

Danger due to heavy loads!

Risk to limbs due to crushing and impact!

The power brake valve has hot surfaces!

Contact with hydraulic fluid!

Bosch Rexroth AG, LT, RE 66200-B/04.2013

Escaped hydraulic fluid due to leakage!

2.7 Personal protective equipment

▶▶ Wear heat-resistant protective clothing, e.g. protective gloves, when touching

RE 66200-B/04.2013, LT, Bosch Rexroth AG

3 General information on damage to prop-

The following safety instructions apply to chapters 6 to 14.

If the power brake valve falls down

Bosch Rexroth AG, LT, RE 66200-B/04.2013

Environmental pollution caused by incorrect disposal!

Leaking or spilt hydraulic fluid!

RE 66200-B/04.2013, LT, Bosch Rexroth AG

The warranty only applies to the delivered configuration.

Bosch Rexroth AG, LT, RE 66200-B/04.2013

5 About these products

5.1 Performance description