Manual de Reparacion MCR Serie 41

Radial Piston Motor MCR-R
Series 41
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S033
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Repair Manual
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RE 15223-S033/07.15
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MCR-R Series 41 ‫ ׀‬RE 15223-S033/07.15 Bosch Rexroth Ltd 2/ 32
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The data specified above only serve to describe the
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product. No statements concerning a certain
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condition or suitability for a certain application can
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be derived from our information. The information
given does not release the user from the obligation
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of own judgment and verification. It must be
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remembered that our products are subject to a
natural process of wear and aging.
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© This document, as well as the data, specifications
and other information set forth in it, are the exclusive
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property of Bosch Rexroth Ltd.
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It may not be reproduced or given to third parties
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Dwithout its consent.
The cover shows an example application. The

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product delivered may differ from the image on the

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cover.
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The original operating instructions were created in

the English language.
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Contents
1. About this Manual .................................................................................................. 4
1.1. Contents........................................................................................................................4
1.2. Validity of this Manual ..................................................................................................5
1.3. Important Documents ..................................................................................................5
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1.4. Hazard Identification and Pictograms...........................................................................6
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2. Safety ..................................................................................................................... 7
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2.1. Basic Safety Information ...............................................................................................7
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2.2. Requirements of Personnel ..........................................................................................9
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2.3. PPE ................................................................................................................................9
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3. About this Product.................................................................................................. 10
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3.1. Identification.................................................................................................................10
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3.2. Motor Variants..............................................................................................................10
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3.3. Functional Description ..................................................................................................11
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4. Repair Procedure .................................................................................................... 13
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4.1. Parts within Rotary Group and Cam Sub Assembly ......................................................13
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4.2. Parts within Rear Case Sub Assembly ...........................................................................17

4.3. Individual Seals within Motor .......................................................................................21
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5. Disposal................................................................................................................... 24
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5.1. Disposal .........................................................................................................................24

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5.2. Environmental Protection.............................................................................................24

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6. Tightening Torques .................................................................................................. 24

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7. Maintenance ........................................................................................................... 25
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7.1. Cleaning and Care .........................................................................................................25

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7.2. Inspection .....................................................................................................................26

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7.3. Maintenance .................................................................................................................26

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8. Troubleshooting ...................................................................................................... 27
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9. Technical Data ......................................................................................................... 29

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10. Appendix ............................................................................................................... 29

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10.1 Spare Parts ...................................................................................................................29

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10.2 General Tools List.........................................................................................................29

10.3 Special Tools List ..........................................................................................................29
10.4 Oil and Grease Specification ........................................................................................30
11. Full Motor - Exploded View .................................................................................... 31
12. Contact Details ...................................................................................................... 32
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1. About this Manual
1.1. Contents
This manual supports the repair, adjustment and re-commissioning of Rexroth MCR-R radial
piston motors. The manual is structured as follows:
• “Safety” on Page 7
Provides basic hints and tips regarding working with and operating radial piston motors.
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Read this chapter before you start working.
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• “About this Product” on Page 9
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Explains how to identify the radial piston motor as well as displaying the range of motor
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variations as manufactured by Bosch Rexroth. Additionally, it provides an overview
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about how the radial piston motor works and information regarding the correct usage.
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Read this chapter to refresh your knowledge of the radial piston motors.
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• “Repair Procedure” on Page 12
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Explains how to replace externally mounted/accessible items of the radial piston motor
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which do not require the opening of the main operational part.
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• “Disposal” on Page 23
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Recommendations on disposal of old or obsolete parts in a responsible method with
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guidelines on Environmental Protection and awareness.
• “Tightening Torques” on Page 23 PA

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An overview of the tightening torques, which have to be regarded for reassembly of the
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radial piston motor.

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• “Maintenance” on Page 24
Explains the procedures of maintaining cleanliness and regular inspection of the radial
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piston motor once it is installed in the system.

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• “Troubleshooting” on Page 26
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An overview of radial piston motor fault analysis.

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• “Technical Data” on Page 28

Explains where to find technical data for the radial piston motors.
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• “Appendix” on Page 28
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Refers to various helpful specifications.

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• “Full Motor – Exploded View” on Page 30

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Illustrates the exploded view of the full motor, as referred to in the repair procedure.
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• “Contact Details” on Page 31

Refers to company contact information.
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1.2. Validity of this Manual

This manual is valid for the Bosch Rexroth radial piston motors MCR-R Series 41. Refer to the
system manufacturer for information about the suitable hydraulic fluids. This repair manual is
intended for use by:
• The system operator
• Authorised dealers
• The system manufacturer
For the system manufacturer, the installation drawing, the data sheet and the operating
instructions from Bosch Rexroth are also obligatory.
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1.3. Important Documents
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Before starting any of the procedures described in this manual, make sure the following
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documents are to hand:
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Assembly Drawing
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0B
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Contains the cross section with components numbered in conjunction with the parts list,
1B
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assembly instructions for your MCR-R radial piston motor.
Installation Drawing
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2B
Contains the outer dimensions, all connections and the hydraulic circuit diagram for your
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3B
MCR-R radial piston motor.
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RE 15223: Technical Data Sheet
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Contains the permissible technical data for the MCR-R Series 41 radial piston motor.
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Parts List
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Contains the spare parts of a radial piston motor. The parts list along with the assembly
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drawing can be requested from Bosch Rexroth and be used to order spare parts.
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RE 15215-B: Operating Instructions

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Contains important information on the safe and correct assembly, transport, commissioning,
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maintenance, disassembly and simple troubleshooting of the radial piston motor MCR-R
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Series 41.
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The following Rexroth publications provide additional information to the installation and
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operation of radial piston motors:

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RE 90220: Mineral-oil Based Hydraulic Fluids

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Describes the requirements of a mineral-oil based hydraulic fluid for operation with Rexroth
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units and assists in selecting a hydraulic fluid for your system.

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RE 90321: Instructions on the Use of Radial Piston Motors at Low Temperatures

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Contains additional information on the use of Rexroth radial piston motors at low temperatures.
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1.4. Hazard Identification and Pictograms

In this manual, there are safety instructions before any steps where there is a risk of personal
injury or damage to equipment. This manual differentiates between the following categories of
hazard:
Table 1: Danger classes in accordance with ANSI Z535.6-2006

Safety Sign Meaning
Identifies a dangerous situation that will result in death or
DANGER serious injuries if not avoided.
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Identifies a dangerous situation that may result in death
WARNING
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or serious injuries if not avoided.
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Identifies a dangerous situation that may result in minor
CAUTION
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to moderate injuries if not avoided.
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NOTICE
Damage to equipment: the product or the environment
may be damaged.
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The following symbols mark notes that are not safety related but which increase the
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understanding of the documentation.
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Table 2: Meaning of Symbols
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Symbol Meaning
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If this information is disregarded, the product can not be used and/or operated to
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the optimum extent.
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 Single, independent step

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1. Numbered instructions:
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2. The numbers specify that the steps are completed one after the other
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2. Safety
2.1. Basic Safety Information

Pay exact attention to the following safety information and that of the system manufacturer to
eliminate injuries and damage to health as well as damage to equipment or the environment.
DANGER
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Danger to Life!
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12B
Working on systems that have not been shut down is life-threatening.

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The work described in this document can only be carried out on a shut down system. Before
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you start any of the tasks:
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 Make sure that the motor cannot be switched on as the drive shaft rotates on supply of
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pressure.
 Make sure that all components and connections that carry energy (electrical, pneumatic,
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hydraulic) have been shut down according to the manufacturer’s instructions and cannot be
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switched on. If possible, disable the main fuse.
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 Make sure that the system is completely unpressurised. Follow the instructions of the
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system manufacturer.
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WARNING
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Danger of fire!
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Hydraulic fluid may be flammable (please consult the material safety data sheet).
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 Keep naked flames and any ignition sources away from the radial piston motor.
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Danger of poisoning or injuries!

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Contact with hydraulic fluids can cause health damage (e.g. eye injuries, skin and tissue
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damage, poisoning due to inhalation).

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When looking for leaks, escaping hydraulic fluid can break into the skin and cause serious
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poisoning and injuries.

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 Look only for leaks, if the radial piston motor is shut down and unpressurised.
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 Always check the hydraulic lines for wear and damage prior to putting the unit into
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operation.
 When checking the lines, wear protective gloves and safety glasses.
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 Should pressurised fluid come into contact with your eyes or skin: Get medical help
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immediately!
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 When handling hydraulic fluids, pay exact attention to the hydraulic fluid manufacturer’s
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safety instructions.
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Danger of injuries!
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Strong magnets used within Piston sub assemblies (MCR-R). Very high injury, malfunction of
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pacemakers, or similar devices, is possible due to magnetic fields.

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 People, who use pacemakers or similar devices, should not handle piston sub assemblies.
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CAUTION
Danger of injuries!
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To avoid injuries, pay attention to the following recommendations regarding safety clothing:
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 When working on the system, always wear steel-toed safety shoes and protective clothing.
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 When working with dangerous substances (for example, certain hydraulic fluids), wear
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protective gloves and protective glasses.

 Motors contain stored energy in the form of compressed springs and this must be released
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using the method specified in this manual.

 When lifting motors with a lifting device use slings/shackles/hooks/eyebolts rated for motor
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weight.
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Danger of burns!
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The radial piston motor heats up during operation. Fingers and hands can be badly burned
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when touching the radial piston motor.
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 Let the radial piston motor cool down prior to any contact.
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 Protect yourself from burns by wearing safety gloves and protective clothing.
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Danger of injuries or damage!
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Incorrectly connected components can considerably impair the functionality of a hydraulic
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system.
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 Make sure that the hydraulic lines are connected properly according to the wiring diagram.
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 Check the correct functioning of all components.

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 Maximum pressures, speeds and shaft loads applied to the motor shall not exceed the
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relevant data sheet limits. If in doubt, consult an authorised Rexroth agent.
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Danger to hearing!
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The noise emission produced by radial piston motors depends on speed, operating pressure
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and installation. During normal application conditions, over 70 dB (A) can be anticipated. This
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can lead to hearing damage.

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 Always use hearing protection when working in the vicinity of the radial piston motor during
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operation.
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NOTICE
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Danger to the environment!

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Hydraulic fluid is hazardous to waters.

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Hydraulic fluid leakage leads to pollution and contamination of the ground and ground water.
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 A suitable container for catching any hydraulic fluid must be placed under the radial piston
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motor.
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 Leaks must be cleaned up immediately.

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 National laws and regulations must be observed at all times. In Germany, hydraulic
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machines or systems are classified as “Systems for handling water-polluting substances for
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the purpose of the Federal Water Act (WGH)”. In this context please note especially §1 and
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§19 of the WHG (§19g, 19i, 19l).

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 • Further information is available in the Rexroth publications “Hydraulic Fluids Based on

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Mineral Oils and Related Hydrocarbons”, RE 90220, and “Fire-resistant and water-free
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hydraulic fluids (HFDR/HFDU)”, RE 90222.

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2.2. Requirements of Personnel

This repair manual is intended for use by qualified personnel with specialised hydraulics
knowledge who have attended a service training course at Rexroth.
Qualified personnel are defined as persons who have sufficient knowledge on the basis of
specialised training and experience, and are familiar with the relevant regulations, so that they
are able to;
• Judge the delegated tasks,

• Recognise possible dangers,
• Take the necessary measures for the elimination of dangers,
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• Know the possible health risks from hydraulic fluids,
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• And have the required repair and installation knowledge.
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Specialised hydraulics knowledge means that the personnel must:
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• Be able to read and completely understand hydraulic plans,
• Especially understand completely the procedures regarding the installed safety
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equipment,
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• And be familiar with the function and structure of hydraulic components.
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2.3. PPE
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Bosch Rexroth recommends an individual risk assessment be carried out on safety and
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environmental grounds in order to dictate the scope of PPE equipment best suited for the motor
repair. D
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3. About this Product
3.1. Identification
The radial piston motor can be identified with the label. The following example shows a label
from an MCR radial piston motor:
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Fig. 1: Label of an MCR motor
1 (Mark the parts)
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8 D 9
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Figure 1 - Rexroth Identification Tag

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Label
1 Manufacturer
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2 Customer Ident. Number (Optional)

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3 Motor Ident. Number

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4 Barcode Motor Ident. Number

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5 Motor Description
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6 Motor Serial Number

7 Barcode Serial Number
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8 Manufacture Date (yrWwk)

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9 Internal Plant Designation

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If there is no label on the rear case, the motor information can be located on the inside centre
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of the rear case. This information will include the Motor Ident. Number (6), Serial Number (6),
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Manufacture Date (8), and Internal Plant Designation (9).

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Additionally the Motor Serial Number (6) along with the Manufacture Date (8) is stamped on
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either the front case, rear case or the end cover of the radial piston motor. The Cam Ident.
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Number, along with the displacement, is stamped on the cam.

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3.2. Motor Variants

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For the MCR-R motors, there are currently only two motor variants, both of which follow the
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same overall design and size (MCR10). The main differences between these two motor
products are the motor’s displacement, and some smaller changes between the internal
designs (i.e. different type of stub shaft and rotary group used, as well as an additional spacer
fitted between the cylinder block and axle). Both of these differences are dependent on the
customer requirements. For continuity purposes, the MCR-10R (Part Number R921811862)
motor has been used as the reference motor in all diagrams in this manual.
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3.3. Functional Description

Before any inspection and repair procedures are conducted on our motors, it is essential that
you are knowledgeable of the motor’s overall structure and functionality. This chapter gives an
overview of the inner structure of our motors, their sub assemblies and mechanical process.
MCR-R Motor Overview – Cross Section
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Figure 2: Cross Sectional View of Motor

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1 Rear Case 2 Distributor

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3 Stub Shaft 4 Cylinder Block

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5 Piston 6 Magnet
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7 Roller 8 Cam Ring

9 Bell housing 10 Axle/Spindle
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The figure above shows the cross section of a fully assembled MCR-10R motor design and
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identifies key components. This demonstrates the inner layout of the motor when fully
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assembled onto the vehicle axle (9, 10) and can be used to help visualize the mechanical
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process description below.

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MCR-R Motor Overview – Mechanical Process
The radial piston motor converts hydrostatic energy into mechanical energy. With the axle (10)
in motion, the rotary group (4, 5, 6, 7) will rotate with the axle. Whilst in motion, hydraulic fluid is
directed through the axle (10) ports, and through the stub shaft (3) ports to the cylinder block
(4), via the flow distributor (2) through galleries. The radially arranged pistons (5) in the cylinder
bores face a pressure increase and perform, via rollers (7), stoke movement against the cam
ring (8). This additional movement of the rotary group follows in conjunction with the movement
created from the axle, creating additional torque.
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MCR-R Motor Overview – Sub Assemblies
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Figure 3: MCR-R Sub Assemblies with Cam Ring and Shipping Cover
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The figure above shows a partially exploded MCR-10R motor split into the two main sub
assemblies; Rear Case (which consists of the Rear Case and the Distributor Sub Assembly),
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and Rotary Group, as well as the Cam Ring and the Cam Shipping Cover. This demonstrates
the layout of the motor when partially disassembled and can be used as a reference when
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dealing with repair of sub assemblies within this manual. For continuity, all exploded diagrams
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used within this manual are taken from engineering drawings of an MCR-10R Motor. While very
small variations do exist between motors, the standard parts used within are consistent with
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each motor and numbered correspondingly on the Bill of Materials.

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For description of the entire motor functionality including details of sub assembly operation, see
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Bosch Rexroth MCR Operating Instructions.

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MCR-R Motor Overview – Fully Exploded

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See Chapter 11 “Full Motor – Exploded View”. This figure shows a fully exploded view of the
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complete MCR-R motor assembly. This can be used as a reference diagram when referring to
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separate sub assemblies within the motor. The numbered labels relate to the technical position
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of each part within the Bill of Materials as certified by Bosch Rexroth. Ensure the Bill of
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Materials and exploded diagram correspond to the motor under repair.

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All other exploded views of sub assemblies are included in each of their individual repair
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procedures.
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4. Repair Procedure
4.1. Parts within Rotary Group and Cam Sub Assembly

This section will detail the disassembly and assembly processes required in order to replace
individual parts within the Rotary Group Sub Assembly, including the Cam Ring. For entire
Rotary Group Sub Assembly and Cam Ring replacement, see the Bosch Rexroth Sub
Assembly Repair Manual for MCR-R motors. This section covers repair of the following parts:
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• Cylinder Block Disassembly
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• Piston Sub Assembly Disassembly
• Cam Ring Disassembly
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• Rotary Group Assembly
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The disassembly process required for each part will be detailed. The user should then refer to
the appropriate step, as guided, in the assembly process.
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Additional Jobs
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- Refer to Chapter 11 “Full Motor – Exploded View” for further reference.
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- Position motor with rear case facing downwards on bench.
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- Clean edges of plugs to remove dirt/debris.
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Service Products
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For all Service Products see Oil and Grease Specification section.
- Bondloc 542 D
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Safety Hazards and Notes
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It is recommended that any fastening bolts and screws are renewed if disassembled.
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 Rotate motor to allow excess hydraulic oil to drain from motor.

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 Make sure that no contaminants can enter the motor during removal and refitting of any
plugs.
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Special Tools
No special tooling is required.
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Figure 4: Rotary Group Sub Assembly – Exploded View

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14 Cylinder Block 14A Spacer

15 Roller 16 Piston
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16A Piston Ring 16B O-Ring

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17 Magnet 18 Retaining Ring

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19 Circlip 20 Cam Ring

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21 Rear Case S/A 32 O-Ring

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44 Socket Head Screw (M12x65) 45 O-Ring

49 Cam Shipping Cover 50 Hex Nut
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The design of the rotary group varies between motor types. If the motor accompanying this
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manual does not include retaining rings (18) and circlips (19) on the rotary group, then skip
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step 5 of 4.1.1. Cylinder Block Disassembly, and step 5 of 4.1.4.Rotary Group Assembly.
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If the rotary group does not include an additional spacer (14A), skip step 3 of 4.1.1. Cylinder
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Block Disassembly, and step 7 of 4.1.4. Rotary Group Assembly.

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4.1.1. Cylinder Block Disassembly

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1. Remove hex nuts (50) and cam shipping cover (49).

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2. Remove all socket head screws (44) and o-rings (45) from rear case (21) using suitable
tooling.
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3. Remove spacer (14A) from cylinder block (14).

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4. Lift cam ring (20) and remove o-ring (32). This will leave the cylinder block (14) sitting
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on the rear case (21). Remove cylinder block (14) from stub shaft (31).
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NOTICE
Be careful when handling the cylinder block (14), because any damage to the timing face can
cause performance issues.
5. Remove circlips (19), and retaining rings (18) from both sides of cylinder block (14).
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WARNING
Due to the strong magnetic field, people with pacemakers or similar devices are not allowed to
handle the piston sub assemblies.
 Before using the air gun, cover the pistons with a cloth to catch the pistons, preventing any
further damage.
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6. Using an air gun, remove pistons (16) from cylinder block (14).
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7. Separate rollers (15) from piston sub assemblies and check all components for
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wear/damage. Any worn or damaged components must be replaced. If replacement is
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required, discard parts and source replacements.
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8. See Step 1 of Rotary Group Assembly section. Ignore any assembly steps which detail
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components that are already assembled. Instead, insert assembled component as
instructed.
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4.1.2. Piston Disassembly
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1. Repeat Cylinder Block Disassembly process up to and including Step 7.
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2. See Step 1 – 4 of Rotary Group Assembly section. Ignore any assembly steps which
detail components that are already assembled. Instead, insert assembled component
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as instructed.
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4.1.3. Cam Ring Disassembly D
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1. Repeat Cylinder Block Disassembly process up to and including Step 2.
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2. Lift cam ring. Remove o-ring (32) and check all components for wear/damage. Any
worn or damaged components must be replaced. If replacement is required, discard
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parts and source replacements.

3. See Step 7 – 8 of Rotary Group Assembly section. Ignore any assembly steps which
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detail components that are already assembled. Instead, insert assembled component
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as instructed.
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4.1.4. Rotary Group Assembly

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1. Position cylinder block (14) upright with timing face pointing toward or away.
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WARNING
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Due to the strong magnetic field, people with pacemakers or similar devices are not allowed to
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handle the piston sub assemblies.

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2. Insert piston o-ring (16B) into piston stem groove. Insert piston ring (16A) over o-ring.
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3. Insert rollers (15) into piston sub assemblies (16) by sliding roller into piston seat.
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4. Insert roller and piston sub assemblies into cylinder block (14) bores.
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Notice orientation of piston ring on piston stem. When placing into cylinder block bores,
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ensure that piston ring openings face left and right, or “9 o’clock” and “3 o’clock”, in
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alternate bores. This distributes any hydraulic leakage in an even manner around the
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cylinder block assisting in motor balance and even flow of leakage.
5. Place retaining rings (18), and circlips (19) onto both sides of cylinder block (14). These
will hold rollers in place during operation.
6. Place cylinder block (14) onto stub shaft (31).
7. Fit spacer (14A) onto cylinder block.
8. Place new o-ring (32) onto cam ring (20), ensuring it is secured in place and evenly
along the circumference.
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Be careful of orientation of cam ring with respect to rear case. Check the appropriate
General Assembly Drawing for correct orientation.
9. Place the cam ring onto the rear case (21), paying attention to correct orientation.
 Before applying any Bondloc, make sure there is no excess Bondloc left. Clean out any
excess found.
10. Apply Bondloc 542 to thread of socket head screw (46) holes on rear case. Insert
socket head screws (46) and torque as specified in appropriate General Assembly
Drawing.
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11. Insert and tighten opposite pair of socket head screws (44) in turn, to the correct torque
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as specified in appropriate General Assembly Drawing.
IT
12. Place cam shipping cover (49) over cam ring, aligning holes with exposed screws (44),
M
and tighten hex nuts (50) on exposed screws.
R
PE
12 of the socket head screws (44) are fitted wrong way round for transportation purposes
only, as shown in the exploded view above and chapter 11 “Full Motor – Exploded View”.
T
O
N
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FI
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13.07.2015
4.2. Parts within Rear Case Sub Assembly

individual parts within the Rear Case Sub Assembly. For entire rear case sub assembly
replacement, see the Bosch Rexroth Sub Assembly Repair Manual for MCR-R motors. This
section covers repair of the following parts within the rotary group:
• Rear Case Disassembly

• Flushing Sub Assembly Disassembly
!
• Check Valve Disassembly
D
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• Rear Case Assembly
IT
M
R
PE
T
Additional Jobs
O
- Refer to Chapter 11 “Full Motor – Exploded View” for further reference.
N
- Position motor with rear case facing downwards on bench.
IS
- Clean edges of plugs to remove dirt/debris.
ES
Service Products
TI
For all Service Products see Oil and Grease Specification section.
R
PA
- Bondloc 542
D
IR
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TO

N
O
plugs.
G
IN
Special Tools
SS
No special tooling required for this procedure.

PA
–
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Figure 5: Rear Case Sub Assembly – Exploded View

TH
TO
21 Rear Case 22 Distributor

23 Stop Pin Plug 24 Distributor Spring
N
25 Flushing Spool Plug 26 O-Ring

O
27 Distributor Seal 28 Distributor Seal

G
29 Distributor Seal 31 Stub Shaft

IN
33 Check Valve Poppet 34 Check Valve Spring

SS
35 Break-off Plug 36 Check Valve Plug

37 O-Ring 44 Socket Head Screw (M12x65)
PA

–
47 O-Ring 48 Motor Label (Optional)

T
351 Flushing Spool 352 Flushing Spool Spring

EN
353 Flushing Spool Washer 354 Flushing Poppet Shim

355 Flushing Poppet 356 Flushing Poppet Spring
M
357 Flushing Poppet Plug 358 O-Ring

C
O
D
4.2.1. Rear Case Disassembly

AL

TI
EN
tooling.
D
FI
Take note of orientation of cam ring with respect to rear case. This orientation must be exactly
N
the same when re-assembling the motor. For assembly orientation, refer to the appropriate
O
General Assembly Drawing.

C
3. Lift cam ring (20) and remove cylinder block (14) from rear case.
4. Lift distributor (22) with stub shaft (31). Remove distributor springs (24).
 Take note of which pockets are occupied with distributor springs (24).
5. Remove stub shaft (31) from distributor (22), and remove distributor seals (27, 28, 29)
from shaft.
6. Position rear case facing upwards and remove stop pin plugs (23) with o-rings (37).
13.07.2015
7. Check all components for wear/damage. Any worn or damaged components must be
replaced. If replacement is required, discard parts and source replacement.
8. See Step 1 of Rear Case Assembly Section. Ignore any steps which detail components
that are already assembled. Instead, insert components as instructed.
4.2.2. Flushing Sub Assembly Disassembly
1. Repeat to Step 6 of Rear Case Disassembly process. This includes the separation of
the stub shaft (31) from the distributor (22).
2. Remove flushing spool plug (25), with o-ring (26), from distributor.
3. Remove flushing spool springs (352), washer (353) and spool (351).
4. Remove flushing poppet plug (357), with o-ring (358), from distributor.
!
D
5. Remove flushing poppet spring (356), shim (354) and poppet (355).
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IT
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R
PE
4.2.3. Check Valve Disassembly
T
O
1. Repeat to Step 6 of Rear Case Disassembly process. This includes the separation of
N
the stub shaft (31) from the distributor (22).
IS
2. Remove check valve plugs (36), with o-rings (37), from both sides of distributor.
ES
3. Remove check valve poppets (33) and springs (34).
TI
R
PA
D
IR
4.2.4. Rear Case Assembly

TH
1. Insert first flushing spool spring (352), followed by flushing spool (351), then flushing
TO
spool washer (353) and second flushing spool spring (352). Insert assembled
components into corresponding flushing bore.
N
2. Insert flushing spool plug o-ring (26) on to flushing spool plug (25).
O
3. Insert flushing spool plug into distributor (22) and torque as specified in appropriate
G

IN
4. Insert flushing poppet shim (354) on to flushing poppet (355), followed by flushing
SS
poppet spring (356). Insert assembled components into corresponding flushing pocket.
PA
5. Insert flushing poppet plug o-ring (358) on to flushing poppet plug (357).
6. Insert flushing poppet plug into distributor (22) and torque as specified in appropriate
–

T
7. Insert o-ring (37) onto check valve plug (36), followed by check valve poppet (33), then
EN
check valve spring (34) onto check valve plug.

M
8. Insert check valves into corresponding bores of distributor (22) and torque as specified
C
in appropriate General Assembly Drawing.

O
9. Insert distributor seals (27, 28, 29) to stub shaft (31) and insert shaft into distributor
D
(22).
AL
10. Insert distributor springs (24) into distributor (22) in the provided pockets, and move
TI
distributor to side.
EN
11. Position motor facing upwards and insert stop pin plugs (23), with o-rings (37), into rear
case. Torque stop pins as specified in appropriate General Assembly Drawing.
D
12. Position rear case facing downwards. Lift distributor and stub shaft together into rear
FI
case (21), aligning stop pins (23) with stop pin pockets on distributor.
N
O
C
Be careful of distributor orientation with respect to rear case. Top hole of distributor should
align with top slit of rear case. Refer to appropriate General Assembly Drawing for correct
orientation.
13. Place cylinder block (14) onto stub shaft (31).

13.07.2015
14. Place o-ring (32) onto cam ring, ensuring it is secured in place and evenly along the
circumference.
Be careful of cam ring orientation with respect to rear case. Refer to appropriate General
Assembly Drawing for correct orientation.
15. Place the cam ring onto the rear case (21), paying attention to correct orientation.
Before applying any Bondloc, make sure there is no excess Bondloc left. Clean out any
excess found.
!
D
TE
IT
16. Apply Bondloc 542 to thread of socket head screws (46) holes on rear case. Insert
M
socket head screws (46) and torque as specified in appropriate General Assembly
R
Drawing.
PE
17. Insert and tighten opposite pair of socket head screws (44) in turn, to the correct torque
as specified in the General Assembly Drawing.
T
18. Place cam shipping cover (49) over cam ring, aligning holes with exposed screws (44),
O
N
and tighten hex nuts (50) on exposed screws.
IS
12 of the socket head screws (44) are fitted wrong way round for transportation purposes
ES
only, as shown in chapter 11 “Full Motor – Exploded View”.
TI
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13.07.2015
4.3. Individual Seals within Motor

individual seals within the motor. The following are included:
• Cam O-Ring (32)

• Distributor Seals (27, 28, 29)
!
D
TE
Additional Jobs
IT
- See Chapter 11 “Full Motor – Exploded View” for further reference.
M
- Clean edges of exposed plugs/screws to remove any dirt/debris
R
- Bleed hydraulic fluid from system
PE
Service Products
T
For reassembly of individual seal repairs, references are made to previously described
O
N
assembly processes. When referred, please use corresponding service products as listed in
that section.
IS
ES
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D
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plugs.
TH
TO
Special Tools
For reassembly of individual seal repairs, references are made to previously described
N
O
assembly processes. When referred, please use corresponding special tools as listed in that
section.
G
IN
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Figure 6: Individual Seals – Exploded Views

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15 Rotary Group S/A 20 Cam Ring

TO
21 Rear Case 22 Distributor S/A

23 Stop Pin 27 Distributor Seal
N
O
28 Distributor Seal 29 Distributor Seal

31 Stub Shaft 32 O-ring
G
IN

SS
47 O-Ring 49 Cam Shipping Cover

PA
50 Hex Nut
–
4.3.1. Cam Ring Seal Repair

T
EN

M
C
tooling.
O
D
3. Lift cam ring (20) and remove o-ring (32).

4. Check all dismantled components for wear/damage. Any worn or damaged
AL
components must be replaced. If replacement is required, discard parts and source

TI
replacements.
EN
5. See Step 7 onwards in the Rotary Group Assembly section. Ignore any assembly steps
D
which detail components that are already assembled. Instead, insert assembled
FI
component as instructed.
N
O
C
13.07.2015
4.3.2. Distributor Seal Repair

tooling.
3. Lift cam ring (20) and remove cylinder block (14) from rear case.
4. Position rear case facing upwards and remove stop pin plugs (23) with o-rings (37).
5. Position rear case facing down, and lift distributor (22) with stub shaft (31).
6. Remove stub shaft (31) from distributor (22), and remove distributor seals (27, 28, 29)
from shaft.
!
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13.07.2015
5. Disposal
5.1. Disposal
Note the following points when disposing of the radial piston motor:
1. Completely empty the radial piston motor.
2. Dispose of the hydraulic fluid according to the national regulations of your country.
3. Disassemble the radial piston motor into its individual parts and properly recycle these
parts.
4. Separate parts by:
!
D
• Cast
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• Steel
IT
• Non-ferrous metal
M
• Electronics
R
• Seals
PE
5.2. Environmental Protection
T
O
N
Careless disposal of the radial piston motor, the hydraulic fluid and the packaging material
IS
could lead to pollution of the environment.
ES
• Therefore, dispose of the radial piston motor, the hydraulic fluid and the packaging material
TI
in accordance with the currently applicable regulations in your country.
R
• Dispose of hydraulic fluid residues according to the applicable safety data sheets for these
PA
hydraulic fluids. D
IR
TH
6. Tightening Torques
TO
N
Tightening torques vary from motor to motor depending on bolt/screw size and application.
O
Therefore when checking the torque setting of a particular bolt/screw, Bosch Rexroth
G
recommends consulting the appropriate General Assembly Drawing for the motor.
IN
SS
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13.07.2015
7. Maintenance
7.1. Cleaning and Care
NOTICE
Damage to the surface caused by solvents and aggressive detergents!
Aggressive detergents may damage the seals on the radial piston motor and cause them to age
!
D
faster.
TE
 Never use solvents or aggressive detergents.
IT
 If in doubt, check the compatibility of the detergent with the seal type (NBR or Viton)
M
specified in the radial piston motor.
R
PE
Damage to the hydraulic system and the seals!
T
Using a high pressure cleaner could damage the speed sensor and the seals of the radial piston
O
motor.
N
 Do not point the high-pressure cleaner at sensitive components, e.g. shaft seal ring, seals in
IS
general, electrical connections and speed sensor.
ES
For cleaning and care of the radial piston motor, observe the following:
TI
 Plug all openings with suitable protective caps/covers.
R
PA
 Check whether all plugs and plug seals are securely seated to ensure that no moisture can
penetrate into the radial piston motor during cleaning.
D
 Use only water and, if necessary, a mild detergent to clean the radial piston motor.
IR
 Remove coarse dirt from the outside of the machine and keep sensitive and important
TH
components, such as sensors and valve block clean.

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7.2. Inspection
In order to enable long and reliable operation of the radial piston motor, Rexroth recommends
testing the hydraulic system and radial piston motor on a regular basis and documenting the
following operating conditions:
Table 3: Checklist for Motor Inspection

Area of Inspection Task to be carried out Interval
Hydraulic system Check the level of hydraulic fluid in the Daily
tank.
!
D
Check operating temperature (at Weekly
TE
comparable load).
IT
Check the quality of the hydraulic fluid. Yearly or every 2000 hrs
M
R
(whichever first)
PE
Radial Piston Motor Check radial piston motor for leakage. Daily
T
Early detection of hydraulic fluid loss
O
can help to find faults on the machine
N
or system and to rectify them. For this
IS
reason, Rexroth recommends that the
ES
radial piston motor and the system
TI
should always be kept in a clean
R
condition.
PA
Check radial piston motor for unusual
D Daily
noise development.
IR
TH
Check fittings for the tight seating. All Monthly

fittings have to be checked when the
TO
system is switched off, depressurised

and cooled down.
N
O
Check tightness of wheel nuts, where Monthly

G
fitted.
IN
SS
Systematic documentation of the operating conditions (e. G. Increasing operating

PA
temperatures) will enable detection of increased wear at an early stage and implementation of
the necessary countermeasures.
–
T
EN
M
7.3. Maintenance
C
O
The radial piston motor is low-maintenance when used as intended. The service life of the
D
radial piston motor is heavily dependent on the quality of the hydraulic fluid. For these reasons,
AL
we recommend changing the hydraulic fluid at least once per year or every 2000 operating
TI
hours (whichever occurs first). An alternate recommendation for the hydraulic fluid would be
EN
sending it to be analysed by the hydraulic fluid manufacturer or a laboratory to determine its

suitability for further use.
D
FI
A radial piston motor life calculation can be requested from the Rexroth engineering
N
department in Glenrothes. This must, in all cases, be carried out prior to installation of a radial
O
C
piston motor on a new machine. Based on these details, a maintenance period is to be

determined by the system manufacturer for the replacement of the bearings and included in the
maintenance schedule of the hydraulic system.
13.07.2015
8. Troubleshooting
Table 4: Troubleshooting Issues
Problem/Symptom Possible Fault Remedy
Unusual Noise Output speed too high, Check motor speed versus
causing cavitation and/or machine specification. If too high,
pistons to lift off cam. reset pump, and/or engine speed.
Charge pressure too low, Check charge pressure versus
causing cavitation and/or machine specification. If
!
D
pistons to lift off cam. necessary, adjust, repair or
TE
replace charge pump (closed
IT
circuit) or other source of charge
M
pressure (open circuit).
R
High case pressure causing Check case pressure versus
PE
pistons to lift off cam, or 2- machine specification. If too high,
check drain line for blockages.
T
speed spool (where fitted)
O
to remain partially shifted.
N
IS
Motor mounting screws are Check motor mounting screws are
loose, causing motor to correctly tightened per machine
ES
rattle against frame. manufacturer’s specifications.
TI
Check wheel or load is attached
R
Improper fixing of wheel or
PA
load to motor output shaft. per machine manufacturer’s
D specifications, and is correctly
aligned.
IR
Improper fixing of hydraulic Check installation of lines per

TH
lines causing rattling machine manufacturer’s

specifications.
TO
against machine frame.

Completely bleed hydraulic
N
Air intake.
system. Check tightness of all
O
connections.
G
IN
High Pressure Fluctuations Out-of-balance or Check load and attachment of

SS
fluctuating load. load per machine manufacturer’s

PA
specifications, and adjust as

necessary.
–
T
High Speed Fluctuations Faulty pump or pump Check pump and pump controller
EN
controller. versus machine manufacturers

M
specifications and adjust, repair or

C
replace as necessary.
O
D
Expected output torque or Insufficient pressure Apply full load to motor(s) and
AL
tractive effort not achieved generated by pump. check maximum pressure per
machine manufacturer’s
TI
specification. If too low, block A

EN
and B lines and check maximum

D
pressure at blocked lines. If

FI
pressure is still too low, adjust,

N
repair or replace pump, pump

O
control or system pressure relief

C
valves as necessary.
Motor not fully run in. Continue to run motor (under

load) for 24 – 48 hours to achieve
maximum efficiency. A continuing
increase in output torque may be
noticed over this period.
13.07.2015
Expected output speed not Insufficient flow generated Check engine/prime mover speed
achieved by pump. and pump flow. Adjust, repair or
replace engine/prime mover or
pump as necessary.
Motor does not rotate Expected motor torque Check system pressure. If
achieved and load exceeds pressure has risen to relief valve
motor torque. setting, reduce load on motor.
No oil being supplied to Check engine/prime mover

motor. speed, pump flow and operation
of control valve (if fitted). Adjust,
!
D
repair or replace engine/prime
TE
mover, pump or valve as
IT
necessary.
M
R
Hydraulic fluid temperature Excessive inlet temperature Check cooling system and
PE
too high of motor. external flushing valve, if fitted.
T
Malfunction of pressure Check appropriate components
O
control valves (e. g. high- and repair or replace if necessary.
N
pressure relief valve,
IS
pressure cut-off, pressure
ES
controller).
TI
Output speed too high. Check motor speed versus
R
machine specification. If too high,
PA
reset pump, and/or engine speed.
D
Motor case drain pressure Check case pressure versus
IR
too high, causing integrated machine specification. If too high,
TH
flushing valve (where fitted) check drain line for blockages.

to close.
TO
Pump charge pressure Check charge pressure versus

N
below opening pressure of machine specification. Reset

O
integrated flushing valve charge pressure, and check/repair

G
(where fitted). charge pump as necessary.

IN
Malfunction of integrated Apply a differential pressure of >

SS
flushing valve (where 10 bar across motor, and check

PA
fitted). case drain flow versus machine

manufacturer’s specification.
–
If insufficient flow is present,

T
EN
check flushing poppet for blocked

orifice. If poppet OK, remove
M
flushing spool and springs, and

C
inspect parts including bore in

O
motor housing. Clean and/or

D
replace parts as required.

AL
TI
External leakage Loose bolts. Ensure all bolts are tightened to

EN
correct torque setting per Service

Manual or motor assembly
D
drawing.
FI
N
Loose fittings. Ensure all fittings are tightened to

O
correct torque setting per

C
manufacturer’s specification.
Improper fixing of motor to Check motor is attached per
wheel axle. machine manufacturer’s
specifications, and is correctly
aligned.
Motor Case drain pressure Check case pressure versus
too high, causing partial machine specification. If too high,
release of brake (disc check drain line for blockages.
brake).
13.07.2015
9. Technical Data
The technical data of this radial piston motor can be found in the data sheet “RE 15223”.
Website www.boschrexroth.com/radial-piston-motors
Also see Bosch Rexroth contact details listed in the Appendix.
!
D
10. Appendix
TE
IT
M
10.1 Spare Parts
R
PE
The list of spare parts for radial piston motors are order specific. When ordering spare parts,
please quote the part number or serial number of the radial piston motor, as well as the part
T
numbers of the spare parts.
O
N
Please address all questions regarding spare parts to the Rexroth Service partner or the
service department of the manufacturing plant in Glenrothes. Details of the manufacturing plant
IS
are available on the radial piston motor’s label:
ES
TI
Bosch Rexroth Limited
R
Viewfield Industrial Estate
PA
Glenrothes, Fife
Scotland, KY6 2RD D
United Kingdom
IR
Phone +44 (0) 1592-631777

TH
Fax +44 (0) 1592-631936

TO
Customer.Service@boschrexroth.co.uk
N
O
For the addresses of foreign subsidiaries, please refer to:

G
IN
Website http://www.boschrexroth.com/en/xc/contact/index#
SS
PA
10.2 General Tools List

–
T
1. Allen key set and double ended ring spanner set.

EN
2. Soft mallet.
M
3. Torque wrench covering the ranges:

C
O
D
a. 20-25 Nm (13-16 lbf.ft)

AL
b. 35-39 Nm (26-29 lbf.ft)

c. 45-50 Nm (33-37 lbf.ft)
TI
EN
4. Small screwdriver.
D
FI
5. Air gun.
N
O
C
10.3 Special Tools List

No special tooling required for these procedures.
13.07.2015
10.4 Oil and Grease Specification

Current and up to date greasing and lubrication instructions on the relevant General Assembly
drawing will indicate as to which is best used for the assembly.
For all latest product codes, please contact Bosch Rexroth using details listed below.
The General Assembly Drawing comments will be written similar to the following:
“Fill hole with 510 ± 20ml of L3 Oil per DO/200/10 prior to fitting.”
Table 5: Oil and Grease Codes
!
D
TE
Code Description
G1 High quality lithium-base grease for general assembly use
IT
and packing of seals and bearings
M
R
PE
G3 A high performance industrial grease of medium/hard
o
consistency (MLG1 No.3). Temperature range -30 C to
T
o
150 C. Used for packing of seals and bearings.
O
N
G4 Hot dip adhesive rust preventative (Petroleum Jelly)
IS
Assembly aid for seals and distributor springs
ES
TI
S1 Lithium base high temperature grease containing
R
molybdenum disulphide (MoS) for specific high
PA
load/temperature use. Only to be used where specifically
called out on drawing. (Brake disc spring contact surfaces).
D
IR
S2 A NLG1 No. 2 special micro-gel based grease blended with

TH
an ester, has a high inherent water resistance and load

carrying properties.
TO
A medium consistency, non-melting grease based on a

N
S3
O
treated clay thickener and designed for the lubricant of low-

G
medium speed rolling bearings. It contains additives to

IN
improve its like at higher temperatures.

SS
L1 Silicon oil for general lubrication for seal assembly.

PA
–
L2 Silicon grease for general lubrication and packing of seals

T
during assembly.
EN
L3 Motor Test Oil

M
C
O
EP2 A multipurpose Lithium Stearate type grease fortified with

D
extreme pressure and water resistance additives.

AL
TI
EN
D
FI
N
O
C
13.07.2015
11. Full Motor - Exploded View
!
D
TE
IT
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O
N
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ES
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TO
N
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IN
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EN
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13.07.2015
12. Contact Details

Bosch Rexroth Limited
Viewfield Industrial Estate
Glenrothes, Fife
Scotland, KY6 2RD
United Kingdom
Phone +44 (0) 1592-631777
Fax +44 (0) 1592-631936
!
D
TE
Customer.Service@boschrexroth.co.uk
IT
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TO
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Radial Piston Motor MCR-R

MCR-R Series 41 ‫ ׀‬RE 15223-S033/07.15 Bosch Rexroth Ltd 2/ 32

The cover shows an example application. The

product delivered may differ from the image on the

The original operating instructions were created in

MCR-R Series 41 ‫ ׀‬RE 15223-S033/07.15 Bosch Rexroth Ltd 3/ 32

4.2. Parts within Rear Case Sub Assembly ...........................................................................17

5.1. Disposal .........................................................................................................................24

5.2. Environmental Protection.............................................................................................24

6. Tightening Torques .................................................................................................. 24

7.1. Cleaning and Care .........................................................................................................25

7.2. Inspection .....................................................................................................................26

7.3. Maintenance .................................................................................................................26

9. Technical Data ......................................................................................................... 29

10. Appendix ............................................................................................................... 29

10.1 Spare Parts ...................................................................................................................29

10.2 General Tools List.........................................................................................................29

MCR-R Series 41 ‫ ׀‬RE 15223-S033/07.15 Bosch Rexroth Ltd 4/ 32

1. About this Manual

• “Tightening Torques” on Page 23 PA

radial piston motor.

piston motor once it is installed in the system.

An overview of radial piston motor fault analysis.

• “Technical Data” on Page 28

Refers to various helpful specifications.

• “Full Motor – Exploded View” on Page 30

• “Contact Details” on Page 31

MCR-R Series 41 ‫ ׀‬RE 15223-S033/07.15 Bosch Rexroth Ltd 5/ 32

1.2. Validity of this Manual

MCR-R radial piston motor.

RE 15215-B: Operating Instructions

operation of radial piston motors:

RE 90220: Mineral-oil Based Hydraulic Fluids

units and assists in selecting a hydraulic fluid for your system.

RE 90321: Instructions on the Use of Radial Piston Motors at Low Temperatures

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1.4. Hazard Identification and Pictograms

Table 1: Danger classes in accordance with ANSI Z535.6-2006

 Single, independent step

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2.1. Basic Safety Information

Working on systems that have not been shut down is life-threatening.

Danger of poisoning or injuries!

damage, poisoning due to inhalation).

poisoning and injuries.

pacemakers, or similar devices, is possible due to magnetic fields.

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protective gloves and protective glasses.

using the method specified in this manual.

when touching the radial piston motor.

Incorrectly connected components can considerably impair the functionality of a hydraulic

 Check the correct functioning of all components.

relevant data sheet limits. If in doubt, consult an authorised Rexroth agent.

can lead to hearing damage.

Danger to the environment!

Hydraulic fluid is hazardous to waters.

 Leaks must be cleaned up immediately.