Bosch Rexroth 0608820115 160 Nm 4DMC160 Sensor

Description

Key Technical Specifications

Bosch Rexroth’s tightening-system documentation lists 4DMC160 / 0608820115 alongside the Size 4 EC304 motor and 4GE59 planetary gearbox. The same documentation shows the 4DMC160 in spindle configurations covering working ranges such as 15–136 Nm and 26–130 Nm, depending on the complete spindle arrangement.

A key point for procurement: 160 Nm is the transducer’s rated torque; it should not automatically be interpreted as the permissible operating range of every complete spindle assembly using the sensor. The gearbox, motor, output drive, and spindle configuration determine the actual tool working range.

Product Introduction

The Bosch Rexroth 0608820115, type code 4DMC160, is a Size 4 measurement transducer used in Bosch Rexroth electric tightening systems. It measures torque within tightening-spindle assemblies and is specified with a 160 Nm rated torque, 1:1 reduction ratio, and 122 mm installation length.

This component is selected according to the complete spindle configuration, not by torque rating alone. Bosch Rexroth documentation pairs the 4DMC160 with specific Size 4 drive and gearbox components. Two same-type transducers can also be configured for redundant measurement through a redundant adapter.

Installation & Configuration Guide

Stage 1: Pre-Installation Preparation — Approximately 10 Minutes

⚠️ Safety First: Place the tightening station in its approved maintenance state. Isolate electrical power and pneumatic or mechanical energy sources associated with the spindle. Apply the site’s lockout/tagout procedure before removing the transducer.

Tools Required:

• ESD wrist strap where electronic connections are exposed
• Appropriate metric hand tools
• Calibrated torque wrench
• Digital multimeter where electrical verification is required
• Connector/wiring labels
• Smartphone or camera
• Bosch Rexroth spindle assembly drawing
• Current tightening-system configuration data

Data Backup:

1. Record 0608820115 / 4DMC160 from the installed nameplate.
2. Photograph the transducer orientation and cable routing.
3. Record the complete tightening-spindle assembly.
4. Record the associated gearbox, motor, and output-drive part numbers.
5. Save the current tightening-controller configuration.
6. Record existing torque calibration data.
7. Photograph connector orientation before disconnecting anything.

⚠️ Do not order this transducer based only on “160 Nm.” Bosch Rexroth has multiple Size 4 tightening components, and the complete mechanical/electrical configuration determines compatibility.

Stage 2: Removing the Old Transducer — Approximately 10 Minutes

1. Confirm that the tightening system is fully isolated.
2. Prevent the spindle from moving during maintenance.
3. Photograph the complete assembly before disassembly.
4. Label the transducer cable and connector.
5. Disconnect the electrical connection without pulling on the cable.
6. Remove the mechanical retaining hardware according to the spindle drawing.
7. Support the transducer during removal.
8. Remove the transducer without striking the sensing/mechanical interface.
9. Inspect mating surfaces, shaft interfaces, fasteners, and cable routing.
10. Keep the original transducer available for dimensional and identification comparison.

⚠️ Do not use the sensor body as a reaction point when loosening a mechanically loaded connection. The transducer is a precision measurement component; unnecessary mechanical shock can compromise measurement accuracy.

Stage 3: Installing the New Transducer — Approximately 10 Minutes

1. Verify 0608820115 / 4DMC160 against the original part.
2. Confirm the Size 4 mechanical configuration.
3. Compare the installation length and mating interfaces with the removed unit.
4. Check the transducer for shipping damage.
5. Install the transducer in the correct orientation.
6. Tighten mechanical fasteners using the torque values specified by the applicable Bosch Rexroth assembly documentation.
7. Route the cable along the original path.
8. Reconnect the electrical connector.
9. Secure the connector and cable against vibration or mechanical interference.
10. Check that the spindle can move through its intended mechanical travel without cable tension.

Self-Checklist:

• 0608820115 verified
• 4DMC160 verified
• Size 4 configuration verified
• Mechanical interface checked
• Installation length checked
• Fasteners tightened to documented values
• Connector fully seated
• Cable routing secured
• No mechanical interference

Stage 4: Power-On & Testing — Approximately 10–20 Minutes

1. Keep the spindle unloaded during the initial electrical check.
2. Restore power according to the machine builder’s approved procedure.
3. Verify that the tightening controller recognizes the measurement system.
4. Check for sensor or transducer-related diagnostic faults.
5. Confirm that the torque reading is stable at zero load.
6. Perform a controlled low-torque test.
7. Compare the measured value against the approved reference equipment.
8. Perform the required torque calibration or verification procedure.
9. Run a representative fastening cycle at a controlled torque.
10. Confirm that the tightening controller records the expected torque value and cycle result.

⚠️ Do not release the station to production simply because the controller sees the sensor. A connected transducer can still have an incorrect mechanical installation, calibration offset, or configuration mismatch.

For production release, record the transducer part number, controller configuration, calibration result, reference instrument, test torque, and acceptance date.

0608820115

0608820115

Frequently Asked Questions (FAQ)

Q1. What is Bosch Rexroth 0608820115?

0608820115 is Bosch Rexroth type 4DMC160, a Size 4 measurement transducer used in electric tightening-spindle systems. The published Bosch Rexroth documentation identifies the component as a measurement transducer and specifies a 160 Nm rated torque.

Q2. Is 0608820115 a servo motor?

No. This distinction matters when ordering a replacement. 0608820115 / 4DMC160 is the measurement transducer, not the EC motor. Bosch Rexroth’s documentation separately identifies the Size 4 EC304 motor as order number 0608701018.

Q3. What is the rated torque of the 4DMC160?

The published specification gives the 4DMC160 a rated torque of 160 Nm. However, the working torque range of a complete tightening spindle can be lower depending on the motor, gearbox, output drive, and spindle configuration.

Q4. Can two 4DMC160 transducers be used for redundancy?

Yes. Product documentation states that a tightening spindle can be configured with redundant measurement transducers by using two transducers of the same type together with a redundant adapter. This is a system-level configuration, so verify the complete spindle and controller arrangement before implementing it.

Q5. What other components are commonly associated with 0608820115?

For Size 4 tightening assemblies, Bosch Rexroth documentation associates the 4DMC160 with components such as the 4GE59 planetary gearbox and EC304 motor. The exact combination depends on the spindle’s required torque range, output speed, and mechanical configuration.

Q6. Is 0608820115 still available as new stock?

Availability varies by supplier and region. Current secondary-market listings show the part offered as new and in stock, while other distributors list it as a legacy/discontinued component. One current listing identifies 0608820115 / 4DMC160 as new stock, while another marketplace notes manufacturer discontinuation for the corresponding legacy product listing. Verify the actual physical unit, condition, and warranty before purchase.

Q7. What should I verify before ordering a replacement?

Provide the supplier with the complete 0608820115 / 4DMC160 identification and, ideally, the complete spindle assembly information. Verify Size 4 mechanical compatibility, rated torque, installation dimensions, connector arrangement, associated gearbox and motor, and controller configuration. Do not substitute another torque transducer solely because its rated torque appears similar. Bosch Rexroth’s component tables distinguish the transducer, gearbox, motor, and output-drive part numbers.