Moog RKP-II User Manual

USER MANUAL

RKP-II

Radial Piston Pump

CA53461-001; Version 1.0, 10/07

Copyright

All rights reserved. No part of the User Manual may be reproduced in any way or form (print, photocopy, microfilm or by any other means) or edited, duplicated or distributed with electronic systems without our prior written consent. Offenders will be held liable for the payment of damages.

We reserve the right to make changes.

Table of Contents

Copyright ................................................................................................................................................... A

List of Tables ............................................................................................................................................. iv

List of Figures .............................................................................................................................................v

1 General Information ..................................................................................1

1.1 Information on the User Manual................................................................................................. 1

1.1.1 Target Groups ................................................................................................................ 1

1.1.1.1 Operator .................................................................................................... 1

1.1.1.2 Trained Staff.............................................................................................. 1

1.1.2 Subject to Change and Validity ...................................................................................... 1

1.1.3 Completeness ................................................................................................................ 1

1.1.4 Safe Keeping.................................................................................................................. 1

1.1.5 Warning Labels .............................................................................................................. 2

1.1.6 Symbols.......................................................................................................................... 2

1.2 Supplemental Documentation.................................................................................................... 2

1.3 Environmental Safety.................................................................................................................. 3

1.3.1 Emissions ....................................................................................................................... 3

1.3.2 Disposal.......................................................................................................................... 3

1.4 Responsibilities ........................................................................................................................... 4

1.5 Warranty and Liability ................................................................................................................. 5

1.6 Manufacturer's Declaration and Declaration of Conformity.................................................... 6

1.7 Trademarks .................................................................................................................................. 6

2 Safety .........................................................................................................7

2.1 Intended Use ................................................................................................................................ 7

2.2 Organizational Measures ............................................................................................................ 8

2.2.1 Safe Operation ............................................................................................................... 8

2.2.2 Selecting and Qualifying Staff ........................................................................................ 8

2.2.3 Structural Modifications.................................................................................................. 9

2.2.4 Work Safety.................................................................................................................... 9

2.3 General Safety Instructions...................................................................................................... 10

2.3.1 Specific Phases of Operation....................................................................................... 10

2.3.1.1 Mounting.................................................................................................. 10

2.3.1.2 Start Up ................................................................................................... 10

2.3.1.3 Maintenance and Repairs ....................................................................... 10

2.3.2 Operating Hydraulic Equipment ................................................................................... 10

2.3.2.1 Safety Devices for Limiting Pressure ...................................................... 10

3 Product Description................................................................................11

3.1 Configuration ............................................................................................................................. 11

3.2 Scope of Delivery ...................................................................................................................... 12

3.3 Nameplate .................................................................................................................................. 13

3.4 Functional Description.............................................................................................................. 14

3.5 Compensator Operation ........................................................................................................... 15

3.5.1 Adjustable Pressure Compensator, F1, F2 .................................................................. 16

3.5.2 Hydraulically Driven Remote Pressure Compensator, H1 ........................................... 17

Table of Contents

3.5.3 Remote Pressure Compensator with Mooring Control, H2 .......................................... 18

3.5.4 Load Sensing Compensator, J1 ................................................................................... 19

3.5.5 Load Sensing Compensator with p-T Control Notch, R1.............................................. 20

3.5.6 Mechanical Stroke Adjustment, B1............................................................................... 21

3.5.7 Servo Control, C1......................................................................................................... 22

3.5.8 Power Control, S1 ........................................................................................................ 23

3.5.9 Power Control, S2 ........................................................................................................ 25

4 Technical Data ........................................................................................ 27

4.1 General Technical Data ............................................................................................................. 27

4.2 Operating Conditions ................................................................................................................ 28

5 Transport and Storage ........................................................................... 29

5.1 Unpacking the Pump ................................................................................................................. 29

5.2 Transporting the Pump ............................................................................................................. 29

5.3 Storing the Pump....................................................................................................................... 31

5.4 Preserving the Pump................................................................................................................. 32

6 Mounting ................................................................................................. 33

6.1 Preparing for mounting............................................................................................................. 33

6.2 Installing the Pump.................................................................................................................... 34

6.3 Planning Lines .......................................................................................................................... 35

6.4 Connecting Pipes ...................................................................................................................... 36

6.5 Electrically connecting the pump ............................................................................................ 37

6.6 Arranging Multiple Pumps ........................................................................................................ 37

6.6.1 Determining the through drive torque........................................................................... 37

6.6.2 Attaching the Adapter Flange ....................................................................................... 40

7 Operation ................................................................................................ 43

7.1 Initial Pump Set-Up.................................................................................................................... 43

7.1.1 Filling up the Pump....................................................................................................... 44

7.1.2 Adjusting the Compensator .......................................................................................... 44

7.1.2.1 Hydraulically Driven Remote Pressure Compensator, H1....................... 44

7.1.2.2 Load Sensing Compensator with p-T Control Notch, R1......................... 45

7.1.2.3 Mechanical Stroke Adjustment ................................................................ 45

7.1.2.4 Servo Control, C1 .................................................................................... 46

7.1.2.5 Power Control, S1, S2 ............................................................................. 47

7.1.2.6 Limiting the Maximum Flow ..................................................................... 48

7.2 Performing Functions Tests ..................................................................................................... 48

7.3 Operating the Pump .................................................................................................................. 49

7.3.1 Start up......................................................................................................................... 49

7.3.2 Flushing the Pump........................................................................................................ 50

7.4 Placing the Pump out of Operation.......................................................................................... 50

7.5 Reconnecting the Pump............................................................................................................ 51

8 Maintenance and Repairs ...................................................................... 53

8.1 Monitoring .................................................................................................................................. 53

8.2 Trouble-shooting ....................................................................................................................... 54

8.3 Moog Service Addresses .......................................................................................................... 54

9 Demounting ............................................................................................ 55

9.1 Demounting the Pump .............................................................................................................. 55

Table of Contents

10 Spare Parts, Accessories, Repairs ........................................................57

11 Index.........................................................................................................59

12 Appendix..................................................................................................61

12.1 Declaration of Conformity ........................................................................................................ 61

12.2 Manufacturer's Declaration ...................................................................................................... 62

12.3 Abbreviations, Symbols and Code Letters ............................................................................. 63

12.4 Tightening Torque ..................................................................................................................... 65

List of Tables

Tab. 1: Supplemental Documentation............................................................................................................ 2

Tab. 2: Description of the Compensator Options ......................................................................................... 15

Tab. 3: General Technical Data ................................................................................................................... 27

Tab. 4: Operating Conditions ....................................................................................................................... 28

Tab. 5: Preservation Conditions................................................................................................................... 31

Tab. 6: Storage Conditions .......................................................................................................................... 31

Tab. 7: Permissible Through Drive Torques ................................................................................................ 37

Tab. 8: Nominal width for Control Line Hose ............................................................................................... 45

Tab. 9: Nominal width for Control Line Hose ............................................................................................... 45

Tab. 10: Mechanical Stroke Adjustment ........................................................................................................ 46

Tab. 11: Adjustment Torque Servo Control.................................................................................................... 46

Tab. 12: Nominal width for Control Line Hose ............................................................................................... 47

Tab. 13: Adjustments Limiting the Maximum Flow......................................................................................... 48

Tab. 14: Flushing Quantity ............................................................................................................................. 50

Tab. 15: Monitoring ........................................................................................................................................ 53

Tab. 16: Trouble-shooting .............................................................................................................................. 54

Tab. 17: Abbreviations, Symbols and Code Letters....................................................................................... 63

Tab. 18: Tightening Torquefor mounting screws............................................................................................ 65

Tab. 19: Tightening Torque for sealing plugs................................................................................................. 65

Tab. 20: Tightening Torque for straight screw-in fittings ................................................................................ 65

List of Figures

Fig. 1: Configuration Radial Piston Pump RKP-II ....................................................................................... 11

Fig. 2: Scope of Delivery............................................................................................................................. 12

Fig. 3: Nameplate for Radial Piston Pump RKP-II ...................................................................................... 13

Fig. 4: Cross Section Radial Piston Pump RKP-II ...................................................................................... 14

Fig. 5: Adjustable pressure compensator, F1, F2....................................................................................... 16

Fig. 6: Hydraulically Driven Remote Pressure Compensator, H1............................................................... 17

Fig. 7: Pressure Compensator with Mooring Control, H2 ........................................................................... 18

Fig. 8: Load sensing compensator, J1........................................................................................................ 19

Fig. 9: Load Sensing Compensator with p-T Control Notch, R1................................................................. 20

Fig. 10: Mechanical stroke adjustment, B1................................................................................................... 21

Fig. 11: Servo control, C1............................................................................................................................. 22

Fig. 12: Power control, S1 ............................................................................................................................ 23

Fig. 13: Characteristic V = 32 cm

Fig. 14: Characteristic V = 63 cm

Fig. 15: Characteristic V = 100 cm

/U ............................................................................................................ 24

/U .......................................................................................................... 24

Fig. 16: Power control, S2 ............................................................................................................................ 25

Fig. 17: Transporting Pump with Lifting Tackle............................................................................................. 30

Fig. 18: Transporting Multiple Pumps with Lifting Tackle ............................................................................. 31

Fig. 19: Radial Piston Pump with Heavy Through Drive and Add-On Radial Piston Pump.......................... 38

Fig. 20: Radial piston pump with tandem mounted gear pump using SAE-A adapter.................................. 39

Fig. 21: Radial piston pump with tandem mounted gear pump using SAE-B adapter.................................. 39

Fig. 22: Adapter flange SAE-A with 9-tooth shaft ......................................................................................... 40

Fig. 23: Adapter flange SAE-A with 13-tooth shaft ....................................................................................... 41

Fig. 24: Servo Control, C1 ............................................................................................................................ 46

Fig. 25: Power Control, S1, S2 ..................................................................................................................... 47

Fig. 26: Limiting the Maximum Flow ............................................................................................................. 48

Fig. 27: Declaration of Conformity ................................................................................................................ 61

Fig. 28: Manufacturer's Declaration.............................................................................................................. 62

For your Notes.

List of Figures

1 General Information Information on the User Manual

1 General Information

1.1 Information on the User Manual

The User Manual at hand refers solely to the radial piston pumps in the series RKP-II and is an integral part of the product. It describes the intended use and safe application of the product in all phases of operation.

1.1.1 Target Groups

1.1.1.1 Operator

with the radial piston pump has read the User Manual and its supplemental documentation, and that it is observed accordingly, especially the relative safety and warning instructions. Ö Chap. "1.4 Responsibilities", Page 4

1.1.1.2 Trained Staff

The trained staff must read the User Manual and its important supplemental documentation and must observe and follow the instructions, especially the respective safety and warning instructions.

1.1.2 Subject to Change and Validity

The information in this User Manual is valid as of the date this version of the User Manual is released. Version number and release date of this User Manual are noted in the footer. The User Manual at hand is subject to change at any time and such may be made without justification.

Information on the User Manual

Target Group: OperatorAmong other things, the operator must ensure that the trained staff working

Target Group: Trained Staff

Subject to Change and Validity of the User Manual

1.1.3 Completeness

The User Manual is only complete along with the supplemental documentation relevant for each particular application. Ö Chap. "1.2 Supplemental Documentation", Page 2

1.1.4 Safe Keeping

The User Manual at hand and any and all relevant supplemental documentation for each respective application must always be kept safely in an easily accessible location and be available at all times in the vicinity of the radial piston pump or close to the machinery the pump is assigned to.

Completeness of the User Manual

Safe Keepingfor the User Manual

Supplemental Documentation 1 General Information

1.1.5 Warning Labels

Warning Labels

Symbols

DANGER Denotes safety instructions, which are meant to warn of

an imminent danger of death or serious bodily injury or of significant property damage.

Non-observance of these safety instructions will inevitably lead to death, serious injuries (crippling injuries) or significant damage to property!

WARNING Denotes safety instructions, which are meant to warn of

possible danger of death or serious bodily injury or of possible significant property damage.

Non-observance of these safety instructions may lead to death, serious injuries (crippling injuries) or significant damage to property!

CAUTION Denotes safety instructions, which are meant to warn of

the risk of slight injuries or minor property damage.

Non-observance of these safety instructions may lead to slight injuries or minor damage to property!

1.1.6 Symbols

Denotes important instructions

Supplemental Documentation

• or - Denotes lists

Ö Denotes reference to another chapter, another page, table or

figure in the User Manual as well as supplemental documentation

1., 2., … Denotes steps in a process, which are to be carried out one after another

1.2 Supplemental Documentation

The supplemental documentation listed here is an integral part of the scope of delivery.

Supplemental Documentation Description

Order data sheet / bill of delivery Includes item numbers, item names, quantities

User Manual RKP II Explosion-proof ATEX supplemental instructions in the event that the

Application Instruction RKP-D with CAN Bus Interface

Catalog Radial Piston Pump for fireresistant fluids

Tab. 1: Supplemental Documentation

radial piston pump is suitable for operation in explosive areas (if required, included in the scope of delivery)

User Manual for the radial piston pump with digital onboard electronics (if required, included in the scope of delivery)

Supplemental instructions for operation with fireresistant fluids (if required, included in the scope of delivery)

1 General Information Environmental Safety

1.3 Environmental Safety

1.3.1 Emissions

If operated properly according to instructions, typically no dangerous emissions emanate from the radial piston pump.

1.3.2 Disposal

When disposing of the radial piston pump, its spare parts or accessories, packaging material no longer needed, hydraulic fluid or additives and substances needed for cleaning purposes, the respective country-specific waste disposal regulations as amended must be observed! In some cases, the items to be disposed of must be disassembled professionally and be separated according to their materials and then be disposed of in the respective waste stream or recycling location accordingly.

Incorporated in the radial piston pumps are, among other things, the following substances or materials:

• Electronic components Ö Application Instruction RKP-D with CAN Bus Interface

• Adhesive and potting compounds

• Parts with galvanized surfaces

• Hydraulic fluid

• Various metals and plastics

Environmental Safety: Emissions

Environmental Safety: Disposal

Responsibilities 1 General Information

1.4 Responsibilities

Responsibility of the manufacturer and that of the operator of the machinery

The manufacturer and the operator of the machinery are both responsible to see that the planning and execution of the work performed with and to the radial piston pump as well as all interactions with the radial piston pump are carried out in accordance with the instructions given in this User Manual and in the relevant supplemental documentation for each respective application. The manufacturer and the operator of the machinery are responsible in detail for the following:

• Staff selection and training Ö Chap. "2.2.2 Selecting and Qualifying Staff", Page 8

• Intended use Ö Chap. "2.1 Intended Use", Page 7

• Safe operation Ö Chap. "2.2.1 Safe Operation", Page 8

• Taking required work safety measures for the respective application and monitoring Ö Chap. "2.2.4 Work Safety", Page 9

• Observing the relevant manufacturer's safety standards and those of the operator of the machinery for each respective application

• Observing the relevant regulations applicable nationally and internationally, as well as applicable standards and directives (such as, e. g., EU Machine Directive and the regulations by the Employer's Liability Association, TÜV or VDE) as amended in their current version when designing, assembling and operating the machinery with all of the installed components.

• Installing a suitable safety system for limiting the pressure in the hydraulic connections Ö Chap. "2.3.2.1 Safety Devices for Limiting Pressure", Page 10

• Using only radial piston pumps in technically flawless condition and safe for operation

• Preventing unauthorized structural modifications, repairs and maintenance work to be carried out or such that are unprofessionally performed.

Ö Chap. "2.2.3 Structural Modifications", Page 9 Ö Chap. "10 Spare Parts, Accessories, Repairs", Page 57

• Defining and adhering to application specific inspection and servicing instructions

• Adhering to all technical data during storage, transport, assembly, disassembly, connecting, start-up, configuring, operating, cleaning, repairing or performing any troubleshooting, especially the ambient conditions as well as to the data of the hydraulic fluid in use.

• Proper storage, transport, assembly, disassembly, connection, start-up, configuration, operation, cleaning, repairing, performing any troubleshooting or disposal

• Easily accessible and available safe keeping of the

• Manual as well as the relevant supplemental documentation for each respective application. Ö Chap. "1.1.4 Safe Keeping", Page 1

• This User Manual and the relevant supplemental documentation for each respective application are to be added to the User Manual of the machinery.

1 General Information Warranty and Liability

1.5 Warranty and Liability

In principle, our general terms and conditions for delivery and payment apply. These shall be available to the buyer at the latest at the time the sales contract is completed.

Among other things, warranty and liability claims are excluded for personal injury or property damage should they be the result of one or more of the following causes:

• Work performed with and to the radial piston pump or handling the radial piston pump by users not qualified for the job Ö Chap. "2.2.2 Selecting and Qualifying Staff", Page 8

• Use in violation with regulations Ö Chap. "2.1 Intended Use", Page 7

• Unsafe operation Ö Chap. "2.2.1 Safe Operation", Page 8

• Failing to take required work safety measures for the respective application Ö Chap. "2.2.4 Work Safety", Page 9

• Not adhering to the instructions in User Manual at hand or to the relevant supplemental documentation for the respective application

• Non-observance of the relevant manufacturer's safety standards and those of the operator of the machinery for each respective application

• Non-observance of the relevant regulations applicable nationally and internationally, or standards and directives (such as, e. g., EU Machine Directive and the regulations by the Employer's Liability Association, TÜV or VDE) as amended in their current version when designing, assembling and operating the machinery with all of the installed components.

• Failure to install a suitable safety system for limiting the pressure in the hydraulic connections Ö Chap. "2.3.2.1 Safety Devices for Limiting Pressure", Page 10

• Using radial piston pumps that are not in technically flawless condition or not safe for operation

• Unauthorized or improperly performed modifications to the design or repairs and maintenance work

Ö Chap. "2.2.3 Structural Modifications", Page 9 Ö Chap. "8 Maintenance and Repairs", Page 53

• Not adhering to the inspection and maintenance instructions from the manufacturer and the operator of the machinery.

• Not adhering to all technical data during storage, transport, assembly, disassembly, connecting, start-up, configuring, operating, cleaning, repairing or resolving any possible failures, especially to the ambient conditions as well as to the data of the hydraulic fluid in use. Ö Chap. "4 Technical Data", Page 27

• Improper storage, transport, assembly, disassembly, connection, start-up, configuration, operation, cleaning, repairing, resolving any possible failures or disposal

• Use of unsuitable or defective accessories or rather unsuitable or defective spare parts Ö Chap. "10 Spare Parts, Accessories, Repairs", Page 57

• Catastrophic events beyond our control or acts of God

Limits to Warranty and Liability

Manufacturer's Declaration and Declaration of Conformity 1 General Information

1.6 Manufacturer's Declaration and Declaration of Conformity

Manufacturer's Declaration and Declaration of Conformity

The declaration of conformity is of significance in the event the radial piston pump is utilized in an explosive area. The manufacturer's declaration is of significance when the radial piston pump is utilized in a non-explosive area. The radial piston pump RKP-II conforms to the standards listed in declaration of conformity and the manufacturer's declaration related to it. The radial piston pump adheres to the requirements of the Machine Directive 98/37/EC. Radial piston pumps for use in explosive areas also adhere to the requirements of the EC Directive 94/9/EC (ATEX). Information on the standards applied can be gathered from the relative Declaration of Conformity and the Manufacturer's Declaration.

Declaration of Conformity and Manufacturer's Declaration Ö Chap. "12 Appendix", Page 61

1.7 Trademarks

Trademarks Moog™ and Moog Authentic Repair Service™ are registered trademarks of

Moog Inc. and its subsidiaries.

All product and company names listed in the User Manual are possibly protected trademarks of their respective manufacturer, the use of which by third parties for their own purposes may be in violation of the manufacturer's rights. A missing ® or ™ symbol may not be interpreted to mean that the name is a brand name that can be used unrestricted.

2 Safety Intended Use

2Safety

2.1 Intended Use

Intended UseThe Radial Piston Pump RKP-II is a work machine used to produce hydraulic

displacement. Certain versions of the radial piston pumps are fitted with an additional safety function for locking (not a hermetic sealing function) the hydraulic displacement.

Use Environment:

The radial piston pump is designed to control and regulate pressures and displacements in commercial applications.

Obvious Misuse:

Operating the unit outside of the specifically defined application and environmental conditions in relationship to:

• Operating pressure

• Temperature

• Speed and rotational direction

• Operational environmental pressure

• Shock / vibration

• Electromagnetic interference resistance

• Operating fluids (viscosity, cleanliness class, chemical ingredients)

• Protection class

• Electrical and electromagnetic connections

• Operation in explosion hazardous areas if not permitted for such use

For incorporating into superordinate levels of machinery, the following applies:

• The Radial Piston Pump is only to be operated as a component for a complete superordinate system, e. g. in a machinery set up.

• The Radial Piston Pump is designed to be used with the specified operating fluid. Use with any other operating fluid requires our express approval.

• The efficient, reliable and safe operation of the Radial Piston Pump requires quality project planning as well as professional execution, transport, storage, mounting, demounting, electrical and hydraulic connections, start-up, configuration, operation, cleaning and servicing.

The Radial Piston Pump may not be put into operation until the following has been assured:

• The superordinate level machinery with all of its installed components adheres to the relevant, nationally and internationally applicable regulations, standards and directives (such as the EU Machine Directive and the applicable regulations by the Employer's Liability Insurance Association, TÜV or VDE) as amended.

• The Radial Piston Pump and all other installed components are in technically sound and fail-safe condition.

Organizational Measures 2Safety

For its intended use, the following applies:

• Observance of the User Manual

• Handling the Radial Piston Pump safely Ö Chap. "2.2.1 Safe Operation", Page 8

• Adhering to the inspection and maintenance instructions from the manufacturer and the operator of the machinery.

• Following all of the corresponding relevant supplemental documentation in accordance with the application

• Observing the relevant manufacturer's safety standards and those of the operator of the machinery for each respective application

• Observing the relevant regulations applicable nationally and internationally, as well as applicable standards and directives (such as, e. g., the EU Machine Directive and the applicable regulations by the Employer's Liability Insurance Association, TÜV or VDE) as amended.

2.2 Organizational Measures

2.2.1 Safe Operation

It is the responsibility of the manufacturer and the operator of the machinery to ensure safe operation of the Radial Piston Pump.

Safe Operation The basic requirement for safe handling and trouble free operation involves

observing the following:

• All relevant safety instructions and user manuals

• All safety instructions or the relevant supplemental documentation for the respective application

• All safety instructions pertaining to the relevant manufacturer's safety standards and those of the operator of the machinery for each respective application

• All relevant nationally and internationally applicable safety and accident prevention regulations, standards and directives, such as the safety instructions of the Employer's Liability Insurance Association, TÜV or VDE, in particular the following standards for the safe operation of machines:

- DIN EN ISO 12100

-DINEN982

Following the safety instructions and the safety and accident prevention regulations, standards and directives helps to prevent accidents, machine failure and property damage!

2.2.2 Selecting and Qualifying Staff

Selecting and Qualifying Staff

WARNING Incorrect handling of the Radial Piston Pump!

May lead to severe personal injury and property damage.

• Any and all work to the Radial Piston Pump may only be performed by user's qualified to do so and those authorized.

2 Safety Organizational Measures

Qualified UsersQualified users are skilled professionals, who have been trained to carry out

these tasks and who have the required knowledge and experience. In particular, such skilled professionals must be licensed to operate, ground and label machines, systems and electric circuits in accordance with applicable safety standards. Project planners must be familiar with the safety concepts for automated technology.

2.2.3 Structural Modifications

Structural ModificationsIn order to prevent damage to the Radial Piston Pump or to any of its

accessories, structural modifications to the equipment may only be performed by us or by an authorized service location. Ö Chap. "8.3 Moog Service Addresses", Page 54

Among other things, warranty and liability claims shall be excluded for personal injury or property damage, if they are the result of unauthorized or improperly carried out structural modifications or tampering with the equipment in any other way. Ö Chap. "1.5 Warranty and Liability", Page 5

2.2.4 Work Safety

Certain components in an equipment system may be the cause of magnetic field and cause interference to sensitive devices.

• Maintain the respective device-related safety clearance.

CAUTION Danger! Toppling Objects!

Toppling tools and accessories may lead to bodily injury.

• Wear suitable protective work equipment such as, e. g., safety shoes.

CAUTION Risk of Burns!

The Radial Piston Pump and the hydraulic connection lines may get very hot during operation and may lead to burns on skin contact.

• Wear suitable protective work equipment such as, e. g., work gloves.

CAUTION Noise Exposure!

When operating the machinery, the operator may be exposed to loud noise, which can lead to hearing damage.

• The operator / manufacturer must take suitable measures to protect against noise, such as, for example, instructing the use of ear protection.

Work SafetyWARNING Danger! Magnetic Fields!

CAUTION Hazardous Operating Fluid!

When exposed to hazardous operating fluid, skin contact or inhaling may lead to bodily injury.

• Wear suitable protective work equipment such as, e. g., work gloves.

General Safety Instructions 2Safety

2.3 General Safety Instructions

General Safety Instructions

General Safety Instructions for specific phases of operation

• Any and all work to the Radial Piston Pump may only be performed by user's qualified to do so and those authorized. Ö Chap. "2.2.2 Selecting and Qualifying Staff", Page 8

• The technical data and especially the information shown on the Radial Piston Pump's nameplate are to be observed and adhered to. Ö Chap. "4 Technical Data", Page 27

2.3.1 Specific Phases of Operation

2.3.1.1 Mounting

• During mounting, make sure that all connections, plugs and sockets are tightly sealed to prevent substances from penetrating into the Radial Piston Pump.

• The Radial Piston Pump must be completely filled with operating fluid.

• Before mounting, the Radial Piston Pump must have adjusted to room temperature and it may not contain any condensation.

2.3.1.2 Start Up

• All hydraulic and electric connections must be in use or closed off.

• Never put the Radial Piston Pump into operation until after all mounting steps have been completed.

General Safety Instructions when operating hydraulic equipment

2.3.1.3 Maintenance and Repairs

• Maintenance and repair work as well as servicing work is to be carried out according to schedule and to the regularly specified times.

• Secure the machinery from being started up during maintenance and repair.

• Make sure the machinery is not under pressure during maintenance work.

2.3.2 Operating Hydraulic Equipment

2.3.2.1 Safety Devices for Limiting Pressure

DANGER Risk of injury and property damage as a result of excess

pressure!

Excess pressure in the machinery may damage parts of the machine and as a result may lead to severe injuries.

• In order to limit the machinery to the maximum permissible operating pressure, it is crucial to install a pressure limitation valve directly at the pump output line.

3 Product Description Configuration

3 Product Description

3.1 Configuration

Configuration

Pos. Description

1 Control piston

2 Rolling bearing

3 Drive shaft

4Drain Port

5 SAE piping connection

6 Sliding stroke ring

7 Slipper pad with working piston

8 Housing

9 Compensator

Fig. 1: Configuration Radial Piston Pump RKP-II

Scope of Delivery 3 Product Description

3.2 Scope of Delivery

Scope of Delivery

Pos. Description

1 Radial Piston Pump RKP-II

2Cap

3 Flange cover

4 Transport protection for shaft ends

Fig. 2: Scope of Delivery

When pump stages are delivered, the through-drive is closed with a cap. The caps are not suitable for operational purposes.

Included in the scope of delivery:

• Radial piston pump RKP-II with flange covers, caps and transport protection for the shaft ends, preserved

• User manual with additional documentation

3 Product Description Nameplate

3.3 Nameplate

Nameplate

Pos. Marking Additional Information

1 Revision status

2 Rotation direction

3 Type key Ö Catalog Radial Piston Pump RKP-II

4 displacement

5 Maximum revolutions for low noise operation

6 Maximum operating pressure

7 Date of manufacture in the format MM/YY

8 Model number

Fig. 3: Nameplate for Radial Piston Pump RKP-II

In the case of multiple pumps, each individual pump has its own nameplate.

Functional Description 3 Product Description

3.4 Functional Description

Functional Description The shaft (Pos. 11) transfers the drive torque to the star-shaped cylinder block

(Pos. 7), free of any axial forces, via a crossdisc coupling (Pos. 10). The cylinder block is hydrostatically supported on the control journal (Pos. 6). The radial pistons (Pos. 5) in the cylinder block run against the stroke ring (Pos. 3) through hydrostatically balanced slipper pads (Pos. 4). The pistons and slipper pads are joined by ball and socket joints and locking rings. The slipper pads are guided in the stroke ring by two retaining rings (Pos. 2) and, when running, are held against the stroke ring by centrifugal force and oil pressure. As the cylinder block rotates, the pistons reciprocate due to the eccentric positioning of the stroke ring, the piston stroke being twice the eccentricity. The eccentric position of the stroke ring is controlled by two diametrically opposed control pistons (Pos. 1, Pos. 8) and the pressure compensator (Pos. 9). The oil flow to and from the pump passes through the pump ports and into and out of the pistons through the porting in the control journal. The bearing supporting the drive shaft is only subjected to external forces. The compensator setting limits the system pressure and adjusts the pump flow between zero and full flow to maintain the set pressure.

Fig. 4: Cross Section Radial Piston Pump RKP-II

3 Product Description Compensator Operation

3.5 Compensator Operation

Compensator OperationThe Radial Piston Pump RKP-II enables a variety of compensator options to be

used. This ensures maximum flexibility.

The following options are described in more detail later on:

No. Compensator Option Description/Characteristics/Application

1 Adjustable pressure

compensator, F1, F2

2 Remote Pressure

Compensator, H1

3 Remote Pressure Compensator

with MooringControl, H2

hydraulically adjustable

4 Load sensing compensator, J1

Combined pressure and flow compensator

5 Load sensing compensator

with p-T control notch, R1

Combined pressure and flow compensator with p-T control notch

6 Mechanical stroke adjustment, B1For displacement systems with fixed flow volume

7 Servo control, C1 The Pump displacement can be adjusted with a

8 Constant Horsepower

Control, S1

(force comparison system)

9 Remote Constant Horsepower

Control, S2

wtih pressure and flow limiter, with superimposed pressure and displacement limitation, controlled hydraulically

RKP-D Radial piston pump with digital on-board electronics

Tab. 2: Description of the Compensator Options

For constant pressure systems with a fixed pressure settings Ö Chap. "3.5.1 Adjustable Pressure Compensator, F1, F2", Page 16

For constant or variable pressure systems with remote pressure setting Ö Chap. "3.5.2 Hydraulically Driven Remote Pressure Compensator, H1", Page 17

For constant pressure systems with variable pressure setting for mooring control Ö Chap. "3.5.3 Remote Pressure Compensator with Mooring Control, H2", Page 18

For displacement systems with variable volume flow and loadsensing pressure control (hydro-mechanical compensator concept) Ö Chap. "3.5.4 Load Sensing Compensator, J1", Page 19

As described in 4 plus: active reduction of pressure peaks during dynamic control processes Ö Chap. "3.5.5 Load Sensing Compensator with pT Control Notch, R1", Page 20

settings, which can be changed manually if needed Ö Chap. "3.5.6 Mechanical Stroke Adjustment, B1", Page 21

hand lever or an actuator Ö Chap. "3.5.7 Servo Control, C1", Page 22

Automatic reduction of displacement in the event of an increasing load so that the capacity of the drive motor is not exceeded Ö Chap. "3.5.8 Power Control, S1", Page 23

As described in 8 plus: an adjustable maximum limit setting for pressure and displacement

Ö Chap. "3.5.9 Power Control, S2", Page 25

Ö Application Instruction RKP-D with CAN Bus

Interface

All compensators are pre-set at the factory. Information on setting the compensators: Ö Chap. "7.1.2 Adjusting the Compensator", Page 44

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