Moog RKP-II User Manual

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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

Compensator Operation 3 Product Description

3.5.1 Adjustable Pressure Compensator, F1, F2

Adjustable Pressure Compensator, F1, F2

Pressure range:

F1: 30–150 bar F2: 80–350 bar

Pos. Description

1 Safety valve p = p

2 Control piston 2

3 Control piston 1

4 Adjustment of zero stroke

5 Valve spool

6 Valve spring

7 Adjustment screw

8 Locknut for the adjustment screw

9 Setting the adjustment screw

+ 30 bar

max.

Fig. 5: Adjustable pressure compensator, F1, F2

3 Product Description Compensator Operation

3.5.2 Hydraulically Driven Remote Pressure Compensator, H1

Pressure pilot valve:

Manually adjustable or proportional pressure valve Q = 1–1.5 l/min.

Hydraulically Driven Remote Pressure Compensator, H1

Pos. Description

1 Safety valve p = p

2 Control piston 2

3 Control piston 1

4 Adjustment of zero stroke

5 Pilot pressure valve

6 Valve spool

7Orifice

9 Locked adjustment screw

10 Locknut for the adjustment screw

11 Set a pilot valve

spring

min.

Fig. 6: Hydraulically Driven Remote Pressure Compensator, H1

max.

+ 30 bar

Compensator Operation 3 Product Description

3.5.3 Remote Pressure Compensator with Mooring Control, H2

Remote Pressure Compensator with Mooring Control, H2

The pressure compensator with Mooring control has an intermediate plate inserted between the pump body and the pressure compensator. The intermediate plate enables the pump's absorption operation.

Pos. Description

1 Control piston 2

2 Control piston 1

3 Intermediate plate

4 Pilot pressure valve:

5 Valve spool

6Orifice

min.

spring

Fig. 7: Pressure Compensator with Mooring Control, H2

8 Locked adjustment screw

9 Intermediate plate

10 Locknut for the adjustment screw

3 Product Description Compensator Operation

3.5.4 Load Sensing Compensator, J1

Metering orifice:

Manually remote adjustable orifice valve or proportional orifice valve.

Pressure pilot valve:

Manually remote adjustable proportional pressure valve Q = 1–1.5 l/min.

Load Sensing Compensator, J1

Pos. Description Pos. Description

1 Metering orifice for flow control 8 ∆p spring

2 Safety valve p = p

3 Control piston 2 10 Locknut for the adjustment screw

4 Control piston 1 11 Set at pilot valve

5 Adjustment of zero stroke 12 Set at metering throttle

6 Pilot pressure valve: 13 Orifice Ø 0.8 ... 0.9 mm

7 Valve spool

+ 30 bar 9 Locked adjustement screw

max.

Fig. 8: Load sensing compensator, J1

Compensator Operation 3 Product Description

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

Load Sensing Compensator with p-T Control Notch, R1

Metering orifice:

Manually remote adjustable orifice valve or proportional orifice valve.

Pressure pilot valve:

Manually remote adjustable proportional pressure valve Q = 1–1.5 l/min. For multiple pumps feeding in one common line, only one compensator with a p-T control notch may be used. This compensator must be set to the higher ∆p value.

Pos. Description Pos. Description

1 Metering orifice for flow control 8 ∆p spring 2 Safety valve p = p 3 Control piston 2 10 Orifice Ø 0.8 ... 0.9mm 4 Control piston 1 11 Locknut for the adjustment screw 5 Adjustment of zero stroke 12 Set at pilot valve 6 Pilot pressure valve: 13 Set at metering throttle 7Valve spool

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

+ 30 bar 9 Locked adjustment screw

max.

3 Product Description Compensator Operation

3.5.6 Mechanical Stroke Adjustment, B1

Mechanical Stroke Adjustment, B1

Pos. Description

1 Adjustment screw

2 Seal nut

Fig. 10: Mechanical stroke adjustment, B1

Compensator Operation 3 Product Description

3.5.7 Servo Control, C1

Servo Control, C1

Pos. Description Pos. Description

1 Stroke ring 4 Adjustment lever for control shaft

2 Pilot spool 5 Control piston 1

3 Spool sleeve 6 Control piston 2

Fig. 11: Servo control, C1

3 Product Description Compensator Operation

3.5.8 Power Control, S1

Power Control, S1

Pos. Description Pos. Description

1 Control piston 2 6 Pilot spool

2 Control piston 1 7 Rocker

3 Adjustment screw (fixed setting, do

not modify)

4 Sensing piston 9 Spring 2

5 Adjusting screw (fixed setting, do not

modify)

Fig. 12: Power control, S1

8 Spring 1

Compensator Operation 3 Product Description

Characteristics for Power Control, S1

Fig. 13: Characteristic V = 32 cm3/U

Fig. 14: Characteristic V = 63 cm3/U

Fig. 15: Characteristic V = 100 cm3/U

Approximation to the power hyperbola by means of two springs. Referenced on n = 1450 1/min.

For other revolutions, the following applies:

n⋅

----------------- -=

1450

3 Product Description Compensator Operation

3.5.9 Power Control, S2

Hydraulically operated power control with superimposed pressure and displacement limitation

Power Control, S2

Pos. Description

1 Pressure p setting

2 Flow control Q setting

3 Control port

Fig. 16: Power control, S2

Compensator Operation 3 Product Description

For your notes.

4 Technical Data General Technical Data

4 Technical Data

4.1 General Technical Data

Displacement

[cm

/R] 1932456380100140

Type of construction

Type of mounting End mounting, centering and hole-circle diameter

Mounting position optional

Weight [kg] 22 33 33 71 71 71 103

Mass moment of inertia [kg/cm

Line connections

Pressure port

Medium pressure version

High-pressure version

Suction port

Medium pressure version

High-pressure version

Recommended pipe OD Drain pipes (lightweight version) [mm]

Radial Piston Pump for open circuits with various control devices

as per DIN/ISO 3019/2 (metric) Attachment flange as per DIN/ISO 3019/1 (dimensions in inches) Attachment flange as per DIN/ISO 3019/2 (metric)

17.7 61 61 186.3 186.3 186.3 380

]

3/4"

3000 psi1"3000 psi1"3000 psi

3/4"

6000 psi1"6000 psi

3/4"

3000 psi

3/4"

6000 psi

15 (5/8") 18 (3/4") 18 (3/4") 22 (7/8") 22 (7/8") 22 (7/8") 22 (7/8")

1 1/2"

3000 psi

1 1/2"

3000 psi

Tab. 3: General Technical Data

– 1 1/4"

1 1/2"

3000 psi2"3000 psi2"3000 psi2"3000 psi

–2"

1 1/4"

3000 psi

6000 psi

3000 psi2"3000 psi

1 1/4"

3000 psi

1 1/4"

6000 psi

1 1/4"

6000 psi

––

1 1/2"

6000 psi

2 1/2"

3000 psi

General Technical Data

Operating Conditions 4 Technical Data

4.2 Operating Conditions

Operating Conditions

Displacement [cm3/R]1932456380100140

Drive type Direct drive with coupling (for other drive types, please contact us)

Ambient temperature

-15 °C up to 60 °C

range

Max. speed at inlet pressure

0.8 bar abs. [min

-1

Max. speed for inlet pressure 1 bar abs. [min

-1

]

Max. speed for low noise operation

-1

[min

]

Min. inlet pressure

2700

]

2900

1800 1800 1800 1800 1800 1800 1800

0.8 bar absolute at pump inlet

2500

2900

1800

2100

2300

1500

1800

1500

1800

1500

1800

suction port

Max. housing pressure 2 bar (1 bar above atmosphere)

Standard version: Continuous pressure [bar] Maximum pressure

280 315

350

280 315 350

280 315

350 [bar] Peak pressure [bar]

– – –

High-pressure version: Continuous pressure [bar] Max. pressure

[bar]

350 385 420

– – –

350 385 420

– – –

Peak pressure [bar]

Hydraulic fluid Mineral oil as per DIN 51 524

Hydraulic fluid

-15 °C up to 80 °C

temperature range

Viscosity Permissible operating range 12 up to 100 mm

Recommended operating range 16 up to 46 mm Hydraulic fluid for viscosity class ISO VG 46 or VG 32 Max. viscosity 500 mm electric motor 1800 min

/s during start-up using

-1

Filtering NAS 1638, Class 9;

ISO/DIN 4406, Class 20/18/15 Achievable using filter fineness β

= 75

Tab. 4: Operating Conditions

Maximum pressure as per DIN 24312

Dirt particle retention rate > 20 µm is 1:75, meaning 98.67 %

For special fluids, such as, e.g., HFA, HFC and emulsions, in part other values apply with regard to pressure, viscosity, temperature and filtering. Information on these values can be found in the following supplemental documentation: ÖCatalog Radial Piston Pump for fire-resistant Fluids

5 Transport and Storage Unpacking the Pump

5 Transport and Storage

For pumps in explosive areas, observe the supplementary documentation as well: Ö User Manual RKP II Explosion-Proof

For any and all tasks to be performed on the pumps, appropriate personal protective equipment should be worn. Ö Chap. "2.2.4 Work Safety", Page 9

5.1 Unpacking the Pump

CAUTION Individual parts may fall out!

If the original packaging is opened improperly, individual parts may fall out and be damaged or lead to injuries of a worker.

• Place the pump in its original packaging on a stable surface.

• Only open the original packaging from the top.

• Dispose of the packaging material in accordance with locally applicable regulations.

Procedure:

1. Remove original packaging.

Transport and Storage

Unpacking the Pump

2. Inspect product and contents according to the purchase order.

3. Check that the packing slip and delivered product match.

4. In the event of transport damage or defects, inform the manufacturer or

the supplier.

5. Store original packaging for later use or dispose of it in accordance with

locally applicable regulations.

5.2 Transporting the Pump

DANGER Risk of crushing!

The pump may topple over during transport and lead to crushing injuries.

• Select lifting tackle to correspond with the overall weight of the pump.

• Attach the lifting tackle to the pump properly.

• Avoid all areas below the floating load.

CAUTION Damage to the drive shaft!

During transport, impact and blows to the drive shaft may damage the pump.

• Do not bang objects against the drive shaft.

• Do not place or set objects onto the drive shaft.

• Do not exceed permissible axial and radial forces to the drive shaft.

Transporting the Pump

Transporting the Pump 5 Transport and Storage

CAUTION Damage to the attached parts!

Any heavy weight on the attached parts, for example the compensator, during transport may result in damage to such.

• Do not attach lifting tackle to the attached parts during transport.

• Make sure that the attached parts do not collide with other objects during transport.

For multiple pumps, add up the weights of the individual pumps.

Procedure:

1. Determine the weight and the dimensions of the pump.

Ö Catalog Radial Piston Pump RKP-II Ö Chap. "4 Technical Data", Page 27

2. Attach suitable lifting tackle to the pump.

- Mount the ring bolts into the attachment flange of the pressure side.

- If the center of gravity is off-center (e. g. for multiple pumps with pump stages of the same weight): Attach the ring bolts to the exterior pumps.

3. Lift the pump carefully and transport it with supervision.

Fig. 17: Transporting Pump with Lifting Tackle

5 Transport and Storage Storing the Pump

Fig. 18: Transporting Multiple Pumps with Lifting Tackle

5.3 Storing the Pump

CAUTION Damage to Property!

Storing the pump improperly may lead to property damage.

• Store the pump as instructed and if necessary, preserve it.

Preservation Conditions

Storage Duration Preservation

up to twelve months not required

> 1 year required

Ö Chap. "5.4 Preserving the Pump", Page 32

Tab. 5: Preservation Conditions

Storage Conditions

Storage Duration Measures

> 1 year Visual inspection

Tab. 6: Storage Conditions

Storing the Pump

Pre-Conditions:

• Pump has been demounted. Ö Chap. "9.1 Demounting the Pump", Page 55

Preserving the Pump 5 Transport and Storage

Procedure:

1. Inspect to assure that all openings have been closed using flange covers

or caps.

2. Check to assure that transportation protection means are attached to the

pump's drive shaft.

3. Make certain that the storage space

- Is clean, dry, frost-protected and free of corrosives and vapors.

- Has a consistent temperature (temperature difference < 10 °C).

4. Depending on storage duration: preserve the pump

Ö Tab. 5, Page 31

5. Check the storage conditions

Ö Tab. 6, Page 31

6. After delivery: No steps need to be taken.

7. After demounting: Pour a small amount of mineral oil into the pump's

interior.

5.4 Preserving the Pump

Preserving the Pump

The pump should only be preserved on the exterior.

WARNING Damage to Property!

Improper preservation or no preservation at all may cause corrosion to the pump.

• If required, properly preserve the pump Ö Chap. " Preservation Conditions", Page 31

Pre-Conditions:

• Pump has been demounted. Ö Chap. "9.1 Demounting the Pump", Page 55

• Pump is clean and dry.

• All openings are closed using flange covers or caps.

Procedure:

1. Apply corrosion preventative (Castrol SafeCoat DW 18X) evenly to the

pump's exterior surface.

2. Allow the pump to dry.

Before the initial set-up of the pump, it does not need to be de-preserved.

6 Mounting Preparing for mounting

6 Mounting

For pumps in explosive areas, the supplementary documentation should also be observed: Ö User Manual RKP II Explosion-Proof

For any and all tasks to be performed on the pump, suitable personal protective equipment should be worn. Ö Chap. "2.2.4 Work Safety", Page 9

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

operating fluid!

Any operating fluid that sprays out under high pressure because of improper mounting may lead to serious injury or property damage.

• Only trained personnel should be allowed to mount the pump.

• Check the cleanliness of the mounting surface.

• Observe the tightening torques for the fasteners. Ö Chap. "12.4 Tightening Torque", Page 65

• Use only specified fasteners (quantity/type).

• Make sure the proper flange and screws are being used as per standard (e. g. SAE).

• Check for the existence and use of the proper O-rings.

• Use the correct sealant based on the operating fluid.

• Mount all connections to be hydraulically sealed.

• Do not exceed the maximum operating pressure in the system.

• Do not exceed the maximum body pressure.

Mounting

DANGER Serious bodily injury!

Starting-up the machine/equipment during the mounting process may lead to serious bodily injuries or death.

• Make sure that the machine/equipment cannot be switched on.

6.1 Preparing for mounting

The pump is pre-assembled at the factory.

Procedure:

1. Pump has been unpacked.

Ö Chap. "5.1 Unpacking the Pump", Page 29

2. The required supplementary documentation is at hand.

3. The hydraulic plans from the machine / equipment manufacturer have

been made available.

4. The required standard tools and mounting material are at hand.

Preparing for mounting

Installing the Pump 6 Mounting

6.2 Installing the Pump

Installing the Pump

WARNING Risk of Crushing!

During mounting, the pump may topple over and crush body parts.

• Select lifting tackle to correspond with the overall weight of the pump.

• Attach the lifting tackle to the pump properly. Ö Chap. "5.2 Transporting the Pump", Page 29

• Avoid all areas below the floating load.

WARNING Risk of injury and poisoning by dangerous operating fluid!

Leaks from dangerous operating fluid may lead to serious injuries.

• Check to ensure that the operating fluid in use does not pose a risk.

• Make sure that the machine / equipment is at zero pressure and idle.

• Wear protective work equipment such as, e. g., work gloves. Ö Chap. "2.2.4 Work Safety", Page 9

DANGER Risk of Death by Electrocution!

Contact with hot parts may lead to severe injuries and even death.

• Make sure that the machine / equipment is idle.

CAUTION Damage to Property from Soiling!

Removing end caps to the pump connections may lead to soiling and as a result property damage.

• Do not remove end caps until shortly before mounting.

WARNING Risk of injury and property damage as a result of

vibration!

Vibrations from machines / equipment parts may lead to bodily injury or property damage.

• Uncouple the pump using suitable antivibration elements.

Pre-Conditions:

• Mounting area is freely accessible.

• Machine / equipment is at zero pressure and idle.

• Operation fluid matches the information on the order data sheet.

• Standard tools and mounting material are at hand.

• Supplementary documentation is available.

• The specified rotation of the pump corresponds with the drive motor.

The pump's mounting position is optional.

6 Mounting Planning Lines

Procedure:

1. Mount the specified half of the coupling to the pump's drive shaft as per

the information provided by the coupling manufacturer.

The threaded bore on the pump's drive shaft can be used to mount the coupling.

2. Make sure that the connection and mounting surfaces are clean.

- If not, clean the connection and mounting surfaces using suitable cleaning agents.

- Use suitable cleaning rags.

- Do not allow the cleaning agent to penetrate into the hydraulic circulation loop.

3. Ensure that the coupling hub is tightened to the drive shaft or that the

drive shaft is lubricated continuously to prevent wear from vibration.

4. Transport the pump to the mounting location.

5. Mount the coupling to the drive according to the information provided by

the coupling manufacturer.

Only bolt the pump down after the coupling has been mounted correctly.

6. Fasten the pump with the coupling at the mounting location. Tighten the

mounting screws with the adequate tightening torque crosswise. Ö Chap. "12.4 Tightening Torque", Page 65

7. For bell housing mounting: Check the coupling's axial clearance as per

the information provided by the coupling manufacturer.

8. For mounting a flange: Align the pump supports in the direction of the

drive.

9. For elastic couplings: After completing the mounting, check the drive to

make sure it does not vibrate.

6.3 Planning Lines

In order to minimize the development of noise from the transmission of structure-borne noise, observe the following:

• Use hoses instead of pipes.

• Secure pipes with elastic clamps.

Suction Line

WARNING Damage to property from cavitation!

Lack of pressure in the suction line may lead to the formation of air bubbles in the operating fluid and as a result may lead to severe damage to the pump.

• Configure the layout of the suction lines so that the inlet pressure cannot be any lower than the minimum of

0.8 bar absolute at the suction port.

• Ensure that the operating fluid has the correct viscosity.

Planning Lines

• Short suction lines with wide inside diameters are needed to ensure that the noise output is low.

• Suction speed < 1 m/sec.

Connecting Pipes 6 Mounting

• Avoid sharp angles and screwed pipe joints (danger of air intake and dispersion, high flow resistance). Use curved pipes or hoses instead.

• Maintain the minimum inlet pressure.

• Only reduce the length of the suction line at the pump entry.

• If a suction filter (min. 0.15 mm mesh aperture) or a shut-off valve is used, install the devices below the fluid level.

Pressure Line

• Ensure sufficient stability.

• Inspect the tightening torques of the screws.

Drain Line

• Install the drain line so that the pump housing is always completely filled with pressure fluid (use the upper connection).

• It should lead directly into the tank separated from the other return lines.

• The end of the line must be below the fluid line in the tank, even at the lowest fluid level.

• The distance from the suction line should be as large as possible. Do not place a filter, cooler or non-return valve in the drain line. Max. length 3 m.

• Pressure at the drain line max. 2 bar absolute (1 bar above atmosphere).

• The recommended outside diameter of the pipe used as a drain line (lightweight version): Ö Tab. 3, Page 27

Connecting Pipes

6.4 Connecting Pipes

For the pump, the connections do not depend on the direction of the rotation.

Procedure:

For securing the control and leak oil port and the suction and pressure flange, the appropriate screw connections must be used.

1. Remove the end caps from each connection.

2. Clean the sealing surfaces and the lines.

3. Connect the lines in accordance with the block diagram (suction line A, pressure line B). Ö Chap. "12.4 Tightening Torque", Page 65

4. For pumps with load sensing compensator with p-T control notch

- The compensator's tank line may not be combined with the pump's

leak oil line.

5. For multiple pump arrangements, which are equipped with the "load sensing compensator with p-T control notch", in the event that a circular flow is required:

- Only connect the tank line to the tank at the compensator of the first pump to activate the p-T control notch.

- Close off the compensators' t-connections for the add-on pumps.

6 Mounting Electrically connecting the pump

6.5 Electrically connecting the pump

The pump's electrical is connected through the control unit: Ö Application Instruction RKP-D with CAN Bus Interface

6.6 Arranging Multiple Pumps

6.6.1 Determining the through drive torque

Additional pump stages can be mounted axially to the pump and as a result, all pumps can be driven by the same shaft. Available for multiple mounting purposes are radial piston pumps (the maximum size to be selected should be equal to pump stage 1) or other pumps with adapter flanges for SAE-A or SAE-B. For the maximum permissible through drive torque of the added pumps, see the table below. Ö Tab. 7, Page 37

Through Drive Torque for Added RKP, SAE-A- or SAE-B Adapters

Pump Stage 1 Pump Stage 2

RKP-II RKP-II SAE-A SAE-B

Size [cm

19 90 Nm – – – 110 Nm –

32/45 185 Nm 185 Nm – – 110 Nm 185 Nm

63/80/100 400 Nm 400 Nm 400 Nm – 110 Nm 280 Nm

140 400 Nm 400 Nm 400 Nm 620 Nm 110 Nm 280 Nm

/R] 19 32

63 80

100

140 – –

Electrically connecting the pump

Arranging Multiple Pumps, Determining the through drive torque

Tab. 7: Permissible Through Drive Torques

The required through drive torque to drive the added on pumps should be determined by using the following variables:

V [cm3/R] : Displacement p [bar] : Pressure

[%] : Hydro-mechanical efficiency

M [Nm] : Through drive torque

Through Drive Torque of Pump Stage 1 to 2:

⋅

ipi

M1159,

⋅=

∑

i2=

---------------- -

Example:

Based on a pump combination RKP 63 + RKP 63 + RKP 32 + AZP 16 280 bar, 210 bar, 150 bar, 50 bar this would mean:

Formula for Through Drive Torque for Multiple Pumps

Arranging Multiple Pumps 6 Mounting

Design of the first through drive

The pressure and the current flow for the first pump have no effect on the torque transferred by the through drive. According to the formula shown above, this torque is the result of

⋅

2p2

= 1,59 · (63 · 210 / 95 + 32 · 150 / 93 + 16 · 50 / 90) Nm

= 318 Nm



159,

------------------- -

⋅=



⋅

3p3

------------------- -

⋅

4p4

------------------- -++

The variable 318 Nm is below the threshold value of 400 Nm listed in the table for adding on an RKP 63 to an RKP 63.

Design of the second through drive

159,

= 1,59 · (32 · 150 / 93 + 16 · 50 / 90) Nm

= 96 Nm

------------------- -

⋅=



⋅

3p3



⋅

4p4

------------------- -+

Again in this case, the variable 96 Nm is below the respective threshold value of 400 Nm for the through drive for the arrangement of an RKP-II 63 to an RKPII 32.

Design of the third through drive

In the same manner, 14 Nm is obtained for the torque required to drive the added on gear pump. As a result, the through drives of these pump arrangements are permissible with the specified pressure values.

Section Diagram Multiple Pumps

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

6 Mounting Arranging Multiple Pumps

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

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

Arranging Multiple Pumps 6 Mounting

6.6.2 Attaching the Adapter Flange

Pre-Conditions:

Attaching the Adapter Flange

• The centering diameters of both the adapter flange and the add-on pump match.

• The dimensions of the through drive shaft match with the add-on pump.

• The flange diameters of both the adapter flange and the add-on pump match.

• The connection surfaces are clean.

Procedure:

1. Attach the adapter flange to the add-on pump without damaging the

O-rings.

2. Bolt the adapter flange to the pump:

- Observe the tightening torques of the fasteners. Ö Chap. "12.4 Tightening Torque", Page 65

For adding on a pump, the following adapter flanges are available:

Adapter flange SAE-A with 9-tooth shaft

Thread

Profile

Shaft end

Bolt

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

Thread

for add-on pump

Flange Code: 82-2 Shaft Code: 16-4 Spline as per: ANSI B92.1 9T 16/32 DP Flat root side fit Conditions for attachment: RKP with heavy-duty through drive

The adapter includes through drive shaft, seals (HNBR), intermediate ring for RKP 63–140 and two fastening screws.

6 Mounting Arranging Multiple Pumps

Adapter flange SAE-A with 13-tooth shaft

Profile

Bolt

Thread

Shaft end

for add-on pump

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

Flange Code: 101-2 Shaft Code: 22-4 Spline as per: ANSI B92.1 13T 16/32 DP Flat root side fit Conditions for attachment: RKP with heavy-duty through drive

The adapter includes through drive shaft, seals (HNBR), intermediate ring for RKP 63–140 and four fastening screws.

Arranging Multiple Pumps 6 Mounting

For your notes.

7 Operation Initial Pump Set-Up

7 Operation

For pumps in explosive areas, observe the supplementary documentation as well: Ö User Manual RKP II Explosion-proof

For any and all tasks to be performed on the pumps, appropriate personal protective equipment should be worn. Ö Chap. "2.2.4 Work Safety", Page 9

7.1 Initial Pump Set-Up

CAUTION Damage to the pump!

Setting up the pump for initial operation without the required basic mechanical and hydraulic knowledge may result in damage to the pump.

• The pump may only be set up initially by qualified personnel.

DANGER Risk of injury and property damage as a result of blows or

impact!

Unexpected and uncontrolled movement of the machine / equipment may lead to severe injury or property damage.

• Only trained personnel should be allowed to initially set-up the pump.

• Have the equipment manufacturer or operator assure that no uncontrolled signals are being transmitted to the pump.

• Have the equipment manufacturer or the operator assure that a pump malfunction (e. g. piston jam caused by crud) is recognized so that a malfunction of the axle / machine / equipment can be prevented.

• Ascertain that all plug connections are wired and allocated correctly.

• Make sure that all hydraulic ports are connected correctly.

• Make certain that the rotational direction of the drive motor is correct.

• Check for correct drive shaft connection to the drive motor.

• Have the equipment manufacturer or operator assure that customer specific parameters were loaded correctly.

Operation

Initial Pump Set-Up

WARNING Risk of poisoning and injury!

Contact with the operating fluid can cause health problems, such as injury to eyes, damage to the skin or inhalation poisoning.

• Before initial set-up, check the lines and connection ports for any damage.

• Adhere to the operating fluid manufacturer's safety instructions.

Initial Pump Set-Up 7 Operation

WARNING Risk of injury and property damage as a result of fire!

Easily inflammable operating fluid may cause fire.

• Keep the pump away from any open flames.

WARNING Risk of Burns!

Pump parts run hot while in operation.

• Do not touch the pump while it is running.

WARNING Risk of injury and property damage as a result of

engaging or winding!

Freely accessible rotating machine / equipment parts may lead to severe injuries or property damage as a result of engaging or winding.

• Use suitable protective devices to ensure that access to the drive shaft is blocked.

7.1.1 Filling up the Pump

Filling up the Pump

Adjusting the Compensator

The pump must be completely filled with operating fluid before initial operation.

Procedure:

1. Fill the pump through the leakage oil port with operating fluid

completely.

7.1.2 Adjusting the Compensator

Information on the compensator functions: Ö Chap. "3.5 Compensator Operation", Page 15

All compensators are pre-set at the factory. In this section, information on the parameters needed to adjust the compensators is provided.

The following information is the same for F, H, J and R compensators:

Tightening torque for the lock nuts of the adjusting screw for adjusting the compensator pressure: SW 19 = 10 Nm + 5 Nm

Procedure:

1. Depending on the compensator, refer to the respective subchapter.

2. If required: Adjust the compensator according to the information provided

in the subchapter.

3. For G compensators: Adjust the compensator using the lockable

adjustment knob.

7.1.2.1 Hydraulically Driven Remote Pressure Compensator, H1

Information on the compensator: Ö Chap. "3.5.2 Hydraulically Driven Remote Pressure Compensator, H1", Page 17

7 Operation Initial Pump Set-Up

The information in this section also applies to: Ö Chap. "3.5.4 Load Sensing Compensator, J1", Page 19

When high dynamics are required for flow control, orifice and control flow volume, contact us to discuss application specific compensator adjustments.

Default Compensator Settings

∆p = 10 bar + 2 bar or ∆p = 20 bar + 2 bar

Hose for Control Line

The following information are recommended values:

Hose length approx. 800 mm

Pump Type NW [mm]

RKP-II 19 6

RKP-II 32, 45 8

RKP-II 63, 80, 100 10

Tab. 8: Nominal width for Control Line Hose

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

Information on the compensator: Ö Chap. "3.5.5 Load Sensing Compensator with p-T Control Notch, R1", Page 20

Default Compensator Settings

RKP-II 16–100: ∆p = 10 bar + 2 bar RKP-II 140: ∆p = 13 bar + 2 bar

Hose for Control Line

The following information provides recommended values:

Hose length approx. 800 mm

Pump Type NW [mm] D1 [mm] D2 [mm]

RKP-II 19, 32, 45 6 0.9 1.2

RKP-II 63, 80, 100 8 0.9 1.2

RKP-II 140 8 0.8 1.1

Tab. 9: Nominal width for Control Line Hose

7.1.2.3 Mechanical Stroke Adjustment

Information on stroke adjustments: Ö Chap. "3.5.6 Mechanical Stroke Adjustment, B1", Page 21

When adjusting the required flow volume, make sure that the stroke ring is held tight between the two adjustment screws. Upon delivery, the pump is set to V

max.

Initial Pump Set-Up 7 Operation

The information in the following table refers to Ö Fig. 10, Page 21

Displacement V [cm

Pos.1 WS8 = 15Nm + 5Nm WS8 = 25Nm + 5Nm

Pos. 2 WS 24 = 200 Nm ± 10 Nm

∆V for 1 mm adjusting screw travel (pitch 1.5 mm/R)

/U] 1932456380100140

3.6 5.6 6.5 8.9 11.3 11.5

Tab. 10: Mechanical Stroke Adjustment

Procedure:

1. Set the adjusting screws of the mechanical stroke adjustment and

tighten them.

- Tightening torque Ö Tab. 10, Page 46

2. Secure the adjusting screws with SEAL-Lock

sealing nuts SW 24

(M16x1.5).

- Tightening torque M

= 200 Nm ± 10 Nm.

3. Attach a note that the seal capacity can no longer be guaranteed after

loosening them five times.

- If required: replace SEAL-Lock

sealing nut.

7.1.2.4 Servo Control, C1

Information about the Servo Control: Ö Chap. "3.5.7 Servo Control, C1", Page 22

The zero position and the end position are set at the factory. Manual or mechanical operations are performed using the adjustment lever.

Pos. Description

1 Zero position (set at the factory)

2 End position / ±V

Displacement V [cm3/R] 1932456380100

Angle α [°] 444757445656

Control torque M [Nm] Zero position 1.2 1.6

(set at the factory)

max.

Fig. 24: Servo Control, C1

End position 1.6 1.7 2.4 2.6 2.6

max. 8

Tab. 11: Adjustment Torque Servo Control

7 Operation Initial Pump Set-Up

Procedure:

1. Regulate the pump's flow volume by positioning the adjustment lever.

7.1.2.5 Power Control, S1, S2

Information on the power control:

Ö Chap. "3.5.8 Power Control, S1", Page 23 Ö Chap. "3.5.9 Power Control, S2", Page 25

The power control settings are set at the factory and may not be changed!

Pos. Description

1 Power control setting (set at the factory; may not be changed)

2 Pressure decrease (set at the factory ∆p = 10 bar + 2 bar)

3 Control port G 1/4"

Fig. 25: Power Control, S1, S2

Default Compensator Settings

∆p = 10 bar + 2 bar

Hose for Control Line

The following information provides recommended values:

Hose length approx. 800 mm

Pump Type NW [mm]

RKP-II 19 6

RKP-II 32, 45 8

RKP-II 63, 80, 100 10

Tab. 12: Nominal width for Control Line Hose

Performing Functions Tests 7 Operation

7.1.2.6 Limiting the Maximum Flow

Pos. Description

1 Adjustment mandrel

2 Cap nut

3 Lock nut

Fig. 26: Limiting the Maximum Flow

Performing Functions Tests

Displacement

V [cm

/R] 1932456380100 140

Pos.1 WS 8 WS 12 WS 10

Pos. 2 WS 24 = 40 Nm +

Pos. 3 WS 24 = 50 Nm +

∆V for 1 mm adjusting screw travel (pitch

1.5 mm/R)

10 Nm

3.6 5.6 6.5 8.9 11.3 11.5

Tab. 13: Adjustments Limiting the Maximum Flow

WS 32 = 80 Nm +

10 Nm

WS 32 = 90 Nm +

10 Nm

WS 27 = 80 Nm +

10 Nm

WS 27 = 90 Nm +

10 Nm

7.2 Performing Functions Tests

The functions tests is performed to ensure that the pump has been installed into the machine / equipment properly.

Pre-Conditions:

• Initial set-up of the pump is complete: Ö Chap. "7.1 Initial Pump Set-Up", Page 43

• The end caps on the through drive of the pump stages have been removed.

• It has been assured that the pump is being supplied with operating fluid.

• The pump has been visually inspected, with particular attention given to the lines and port connections.

Procedure:

1. Carry out the functions test in accordance with the instructions provided

by the machine / equipment manufacturer.

7 Operation Operating the Pump

2. In doing so, watch especially for:

- Noise development

- Any exterior leaks

7.3 Operating the Pump

DANGER Bodily injuries and property damage!

Incorrectly setting the pump in operation may lead to unexpected and uncontrolled movements of the machine / equipment and as a result may lead to bodily injuries or property damage.

• Only trained personnel should be allowed to operate the pump.

• Have the equipment manufacturer or operator assure that no uncontrolled signals are being transmitted to the pump.

WARNING Risk of Burns!

Pump parts run hot while in operation.

• Do not touch the pump while it is running.

WARNING Damage to Property!

Operating the pump without operating fluid will result in the pump running dry and damage to the pump.

• Only start up the pump when the pump housing is completely filled with operating fluid.

Operating the Pump

7.3.1 Start up

• Pump has been filled. Ö Chap. "7.1.1 Filling up the Pump", Page 44

• The temperature of the operating fluid in the tank does not exceed the pump temperature by more than 25 °C.

Procedure:

If the temperature of the operating fluid in the tank exceeds the pump temperature by more than 25 °C, the pump should only be switched on in short intervals of 1 to 2 seconds until it has heated up.

1. Start up the drive motor.

2. Check the rotational direction of the drive motor.

3. Operate the pump at low pressure until the hydraulic system has been

de-aerated.

4. For pumps with HF fluids: Run the pump for approx. one hour at low

pressure (30–50 bar).

Start upPre-Conditions:

Placing the Pump out of Operation 7 Operation

7.3.2 Flushing the Pump

Flushing the Pump

Placing the Pump out of Operation

If the pump is operated for longer periods of time at low pressure without delivery (t > 15 min, p < 30 bar, Q = 0 l/min) it will be necessary to flush the pump to dissipate the heat.

Procedure:

1. The flushing line must be connected to the pump's lowest leakage

connection.

2. Flush the pump using operating fluid quantities depending on pump size:

Displacement V [cm3/R] 1932456380100140

Flushing quantity [l/min] 4–6 6–8

Tab. 14: Flushing Quantity

7.4 Placing the Pump out of Operation

DANGER Risk of injury and property damage as a result of blows or

impact!

Unexpected and uncontrolled movement of the machine / equipment may lead to severe injury or property damage.

• Only trained personnel should be allowed to remove the pump.

• Have the equipment manufacturer or operator assure that no uncontrolled signals are being transmitted to the pump.

• Make sure that the drive motor cannot start up.

WARNING Risk of injury and poisoning by dangerous operating fluid!

Leaking operating fluid may lead to severe personal injury and property damage.

• Only trained personnel should be allowed to place the pump out of operation.

Pre-Conditions:

• The drive motor has been switched of and is secured from being switched back on.

• Machine / equipment is at zero pressure and idle.

• Pump has cooled down.

Procedure:

1. Close the fittings on the suction and pressure side.

2. Completely drain the pump through the leakage oil port.

3. Depending on what is required:

- Remove the pump: Ö Chap. "9.1 Demounting the Pump", Page 55

- Storing the Pump: Ö Chap. "5.3 Storing the Pump", Page 31

7 Operation Reconnecting the Pump

7.5 Reconnecting the Pump

Reconnecting the PumpPre-Conditions:

• If the pump was stored: Measures were carried out that were necessary because of the duration of storage. Ö Tab. 6, Page 31

• Pump is installed. Ö Chap. "6 Mounting", Page 33

Procedure:

1. Carry out all steps applicable for the initial set-up of the pump.

Ö Chap. "7.1 Initial Pump Set-Up", Page 43

Reconnecting the Pump 7 Operation

For your notes.

8 Maintenance and Repairs Monitoring

8 Maintenance and Repairs

For pumps in explosive areas, the supplementary documentation should also be observed: Ö User Manual RKP II Explosion-proof

For any and all tasks to be performed on the pump, suitable personal protective equipment should be worn. Ö Chap. "2.2.4 Work Safety", Page 9

8.1 Monitoring

Tasks Intervals

Check pump for leakage Daily

Check pump for noises Daily

Check that fasteners are tightened Monthly

Check the machine's operating temperature at constant operating conditions

Check the machine's operating fluid level Daily

Check the operating fluid quality Annually or every 2000

Tab. 15: Monitoring

Weekly

operating hours

Maintenance and Repairs

Monitoring

Trouble-shooting 8 Maintenance and Repairs

8.2 Trouble-shooting

Trouble-shooting

Should repairs be needed because of any trouble with the pump, these should only be carried out by one of our service technicians or by an authorized service location.

Ö Chap. "2.2.3 Structural Modifications", Page 9 Ö Chap. "8.3 Moog Service Addresses", Page 54

Trouble Cause Repair

Radial Piston Pump

Peculiar noises Cavitation,

Pump is sucking air, speed is too high, mechanical damage

Flow volume too low or non-existent

Pressure too low or non-existent

Fluctuations in the pressure or displacement

Pump does not cut off, leakage in the pump, comparing performance of drive motor and pump shows no match, wear caused by dirt, engine damage

Pump is sucking air, leakage in the pump, wear caused by dirt, engine damage unstable compensator

Configure the inlet suction so that the pressure in the suction line is not below minimum, limit the speed settings, contact us and have damaged parts replaced

Check inlet suction, check for wear, check adjustable parts, contact us and have damaged parts replaced

Check cut-off, seal leaky lines, check actuation, contact us and have damaged parts replaced

Seal leaking areas, check the configuration of the antivibration orifice and if necessary, use the correct antivibration orifice, check the dimensions of the control oil hose and if necessary, replace with the correct control oil hose, contact us and have damaged parts replaced

Tab. 16: Trouble-shooting

8.3 Moog Service Addresses

Moog Service Addresses

Visit www.moog.com/worldwide to find the location nearest you for application engineering, repairs and service.

9 Demounting Demounting the Pump

9 Demounting

For pumps in explosive areas, the supplementary documentation should also be observed: Ö User Manual RKP II Explosion-Proof

For any and all tasks to be performed on the pumps, appropriate personal protective equipment should be worn. Ö Chap. "2.2.4 Work Safety", Page 9

9.1 Demounting the Pump

In this segment, instructions are given on how to dismantle the pump to prepare it for shipping to us or to one of our authorized service locations for pump repairs to be performed and not on how to disassemble the pump.

WARNING Risk of crushing!

During demounting, the pump may topple over and crush body parts.

• Select lifting gear appropriate for the overall weight of the pump.

• Attach the lifting gear to the pump properly. Ö Chap. "5.2 Transporting the Pump", Page 29

• Avoid all areas below the floating load.

Demounting

Demounting the Pump

WARNING Risk of injury and poisoning by dangerous operating fluid!

Leaks from dangerous operating fluid may lead to serious injuries.

• Check to ensure that the operating fluid in use does not pose a risk.

• Make sure that the machine / equipment is at zero pressure and zero voltage.

• Wear protective work equipment such as, e. g., work gloves. Ö Chap. "2.2.4 Work Safety", Page 9

WARNING Risk of death by electrocution!

Contact with live parts may lead to severe injuries and even death.

• Make sure that the machine / equipment is at zero voltage.

CAUTION Damage to property from contamination!

Missing end caps to the pump connections may lead to contamination and resulting damage to property.

• Replace the end caps immediately after demounting the lines on the pump.

Demounting the Pump 9 Demounting

Pre-Conditions:

• The pump is idle: Ö Chap. "7.4 Placing the Pump out of Operation", Page 50

• Demounting location is freely accessible.

• Machine / equipment is at zero pressure and zero voltage.

• Operating fluid has been inspected for risks and any necessary safety precautions have been taken.

• Standard tools are available.

• Supplementary documentation is available.

Procedure:

1. Remove the electrical connections from the pump:

Ö Application Instruction RKP-D with CAN Bus Interface

2. Place the collecting tray for leaking operating fluid underneath the pump.

3. Remove the lines from the pump.

4. Completely drain the pump.

5. Attach the end caps and the flange covers to the pump.

6. Attach suitable lifting tackle to the pump.

Ö Chap. "5.2 Transporting the Pump", Page 29

7. Detach the pump with the coupling from the drive motor.

8. Place the pump onto a firm and stable surface.

9. Detach the lifting gear from the pump.

10. Detach the coupling from the pump's drive shaft in accordance with the

instructions provided by the coupling manufacturer.

11. Attach transport protection means for shaft ends to the pump's drive shaft.

10 Spare Parts, Accessories, Repairs

The operator is not authorized to install spare parts and accessories. Repairs or other structural modifications to the pump may only be carried out by us or by an authorized service repair shop. Ö Chap. "2.2.3 Structural Modifications", Page 9

For all tasks described in this User Manual, commercially available standard tools may be used.

CAUTION Property damage to the pump or equipment!

Unsuitable or defective accessories or spare parts may lead to pump or machine / equipment failure as a result of damage.

• We recommend: Only use original accessories or spare parts.

• All warranties and liability claims shall be void for injuries or property damage as a result of using unsuitable or defective accessories or spare parts. Ö Chap. "1.5 Warranty and Liability", Page 5

1. For repairs to the pump:

Ö Chap. "9.1 Demounting the Pump", Page 55

2. Package the pump for transport to our facility or to an authorized service

repair shop, preferably in its original packaging material. Ö Chap. "8.3 Moog Service Addresses", Page 54

Spare Parts, Accessories

Tools

RepairsSteps to be taken when carrying out repair work:

For your notes.

10 Spare Parts, Accessories, Repairs

11 Index A…S

A B C D E F G H I J K L M N O P Q R S T U V W X Y Z

11 Index

Accessories • 57 Arranging multiple pumps

Attaching the adapter flange • 40 Determining the through drive torque • 37

Declaration of Conformity • 61 Demounting • 55

Demounting the Pump • 55

Duplication of the User Manual is strictly prohibited • A

Environmental Safety

Disposal • 3 Emissions • 3

General Safety Instructions

Operating hydraulic equipment • 10 Specific phases of operation • 10

General safety instructions • 10

Mounting • 33

Arranging multiple pumps • 37 Connecting pipes • 36 Electrically connecting pump • 37 Installing the pump • 34 Planning lines • 35 Preparing for mounting • 33

Nameplate • 13

Operating the pump

Flushing the pump • 50 Start up • 49

Operation • 43

Initial Pump Set-Up • 43 Operating the pump • 49 Performing Functions Tests • 48 Placing the Pump out of Operation • 50 Reconnecting the Pump • 51

Organizational measures

Safe operation • 8 Selecting and qualifying staff • 8 Structural modifications • 9 Work Safety • 9

Information on the User Manual • 1

Supplemental Documentation • 2 Symbols • 2 Target Groups • 1 Warning Labels • 2

Initial Pump Set-Up

Adjusting the Compensator • 44 Filling up the pump • 44

Intended use • 7

Maintenance and Repairs • 53

Monitoring • 53 Moog Service Addresses • 54

Trouble-shooting • 54 Manufacturer's Address • A Manufacturer's Declaration • 6, 62 Manufacturer's Declaration and Declaration of Conformity • 6 Moog GmbH Address • A

Product Description

Configuration • 11 Functional Description • 14 Nameplate • 13 Scope of Delivery • 12

Repairs • 57 Reproduction of the User Manual is strictly prohibited • A Responsibilities • 4

Spare parts • 57

A B C D E F G H I J K L M N O P Q R S T U V W X Y Z

T…W 11 Index

A B C D E F G H I J K L M N O P Q R S T U V W X Y Z

Technical Data • 27

General Technical Data • 27

Operating Conditions • 28 Tools • 57 Trademarks • 6 Transport and Storage • 29

Preserving the Pump • 32

Storing the pump • 31

Transporting the Pump • 29

Unpacking the Pump • 29

User Manual

Duplication strictly prohibited • A

Protected by Copyright • A

Reproduction strictly prohibited • A

Reservation to make changes • A

Warranty and Liability • 5

A B C D E F G H I J K L M N O P Q R S T U V W X Y Z

12 Appendix Declaration of Conformity

12 Appendix

12.1 Declaration of Conformity

Fig. 27: Declaration of Conformity

Manufacturer's Declaration 12 Appendix

12.2 Manufacturer's Declaration

Fig. 28: Manufacturer's Declaration

12 Appendix Abbreviations, Symbols and Code Letters

12.3 Abbreviations, Symbols and Code Letters

Abb. Explanation

Symbol for filter efficiency

∆p Symbol for pressure change

∆p

Symbol for nominal pressure change

ν Symbol for viscosity

A Connection port (consumer load connection)

ANSI American National Standards Institute (http://www.ansi.org)

ATEX Atmosphère explosible (synonymous for the EU Directive pertaining to

explosion protection)

B Connection port (consumer load connection)

DOrifice

D1, D2 Orifice diameter

DIN Deutsches Institut für Normung e. V. (http://www.din.de)

EN Europa-Norm (=European Standard)

EU European Union

HFA Special operating fluid: consists of approx. 95% water

HFC Special operating fluid: water-based polymer solution

HNBR Hydrogenated NitrileButadieneRubber

(sealant material, such as e. g.: o-rings)

ISO International Organization for Standardization (http://www.iso.org)

M Symbol for through-drive torque

Tightening torque

n Revolution speed

max.

Max. revolution speed

NW NominalWidth

Symbol for hydraulic-mechanical efficiency

p Symbol for pressure (Pressure)

min.

max.

Symbol for nominal pressure

Symbol for maximum operating pressure

Symbol for minimum pressure

Symbol for maximum pressure

p Connection port (pressure connection)

Q Symbol for displacement

Q Symbol for a pump's delivery rate

R Revolution

SAE American series of standards (parallel to DIN-EN standards)

WS Wrenchsize

t Symbol for time

T Symbol for temperature

T Connection port (Tank connection)

TÜV Technischer Überwachungsverein

/R] Displacement

V[cm

V Symbol for volume (e. g. tank capacity)

V Symbol for delivery volume

max.

Symbol for maximum delivery volume

Tab. 17: Abbreviations, Symbols and Code Letters (Part 1 of 2)

Abbreviations, Symbols and Code Letters

Abbreviations, Symbols and Code Letters 12 Appendix

Abb. Explanation

∆V Change in pump displacement

VDI Verein Deutscher Ingenieure e. V. (http://www.vdi.de)

VDE Verband der Elektrotechnik Elektronik Informationstechnik e. V.

(http://www.vde.de)

X Connection port (control pressure connection)

L Connection port (leakage connection)

Tab. 17: Abbreviations, Symbols and Code Letters (Part 2 of 2)

12 Appendix Tightening Torque

12.4 Tightening Torque

The data on the tightening torque in this segment is considered as reference values only. Preference should be given to the data provided by each manufacturer of the particular machine part!

Flange for Suction and Pressure Connection

Flanges with corresponding screws and sealing elements are to be used in accordance with the information provided by the flange manufacturer. Respective tightening torques should be gathered from the information provided by the flange manufacturer or as per standard ISO 6162.

Mounting Screws

As per DIN 13 or ISO 68, in individual cases, tightening torques should be checked in accordance with VDI 2230.

Mounting screws for SAE-A- and SAE-B flange:

Adapter Flange Type Thread Size Max. Permissible Tightening Torque

SAE-A M 10 58 ... 78 Nm

SAE-B M 10 62 ... 75 Nm

SAE-B M 12 105 ... 130 Nm

Tab. 18: Tightening Torquefor mounting screws

Sealing Plugs Form E with ED Seal (Reference Values)

Tightening Torque

Thread Size Max. Permissible Tightening Torque

M 18x1.5 65 Nm (+10%)

M 22x1.5 90 Nm (+10%)

M 26x1.5 135 Nm (+10%)

G 1/4" 30 Nm (+10%)

G 3/8" 60 Nm (+10%)

Tab. 19: Tightening Torque for sealing plugs

Straight Screw-in Sockets Form E with ED Seals (Reference Values)

Thread Size Max. Permissible Tightening Torque

M 18x1.5 70 Nm (+10%)

M 22x1.5 125 Nm (+10%)

M 26x1.5 180 Nm (+10%)

G 1/4" 35 Nm (+10%)

G 3/8" 70 Nm (+10%)

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

Tightening Torque 12 Appendix

For your notes.

MOOG.COM/INDUSTRIAL

For the location nearest you, contact moog.com/industrial/globallocator.

Argentina +54 11 4326 5916 info.argentina@moog.com Australia +61 3 9561 6044 info.australia@moog.com Brazil +55 11 5523 8011 info.brazil@moog.com China +86 21 2893 1600 info.china@moog.com Germany +49 7031 622 0 info.germany@moog.com Finland +358 9 2517 2730 info.finland@moog.com France +33 1 4560 7000 info.france@moog.com United Kingdom +44 1684 296600 info.unitedkingdom@moog.com Hong Kong +852 2 635 3200 info.hongkong@moog.com India +91 80 4120 8799 info.india@moog.com Ireland +353 21 451 9000 info.ireland@moog.com Italy +39 0332 421 111 info.italy@moog.com Japan +81 463 55 3615 info.japan@moog.com Korea +82 31 764 6711 info.korea@moog.com Luxembourg +352 40 46 401 info.luxembourg@moog.com Netherlands +31 252 462 000 info.netherlands@moog.com Norway +47 64 94 19 48 info.norway@moog.com Austria +43 664 144 65 80 info.austria@moog.com Russia +7 31713 1811 info.russia@moog.com Sweden +46 31 680 060 info.sweden@moog.com Switzerland +41 71 394 5010 info.switzerland@moog.com Singapore +65 6773 6238 info.singapore@moog.com Spain +34 902 133 240 info.spain@moog.com South Africa +27 12 653 6768 info.southafrica@moog.com USA +1 716 652 2000 info.usa@moog.com

User Manual RKP-II (CA53461-001; Version 1.0, 10/07)

Moog RKP-II User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Copyright

Table of Contents

List of Tables

List of Figures

1 General Information

1.1 Information on the User Manual

1.1.1 Target Groups

1.1.1.1 Operator

1.1.1.2 Trained Staff

1.1.2 Subject to Change and Validity

1.1.3 Completeness

1.1.4 Safe Keeping

1.1.5 Warning Labels

1.1.6 Symbols

1.2 Supplemental Documentation

1.3 Environmental Safety

1.3.1 Emissions

1.3.2 Disposal

1.4 Responsibilities

1.5 Warranty and Liability

1.6 Manufacturer's Declaration and Declaration of Conformity

1.7 Trademarks

2Safety

2.1 Intended Use

2.2 Organizational Measures

2.2.1 Safe Operation

2.2.2 Selecting and Qualifying Staff

2.2.3 Structural Modifications

2.2.4 Work Safety

2.3 General Safety Instructions

2.3.1 Specific Phases of Operation

2.3.1.1 Mounting

2.3.1.2 Start Up

2.3.1.3 Maintenance and Repairs

2.3.2 Operating Hydraulic Equipment

2.3.2.1 Safety Devices for Limiting Pressure

3 Product Description

3.1 Configuration

3.2 Scope of Delivery

3.3 Nameplate

3.4 Functional Description

3.5 Compensator Operation

3.5.1 Adjustable Pressure Compensator, F1, F2

3.5.2 Hydraulically Driven Remote Pressure Compensator, H1

3.5.3 Remote Pressure Compensator with Mooring Control, H2

3.5.4 Load Sensing Compensator, J1

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

3.5.6 Mechanical Stroke Adjustment, B1

3.5.7 Servo Control, C1

3.5.8 Power Control, S1

3.5.9 Power Control, S2

4 Technical Data

4.1 General Technical Data

4.2 Operating Conditions

5 Transport and Storage

5.1 Unpacking the Pump

5.2 Transporting the Pump

5.3 Storing the Pump

5.4 Preserving the Pump

6 Mounting

6.1 Preparing for mounting

6.2 Installing the Pump

6.3 Planning Lines

6.4 Connecting Pipes

6.5 Electrically connecting the pump

6.6 Arranging Multiple Pumps

6.6.1 Determining the through drive torque

6.6.2 Attaching the Adapter Flange

7 Operation

7.1 Initial Pump Set-Up

7.1.1 Filling up the Pump

7.1.2 Adjusting the Compensator

7.1.2.1 Hydraulically Driven Remote Pressure Compensator, H1

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

7.1.2.3 Mechanical Stroke Adjustment

7.1.2.4 Servo Control, C1