INSTRUCTION MANUAL RKP

CHANGING PILOT VALVE AND LVDT

Radial Piston Pump (RKP)

CA96722-001; Version 1.1, 04/11

Instruction manual for changing pilot valve and LVDT at MOOG RKP-D and
MOOG-EHV
First steps before starting working at the pump:
1) machine without pressure
2) switch off the motor
3) machine without power supply

1 Exchange pilot valve

The valve is factory made configured to the pump type. Adjustment works at the pilot valve are
not necessary when exchanging the valve.

tightening torque
Pos. 1.1 mounting screws for valve 6-8 Nm
Pos. 1.2 mounting screws for LVDT 6-8 Nm
Pos. 1.3 cover for LVDT ~5 Nm
Pos. 3.1 pressure tube see chapter 2

electrical connections MOOG-EHV:

Pos 1.4 solenoid-current pilot valve (to Bosch-card b6;b8)
Pos 1.5 stroke spool of pilot valve (to Bosch-card b22; z30; b24; b30)

Pos 1.6 stroke of pump stroke ring (TF modulated signal from LVDT)
Pos 1.7 stroke of pump stroke ring (to Bosch-card b26; z30; b28; b30)

1.1 1.6

1.7

1.5

1.4 1.2 1.3

picture 1: MOOG-EHV pilot valve mounted on pump

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electrical connections RKP-D:
note: see actual RKP-D-catalogue for detailed description of the functionality

2 Disassembly / Assembly LVDT housing

There is no active electronic included in the LVDT housing only a passive coil system. This housing
could only be disassembled with the pressure tube together. See picture 2:

Attention:
The adjustment system of the coils is connected to the pressure tube (difference to former system
Bosch!)
It’s recommended to have approx. 60mm space in direction of disassembly of the LVDT to move
the pressure tube incl. pressure tube out of the stick core. Don’t damage the stick core during
moving the LVDT housing! A twisted stick core could lead to a failure.
When unfastening the pressure tube the hydraulic system will be opened (connection to high
pressure area of the pump!). Make sure there is no pressure at the system before starting!

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 pressure tube 3.1

stick core

LVDT housing

screw for zero adjustment

way for movement

80mm

coil system

USIT-ring washer

O-ring sealing ( 32x2 NBR)

picture 2: schematic of the mounted LVDT

Procedure for disassembly:

1. remove the screws of the LVDT housing 1.2

2. lift the LVDT housing approx. 10mm (it’s not possible to pull the pressure tube completely out
of the housing, only for ~10mm. Reason is the internal wiring of the coil system)
3. disassembly/unfastening the pressure tube with open-end wrench (spanner gap 15mm) -> see
picture 3
4. move out of the complete LVDT assembly for ~80mm
5. remove of the complete LVDT including coil, housing, pressure tube and wiring
CAUTION: During removing could flow somewhat of hydraulic fluid out of the manifold

Procedure for assembly:

In reverse order to disassembly. Pay attention to tightening torques! Following procedure for
fastening of the pressure tube:
a) pressure tube and USIT washer (new one!) premount with torque of 23…27Nm and
unfastening again
b) pressure tube and USIT washer fastening with torque 14…17,5Nm
c) mount of the LVDT housing

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picture 3: lift of the LVDT housing to unfastening the pressure tube with open-end wrench

3 Adjustment zero point with MOOG-EHV

manual only valid for pumps with internal pressure supply
dismount cover for LVDT 1.3
note: adjustment screw (spanner gap 10) is self locking
electrical connections for the used Bosch-card are detailed in catalogue “RKP-EHV”

a) rough adjustment at stop:

1. Motor stop. Make sure that the Bosch-card has still the 24V power supply for the solenoid of
the pilot valve
2. rough adjustment with adjustement screw spanner gap 10 (picture 4). Signal at b26 approx.-
9,5 Volt (relation ground b28). The voltage value b26, relation ground b28 should be also
viewable at the machine visualisation

b) zero point adjustment of the pump stroke ring

if it`s possible to give setpoint signals stroke ring (adjustment at test rig)
- hydraulic system is closed (all tubes/hoses connected)
- switch on the motor
- adjustment to 1500rpm and 100bar
- setpoint signal stroke ring z20 (relation ground b20) 5Volt
- notate the actual voltage value of the pilot valve spool b22 (relation ground b24)
- setpoint signal stroke ring z20 (relation ground b20) 0Volt
- look at actual value of the pilot valve spool b22 (relation ground b24)
-> should be 200mV (+/-50mV) below the value of the pilot valve spool at 5Volt
setpoint signal stroke ring
-> if necessary readjustment with the adjustment screw (picture 4)
-> if readjustment was necessary then switch setoint signal stroke ring again to
5Volt and after them back to 0Volt (3…5 times!)
-> control of the pilot valve spool value is now in
the correct range

if no direct changing of the setpoint is possible (practical solution)

- hydraulic system is closed
- remove connector 1.4 of the valve solenoid (no power supply of the solenoid)
- switch on the motor
- there should be at b26 (relation b28) approx. 0 Volt
- if necessary readjust with adjustment screw (picture 4)

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After the adjustment close the LVDT housing with cover screw 1.3

adjustment screw for zero

point spanner gap 10

picture 4: view of LVDT with dismounted cover screw

4 Adjustment zero point with RKP-D

manual only valid for pumps with internal pressure supply
dismount cover for LVDT 1.3
note: adjustment screw (spanner gap 10) is self locking
connection with MOOG-software program “MoVaCo” via CAN-interface to the RKP-D
-> condition: read of the RKP-D application instruction CA58548-001 before starting
-> the different used values are visible with the following parameter:

actual value stroke ring position splval

setpoint value stroke ring position spldem
actual value valve spool position splvalplt
actual value pressure prsval

a) rough adjustment at stop

1. Motor stop. Make sure that the valve has still the 24V power supply for the solenoid of the pilot
valve
2. rough adjustment with adjustement screw spanner gap 10 (picture 4). Actual value stroke ring
position is readable with “splval” at the Datalogger of MoVaCo. Another way is the signal at
pin 6 of X1 approx.19,6mA (relation ground pin 10) or 9,8Volt if the valve is a version with
voltage output

b) zero point adjustment of the pump stroke ring (adjustment at test rig)
1. hydraulic system is closed (all tubes/hoses connected)
2. switch on the motor
3. adjustment to 1500rpm and 100bar
- setpoint signal stroke to 50%
- notate the actual voltage value of the pilot valve spool splvalplt
- setpoint signal stroke to 0%
- look at actual value of the pilot valve spool splvalplt
-> should be 2% (+/- 0,5%) below the value of the pilot valve spool at 50%
setpoint signal stroke ring
-> if necessary readjustment with the adjustment screw (picture 4)
-> if readjustment was necessary then switch setoint signal stroke ring again to
50% and after them back to 0% (3…5 times!)

page 6
 -> control of the pilot valve spool value is now in
the correct range

After the adjustment close the LVDT housing with cover screw 1.3

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© 2007 Moog GmbH

Instruction Manual RKP
(CA96722-001; Version 1.1, 04/11)

All rights reserved.

Subject to changes.

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