Conversion from EHV => EHV2

and field service

from the German presentation by

Michael Sieber, 12.8.05
 Overview

• Background information
• System information

• Field replacement

Page 2 (of 21)

 Background information

From October 2005, the RKP-EHV will be gradually replaced by the

new RKP-EHV2 (2nd Generation)

The new pump has a new pilot and a new position transducer (LVDT) It is
internally different with an increased number of pistons and a new sliding
stroke ring

The change effects new machines as well as field service

This presentation covers the various issues that will occur in the field.

Page 3 (of 21)

 Background information
List of previous pilots and their replacements

RKP19 internal supply 0811 404 166 D920-130

RKP32 internal supply 0811 404 166 D920-131
RKP45 internal supply 0811 404 163 D920-132
RKP63 internal supply 0811 404 163 D920-133
RKP80 internal supply 0811 404 163 D920-134
RKP100 internal supply 0811 404 163 D920-134
RKP140 internal supply 0811 404 175 D920-136
RKP19 external supply 0811 404 161 D920-137
RKP32 external supply 0811 404 161 D920-138
RKP45 external supply 0811 404 164 D920-139
RKP63 external supply 0811 404 164 D920-140
RKP80 external supply 0811 404 164 D920-141
RKP100 external supply 0811 404 164 D920-141
RKP140 external supply 0811 404 174 D920-143

Bosch-Pilot valve Moog-Pilot valve

0811 404 XXX D920-XXX

Page 4 (of 21)

 Background information
List of transducers previously used and their replacements

Old Bosch transducer new Moog transducer

incl. core incl. pressure tube, core, seals
incl. pressure tube screws
RKP19 1837 001 313 CA49326-001
RKP32 1837 001 314 CA49326-001
RKP45 1837 001 302 CA49326-001
RKP63 1837 001 315 CA49326-001
RKP80 1837 001 317 CA49326-001
RKP100 1837 001 317 CA49326-001
RKP140 1837 001 400 CA49336-001

Bosch core Moog transducer

Bosch transducer Moog core

(requires a new
Bosch pressure tube core extension)
Moog pressure tube
Tracking rod - new centering
not part of this supply! spigot
Page 5 (of 21)
 Background information

Comments about the transducers

-The new Moog LVDT parts are all different to the old Bosch parts.

Further, the flange interface differs because a centralising counter-bore is required. Hence mechanical
interchangeability is ruled out from the start.

Consequently, a mix of old and new parts is in no way possible

-The Bosch Transducer is matched with the Bosch core. It is supplied only as a matched set and cannot be
separated. If the Bosch transducer is changed without fitting the matched core that comes with it, then a gain
(hence flow) error results. Generally this error is small and this repair is acceptable in an emergency. It is however
necessary that the transducer mechanical null be
re-set by experienced personnel.

- Finally any remaining flow errors can be minimized by adjustments on the pQ-card, namely:
- Poti “Qmax” for the Qmax-adjustment
- Poti “Valve” for the Qmin-adjustment

Page 6 (of 21)

 Background information

Transducer notes

-The Moog transducer is not paired with the Moog core so that the transducer can be changed without changing
the core. However the mechanical null must still be re-adjusted and this should only be done by trained personnel.
- Finally any remaining flow errors can be minimized by adjustments on the pQ-card, namely:
- Poti “Qmax” for the Qmax-adjustment
- Poti “Valve” for the Qmin-adjustment

- General Note
The Moog warranty for the pump is void if any conversion or adjustments of the transducer takes place
It cannot be assumed from the information in these briefing notes that Moog officially approves of Moog transducer
repairs – rather the notes are provided with the knowledge that such unauthorised repairs have been carried out for
years in individual cases and that this practice will probably continue with the new EHV2.

Page 7 (of 21)

 Overview

• Background information

• System information
• Field replacement

Page 8 (of 21)

 Overview EHV (old)

Bosch-Transducer

Bosch-pL6-Pilot valve

Bosch-pQ-Card

Page 9 (of 21)

 Overview EHV (old)
Interconnection diagram

Bosch-Card
Bosch-transducer
b6,b8 b22, b24, z30,b30 b26,b28,z30,b30
Matched !

Control ring Bosch-Extension +

LVDT Bosch-Core
Pilot
Magnet LVDT
Bosch-block

Bosch-pL6

Page 10 (of 21)

 Overview EHV2 (new)

Features
- Change-over solution for existing EHV pumps
- same connector as EHV pump
- same dynamic behaviour as the EHV-Pump
(ie no new adjustment to the pQ-Karte is needed)

Based on:
- new Moog Transducer
- new Moog Pilot valve and new block
- new Pump working elements & housing

To note:
- The dimensions of the Pilot valve, the transducer and
the pump are slightly different (the pump has a
larger suction port)
- The Bosch-Controller Card is still needed to maintain
Warning: this picture is of a pre-series unit with
the same tuned response the solenoid connector in a different position!

Page 11 (of 21)

 EHV2 (new)
Interconnection diagram

Moog transducer
Bosch-Card
b26,b28,z30,b30 b22, b24, z30,b30 b6,b8
Not matched
LVDT
Pilot

Bosch-extension +
Magnet Bosch-core
Transducer
conditioner

Moog-D920

Moog-block
with
recessed
counterbore

Control Ring
LVDT

Page 12 (of 21)

 Overview

• Background information

• System information

• Field replacement

Page 13 (of 21)

 Warning

If any of the listed replacement options are carried out by the end user,
then Moog warranty no longer applies.

Full warranty only applies if these repairs are done by Moog or their authorised
agent.

Improper execution of these measures can lead to faults or faulty pump operation.

Page 14 (of 21)

 Scenario 1:
Bosch Pilot valve is defective
-original condition-
The Bosch-LVDT
Bosch Card stays on the Pump !
Bosch-transducer / LVDT
b6,b8 b22, b24, z30,b30 b26,b28,z30,b30

Control
Bosch-extension +
Ring
Bosch-core
Pilot LVDT
Magnet LVDT
defective !
Bosch block

Bosch-pL6

Action:
Fit Moog pilot valve !

Page 15 (of 21)

 Scenario 1:
Bosch-Pilot valve is defective
-after repair with Moog Pilot-

Bosch-Card
Bosch transducer
b6,b8 b22, b24, z30,b30 b26,b28,z30,b30

LVDT

Control
Pilot

Bosch-extension +
Ring
Bosch-core
LVDT
Transducer
conditioner

Moog-D920
Bosch block

new !
No connector

Magnet
protective
required

Sealed
with a

cap

Page 16 (of 21)

 Scenario 2:
Bosch-Transducer is defective

Bosch-Card Bosch transducer

b6,b8 b22, b24, z30,b30 b26,b28,z30,b30 Defective!

Control Bosch-extension +
Ring Bosch-core
LVDT
Pilot
Magnet LVDT
Regular Actions:
- Return to Moog for change-over to Moog LVDT and Moog pilot.
- Return to Moog for Bosch LVDT repair – only possible in the short term
Emergency repair :
Bosch-pL6 • Fit a new Bosch LVDT
• Leave existing Bosch Core & Core extension & pressure tube in
the pump
• Trained personnel to retrim null
• Readjust Qmin and Qmax on the controller

Page 17 (of 21)

 Scenario 3:
Moog-Pilot valve is defective

Bosch-card Moog transducer

b26,b28,z30,b30 b22, b24, z30,b30 b6,b8

LVDT
Pilot

Magnet
Transducer
conditioner

Moog-D920

defective !

Control ring Action

LVDT - Change the Moog pilot valve !
- Readjust Qmin and Qmax on the controller

Page 18 (of 21)

 Scenario 4:
Moog-Transducer is defective
Null adjust screw !
Bosch-card
Moog transducer
b26,b28,z30,b30 b22, b24, z30,b30 b6,b8

LVDT defective !
Pilot

Magnet
conditioner
Transducer

Moog-D920

Regular Action:
- Return to Moog for Moog LVDT change-over
- Emergency repair by trained personnel
• Replace Moog transducer with built-in pressure tube.
control ring • Leave Core + Core holder in the pump
LVDT • Retrim the mechanical null
• Check Qmin and Qmax on the controller card and trim if required

Page 19 (of 21)

 Scenario 4:
Moog transducer is defective
Zeroing or nulling the Moog transducer:

Null Adjust! Sealing screw 5Nm

Vibration-proof
Moog Transducer Null-adjust screw SW10

Transducer + pressure tube

is one assembly!

Page 20 (of 21)