Post on 08-Jul-2018
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Table of Contents1) Table of Contents
Power Unit Startup Unit Schematics, and Drawings 2) K3VL Series Piston Pump
3) Electric Motor 4) Filtration 5) Manual Pump 6) JIC Style Reservoir
7) RM Series Heat Exchanger
8) Valves
9) Miscellaneous 10) Operational/Maintenance
Service Bulletins
Y o
u r F l u i d
P o w e r
S o u r c e
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SID DIVISION
POWER UNIT START UP MANUAL
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Table of Contents
Introduction ............................................................................................................................................ 3
Description ............................................................................................................................................ 3
Preparation of Use ............................................................................................................................. 3,4
Installation ............................................................................................................................................... 4
Start-up Procedures ......................................................................................................................... 5,6
Special Tools ........................................................................................................................................... 6
General Maintenance ...................................................................................................................... 6
Maintenance Suggestions ............................................................................................................... 7,8
Troubleshooting / General Information ................................................................................. 8,9
Troubleshooting Pumps ................................................................................................................. 9,10
Troubleshooting Solenoid Valves .............................................................................................. 11
WARNING
FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF THIS PRODUCTS AND/OR SYSTEMS
DESCRIBED OR RELATED ITEMS CAN CAUSE DEATH, PERSONAL INJURY AND PROPERTY DAMAGE
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Introduction
This manual provides descriptive operation and maintenance instructions for standard Hydraulic Power
Units manufactured by COMOSO. Any additional information may be obtained from COMOSO by
referencing the Unit’s Model Number and Serial Number stamped on the Reservoir Nameplate.
Some of the Information in this manual may not apply to your power unit. Information on custom unitsmay require service and application information from other sources.
Warning
It is imperative that personnel involved in the installation, service, and operation of the power unit be
familiar with how the equipment is to be used. They should be aware of the limitations of the system and its
component parts and have knowledge of good hydraulic practices in terms of safety, installation, and
maintenance.
Description
The standard Hydraulic Power Unit usually consists of an oil reservoir which incorporates sump drain; oillevel gage, filler/breather assembly and spare return connections.
The pump will be coupled to the motor using either an integral close-coupled configuration or flexible shaft
coupling.
Customer type power units may have heat exchangers for oil cooling; pressure or return filters, oil
immersion heaters, directional valves, and other pressure and flow control valves, or monitoring
instrumentation.
Preparation For Use
Unpacking and Checking
The Power unit is mounted on skids and carefully packed for shipment. Do not remove it from the skid
until it has been carefully checked for damage that may have occurred in transit. Report all damage
immediately to the carrier and send a copy to the vendor. All open ports on the Power Unit were plugged at
the factory to prevent the entry of contamination. These plugs must not be removed until just before piping
connections are made to the unit.
Storage
If the Power Unit is not going to be installed immediately it should be stored indoors, covered with
waterproof sheet, and all open ports plugged. If long-term storage is expected (6 months or more) we
recommend filling~ the reservoir completely with clean hydraulic fluid to prevent the entry of moisture.
Removing from Shipping Skids
Vertical Power Units should be removed from the skid by wrapping a heavy-duty nylon strap around the
base of the motor mounting feet. This strap should be firmly secured to the lift truck forks when unit is
lifted.
Small horizontal style Power Units should be moved with a forklift truck, with 2 x 4 boards under the
reservoir belly, to distribute and steady the load. Larger horizontal style Power Units have lifting holes in
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the reservoir end plates. Extra heavy 1 in. pipes can be inserted into the lifting holes for allowing movement
with a forklift truck. L-shaped reservoirs are provided with clearance and cross braces under the base plate
for movement with a forklift truck.
Installation
Locating Power Unit
The unit should be installed indoors, and preferably in a clean, dry environment with an ambient
temperature of 60 to 1000F. The unit can be installed outdoors if the reservoir was provided with optional
weatherproof construction, and provisions were made for extreme temperature conditions. The reservoir
can be secured to the floor or base using the four mounting holes located on the reservoir legs.
Service Connections
Water (If water cooled heat exchange has been provided) Connect the water supply to the inlet of the heat
exchanger, with a shut-oft valve and strainer (if not supplied by COMOSO). If a temperature Control Valve
has been provided, it also should be installed on the inlet side. The outlet of the heat exchanger should be
connected directly to the facility drain system. On single pass heat exchangers the water connections should
be installed as shown below. On multi-pass heat exchanger the water flow direction is not important.
Electrical Connect the pump motor to the power source following the good practices as outlined in the
National Electric Code and any local codes which may apply. Verify that the available voltage is the same
as the voltage identified on the motor nameplate. Most motors have dual voltage ratings; so verify that the
leads in the conduit box have been connected together as defined on the motor nameplate to match the
facility power source available.
If solenoid valves, pressure/temperature switches, or oil immersion heaters have been provided on the
power unit, refer to the component name tag or other service information in this manual for operating
voltage and ratings.
Supply and Return Connections
Complete all necessary interconnecting piping between the power unit and hydraulic actuators. The line
sizes should be determined based on oil flow, operating pressure and allowable pressure drop between the
power unit and actuator.
Warning
Check to insure that the proper rated hose or pipe is used on pressure lines.
One of the key ingredients for good service and long life from a hydraulic system is cleanliness, and since
most dirt infiltrates a hydraulic system during installation, we recommend the following:
a) All open ports on the power unit, cylinders, etc. must remain plugged with tape or plastic plugs until just before the hydraulic connections are made.
b) All interconnecting tubing, pipe, or hose should be clean, and free of rust, scale and dirt. The ends of
all connectors should be plugged until just before they are to be installed in the system.
c) All openings in the reservoir such as the filler /breather or access end covers holes must remainclosed during installation. --
d) If Teflon tape or pipe dope is used, be sure it doesn’t extend beyond the first thread of the pipe fitting.
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Reservoir Filling
The reservoir must be filled with clean fluid thru the filler cap on the reservoir. The type of fluid must be —
compatible with the seals used on the power unit, and must comply with the recommendations of the
manufacturers of the component parts
Refer to the component manufacturer’s catalog for — fluid requirements. The cleanliness of the fluid goinginto the reservoir is very important, and in some cases, even new oil out of the drum is not adequate. We
recommend that any fluid being transferred into the reservoir be done with the transfer pump with a 10 -
micron filter installed. A Parker filter cart is available for this purpose.
Start-Up Procedure
1) Open any ball or gate valve (if applicable) located — In the pump suction line.
2) Back the system relief valve and/or pump pressure compensator adjustment knob out, so that the
pressure will be near zero during the initial start.
Note:
If the Power unit has been provided with a variable displacement pump or any piston pump , the pump case
should be filled with clean oil prior to priming . In most cases this can be accomplished by disconnecting
the pump case drain line and pouring the oil into the pump case drain port.
3) If the system has been provided with an open center directional valve, the oil during start-up will flow
directly back to tank. If the system has a closed center valve, it may be necessary to loosen a fitting
momentarily at the pump discharge, to bleed any air in the pump during the priming operation.
4) Jog the pump motor once, and verify that the pump is rotating in the same direction as the arrow tag on
the pump case. If the direction is incorrect, reverse two (2) of the three (3) motor leads, and recheck the
rotation.
5) Jog the pump/motor (3) to (6) times to prime the pump and allow the pump to run for several minutes at
zero pressure. Check the piping for any leaks and correct immediately. (Leaks in fittings and tubing can be
the result of vibration during shipping.)
6) Begin adjusting the relief valve and /or pump compensator to increase the pressure gradually. Note:
On systems with open center directional valves, it will be necessary to actuate the valve to build pressure.
7) Continue increasing pressure until normal operating pressure is obtained, and recheck system for leaks.
Lock adjustment screws in place.
Note
If the system has been provided with a pressure compensator pump and a relief valve, adjust the relief valve
approximately 200 PSI higher than the compensator so that excessive heat is not generated by the reliefvalve.
8) During the start-up sequence, all filters should be monitored closely. Replace any filters element
immediately, as soon as they begin to go into by-pass as indicated on the visual indicator.
9) After the entire system has been wetted with fluid, refill the reservoir to the normal operating level.
10) Verify that the cooling water to the heat exchanger (if applicable) is flowing. If the power unit has been
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provided with a water control valve (Model WTC**), and the oil temperature is exceeding 1350F, adjust
the valve to increase the water flow.
Special Tools
All normal service and maintenance on standard power units can be accomplished with standard hand tools.
No special tools are required.
General Maintenance
Electric Motors — Lubricate as recommended by the motor manufacturer
Filters- Change or clean as required or as indicated on filters supplied with visual indicators. Make sure to
check indicators shortly after start-up.
Suction Strainers- Should be cleaned after 10 hours of operation initially and every 100 hours thereafter.
Reservoirs- Maintain oil level at all times. The oil should be checked after the first 100 hours and verify
that the class of oil meets the requirements of the pump being used. Change the oil every 1000 to 2000hours depending on the application and operation environment.
Recommended Spare Parts
Spare filter elements should be purchased with the power unit, and be available during the start-upoperation. Other spare parts may be required, and are a function of the duty cycle of the hydraulic system,
operation environment, and the acceptable down time of the equipment Please review the spare parts
section for recommendations.
Preventive Maintenance
Filter Service
Filters must be maintained. The key to good filtration is filter maintenance. A machine may be equipped
with the best filters available and they may be positioned in the system where they do the most good; but, if
the filters are not serviced and cleaned when dirty, the money spent for the filters and their installation has been wasted. A filter, which gets dirty after one day of service and is cleaned 29 days later, gives 29 days
of non-filtered fluid. A filter can be no better than the maintenance provided.
Maintenance Suggestions
1) Set up filter maintenance schedule and follow it diligently.
2) Inspect filter elements that have been removed from the system for signs of failure which may indicate
that the service interval should be shortened and of impending system problems.
3) Never return to the system any fluid, which has leaked out.4) Always keep the supply of fresh fluid covered tightly.
5) Use clean containers, hoses, and funnels when filling the reservoir, Use a filter cart when adding oil is
highly recommended.
6) Use common sense precautions to prevent entry of dirt into components that have been temporarily
removed from the circuit.
7) Make sure that all clean-out holes, filter caps, and breather cap filters on the reservoir are properly
fastened.
8) Do not run the system unless all normally provided filtration devices are in place.
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9) Make certain that the fluid used in the system is of a type recommended by the manufacturers of the
system or components.
10) Before changing from one type of fluid to another (e.g., from petroleum base oil to a fire resistant
fluid), consult component and filter manufacturers in selection of the fluid and the filters that should be
used. Also consult the publication “Recommended Practice for the use of Fire Resistant Fluids for Fluid
Power Systems” published by the National Fluid Power Association,
11) COMOSO offers an oil sampling kit, which can be used to ascertain the condition of the system fluid.
Maintaining Proper Oil Temperature
Hot oil in your equipments hydraulic system is one of the primary causes of poor operation, component
failure and downtime. Here are some pointers on maintaining proper oil temperature.
The oil in your hydraulic system was designed for operation within a specified temperature range. You may
be able to run it at hotter temperatures for short periods of time, intermittently, without adverse effects. If
you run continuously with oil that’s too hot, your equipment will operate poorly causing key component
failure and machine downtime.
“Hot oil” is a relative term. In most cases, 1200F at the reservoir is considered an ideal operating
temperature. Always take an oil temperature reading at the reservoir, not at a component or any of the
piping.
Some hydraulic systems are designed to operate at 1300F or higher. If you don’t know the maximum
operating temperature for your equipment, check your component manual for temperature and viscosity
limitations.
How can you keep your equipment’s hydraulic system from running too hot?
1) Set up a regular schedule for checking the oil temperature, appearance, smell and feel. Change oil as
recommended by the equipment manufacturer.
2) Be prompt about removing, checking and repairing or replacing valves, pumps or other components that
are running hot.--
3) If relief or flow-control valves are running hot, check and adjust their settings. Follow your -equipment
owner’s manual.
4) Break in new components gradually. New, close fitting parts expand at different rates, and are especially
prone to seize when they get too hot.
5) Start a cold pump motor on hot oil by jogging just CCC enough to draw the hot oil into the component.
Then wait a few minutes to allow the temperature to equalize in all the pump’s parts. Repeat until the temperature on the outside of the pump is the same as that on the piping.
6) Keep your equipment clean. A thick layer of dirt acts as insulation. It will prevent the hydraulic system
from dissipating heat through the walls of the reservoir. 7) On hot days and in hot climates, check and change the oil more frequently. Be sure to use oilrecommended for hot weather operation by the equipment manufacturer or oil supplier .
Measuring Oil TemperatureThere are several ways to check the temperature of the oil. The best, most accurate method is by means of a
thermometer. On some machines, this is mounted on the reservoir. Make it a habit to check the
thermometer periodically, after the equipment has been running for more than an hour.
To estimate the reservoir temperature, if a thermometer is not available, one can perform a palm test. One
should use extreme caution when performing this test. First check the reservoir with your fingertips. If it is
not too hot to touch, place your palm on the reservoir. If you can hold your palm to the reservoir without to
much discomfort, the average temperature of the oil is 130° F or below.
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Isolating Trouble-Spots
To determine which components are running hot” and overheating the oil, feel the outlet fittings and lines
at the valves, pumps and motors. If the oil temperature is normal going into a component but hot coming
out, that could be one of the potential problem areas.
A sticking valve can cause excessive heat. If a spool does not return promptly to the neutral position, the
pump flow will be dumping continuously. This builds up heat rapidly.
If a relief valve is set too low, part of the oil will be dumped across the valve with every cycle. This too,
generates excessive heat. Even when all valves are set properly, they may not be operating well because of
worn orifices or seals
Always remove and check the hot components first.
Check Oil Samples Periodically
Checking oil temperature periodically is good preventive maintenance. So too is the practice of periodically
siphoning an oil sample from the reservoir, and comparing it with a sample of clean, new oil.
Oil that has been running too hot will look darker and feel thinner than new oil. It will also smell burned.
Normally it will contain more contaminants, because hot oil leads to accelerated wear of component parts.
Troubleshooting
Dirty Oil
1) Components not properly cleaned after servicing.
2) Inadequate screening in fill pipe.
3) Air breather left off. (No air breather provided or insufficient protection of air breather).
4) Tank not properly sealed.5) Pipe lines not properly covered while servicing machine.
6) Improper tank baffles not providing settling basin for heavy materials.7) Filter dirty or ruptured
Fire resistant fluids
1) Incorrect seals cause binding spools.
2) Paint, varnish or enamel in contact with Lids can cause sludge deposits on filters and around seal areas.
3) Electrolytic action is possible with some metals, usually zinc or cadmium.
4) Improve mixtures can cause heavy sludge formations.
5) High temperatures adversely affect some of (he fluids, particularly the water base fluids.
6) Adequate identification of tanks containing these fluids should be provided so that they will be refilled
with the proper media.
7) As with mineral base oils, nuisance leaks should be remedied at once.8) Make certain replacement parts are compatible with fluid media
Foaming Oil
1) Tank line not returned below fluid level.2) Broken pipe.
3) Line left out between a bulkhead coupling and the bottom of the tank after cleaning.
4) Inadequate baffles in reservoir.
5) Fluid contaminated with incompatible foreign matter.
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6) Suction leak to pump aerating oil.
7) Lack of anti-foaming additives
Moisture in Oils
1) Cooling coils not below fluid levels.2) Cold water lines fastened directly against hot tank causing condensation within the tank.3) Soluble oil solution splashing into poorly sealed tanks or fill pipes left open. —
4) Moisture in cans used to replace fluid in tanks. Z
5) Extreme temperature differential in certain geographical locations.
6) Drain not provided at lowest point in tank to remove water collected over possibly long operating
periods.
Overheating of System
1) Relief valve set too close to compensator pressure setting.
2) Water shut off or heat exchanger clogged.3) Continuous operation at relief setting.
a. Stalling under load. etc. b. Fluid viscosity too high or too low.
4) Excessive slippage or internal leakage.a. Check stall leakage part pump, motors and cylinders.
b. Fluid viscosity too low.5) Reservoir sized too small6) Case drain line from pressure compensated pump-returning oil too close to suction line.
a Re-pipe case drain line to opposite side of reservoir battling.7) Pipe, tube or hose too small causing high velocity.8) Valving to small, causing high velocity.9) Improper air circulation around reservoir.10) System relief valve set too high.11) Power unit operating in direct sunlight or ambient temperature is too high.
Foreign matter sources in circuit1) Pipe scale not properly removed.2) Sealing compound (pipe dope. Teflon tape) allowed to get inside fittings.3) Improperly screened fill pipes and air breathers.4) Burrs inside piping.5) Tag ends of packing coming loose.6) Seal extrusions from pressure higher than compatible with the seal or gasket.7) Human element... not protecting components while being repaired and open lines left unprotected.8) Wipers or boots not provided on cylinders or rams where necessary.9) Repair parts and replacement components not properly protected while stored in repair depot. (Rust and
other contaminants).
Troubleshooting Pumps
Pump makes excessive noise
1) Check for vacuum leaks in the suction line. (Such as leak in fitting or damaged suction line.)2) Check for vacuum leaks in the pump shaft seal if the pump is internally drained. Flooding connectionswith the fluid being pumped may cause the noise to stop or abate momentarily. This will locate the point ofair entry.3) Check alignment with drive mechanism. -~ Misalignment will cause premature wear and it subsequenthigh noise level in the operation.4) Check manufacturer’s specifications relative to wear possibilities and identification of indications ofwear as high operating noise level etc.5) Check compatibility of fluid being pumped against E manufacturer’s recommendations6) Relief or unloading valve set too high Use reliable gauge to check operating pressure. Relief valve mayhave been set too high with a damaged pressure gauge. Check various unloading devised to see that it they
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are properly controlling the pump delivery.7) Aeration of fluid in reservoir (return lines above fluid level).8) Worn or sticking vanes (vane type pump).9) Worn cam ring (van type pump).
10) Worn or damaged gears and housing (gear pump).
11) Worn or faulty bearing.
12) Reversed rotation13) Cartridge installed backwards or improperly —14) Plugged or restricted suction line or suction strainer.15) Plugged reservoir filler breather.16) Oil viscosity too high or operating temperature too low.17) Air leak in suction line or fittings may cause irregular movement of hydraulic system.18) Loose or worn pump parts19) Pump being driven in excess of rated speed.20) Air leak at pump shaft seal.21) Oil level to low and drawing air in through inlet. Z22) Air bubbles in intake oil.23) Suction filter too small or too dirty.24) Suction line too small or too long.
25) Pump housing bolts loose or not properly torqued
Pump failure to delivery fluid
1) Low fluid level in reservoir
2) Oil intake pipe suction strainer plugged.
3) Air leak in suction line and preventing priming.
4) Pump shaft turning too slowly
5) Oil viscosity too high.
6) Oil lift too high.
7) Wrong shaft rotation
8) Pump shaft or parts broken.
9) Dirt in pump.10) Variable delivery pumps (improper stroke).
Oil leakage around pump1) Shaft seal worn.
2) Head of oil on suction pipe connection — connection leaking
3) Pump housing bolts loose or improperly torqued.
4) Case drain line too small or restricted (shaft seal leaking).
Excessive pump wear
1) Abrasive dirt in the hydraulic oil being circulated through the system.2) Oil viscosity too low.3) System pressure exceeds pump rating.
4) Pump misalignment or belt drive too tight
5) Air being drawn in through inlet of pump.
Pump parts inside housing broken
1) Seizure due to lack of oil.
2) Excessive system pressure above maximum pump rating.
3) Excessive torquing of housing bolts.4) Solid matter being drawn in from reservoir and wedged in pump
Troubleshooting Solenoid ValvesSolenoid failures
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1) Voltage too low. If voltage is not sufficient to complete the stroke of the solenoid, it will burn out the
coil
2) Voltage too high. Excessive voltage can also burn out coils.
3) Signal to both solenoids of a double solenoid valve simultaneously. One or both of the solenoids will be
unable to complete their stroke and will burn out. (Make certain the electrical signal is interlocked so that
this condition cannot exist).
4) Mechanical damage to leads (Short circuit, open connections, etc.)5) Tight spool or other mechanical parts of the valve being actuated can prevent the solenoid from
completing its stroke and subsequently burning out.
6) Replacement springs too heavy in valve. Overloads solenoid and shortens life.
7) Dirty contacts may not supply sufficient current to solenoid to satisfy inrush demands.
8) Low voltage direct current solenoids may be affected by low battery capacity on cold mornings directly
after starting cold engine (DC)
9) Long feed lines to low voltage solenoids may cause sufficient voltage drop to cause erratic operation
Solenoid valve fails to operate1) Is there an electrical signal to the solenoid or operating device? Is the voltage too low? — (Check with
voltmeter or a test light in emergency.)
2) If the supply to the pilot body is orificed, is the orifice restricted? (Remove orifice and check for foreign
matter. — Flushing is sometimes necessary because of floating impediment.)
3) Has foreign matter jammed the main spool? (Remove end caps and see that main spool is free in its
movement, remember that there will be a quantity of fluid escaping when the cap is removed and provide acontainer to catch it.)
4) Is pilot pressure available? Is the pilot pressure adequate? (Check with gauge on main pressure input
port for internally piloted types and in the supply line to the externally piloted type.)
5) Is pilot drain restricted? (Remove pilot drain and let the fluid pour into an open container while the
machine is again tried for normal operation. Small lines are often crushed by machine parts banging against
them, causing a subsequent restriction to fluid flow.)
6) Is pilot tank port connected to main tank port where pressures are high enough to neutralize pilot input
pressure? (Combine pilot drain and pilot tank port and check for operation with the combined flow draining
into an open container. Block line to main tank from pilot valve, if this corrects the situation, reroute pilot
drain and tank line.)7) Are solenoids improperly interlocked so that a signal is provided to both units simultaneously? (Put test
light on each solenoid lead in parallel and watch for simultaneous lighting. Check electrical interlock. This
condition probably burns out more solenoids than any other factor.)
8) Has mounting pad been warped from external heating? (Loosen mounting bolts slightly and see if valve
functions. End caps can also be removed and check for tight spool.)
9) Is fluid excessively hot? (Check for localized heating which may indicate an internal leak. Check
reservoir temperature and see if it is within machine specifications.)
10) Is there foreign matter in the fluid media causing gummy deposits? (Check for contamination. Make
certain seals and plumbing are compatible with the type of fluid being used.)
11) Is an adequate supply of fluid being delivered to actuate the load? (Many times there is sufficient
pressure to shift the valve but not enough to actuate the workload. Check pump supply pressure and
volume if necessary. Physical measurement of flow through relief valve with units blocked may be
necessary.)12) Check circuit for possible interlocks on pressure sources to valve or to pilot.
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Sizes 45, 60, 80, 112,
140 and 200
Up to 203 kW
and 320bar
Features
◊ SAE and ISO mount.
◊ Small installation envelope.
◊ Through drive.
◊ SAE and metric ports.
◊ Side and rear porting.
◊ Vertical mount capability.
◊ Multiple drain ports.
◊ CW and CCW rotation.
◊ Opposed stroking pistons.
◊ Rated pressure 320 bar.
◊ Swash plate pillow support.
◊ Maximum displacement stop.
◊ Servo assist springs.
◊ Hydrostatic pillow bearing.
◊ Overcentre bleed.
◊ Pressure compensation.
◊ Integral proportional pressure.
◊ Load sensing.
◊ Integral unload.
◊ Torque limiter.
◊ Rigid construction.
◊ Long life roller bearings.
◊ Various sealing options.
◊ Low pulsation.
◊ Proven rotating group.
◊ Separate swash plate.
◊ Spherical valve plate.
◊ Super-finished bores.◊ Solid pistons.
Swash-plate
Axial Piston Pump
B Series K3VL
Pumps Industrial Products
Data Sheet
P-1002/02.09
GB
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General Description
The K3VL Series Swash Plate Type Axial Piston Pumps are designed to specifically satisfy the marine
and general industrial machinery market where a high pressure variable displacement pump is required.
K3VL Pumps are available in nominal displacements ranging from 45 to 200 cm3/rev with various
pressure, torque limiter, and combination load sensing control options.
Technical DescriptionThe components of the K3VL pump can be divided into three sub-groupings:
Rotating Group – Providing the main rotary pumping action.
Swash Plate Group – To vary the pump’s delivery flow rate.
Valving Cover Group – Providing the switching of oil between suction and delivery ports.
Pumps Industrial Products
K3VL80 Cross Section
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Technical Description (continued)
The Rotating Group
The Rotating Group comprises:
(a) Valve plate 313(b) Cylinder block, 141
(c) Pistons, 9 x 151 + Shoes, 9 x 152
(d) Setting plate, 153
(e) Spherical bush, 156
(f) Cylinder springs, 9 x 157
The drive shaft is coupled to the cylinder block through a splined section and supported at both of its
ends by bearings. The shoe is swaged over the spherical end of the piston forming a spherical ball joint.
Additionally the shoe has a hydrostatic pocket to balance the hydraulic thrust developed by the piston
pressure allowing the shoe to lightly slide against the shoe plate.
The subgroup consisting of the pistons and shoes are pressed against the shoe plate by the cylinder
springs acting through the setting plate and the spherical bush. The force developed by these cylinder
springs also press the cylinder block against the valve plate. Only the K3VL45-60 units use a single
centralised spring with individual push pins provide the shoe and cylinder block hold down force.
Swash Plate Group
The Swash Plate Group comprises:
(a) Swash plate, 212
(b) Shoe plate, 211(c) Swash plate support, 251
(d) Tilting bush, 214
(e) Tilting pin, 531
(f) Servo piston, 532
The swash plate on the reverse side to the shoe location is a cylindrical form which is a “pillow”
supported by the hydrostatic bearing provided by the swash plate support. The tilting bush is inserted
into the swash plate and into this is installed the spherical portion of the tilting pin which is coupled to
the servo piston.
Any linear movement of the servo piston produced by the regulator pressure applied to either end is
translated through the tilting pin into an angular movement of the swash plate which varies the tilting or
swash angle of the pump. A screw adjuster and lock nut is available to adjust the maximum tilting angle
condition. The servo assist springs are provided to ensure good on stroking response particularly at low
operating pressures.
Pumps Industrial Products
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Technical Description (continued)
Valve Cover Group
The Valve Cover Group comprises:
(a) Valve cover, 312(b) Valve pin, 885
The valve plate with its two “kidney” shaped ports is installed onto the valve plate located by the valve
plate pin. These two ports serve to supply and exhaust oil to and from the cylinder block. The oil
passage switched by the valve plate is connected to the externally piped suction and outlet pressure
ports through the valve cover. This valve plate is spherical in form for all but the smallest 45-60 unit.
Pump Operation
When the pump’s drive shaft is driven by a prime mover (Electric motor, Engine etc.), the cylinder block
being spline coupled to the shaft will also rotate. If the swash plate has been tilted, the pistons arranged
in the cylinder block due to the shoe being retained on the swash plate surface will both rotate with the
cylinder block and reciprocate once per revolution. Paying attention to one such piston then it will move
away from the valve plate for half a rotation (suction stroke) and move towards the valve plate for the
second half of rotation (oil delivery stroke). The larger the tilt angle, the longer the piston stroke and the
higher is the pump’s displacement. As the swash plate tilting angle approaches so the piston makes no
stroke and thereby delivers no oil.
Through Drive Option
By suitable use of adaptors and splined couplings a wide variety of through drive mounting capabilitiesare available. The formation of these kits and their relevant part numbers will be found in the installation
section.
Pumps Industrial Products
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Technical Data
For applications outside the following parameters, please consult Kawasaki Precision Machinery (UK) Ltd.
Hydraulic Data
Pressure Fluid Mineral oil, polyol ester and water glycol.
Use a high quality, anti-wear, mineral based hydraulic fluid when the
pressure exceeds 207 bar. In applications where fire resistant fluids
are required consult Kawasaki Precision Machinery (UK) Ltd. The
following chart illustrates the effects on pump life when non-standard
fluids are used:
Fluid selection
Pumps Industrial Products
V G 2 2
V G 3 2
V G 4 6
V G 6 8
V G 1 0 0
1000
600
200
100
10-20° 0° 20° 40° 60° 80° 100°
15
20
40
6080
allowable temperature range
fluid temperature (°C)
k i n e m a
t i c v i s c
o s
i t y
( c S t )
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Technical Data (cont inued)
Filtration & Contamination Control
Filtration
The most important means to prevent premature damage to the pump and associated equipment and toextend its working life, is to ensure that hydraulic fluid contamination control of the system is working
effectively.
This begins by ensuring that at the time of installation that all piping, tanks etc. are rigorously cleaned in
a sanitary way. Flushing should be provided using an off line filtration system and after flushing the filter
elements should be replaced.
A full flow return line filter of 10 micron nominal should be utilised and in addition a 150 micron mesh
suction strainer is recommended. Typical filtration circuits are shown in the K3VL brochure.
To prevent contaminant ingress from the external environment a 5 to 10 micron filter within the tanks
breather is also recommended.
Suggested Acceptable Contamination Level
The relationship between contamination level and pump life is very dif ficult to predict as it depends on
the type and nature of the contaminant present in the system. Sand or Silica in particular, due to its
abrasive nature, does significantly reduce the expected life of a pump. Based on the precondition that
there is no significant presence of Silica type substances then a minimum Cleanliness level of -/18/15
ISO 4406 or SAE AS 4059E Table 1 Class 9 (NAS 9).
Working Fluid Types
Anti-Wear Type Hydraulic fluid
It is generally recommended to use an anti-wear type hydraulic fluid as the mineral oil type when the
operating pressure exceeds 210 bar.
Fire-resistant Fluids
Some kind of fire-resistant fluids require special materials for seals, paint and metal finishing. Please
consult Kawasaki Precision Machinery (UK) Limited and provide details of the particular fluid
specification and the working conditions so that any special requirements can be ascertained.
In general, fire-resistant fluids have a low viscosity index and their viscosity also changes significantly
with operating temperature and service life. For this reason, the circuit should be provided with an
adequately sized cooler or forced cooling so that temperatures can be stabilised. Due to the inherent
water content of some of these fluids the minimum allowable suction pressure will be higher than that
of an equivalent mineral oil and so needs to be fully evaluated by Kawasaki Precision Machinery (UK)
Limited. The following table provides an overview of the precautions and characteristics
that can be expected with these types of fluids.
Pumps Industrial Products
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Technical Data (cont inued)
Fire-resistant Fluids (continued)
Pumps Industrial Products
Maximum Pressure
(bar)320 320 210
mineral oilfluid type:- polyol ester water glycolparameter:-
Recommended Temperature
Range (deg C)20 ~ 60 20 ~ 60 10 ~ 50
Expected life expectancy compared
to mineral oil100% 50% ~ 100% 20% ~ 80%
Cavitation susceptability
recommended usable (higher density)
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Technical Data (cont inued)
Pump Start Up Precautions
Pump Case Filling
Be sure to fill the pump casing with oil through the drain port filling only the suction line with oil is totallyin suf ficient. The pump contains bearings and high-speed sliding parts including pistons with shoes and
spherical bushes that need to be continuously lubricated. Part seizure or total premature failure will
occur very quickly if this procedure is not rigidly followed.
Piping & Circuit Checking
Check to see that the piping and full hydraulic circuit is completed and that any gate valves etc. are
open.
Direction of Rotation
Check to ensure that direction of rotation is correct and that the suction and delivery lines are
connected correctly.
Start Up
Jog start the motor and check once more for correct rotation. Run the pump unloaded for a period to
ensure that all residual air within the system is released. Check for external leakage, abnormal noise
and vibrations.
Case Drain Pressure
Please ensure, as stated previously, that the maximum steady state drain line pressure at the pump
casing does not exceed 1 bar. (Maximum peak pressure 4 bar). A suitable drain line hose and drain line
filter when required must be selected to ensure this.
Long Term Out of Usage
It is undesirable to leave the pump out of use for a long period of a year or more. In such a situation
it is recommended that the pump is run for a short period on a more frequent basis even if it is just
unloaded. With regard to a pump held in storage then rotating the shaft on a frequent basis is suf ficient.
If the pump is left out for more than the suggested time it will require a service inspection.
Pumps Industrial Products
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pump model
capacity
pressure ratingsrated
peak
cc/rev
bar
bar
bar
bar
Kg
L
Nm 150 150
25
0.6
45 60
60
250
280
2400
3000
45
320
350
2700
3250
225 225
ISISO100
ISO 25mm ISO
SAE “E”
SAE “D”
SAE “C-C”
SAE “B-B”
SAE “C”
SAE “B”
SAE “A”
input shaft
mounting flange
maximum allowable input torque
case fill capacity
weight
case drain
pressure
max. continuous
minimum operating speed
max. boosted
self primespeed ratings
peak
allowable
through drive
torque
SAE B-BSAE B-B
SAE B-B SAE B-B SAE B-B SAE B-B
SAE BSAE B
Nm
cSt
type
type
form Spline SplineSpline & Key Spline & KeyKey
maximum contamination level
viscosity range
temperature range
bolts
rpm
rpm
rpm
22222
C
Pumps
Technical Data (cont inued)
Specifi cations
The following table indicates all of the specifications for the complete K3VLpump range from 45-200cc.
More detailed ef ficiency curves and other related information will be found in a later section.
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Industrial Products
34
4
1
600
80 112
112 140
140 200
200
350
400
1900
2200
320
350
80
2400 2200 2100
2700 25003000
0.8
60 60 100
1.4 1.4 3
400 1000 1800
SAE ESAE EISO180ISO125
ISO 32mm ISO 45mm ISO 45mm
ISO180 SAE DSAEAE C
AE C SAE D SAE FSAE C, C-C
and D
SAE C, C-C
and D
e & Key Spline & Key Spline & Key Spline & Key SplineKey
61
150
225
400
680
699
-20 – + 95
10 to 1,000
699
Key Key
981*1 981*1
44442 2 and 4 bolt 2 and 4 bolt2
8/15 ISO 4406 or SAE AS 4059E Table 1 Class 9 ( NAS 9 )
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Technical Data (cont inued)
Specifi cations
Notes:
Rated Pressure
Pressure at which life and durability will not be affected.
Peak Pressure
The instant allowable surge pressure as defined by BS ISO 2944:2000. Life and durability
however will be shortened.
Maximum Self Priming Speed
Values are valid for an absolute suction pressure of 1 bar. If the flow is reduced, or
if the inlet pressure is increased the speed may also be increased
Maximum Boosted Speed
Values stated are the absolute maximum permitted speed for which an increased inlet
pressure will be required.
Weight
Approximate dry weights, dependant on exact pump type. Hydraulic Fluid Mineral anti wear
hydraulic fluid – for other fluid types please consult KPM
Viscosity Range
If viscosity is in range 200 to 1,000 cSt, then warming up is necessary before commencing
full scale running.
*1
In case of reduced torque input shafts
SAE C shaft Input Torque reduced to 400 Nm
SAE CC shaft Input Torque Reduced to 680 Nm
Pumps Industrial Products
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Ordering Code – K3VLSeries
Pumps Industrial Products
K3VL 80 B - 1 0 R S S L 0 12D /1-H*
K3VL Series Pump
Maximum displacement
45 45 cm3/rev
60 60 cm3/rev
80 80 cm3/rev
112 112 cm3/rev
140 140 cm3/rev
200 200 cm3/rev
Design series
B
Hydraulic Fluid Type
– Mineral oil
W Water glycol (not K3VL 200)
All other fluids contact Kawasaki
Circuit Type
1 Open Circuit
Through drive & porting
0 Single pump, side ported
A SAE-A through drive, side ported
B SAE-B through drive, side ported
BB SAE-BB through drive, side ported
C SAE-C through drive, side ported
D SAE-D through drive, side ported
E SAE-E (K3VL 200 only)
R Single pump, rear portedS Single pump with plastic cover (Stock Pump)
N Single pump with Steel cover, side ported
Direction of rotation
R Clockwise rotation
L Counter-clockwise rotation
Mounting flange & shaft
S SAE spline & mount (see drawing for detail)
M ISO key & mount (see drawing for detail) (not 200)
F SAE-D mount with SAE-F spline shaft
K SAE key & mount (see drawing for detail)
T* SAE-B spline & SAE- B 2 bolt mount for 45
(not 80) SAE- CC spline & SAE- D 4 bolt mount
for 112/140 (not 200)
U* 45 only, SAE-B key & SAE-B 2 bolt mount
C* 112/140 only, SAE-C spline & SAE- C 2 bolt mount
R* 112/140 only, SAE- C spline & SAE- D 4 bolt mount
X* 112/140 only, SAE- C key & SAE- C 2 bolt mount
W* 112/140 only, SAE -CC spline & SAE- C 2 bolt mount
(*Non standard options)
A
Addit ional control op tions
Blank Without additional
limiter Torque limit contro l
/1-S* Special low setting
contact Kawasaki
/1-L* Low setting range
/1-M* Medium setting
range
/1-H* High setting range
Displacement control
(Without torque limit)
/1-E0 Electrical displacement
control (pilot pressure
required)
/1-Q0 Pilot operated
displacement control
Unloader solenoid
(Type N below)
blank For all other options
except PN & LN
115A 115V AC, 50.60Hz,
DIN 43550 Plug
235A 230V AC, 50.60Hz,
DIN 43550 Plug
12D 12V DC, DIN 43550 Plug
24D 24V DC, DIN 43550 Plug
Design
Addit ional pressure control
0 No additional control
N With integrated unloading valve
V With integrated remote control valve
M With integrated unloading control valve
1 Load sensing only (R4 plugged)
Control device configuration
P Remote pressure compensator
L Load sensing & pressure control
Porting threads
M Metric threaded
S UNC threaded
/ - -
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Bearing Life
Noise Level
Performance K3VL45
Pumps Industrial Products
1.00 0.75 0.50 0.25
0
0 50 100 150 200 250 300 350
10
20
30
40
50
60
70
80
90
100
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1.00
60
70
75
80
83
86
88
89
90
Ratio of displacement
Delivery Pressure (bar)
V o
l u m e
t r i c E f f i c i e n c y
( % )
R a
t i o o
f D i s p l a c e m e n
t
Pump Ef fi ciency (%)
28 30 32 34 36 38 40 42 44
-0.2 bar
-0.1 bar
0 bar
+0.1 bar
+0.2 bar
2200
2400
2600
2800
3000
3200
Displacement q [cc/rev]
S p e e
d N ( r p m )
Suction
PressurePs (bar)
gauge
at the suction
pump of the
port pump
Self Priming Capability
1
B e a r i n g L i f e L 1 0 [ h r ]
1000000
1000
1000rpm1200rpm
1500rpm1800rpm
E/M capacity [kW]
100
10000
100000
85
80
75
70
65
60
55
50
100 150
Delivery pressure Pd [kgf/cm2]
N o i s e L e v e l [ d b ( A ) ]
200 250 300 350
1800rpm
1500rpm
q = 45cc/rev
10
500
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Pumps Industrial Products
Bearing Life
Noise Level
Pump Ef fi ciency (%)
Self Priming Capability
Performance K3VL60
B e a r i n g L i f e L 1 0 [ h r ]
1000000
1000
1500rpm1000rpm1800rpm1200rpm
E/M capacity [kW]
100
10000
100000
85
80
75
70
65
60
55
50150100 200
Delivery pressure Pd [kgf/cm2]
N o i s e L e v e l [ d b ( A ) ]
250 300 350
1500rpm
1800rpm
q = 60cc/rev
1.00 0.75 0.50 0.25
0 100 150 200 250
100
75
50
25
00.00
0.25
0.50
0.75
1.00
86
85
84
8280
75
7065
60
Ratio of displacement
Delivery Pressure Pd (kgf / cm2 )
R a t i o o f D i s p l a c e m e n t [ q / q m a x ]
V o l u m e t r i c E f f i c
i e n c y ( % )
36 39 42 45 48 51 54 57 60
Ps = -0.2bar
Ps = -0.1bar
Ps = 0bar
Ps = +0.1bar
Ps = +0.2bar
2000
1800
2200
2400
2600
2800
3000
Displacement q [cc/rev]
S p e e d N ( r p m
)
50
1
0 50
10
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B e a r i n g
L i f e
L 1 0 [ h r ]
1000000
1000
1500rpm
1000rpm
1800rpm
1200rpm
1 10
E/M capacity [kW]
100
10000
100000
Bearing Life
Noise Level
Performance K3VL80
Pumps Industrial Products
1.00 0.75 0.50 0.25
0
0 50 100 150 200 250 300 350
10
20
30
40
50
60
70
80
90
100
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1.00
70
75
80
83
8587
89
91
92
Ratio of displacement
Delivery Pressure Pd [kgf/cm2]
V o l u m e t r i c E f f i c
i e n c y ( % )
R a t i o o f D i s p l a c e m e n t
Pump Ef fi ciency (%)
Self Priming Capability Ps = +0.3bar
Ps = +0.2bar
Ps = +0.1bar
Ps = 0bar
Ps = -0.1bar
Ps = -0.2bar
3000
2800
2600
2400
2200
2000
50 55 60 65 70 75 80
Displacement q [cc/rev]
S p e e
d N [ m i n - 1
]
85
80
75
70
65
60
55
50
150100 200
Delivery pressure Pd [kgf/cm2]
N o i s e L e v e l [ d b ( A ) ]
250 300 350
1800rpm
1500rpm
q = 80cc/rev
0 50
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Performance K3VL112
Pumps Industrial Products
1.00 0.75 0.50 0.25
0
0 50 100 150 200 250 300 350
10
20
30
40
50
60
70
80
90
100
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1.00
83
80
75
70
85
87
89
91
92
Ratio of displacement
Delivery Pressure (bar)
V o l u m e t r i c E f f i c i e n c y ( % )
R a t i o o f D i s p
l a c e m e n t
Pump Ef fi ciency (%)
70 80 90 100 110
Ps = -0.2bar
Ps = -0.1bar
Ps = 0bar
Ps = +0.1bar
Ps = +0.3bar
Ps = +0.2bar
1800
2000
2200
2400
2600
2800
Displacement q [cc/rev]
S p e e
d N [ m i n - 1
]
Bearing Life
Noise Level
Self Priming Capability
1000000
1000
1000rpm1200rpm
1500rpm1800rpm
E/M capacity [kW]
100
10000
100000
85
80
75
70
65
60
55
50
150100 200
Delivery pressure Pd [kgf/cm2]
N o i s e L e v e l [ d b ( A ) ]
250 300 350
1800rpm
1500rpm
q = 112cc/rev
1
0 50
10
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10
0
1
B e a r i n g L i f e L 1 0 [ h r ]
1000000
1000
1000rpm 1200rpm
1500rpm
1800rpm
E/M capacity [kW]
100
10000
100000
85
80
75
70
65
60
55
50
150100 200
Delivery pressure Pd [kgf/cm2]
N o i s e L e v e l [ d b ( A ) ]
250 300 350
1800rpm
1500rpm
q = 140cc/rev
Performance K3VL140
Pumps Industrial Products
1.00 0.75 0.50 0.25
0
0 50 100 150 200 250 300 350
10
20
30
40
50
60
70
80
90
100
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1.00
91
89
87
85
83
807570
92
Ratio of displacement
Delivery Pressure Pd [kgf / cm2 ]
V o
l u m e
t r i c E f f i c i e n c y
( % )
R a
t i o o
f D i s p
l a c e m e n
t [ q / q m a x
]
Pump Ef fi ciency (%)
Self Priming Capability
Bearing Life
90 100 110 120 130 140
Ps = -0.2bar
Ps = -0.1bar
Ps = 0bar
Ps = +0.1bar
Ps = +0.3bar
Ps = +0.2bar
1800
2000
2200
2400
2600
2800
Displacement q [cc/rev]
S p e e
d N [ m i n - 1
]
Noise Level
50
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120 140 160 180 200
Ps = -0.2bar
Ps = -0.1bar
Ps = 0bar
Ps = +0.1bar
Ps = +0.2bar
1700
1600
1800
1900
2000
2100
3000
Displacement q [cc/rev]
S p e e d N ( m i n - 1 )
85
80
75
70
65
60
55
50
150100 200
Delivery pressure Pd [kgf/cm2]
N o i s e L e v e l [ d b ( A ) ]
250 300 350
1500rpm
1800rpm
q = 200cc/rev
B e a r i n g L i f e L 1 0 [ h r ]
1000000
100000
10000
1000
1000rpm
1200rpm1500rpm
1800rpm
10 100 1000
E/M capacity [kW]
Performance K3VL200
Pumps Industrial Products
1.00 0.75 0.50 0.25
0 50 100 150 200 250 300 350
100
75
50
25
00.00
0.25
0.50
0.75
1.00
89
87
85
83
80
75
70
91
90
Ratio of displacement
Delivery Pressure (bar)
V o
l u m e
t r i c E f f i c i e n c y
( % )
R a
t i o o
f D i s p l a c e m e n
t
Pump Ef fi ciency (%)
Self Priming Capability
Bearing Life
Noise Level
0 50
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Bearing Life (continued)
Bearing Life Correction Factors for Partial Displacement
Pumps Industrial Products
75%
Displacement %
B e a r i n g l i f e a d j u s t m e n t f a c t o r ( % )
50%
0%
200%
260%
400%
600%
800%
1000%
1200%
60% 70% 80% 85% 90%
All bearing life curves on the previous pages refer to L10 life at full displacement. The foregoing curveis therefore to be used where duty cycle considerations require one to compute weighted life, which
include partial displacement conditions.
For example as shown above if the bearing life at full displacement from the previous graphs was say
50,000 hours, then at the same operating condition with only 75% displacement the bearing life would
be 260% of 50,000 hours or 130,000 hours.
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Radial Loading Capacity
No axial shaft loading possible Radial loading is achievable but in specific orientation:-
In addition because of the high bearing capacity of this front bearing, radial shaft loading can be
allowed provided that its orientation is such that it is this front bearing that takes the additional load
(See diagram below).
Pumps Industrial Products
acceptable
not acceptable
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Functional Description of Regulator
Pumps Industrial Products
Key to Hydraulic Circuit Annotations
Annotat ions
A1
A2
a1
a2
B2
B1
b
Dr
Pi
Pc
Pi
PL
Psv
Ps
Description
Main pump delivery
Auxiliary pump delivery
Gauge port main pump delivery
Gauge port auxiliary pump delivery
Gear pump suction
Main pump suction
Suction gauge port
Drain
Pilot pressure
Remote pilot port, Pressure compensator
Pilot port displacement control
Load sense port
Pressure assist port
Inlet pressure
Notes: The optional attached gear pump is recommended for all displacement control options.
Hydraulic circuit diagrams illustrate the attached gear pump.
Regulator Code Control Curves Hydraulic Circuit
L0/L1 Load Sense and
Pressure Cut-off
Pump displacement is
controlled to match the flow
requirement as a function
of the system differential
pressure (load pressurevs delivery pressure). In
addition, there is a pressure
cut off function incorporated
into the control. With the L1
option,the bleed-off orifice
R4 is plugged.
Q
P
PL
Dr
Tair
R1
R4
DifferentialPressure Spool
Cut-off Pressure Spool
B
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Functional Description of Regulator (continued)
Pumps Industrial Products
Regulator Code Control Curves Hydraulic Circuit
LN Load Sense and
Pressure Cut-off w ith
Integrated Unloading Valve(Normally Closed)
An integrated unloading
valve is sandwiched between
the Load Sense regulator
and pump to effectively
de-stroke the swashplate
when an electric signal is
provided.
Q
P
Dr B
A
Tair
PL
R3
R1
Cut-off Pressure Spool
UnloadingSolenoid
Valve
DifferentialPressure Spool
Regulator Code Control Curves Hydraulic Circuit
LM Load Sense and
Pressure Cut-off w ith
Integrated Unloading Valve
(Normally Open)
An integrated unloading
valve is sandwiched between
the Load Sense regulator
and the pump. An electricalsignal must be provided to
prevent the Load Sense line
from draining.
Q
P
Dr B
A
Tair
PL
R3
R1
Cut-off Pressure Spool
DifferentialPressure Spool
Regulator Code Control Curves Hydraulic Circuit
LV Load Sense and Pressure
Cut-off with Integrated
Proportional Relief Valve
An integrated proportional relief
valve is sandwiched between
the Load Sense regulator and
pump to control the maximum
pressure setting by varying an
electric signal to the valve.
A separate amplifier is required.
Q
P
Dr B
A
Tair
PL
R3
R1
Cut-off Pressure Spool
ProportionalRelief Valve
DifferentialPressure Spool
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Functional Description of Regulator (continued)
Pumps Industrial Products
Regulator Code Control Curves Hydraulic Circuit
L0/1 Load Sense and
Pressure Cut-off with
Torque Limiting
L0/L1 control functions as
previously noted. In response
to a rise in delivery pressure
the swashplate angle is
decreased, restricting the
input torque. This regulator
prevents excessive load
against the prime mover.
The torque limit control
module is comprised of two
springs that oppose the spool
force generated by the systempressure. By turning an outer
and inner spring adjustment
screw, the appropriate input
torque limit can be set.
Q
P
Dr B
A
Tair
PL
R4
R1
Cut-off Pressure Spool
Torque Limiter Spool
DifferentialPressure Spool
Regulator Code Control Curves Hydraulic Circuit
P0 Pressure Cut-off
As system pressure rises
to the cut-off setting, the
swashplate de-strokes
to prevent the system
pressure from exceeding the
compensator setting. It is
imperative that a safety relief
valve be installed in the
system.
Note: By connecting the Pc
port to a remote pressure
control, variable pump
pressure control can be
achieved.
Q
P
Dr B
A
Tair
Pc
R2
R1
Cut-off Pressure Spool
DifferentialPressure Spool
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Functional Description of Regulator (continued)
Pumps Industrial Products
Regulator Code Control Curves Hydraulic Circuit
PN Pressure Cut-off with
Integrated Unloading Valve
(Normally Closed)
An integrated unloading valve
is sandwiched between the
Pressure Cut-off regulator and
pump to effectively de-stroke
the swashplate when an
electric signal is provided.
Q
P
Regulator Code Control Curves Hydraulic Circuit
PM Pressure Cut-off with
Integrated Unloading Valve
(Normally Open)
An integrated unloading valve
is sandwiched between the
Pressure Cut-off regulator
and the pump.
An electrical signal must
be provided to prevent the
Pressure cut-off line from
draining. Dr B
A
Tair
Pc
R2
R1
Cut-off Pressure Spool
DifferentialPressure Spool
Dr B
A
Tair
Pc
R2
R1
Cut-off Pressure Spool
SolenoidValve
DifferentialPressure Spool
Q
P
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Functional Description of Regulator (continued)
Pumps Industrial Products
Regulator Code Control Curves Hydraulic Circuit
PV Pressure Cut-off with
Integrated Proportional
Relief Valve
An integrated proportional
relief valve is sandwiched
between the Pressure Cut-
off regulator and the pump
to control the maximum
pressure setting by varying an
electric signal to the valve.
A separate amplifier is
required.
Q
P
Dr B
A
Tair
Pc
R2
R1
Cut-off Pressure Spool
ProportionalRelief Valve
DifferentialPressure Spool
Regulator Code Control Curves Hydraulic Circuit
P0/1 Pressure Cut-off withTorque Limit ing
P0/1 control functions as
previously noted. In responseto a rise in delivery pressure
the swashplate angle is
reduced, restricting the input
torque. This regulator prevents
excessive load against the
prime mover.
The torque limit control module
is comprised of two springs
that oppose the spool force
generated by the system
pressure. By turning an outerand inner spring adjustment
screw, the appropriate input
torque limit can be set.
Note: By connecting the Pc
port to a remote pressure
control, variable pump
pressure control can be
achieved.
Dr B
A
Tair
PC
R2
R1
Cut-off Pressure Spool
Torque SpoolLimiter
DifferentialPressure Spool
Q
P
Outer Spring
Adjustment
Delivery Pressure
P u m p F l o w
Outer Plus Inner Spring Adjustment
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Functional Description of Regulator (continued)
Pumps Industrial Products
Regulator Code Control Curves Hydraulic Circuit
/1-E0 Electrical
Displacement Control
Varying the input current
signal to the pump controller’s
electronic proportional
pressure reducing valve
(PPRV) allows the user
to control the pump
displacement. As the current
signal to the PPRV increases,
the pump displacement
increases proportionally.
Note: An external pressure
supply of 40 bar is required at
the PSV Port (50bar max).
Qmax
P u m p F l o w R a t e
( Q )
Qmin
Input Current (mA) of Proportional
Pressure Reading Valve
360 600
Customer Supplied
Psv
Pc
Regulator Code Control Curves Hydraulic Circuit
/1-Q0 Pilot Operated
Displacement Control
Varying the input pressure
signal to the PSV port allows
the user to control the pump
displacement. As the pressure
signal to the PSV increases,
the pump displacement
increases proportionally.
Qmax
P u m p F l o w R a t e ( Q )
Qmin
Pilot Pressure (bar)
90 28
a
Psv
Pc
A
BDr
Customer
Supplied
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Torque Limiter Settings
The following tabulations show the power limitation at various electric motor speeds for a specific pump.
When selecting a control setting please ensure that the power limitation of a particularly sized electric
motor to your national standard is not exceeded.
Pumps Industrial Products
K3VL45
KW 970 1150 1450 1750
3.7 S3 S4
5.5 L3 S1 S3 S4
7.5 L1 L2 L4 S2
11 M1 M3 L1 L2
15 H3 H4 M2 M4
18.5 H2 H4 M2
22 H3 H4
30 H1
37
45
55
75
90
K3VL60
KW 970 1150 1450 1750
3.7
5.5 S2 S4
7.5 L4 S1 S3
11 M4 L2 L4 S1
15 M2 M3 L1 L3
18.5 H2 M1 M3 L1
22 H2 M2 M3
30 H1 H3
37 H1
45
55
75
90
K3VL80
KW 970 1150 1450 1750
3.7
5.5 S2 S4
7.5 L6 S1 S3
11 L2 L4 L6 S1
15 M4 L1 L3 L5
18.5 M1 M3 L1 L3
22 H3 M1 M4 L1
30 H1 H2 H4 M2
37 H2 H4
45 H1 H2
55 H1
75
90
K3VL112
KW 970 1150 1450 1750
3.7
5.5
7.5 S5 S6
11 S1 S3 S5 S6
15 L3 L4 S2 S4
18.5 M4 L2 L4 S2
22 M2 M4 L3 L4
30 H4 M1 M3 L1
37 H2 H3 M1 M3
45 H2 H4 M1
55 H2 H4
75 H1
90
K3VL140
KW 970 1150 1450 1750
3.7
5.5
7.5
11 S2 S4
15 L6 S1 S3
18.5 L3 L5 S1 S3
22 L1 L3 L6 S1
30 M2 M3 L2 L4
37 H4 M1 M3 L2
45 H2 H4 M2 M3
55 H2 H4 M2
75 H1 H3
90 H1
K3VL200
KW 970 1150 1450 1750
3.7
5.5
7.5
11
15
18.5 S1
22 L4 S1
30 L2 L3 L5
37 M3 L1 L3
45 M1 M3 L2
55 H5 M1 M3
75 H1 H3 H6
90
110
132
H1 H4
H2
S2
L5
L3
L2
M2
H6
H4
H2
S-rating Springs
Please contact Kawasaki
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Installation
Recommended Pump Mounting
The pump should be mounted horizontally with the case drain piping initially rising above the level of the
pump before continuing to the tank as shown in the illustration below. Do not connect the drain line to
the suction line.
The uppermost drain port should be used and the drain piping should be equal or larger in size than the
drain port to minimise pressure in the pump case. The pump case pressure should not exceed 1 bar as
shown in the illustration below. (Peak pressure should never exceed 4 bar.)
Pumps Industrial Products
Drain line
“Goose neck” configuration is required, this prevents direct drop of oil level in the pump case.
Cautions
A) Suction and drain pipes must be immersed by 200mm
minimum from the lowest oil level under operating conditions.
B) Height from the oil level to the centre of the shaft must be
within 1m.
C) The oil in the pump case must be refilled when the pump
has not been operated for one month or longer.
4 bar (peak)
1 bar
(normal)
0.1 sec
P
Mounting the Pump Above the Tank
Suction line
200mmminimum
depth
200mmminimum
depth w
i t h i n 1 m
M u s
t b e
h i g h e r
t h a n
t o p o
f P u m p
C a s e
200mmminimum
depth
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Installation (continued)
Mounting the Pump Vertically (shaft up)
For applications requiring vertical installation (shaft up) please remove the air bleed plug and connect
piping as shown in the illustration below.
The oil level in the tank should be higher than the pump-mounting flange as shown in illustration [a]
below. If the oil level in the tank is lower than the pump mounting flange then forced lubrication is
required through the air bleed port 1 ~ 2 l/min.
When installing the pump in the tank and submerged in the oil, open the drain port and air bleed port to
provide adequate lubrication to the internal components.
When installing the pump outside the tank run piping for the drain and air bleed ports to tank (see
illustration [c]). If the drain or air bleed piping rise above the level of oil (see illustration [b]) fill the lines
with oil before operation.motor to your national standard is not exceeded.
Pumps Industrial Products
A check valve with cracking pressure of 0.1 bar should be fitted to the case drain line as shown.
Recommended Kawasaki check valves are as follows: (refer to Kawasaki industrial valve
information - data sheet C1001)
pipe for air bleeding
min. oil level
air bleeder plug port
drain portpipe for draining
Dr
T
TDr
Dr Dr
[c][b][a]
check valvecracking pressure
0.1 bar
oiloil
Model
K3VL45/60
K3VL80
K3VL112
K3VL140
K3VL200
Recommended Kawasaki check valve
C10G – 10/01-*
C15G – 10/01-*
C15G – 10/01-*
C15G – 10/01-*
C15G – 10/01-*
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datums
LP1
L1
LA1’
LA2’
LP2’
LP3’
LA1
LP2
MP2MP1 MP3
LA2L2
L2 L3
dial gauge (reading a)
δ =a/2 0.025mm
dial gauge (reading b)
α=SIN-1 (b/D)
0.2°
δ
D
α
datums
b
MA2MA1
Drive Shaft Coupling
Use a flexible coupling to connect the pump shaft to an engine flywheel or electric motor shaft.
Alignment should be within 0.05mm TIR as shown in the illustration below.
Do not apply any radial or axial loading to the pump shaft. For applications where radial or side loads
exist please contact Kawasaki Precision Machinery (UK) Ltd. for recommendations.
Do not force the coupling on or off the pump shaft. Use the threaded hole in the end of the pump shaft
to fix or remove the coupling.
Pumps Industrial Products
For engine drives a split type pinch bolt drive flange and flexible coupling is recommended.
Through Drive Limitations
Apart from predefined maximum throughput limitations, one must also ensure that to prevent a possible
excessive bending moment occurring that the maximum combined bending moment of the combination
is not exceeded as determined in the following expression
MPX = mass of pump [kg]
LPX = length of pump [mm]
Lx = distance of CofG from pump mounting face [mm]
MAX = mass of adaptor kit [kg]LAX = width of adaptor kit [mm]
Bending Moment = ((L1.mP1) + (LA1’.mA1) + (LP2’.mP2) +(LA2’.mA2) +LP3’.mP3) +…)/102[Nm]
((L1.mP1)
+ (LP1+(LA1/2)).mA1
+ (LP1+LA1+L2).mP2
+ (LP1+LA1+LP2(LA2/2)).mA2)
+ (LP1+LA1+LP2+LA2).mP3) +……)/102
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Through Drive Limitations (continued)
Electrical Displacement Control Appl ication
The standard minimum flow setting for the K3VL pump is 0.5-3.0% of the maximum pump delivery. The
pumps minimum displacement stop can be modified if a greater minimum flow rate is required. In order
for the electronic displacement control to function, a minimum pilot pressure for 40 bar must be supplied
to the Psv port on the regulator. A gear pump attached to the rear of the K3VL pump or an external
pressure source can be used to provide the required pilot pressure.
Proportional Pressure Reducing Valve Specifi cation
Maximum Pilot Pressure : 50 bar If higher pressure required contact KPMMax Flow : 10 l/min
Hydraulic oil : Mineral oil
Oil temp range : -20~+90°C
Viscosity range : 5~500 cst
Allowable contamination : NAS grade 10 and below
Electrical specifications,
Rated current : 700 mA
Recommended dither : 80 Hz / 200 mAp-p
Coil resistance : 17.5 (at 20°C)
Ambient temperature range : -30~+80°C
Water resistance : According to JIS D 0203 S2
Pumps Industrial Products
Pump overall length [mm] (Lp)
Single Stock
Pump Pump Pump
Size Type “0” Type “S”45/60 244 244
80 272 272
112/140 308 308
200 359 359
Pump approximate weight [kg] (Mp)
Without torque limiter With torque limiter
Single Stock Single Stock
Pump Pump Pump Pump Pump
Size Type “0” Type “S” Type “0” Type “S”
45/60 25 28 27 30
80 35 38 37 40112/140 65 69 67 71
200 95 103 97 105
Pump CofG from mount [mm] (L)
Single Stock
Pump Pump Pump
Size Type “0” Type “S”
45/60 120 120
80 130 130
112/140 150 150
200 190 190
Pump
Size
45/60
80
112/140
200
Maximum Permisable
Bending Moment (Nm)
137
244
462
930
Adaptor Ki ts weight (Ma) & Wid th (La)
Pumpsize
45/60
Adaptor Kit
Weight(Max)
Width(Lax)
SAE “A” 0 0
SAE “B” & “BB” 2 20
80
SAE “A” 0 0
SAE “B” & “BB” 3 20
SAE “C” 4 24.5
SAE “A” 0 0
SAE “B” & “BB” 3 25
SAE “C” & “CC” 5 30
SAE “D” 10 43
112& 140
SAE “A” 1 6
SAE “B” & “BB” 8 25
SAE “C” & “CC” 8 30
SAE “D” 10 38
SAE “E” 15 38
200
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Unit Dimensions (continued)
Electrical Displacement Control
Pumps Industrial Products
G
F
ACB
Pc
ED
PsvPsv
Pump Size
Installation Dimensions (mm)
K3VL45/60 21
A
K3VL80
K3VL112/140
K3VL200
25
38
57
52
B
59
64
61
90
C
83
78
80
187
D
202
244
258
157
E
172
214
229
226
F
233
247
257
210
G
217
231
249
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Unit Dimensions (continued)
Pumps Industrial Products
Unloading valve module (Type N,M)
K3VL45-60
K3VL80
K3VL112/140
K3VL200
A
169
169
202
212
B
155
166
190
205
Proportional pressure module (*V)
K3VL45-60
K3VL80
K3VL112/140
K3VL200
A
179
179
212
222
B
233
244
280
295
A: Distance between the centre line of the pump and the top of the bolt head for the cut off regulator.
B: Distance between the centre line of the pump and top of the solenoid valve.
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Unit Dimensions
K3VL45/60 Installation
K3VL45 with Cut-Off / Load Sense Control
& Torque Limit Module (Clockwise Rotation)
Pumps Industrial Products
See Torque Limit Detail
and Adjustment
See Max. Flow Adjustment Detail
Adjustment screw for
horsepower setting
Adjustment screw for
differential pressure
Adjustment screw
for cut-off pressure
See PortDetails
See PortDetails
119
154
160
218
184
1 4 . 3
1
4 . 3
91
ø38ø25
A
91
184
26.2 ±0.2
5 2
. 4 ± 0
. 2
13
35.7 ±0.2
6 9
. 8 ± 0
. 2
7 3
1
6 5 7
0
7 0
ø 9 0
1 4 4 4
0
4 0
8 0
8 0
9 9 8
9
5 5
6.5
PLPC
PLPC
PLPCPLPCPLPC
Tair Tair
4 5 °
4 5 ° Dr
Dr
Dr
Dr
B
A
Dr
Dr
B
B
A
Note
for counter clockwise rotation,the suction port “B” and the
delivery port “A” are reversed
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Unit Dimensions (continued)
K3VL45/60 Mounting Flange and Shaft Options
Pumps Industrial Products
ø 1 4 6
ø 1
4 0
SAE "B" 2 hole
SAE J744-101-2
SAE "BB" 30° Involute Spline Shaft
SAE J744-25-4 15T 16/32 DP
SAE "BB" Straight Shaft
SAE J744-25-1
Shaft end
ISO 3019/2-G25N
Flange
ISO 3019/2-100A2HW
9.7
52
38
19
38
32
M8
25
42
36
M8
19
25
ø 2 4
. 9 8 1
33
46
ø 1 0 1
. 6 h 7
0 - 0 . 0
3 5
ø 1 0 0 h 8
0 - 0 . 0
5 4
ø 2 5
. 4 0 - 0
. 0 5
6 3
. 5 + 0
. 0 3
0
2 8
. 1 ± 0
. 1 3
9 +0.50
ø 2 8
0 - 0
. 3
ø
8 0 - 0
. 0 3 6
ø 2 5 j 6
+ 0
. 0 0 9
- 0 . 0 0
4
SAE Type ISO Type
SAE Spline Shaft SAE Straight Shaft
ISO Straight Shaft
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Unit Dimensions (continued)
K3VL45/60 Rear Por t
Pumps Industrial Products
PLPCPLPC
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