comoso fluid power sid division power unit start up manual

8/19/2019 COMOSO Fluid Power SID Division Power Unit Start Up Manual

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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.


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.



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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.



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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


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.



22/185


Fire-resistant Fluids (continued)


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)


23/185


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.



24/185

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


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.


25/185

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 )


26/185


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



27/185

Ordering Code – K3VLSeries


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

/ - -


28/185

Bearing Life

Noise Level

Performance K3VL45


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


29/185


Bearing Life

Noise Level



Performance K3VL60


1000000

1000

1500rpm1000rpm1800rpm1200rpm

E/M capacity [kW]

100

10000

100000

85

80

75

70

65

60

55

50150100 200


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


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


S p e e d N ( r p m

)

50

1

0 50

10


30/185

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


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


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


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


S p e e

d N [ m i n - 1

]

85

80

75

70

65

60

55

50

150100 200


N o i s e L e v e l [ d b ( A ) ]

250 300 350

1800rpm

1500rpm

q = 80cc/rev

0 50


31/185

Performance K3VL112


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



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


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


S p e e

d N [ m i n - 1

]

Bearing Life

Noise Level


1000000

1000

1000rpm1200rpm

1500rpm1800rpm

E/M capacity [kW]

100

10000

100000

85

80

75

70

65

60

55

50

150100 200


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


32/185

10

0

1


1000000

1000

1000rpm 1200rpm

1500rpm

1800rpm

E/M capacity [kW]

100

10000

100000

85

80

75

70

65

60

55

50

150100 200


N o i s e L e v e l [ d b ( A ) ]

250 300 350

1800rpm

1500rpm

q = 140cc/rev

Performance K3VL140


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


Delivery Pressure Pd [kgf / cm2 ]

V o

l u m e


( % )

R a

t i o o

f D i s p

l a c e m e n

t [ q / q m a x

]



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


S p e e

d N [ m i n - 1

]

Noise Level

50


33/185

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


S p e e d N ( m i n - 1 )

85

80

75

70

65

60

55

50

150100 200


N o i s e L e v e l [ d b ( A ) ]

250 300 350

1500rpm

1800rpm

q = 200cc/rev


1000000

100000

10000

1000

1000rpm

1200rpm1500rpm

1800rpm

10 100 1000

E/M capacity [kW]

Performance K3VL200


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



V o

l u m e


( % )

R a

t i o o

f D i s p l a c e m e n

t



Bearing Life

Noise Level

0 50


34/185

Bearing Life (continued)

Bearing Life Correction Factors for Partial Displacement


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.


35/185

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).


acceptable

not acceptable


36/185

Functional Description of Regulator


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


37/185

Functional Description of Regulator (continued)



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


UnloadingSolenoid

Valve



LM Load Sense and

Pressure Cut-off w ith

Integrated Unloading Valve

(Normally Open)

An integrated unloading


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




LV Load Sense and Pressure

Cut-off with Integrated

Proportional Relief Valve

An integrated proportional relief


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


ProportionalRelief Valve



38/185




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


Torque Limiter Spool



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




39/185




PN Pressure Cut-off with


(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


PM Pressure Cut-off with


(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



Dr B

A

Tair

Pc

R2

R1


SolenoidValve


Q

P


40/185




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


ProportionalRelief Valve



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


Torque SpoolLimiter


Q

P

Outer Spring

Adjustment

Delivery Pressure

P u m p F l o w

Outer Plus Inner Spring Adjustment


41/185




/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


/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


42/185

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.


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


43/185

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.)


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


44/185

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.


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-*


45/185

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.


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


46/185

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


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


47/185

Unit Dimensions (continued)

Electrical Displacement Control


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


48/185



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.


49/185

Unit Dimensions

K3VL45/60 Installation

K3VL45 with Cut-Off / Load Sense Control

& Torque Limit Module (Clockwise Rotation)


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


50/185


K3VL45/60 Mounting Flange and Shaft Options


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


51/185


K3VL45/60 Rear Por t


PLPCPLPC

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