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Pumps Industrial Products
Sizes 45, 80, 112, 140and 200
Up to 203 kW and 320bar
Swash-plateAxial Piston Pump
B Series K3VL
Data SheetP-1002/01.06
GB
ModelK3VL
Page1.64
Data SheetP-1002/01.06
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.
◊ Sine wave valve plate.
◊ Separate swash plate.
◊ Spherical valve plate.
◊ Super-finished bores.
◊ Solid pistons.
Pumps Industrial Products
ModelK3VL
Page2.64
Data SheetP-1002/01.06
General Description
The K3VL Series Swash Plate Type Axial Piston Pumps are designed to specifically satisfy the mobile,marine and general industrial machinery market where a medium pressure variable displacement pump isrequired. K3VL Pumps are available in nominal displacements ranging from 45 to 140 cm3/rev with variouspressure, torque limiter, and combination load sensing control options.
Technical Description
The 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
Pumps Industrial Products
ModelK3VL
Page3.64
Data SheetP-1002/01.06
Technical Description (continued)
The Rotating Group
The Rotating Group comprises:
(a) Drive shaft, 111(b) Cylinder block, 141(c) Pistons, 9 x 151(d) Shoes, 9 x 152 (e) Setting plate, 153 (f) Spherical bush, 156(g) 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 bybearings and the drive shaft. 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 developedby 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 cylindersprings also press the cylinder block against the valve plate. With the smallest K3VL45 unit a single cen-tralised spring with individual push pins provide the shoe and cylinder block hold down force.
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 swashplate 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 translat-ed through the tilting pin into an angular movement of the swash plate which varies the tilting or swash angleof the pump. A screw adjuster and lock nut is available to adjust the maximum tilting angle condition. Theservo assist springs are provided to ensure good on stroking response particularly at low operating pres-sures.
The valve plate with its two "kidney" shaped ports is installed onto the valve plate located by the valve platepin. These two ports serve to supply and exhaust oil to and from the cylinder block. The oil passageswitched 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 unit.
Pump Operation
When the pump’s drive shaft is driven by a prime mover (Electric motor, Engine etc.), the cylinder blockbeing spline coupled to the shaft will also rotate. If the swash plate has been tilted, the pistons arranged inthe 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 moveaway from the valve plate for half a rotation (suction stroke) and move towards the valve plate for the sec-ond half of rotation (oil delivery stroke). The larger the tilt angle, the longer the piston stroke and the higheris the pump’s displacement. As the swash plate tilting angle approaches so the piston makes no stroke andthereby delivers no oil.
Through Drive Option
The pump is available with a through drive capability (see installation section) where a through drive shaftwith splined end is incorporated capable of taking a similar torque to that of the pump itself and an SAE "A"mounting interface is provided.
By suitable use of adaptors and splined couplings a wide variety of through drive mounting capabilities areavailable. The formation of these kits and their relevant part numbers will be found in the installation sec-tion.
Pumps Industrial Products
ModelK3VL
Page5.64
Data SheetP-1002/01.06
Technical Data
For applications outside the following parameters, please consult Kawasaki Precision Machinery (UK) Ltd.
Hydraulic Data
Pressure Fluid Mineral oil, phosphate ester, fatty acid ester and water glycol.Phosphate ester is only suitable for use with FPM seals.
Use a high quality, anti-wear, mineral based hydraulic fluid when thepressure exceeds 207 bar. In applications where fire resistant fluids are required consult Kawasaki Precision Machinery (UK) Ltd. The fol-lowing chart illustrates the effects on pump life when non-standard flu-ids are used:
Fluid selection
allowable temperature range
fluid temperature (°C)
kine
mat
icvi
scos
ity(c
St)
-20° 0° 20° 40° 60° 80° 100°
1000
600400
200
1008060
40
20
15
10
VG100
VG68
VG46
VG32
VG22
Pumps Industrial Products
ModelK3VL
Page6.64
Data SheetP-1002/01.06
Technical Data (continued)
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 effec-tively.
This begins by ensuring that at the time of installation that all piping, tanks etc. are rigorously cleaned in asanitary 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 suc-tion 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 tanksbreather is also recommended.
Suggested Acceptable Contamination Level
The relationship between contamination level and pump life is very difficult to predict as it depends on thetype and nature of the contaminant present in the system. Sand or Silica in particular, due to its abrasivenature, 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 minimumCleanliness level of 18/15 to ISO/DIS 4406 (NAS Class 9) is recommended.
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 oper-ating pressure exceeds 210 bar.
Fire-resistant Fluids
Some kind of fire-resistant fluids require special materials for seals, paint and metal finishing. Please con-sult Kawasaki Precision Machinery (UK) Limited and provide details of the particular fluid specification andthe 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 withoperating temperature and service life. For this reason, the circuit should be provided with an adequatelysized 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 behigher than that of an equivalent mineral oil and so needs to be fully evaluated by Kawasaki PrecisionMachinery (UK) Limited. The following table provides an overview of the precautions and characteristics thatcan be expected with these types of fluids.
Expected life expectancy compared100% 60% ~ 100% 50% ~ 100% 20% ~ 80%to mineral oil
recommended usable (higher density)
Pumps Industrial Products
ModelK3VL
Page8.64
Data SheetP-1002/01.06
Technical Data (continued)
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 totallyinsufficient. The pump contains bearings and high-speed sliding parts including pistons with shoes andspherical bushes that need to be continuously lubricated. Part seizure or total premature failure will occurvery 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
Check to ensure that direction of rotation is correct and that the suction and delivery lines are connected cor-rectly.
Start Up
Jog start the motor and check once more for correct rotation. Run the pump unloaded for a period to ensurethat 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 casingdoes not exceed 1 bar. (Maximum peak pressure 4 bar). A suitable drain line hose and drain line filter whenrequired 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 rec-ommended that the pump is run for a short period on a more frequent basis even if it is just unloaded. Withregard to a pump held in storage then rotating the shaft on a frequent basis is sufficient. If the pump is leftout for more than the suggested time it will require a service inspection.
Pumps Industrial Products
ModelK3VL
Page9.64
Data SheetP-1002/01.06
Notes:Rated PressurePressure at which life and durability will not be affected.Peak PressureThe instant allowable surge pressure as defined by DIN 24312. Life and durability however will beshortened.Maximum Self Priming SpeedValues are valid for an absolute suction pressure of 1 bar. If the flow is reduced, or if the inletpressure is increased the speed may also be increased (refer to section 4.2)Maximum Boosted SpeedValues stated are the absolute maximum permitted speed for which an increased inlet pressurewill be required. (refer to section 4.2)WeightApproximate dry weights, dependant on exact pump type.Hydraulic FluidMineral anti wear hydraulic fluid – for other fluid types please consult KPMViscosity RangeIf viscosity is in range 200 to 1,000 cSt, then warming up is necessary before commencing full scale running.
Technical Data (continued)
Specifications
The following table shows the specifications for the complete K3VL pump range.
More detailed efficiency curves and other related information will be found in a later section.
pump model 45 80 112 140 200
capacity cc/rev 45 80 112 140 200
pressure ratings rated bar 320
peak bar 350
Speed ratings self prime rpm 2700 2400 2200 2200 1900
max. bosted rpm 3250 3000 2700 2500 2200
min operating speed rpm 600
casedrain max bar 1
pressures peak bar 4
Weight kg 25 34 60 60 100
case fill capacity cc 600 800 1000 1000
max allowable input torque Nm 225 400 981 981 1000
mounting flange type SAE B ISO 100 SAE C ISO 125 SAE D ISO 180 SAE D ISO180 SAE E
bolts 2 2 2 2 4 4 4 4 4
type SAEB-B ISO 25mm SAE C ISO 32mm SAE D ISO 45mm SAE D ISO 45mm SAE D
Parallel control control(Without torque limit)/1-PP Parallel pressure
compensation control
Unloader solenoid(Type N below)blank For all other options
except PN & LN115A 115V AC, 50.60Hz,
DIN 43550 Plug235A 230V AC, 50.60Hz,
DIN 43550 Plug12D 12V DC, DIN 43550 Plug24D 24V DC, DIN 43550 Plug
Through drive & porting0 Single pump, side portedA SAE "A" through drive, side portedB SAE "B" through drive, side portedBB SAE "BB" through drive, side portedC SAE "C" through drive, side portedD SAE "D" through drive, side portedR Single pump, rear portedS Single pump with plastic cover (Stock
Pump)N Single pump with Steel cover, side ported
Additional pressure control0 No additional controlN With integrated unloading valveV With integrated remote control
valveR With inverse integrated remote
control valve1 Load sensing only (R4 plugged)
Circuit type1 Open circuit
Direction of rotationR Clockwise rotationL Counter-clockwise rotation
Control device configurationP Remote pressure compensatorL Load sensing & pressure control
Porting threadsM Metric threadedS UNC threaded
Mounting flange & shaftS SAE spline & mount (see drawing for detail)M ISO key & mount (see drawing for detail)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 mountfor 112/140
U* 45 only, SAE B key & SAE B 2 bolt mountC* 112/140 only, SAE C spline & SAE C 2 bolt mountR* 112/140 only, SAE C spline & SAE D 4 bolt mountX* 112/140 only, SAE C key & SAE C 2 bolt mountW* 112/140 only, SAE CC spline & SAE C 2 bolt mount(*Non standard options)
Design seriesB
Pumps Industrial Products
ModelK3VL
Page11.64
Data SheetP-1002/01.06
Speed (rpm)
Inpu
tP
ower
(KW
)
Del
iver
yP
ress
ure
Pd
(bar
)
0 500 1000 1500 2000 2500 3000 3500
90
80
70
60
50
40
30
20
10
0
320300
250
200
150
100
5025
K3VL45 Theoretical Power Curve
Performance - K3VL45
Performance Curve(Speed Range 1500 rpm & 1800 rpm with atmospheric inlet)Test temperature 50°C, Viscosity 31cSt (ISO VG 46)
Power CurveNote: Atmospheric Inlet, Full displacement
Delivery Pressure (bar)
Rat
ioof
Dis
plac
emen
t
Vol
umet
ricE
ffici
ency
(%)
0 50 100 150 200 250 300 350
1.00
0.90
0.80
0.70
0.60
0.50
0.40
0.30
0.20
0.10
0.00
100
90
80
70
60
50
40
30
20
10
0
Ratio of displacement1.00 0.75 0.50 0.25
90
89
88
86
83
80
75
70
60
Pumps Industrial Products
ModelK3VL
Page12.64
Data SheetP-1002/01.06
Performance K3VL80
Performance Curve(Speed Range 1500 rpm & 1800 rpm with atmospheric inlet)Test temperature 50°C, Viscosity 31cSt (ISO VG 46)
Power CurveNote: Atmospheric Inlet, Full displacement
Speed (rpm)
Inpu
tP
ower
(KW
)
Del
iver
yP
ress
ure
Pd
(bar
)
0 500 1000 1500 2000 2500 3000 3500
150
100
50
0
320300
250
200
150
100
5025
K3VL80 Theoretical Power Curve
Delivery Pressure (bar)
Rat
ioof
Dis
plac
emen
t
Vol
umet
ricE
ffici
ency
(%)
0 50 100 150 200 250 300 350
1.00
0.90
0.80
0.70
0.60
0.50
0.40
0.30
0.20
0.10
0.00
100
90
80
70
60
50
40
30
20
10
0
Ratio of displacement1.00 0.75 0.50 0.25
92
91
89
87
85
83
80
75
70
Pumps Industrial Products
ModelK3VL
Page13.64
Data SheetP-1002/01.06
Speed (rpm)
Inpu
tP
ower
(KW
)
Del
iver
yP
ress
ure
Pd
(bar
)
0 500 1000 1500 2000 2500 3000
200
150
100
50
0
320300
250
200
150
100
5025
K3VL112 Theoretical Power Curve
Delivery Pressure (bar)
Rat
ioof
Dis
plac
emen
t
Vol
umet
ricE
ffici
ency
(%)
0 50 100 150 200 250 300 350
1.00
0.90
0.80
0.70
0.60
0.50
0.40
0.30
0.20
0.10
0.00
100
90
80
70
60
50
40
30
20
10
0
Ratio of displacement1.00 0.75 0.50 0.25
92
91
89
87
8583
8075
70
Performance - K3VL112
Performance Curve(Speed Range 1500 rpm & 1800 rpm with atmospheric inlet)Test temperature 50°C, Viscosity 31cSt (ISO VG 46)
Power CurveNote: Atmospheric Inlet, Full displacement
Pumps Industrial Products
ModelK3VL
Page14.64
Data SheetP-1002/01.06
Speed (rpm)
Inpu
tP
ower
(KW
)
Del
iver
yP
ress
ure
Pd
(bar
)
0 500 1000 1500 2000 2500 3000
200
150
100
50
0
320300
250
200
150
100
50
25
K3VL140 Theoretical Power Curve
Delivery Pressure (bar)
Rat
ioof
Dis
plac
emen
t
Vol
umet
ricE
ffici
ency
(%)
0 50 100 150 200 250 300 350
1.00
0.90
0.80
0.70
0.60
0.50
0.40
0.30
0.20
0.10
0.00
100
90
80
70
60
50
40
30
20
10
0
Ratio of displacement1.00 0.75 0.50 0.25
93
92
90
88
86
83807570
Performance - K3VL140
Performance Curve(Speed Range 1500 rpm & 1800 rpm with atmospheric inlet)Test temperature 50°C, Viscosity 31cSt (ISO VG 46)
Power CurveNote: Atmospheric Inlet, Full displacement
Pumps Industrial Products
ModelK3VL
Page15.64
Data SheetP-1002/01.06
Speed (rpm)
Inpu
tP
ower
(KW
)
Del
iver
yP
ress
ure
Pd
(bar
)
0 500 1000 1500 2000 2500
400
360
320280
240
200160
120
80
40
0
320300
250
200
150
100
5025
K3VL200 Theoretical Power Curve
Delivery Pressure (bar)
Rat
ioof
Dis
plac
emen
t
Vol
umet
ricE
ffici
ency
(%)
0 50 100 150 200 250 300 350
1.00
0.75
0.50
0.25
0
100
75
50
25
0
Ratio of displacement1.00 0.75 0.50 0.25
91
90
89
87
85
83
80
75
70
Performance - K3VL200
Performance Curve(Speed Range 1500 rpm & 1800 rpm with atmospheric inlet)Test temperature 50°C, Viscosity 31cSt (ISO VG 46)
Power CurveNote: Atmospheric Inlet, Full displacement
Pumps Industrial Products
ModelK3VL
Page16.64
Data SheetP-1002/01.06
Self Priming Curves
K3VL45 Self Priming Capability
K3VL80 Self Priming Capability
Displacement q [cc/rev]
Spe
edN
(rpm
) SuctionPressurePs (bar)
28 30 32 34 36 38 40 42 44
3200
3000
2800
2600
2400
2200
+0,2 bar
+0,1 bar
0 bar
-0,1 bar
-0,2 bar
at the suction portof the pump port
Displacement q [cc/rev]
Spe
edN
(rpm
)
SuctionPressurePs (bar)
50 55 60 65 70 75 80
3000
2800
2600
2400
2200
2000
+0,3 bar
+0,2 bar
+0,1 bar
0 bar
-0,1 bar
-0,2 bar
at the suction portof the pump port
Pumps Industrial Products
ModelK3VL
Page17.64
Data SheetP-1002/01.06
Self Priming Curves (continued)
K3VL112 Self Priming Capability
K3VL140 Self Priming Capability
Displacement q [cc/rev]
Spe
edN
(rpm
)
Suction PressurePs (bar)
70 80 90 100 110
2600
2400
2200
2000
1800
+ 0,2 bar
+0,1 bar
0 bar
-0,1 bar
-0,2 bar
at the suction portof the pump port
Displacement q [cc/rev]
Spe
edN
(rpm
)
Suction PressurePs (bar)
90 100 110 120 130 140
2400
2200
2000
1800
+0,1 bar
0 bar
-0,1 bar
-0,2 bar
at the suction portof the pump port
Pumps Industrial Products
ModelK3VL
Page18.64
Data SheetP-1002/01.06
Self Priming Curves
K3VL200 Self Priming Capability
Displacement q [cc/rev]
Spe
edN
(rpm
) SuctionPressurePs (bar)
120 130 140 150 160 170 180 190 200
2800
2600
2400
2200
2000
1800
1600
+0,3 bar
+0,2 bar
+0,1 bar
0 bar
-0,1 bar
-0,2 bar
at the suction port of the pump port
Pumps Industrial Products
ModelK3VL
Page19.64
Data SheetP-1002/01.06
Pressure pulsation
K3VL45 pulsation graph
K3VL80 pulsation graph
Delivery pressure Pd (bar)
Pul
satio
nw
idth
(bar
)
0 50 100 150 200 250 300 350
20
15
10
5
0
1800rpm
1500rpm
Delivery pressure Pd (bar)
Pul
satio
nw
idth
(bar
)
0 50 100 150 200 250 300 350
20
15
10
5
0
1800rpm
1500rpm
Pumps Industrial Products
ModelK3VL
Page20.64
Data SheetP-1002/01.06
Pressure pulsation (continued)
K3VL112 pulsation graph
K3VL140 pulsation graph
Delivery pressure Pd (bar)
Pul
satio
nw
idth
(bar
)
0 50 100 150 200 250 300 350
20
15
10
5
0
1800rpm
1500rpm
Delivery pressure Pd (bar)
Pul
satio
nw
idth
(bar
)
0 50 100 150 200 250 300 350
20
15
10
5
0
1800rpm
1500rpm
Pumps Industrial Products
ModelK3VL
Page21.64
Data SheetP-1002/01.06
Pressure pulsation (continued)
K3VL200 pulsation graph
Delivery pressure Pd (bar)
Pul
satio
nw
idth
(bar
)
0 50 100 150 200 250 300 350
20
15
10
5
0
1800rpm
1500rpm
Pumps Industrial Products
ModelK3VL
Page22.64
Data SheetP-1002/01.06
Bearing Life (Full Displacement)
K3VL45Note: Service and other life factors have unity value
K3VL80Note: Service and other life factors have unity value
Speed (rpm)
Bea
ring
Life
L10
(hrs
)
0 500 1000 1500 2000 2500 3000 3500
10,000,000
1,000,000
100,000
10,000
1,000
50 bar
100 bar
150 bar
200 bar
250 bar
320 bar300 bar
Speed (rpm)
Bea
ring
Life
L10
(hrs
)
0 500 1000 1500 2000 2500 3000 3500
10,000,000
1,000,000
100,000
10,000
1,000
50 bar
100 bar
150 bar
200 bar250 bar
320 bar300 bar
Pumps Industrial Products
ModelK3VL
Page23.64
Data SheetP-1002/01.06
Bearing Life (Full Displacement) (continued)
K3VL112Note: Service and other life factors have unity value
K3VL140Note: Service and other life factors have unity value
Speed (rpm)
Bea
ring
Life
L10
(hrs
)
0 500 1000 1500 2000 2500 3000
10,000,000
1,000,000
100,000
10,000
1,000
50 bar
100 bar
150 bar
200 bar
250 bar
320 bar
Speed (rpm)
Bea
ring
Life
L10
(hrs
)
10,000,000
1,000,000
100,000
10,000
1,000
50 bar
100 bar
150 bar
200 bar
250 bar
320 bar300 bar
300 bar
0 500 1000 1500 2000 2500 3000
Pumps Industrial Products
ModelK3VL
Page24.64
Data SheetP-1002/01.06
Bearing Life (Full Displacement) (continued)
K3VL200Note: Service and other life factors have unity value
Speed (rpm)
Bea
ring
Life
L10
(hrs
)
0 500 1000 1500 2000 2500
10,000,000
1,000,000
100,000
10,000
1,000
50 bar100 bar150 bar200 bar250 bar300 bar320 bar
Pumps Industrial Products
ModelK3VL
Page25.64
Data SheetP-1002/01.06
Bearing Life (Industrial situation)
K3VL45 Note: Service and other life factors have unity value
K3VL80Note: Service and other life factors have unity value
E/M capacity [kW]
Bea
ring
Life
L10
(hr)
1 10 100
1,000,000
100,000
10,000
1,000
1200 rpm1000 rpm
1500 rpm1800 rpm
E/M capacity [kW]
Bea
ring
Life
L10
(hr)
1 10 100
1,000,000
100,000
10,000
1,000
1200 rpm 1800 rpm1000 rpm 1500 rpm
Pumps Industrial Products
ModelK3VL
Page26.64
Data SheetP-1002/01.06
E/M capacity [kW]
Bea
ring
Life
L10
(hr)
1 10 100
1,000,000
100,000
10,000
1,000
1200 rpm1000 rpm
1500 rpm1800 rpm
Bearing Life (Industrial Situation) (continued)
K3VL112Note: Service and other life factors have unity value
K3VL140Note: Service and other life factors have unity value
E/M capacity [kW]
Bea
ring
Life
L10
(hr)
1 10 100
1,000,000
100,000
10,000
1,000
1200 rpm1000 rpm
1800 rpm1500 rpm
Pumps Industrial Products
ModelK3VL
Page27.64
Data SheetP-1002/01.06
E/M capacity [kW]
Bea
ring
Life
L10
(hr)
10 100 1000
1,000,000
100,000
10,000
1,000
1200 rpm
1000 rpm
1500 rpm
1800 rpm
Bearing Life (Industrial Situation) (continued)
K3VL200Note: Service and other life factors have unity value
Pumps Industrial Products
ModelK3VL
Page28.64
Data SheetP-1002/01.06
Bearing Life (continued)
Bearing Life Correction Factors for Partial Displacement
All bearing life curves on the previous pages refer to L10 life at full displacement. The foregoing curve istherefore to be used where duty cycle considerations require one to compute weighted life, which includepartial displacement conditions.
For example as shown above if the bearing life at full displacement from the previous graphs was say50,000 hours, then at the same operating condition with only 75% displacement the bearing life would be260% of 50,000 hours or 130,000 hours.
Displacement (%)
Bea
ring
life
adju
stm
ent
fact
or(%
)
50% 60% 70% 80% 90% 100%
1200%
1000%
800%
600%
400%
200%
0%
260%
75%
Pumps Industrial Products
ModelK3VL
Page29.64
Data SheetP-1002/01.06
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 pro-vided that its orientation is such that it is this front bearing that takes the additional load (See diagram belowand the bearing life and radial loading curves).
Note: The optional attached gear pump is recommended for all displacement control options. Hydrauliccircuit diagrams illustrate the attached gear pump.
Key to Hydraulic Circuit Annotations
Annotation Description
A1 Main pump delivery
A2 Auxiliary pump delivery
a1 Gauge port main pump delivery
a2 Gauge port auxiliary pump delivery
B2 Gear pump suction
B1 Main pump suction
b Suction gauge port
Dr Drain
Pi Pilot pressure
Pc Remote pilot port, Pressure compensator
Pi Pilot port displacement control
PL Load sense port
Psv Pressure assist port
Ps Inlet pressure
Regulator Code Control Curves Hydraulic Circuit
LO/L1 Load Sense andPressure Cut-off
Pump displacement is controlledto match the flow requirement asa function of the system differen-tial pressure (load pressure vsdelivery pressure).In addition, there is a pressurecutoff function incorporated intothe control. With the L1 option,the bleed-off orifice R4 isplugged.
PL
R4
AR1
Dr B
T air
Differential Pressure Spool
Cut-off Pressure Spool
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ModelK3VL
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Data SheetP-1002/01.06
Regulator Code Control Curves Hydraulic Circuit
LN Load Sense and PressureCut-off with IntegratedUnloading Valve
An integrated unloading valve issandwiched between the LoadSense regulator and pump toeffectively de-stroke the swash-plate when an electric signal isprovided.
LV Load Sense and PressureCut-off with IntegratedProportional Relief Valve
An integrated proportional reliefvalve is sandwiched between theLoad Sense regulator and pumpto control the maximum pressuresetting by varying an electric sig-nal to the valve.
A separate amplifier is required.
PL
R3
R1
Dr B
A
T air
Differential Pressure Spool
Cut-off Pressure Spool
UnloadingSolenoid
Valve
PL
R3
R1
Dr B
A
T air
Differential Pressure Spool
Cut-off Pressure Spool
ProportionalRelief Valve
Functional Description of Regulator (continued)
Pumps Industrial Products
ModelK3VL
Page35.64
Data SheetP-1002/01.06
Functional Description of Regulator (continued)
Regulator Code Control Curves Hydraulic Circuit
L0/1 Load Sense and PressureCut-off with Torque Limiting
L0/L1 control functions as previ-ously noted.
In response to a rise in deliverypressure the swashplate angle isdecreased, restricting the inputtorque. This regulator preventsexcessive load against the primemover.
The torque limit control module iscomprised of two springs thatoppose the spool force generat-ed by the system pressure. Byturning an outer and inner springadjustment screw, the appropri-ate input torque limit can be set.
PO Pressure Cut-off
As system pressure rises to thecut-off setting, the swashplatede-strokes to prevent the systempressure from exceeding thecompensator setting. It is impera-tive that a safety relief valve beinstalled in the system.
Note: By connecting the Pc portto a remote pressure control,variable pump pressure controlcan be achieved.
An integrated unloading valve issandwiched between thePressure Cut-off regulator andpump to effectively de-stroke theswashplate when an electric sig-nal is provided.
An integrated proportional reliefvalve is sandwiched betweenthe Pressure Cut-off regulatorand the pump to control themaximum pressure setting byvarying an electric signal to the valve.
A separate amplifier isrequired.
P0/1 Pressure Cut-off withTorque Limiting
P0/P1 control functions aspreviously noted. In response to arise in delivery pressure theswashplate angle is reduced,restricting the input torque. Thisregulator prevents excessive loadagainst the prime mover.
The torque limit control module iscomprised of two springs thatoppose the spool force generatedby the system pressure. Byturning an outer and inner springadjustment screw, the appropriateinput torque limit can be set.
Note: By connecting the Pc portto a remote pressure control,variable pump pressure controlcan be achieved as indicatedbelow.
Regulator Code Control Curves Hydraulic Circuit
Pum
pF
low
Delivery Pressure
Outer SpringAdjustment
Outer Plus InnerSpring
Adjustment
PL
R2
R1
Dr B
A
T air
Differential Pressure Spool
Cut-off Pressure Spool
ProportionalReliefValve
PC
R2
R1
Dr B
A
T air
Differential Pressure Spool
Cut-off Pressure Spool
Torque SpoolLimiter
Pumps Industrial Products
ModelK3VL
Page37.64
Data SheetP-1002/01.06
Functional Description of Regulator (continued)
/1-E0 Electrical DisplacementControl
Varying the input current signalto the pump controller’selectronic proportional pressurereducing valve (PPRV) allowsthe user to control the pumpdisplacement. As the currentsignal to the PPRV increases,the pump displacementincreases proportionally.
Note: An external pressuresupply of 40 bar is required atthe PSV Port (50bar max).
/1-Q0 Pilot OperatedDisplacement Control
Varying the input pressuresignal to the PSV port allowsthe user to control the pumpdisplacement. As the pressuresignal to the PSV increases,the pump displacementincreases proportionally.
Regulator Code Control Curves Hydraulic Circuit
Qmax
Qmin
360 600
Input Current (mA) of ProportionalPressure Reading Valve
Pum
pF
low
Rat
e(Q
)
PSV
PC
Dr B
A
Qmax
Qmin
0 9 28
Pilot Pressure (bar)
Pum
pF
low
Rat
e(Q
)
PSV
PC
Dr B
A
a
Pumps Industrial Products
ModelK3VL
Page38.64
Data SheetP-1002/01.06
Functional Description of Regulator (continued)
Regulator Code Hydraulic circuit
Parallel control(Without torque limiter)/1-PP Parallel pressurecompensation control
As system pressure rises to theCut-off setting, the swashplatede-strokes to prevent the systempressure exceeding the compen-sator setting. It is imperative thata safety relief valve be installedin the system.Note: By connecting the Pcports together multiple pumps inparallel operation is achieved.
PC PdPC Pd
R2
R1
Dr B
A
X
T air
Differential PressureSpool
Cut-off PressureSpool
R2
R1
Dr B
A
X
T air
Differential PressureSpool
Cut-off PressureSpool
CustomerSupply
Pumps Industrial Products
ModelK3VL
Page39.64
Data SheetP-1002/01.06
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 electricmotor to your national standard is not exceeded.
The pump should be mounted horizontally with the case drain piping initially rising above the level of thepump before continuing to the tank as shown in the illustration below. Do not connect the drain line to thesuction line.
The uppermost drain port should be used and the drain piping should be equal or larger in size than thedrain port to minimise pressure in the pump case. The pump case pressure should not exceed 1 bar asshown in the illustration below. (Peak pressure should never exceed 4 bar.)
Mounting the Pump Above the Tank
Suction line
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
200mmminimum
depth
200mmminimum
depth
with
in1m
200mmminimum depth
Mus
tbe
high
erth
anto
pof
Pum
pC
ase
Pumps Industrial Products
ModelK3VL
Page41.64
Data SheetP-1002/01.06
Installation (continued)
Mounting the Pump Vertically (shaft up)
For applications requiring vertical installation (shaft up) the pump must be provided with additional meansto lubricate the front bearing. Do not use a standard pump for this type of application. (Mounting orientation "V" type should be used.)
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 toprovide 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.
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)
min. oil level
air bleederplug port
drain port
pipe for air bleeding
pipe for draining
check valvecracking pressure0.1 bar
[a] [b]
T
T
DrDr
Dr Dr
[c]
oil oil
Model Recommended Kawasaki check valve
K3VL45 C10G – 10/01-*
K3VL80 C15G – 10/01-*
K3VL112 C15G – 10/01-*
K3VL140 C15G – 10/01-*
K3VL200 C15G – 10/01-*
Pumps Industrial Products
ModelK3VL
Page42.64
Data SheetP-1002/01.06
Drive Shaft Coupling
Use a flexible coupling to connect the pump shaft to an engine flywheel or electric motor shaft. Alignmentshould 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 existplease 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 possibleexcessive bending moment occurring that the maximum combined bending moment of the combination isnot exceeded as determined in the following expression
dial gauge (reading a)δ =a/2 0.025mm
dial gauge (reading b)α =SIN-1 (b/D)
0.2°
α
δ
D
b
datumsdatums
LP1
mP1 mP2 mP3
mA1 mA2
LA1 LA2L2
L2 L3L1
LA1'
LP2'
LA2'
LP3'
LP2
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]
The standard minimum flow setting for the K3VL pump is 0.5-3.0% of the maximum pump delivery. Thepumps minimum displacement stop can be modified if a greater minimum flow rate is required. In order forthe electronic displacement control to function, a minimum pilot pressure for 40 bar must be supplied to thePsv port on the regulator. A gear pump attached to the rear of the K3VL pump or an external pressuresource can be used to provide the required pilot pressure.
Maximum Pilot Pressure : 50 bar If higher pressure required contact KPMMax Flow : 10 l/minHydraulic oil : Mineral oilOil temp range : -20~+90°CViscosity range : 5~500 cstAllowable contamination : NAS grade 10 and belowElectrical specifications,
317 Sub Plate K3VK 200 1 2924750-0675 2924750-0667 2924750-0677 2924750-0686
407 SHCS 8 0SBM1230 0SBM1230 0SBM1245 0SBM1245
712 O-Ring 1 00RBG120 00RBG125 00RBG125 00RBG125
742 O-Ring 1 00RBG105 00RBG130 PCPP155 PCPP170
Pumps Industrial Products
ModelK3VL
Page63.64
Data SheetP-1002/01.06
Unit Dimensions (continued)
Electrical Displacement Control
Installation Dimensions (mm)
G
F
AB C
ED
PSVPSV
PC
Pump Size A B C D E F G
K3VL45 21 52 90 187 157 226 210
K3VL80 25 59 83 202 172 233 217
K3VL112/140 38 64 78 244 214 247 231
Unit Dimensions (continued)
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.