Copy of K8724 K3VL Marketing Kit - MCR-28€¦ · The K3V series of swash plate piston pumps was developed from the NV series specifically for the earth moving and construction Industry

K3VL B SERIES

Marketing Kit

Medium PressureSwash-plate Type Axial Piston Pumps

for Open Circuit Applications

K3VLB SERIES

Page 1 of 168

K3VL Marketing Kit

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Table of Contents

Section Description Page No

1. Introduction 3

2. History of Development 4Kawasaki History, NV, K3V, K3VG etc

3. General Description 6Model Range, Specifications, Model Coding

4. Technical Description of Pump 10Design, Functionality, Features & Benefits,Performance Characteristics,

5. Control Regulators 43Design, Functionality, Performance Characteristic

7. Applicational Precautions 98Start Up, Mounting, Vertical Up, Viscosity, Temperature,Through Drives

8. Commercial Information 107Strategy, Pricing, Lead Times, Stocking Policy, FAQís

9. Competitive Information 117Product Offerings, Comparisons, Cross References

10. Installation 127Generic Installation Drawings, Adapter Kits, Sensitivities

11. Literature 147Application Check List, SPR, Part Number Formulation,Exploded Views, Controller Specification

12. Appendix 148

13. Index 165

Note: This Marketing Kit is a company confidential document and must notbe passed on, in part, or in its entirety to any third party without theexpress agreement of KPM.

K3VL Marketing Kit

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1. Introduction

The NEW K3VL ìBî Series

In keeping with Kawasakiís commitment to new product development, fouryears after the successful launch of the K3VL series of piston pumps, the newK3VL B series is now available. Continuing to develop in accordance withcustomer' demands the B series offers further decreases in noise emissions,increased control options, and further increases in reaction times inconjunction with precise hysterisis and increased stability.

An increase in the capacity range has been achieved by adding a 200ccpump to the K3VL stable for the summer of 2005. Since its launch K3VLproduction volumes have shown dramatic increases with proven success inMarine, Industrial and Mobile/Off-highway applications.

During this period of rapid growth inward investment in machinery andpersonnel has enabled Kawasaki to produce one of the most competitivemedium pressure, variable displacement axial piston pump offerings in themarket.

This marketing kit details the technical improvements achieved and generaltechnical detail to assist our distribution network to stock and sell this nowproven and highly versatile range of K3VL Medium to High Pressure AxialPiston Pumps.

KPM(UK)May 2005

Note: This Marketing Kit is a company confidential document and must not be passed on, in part, or in its entirety to any third party without theexpress agreement of KPM.

K3VL Marketing Kit

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2. History of Development

Kawasaki Heavy Industries, Precision Machinery Division, have beenmanufacturing and selling hydraulic equipment and in particular pumps forover 80 years. They began in 1916 manufacturing Hele-shaw radial pistonpumps branching later into screw pump manufacture and latterly into axialpiston units of both the bent axis and swash plate designs.

Hele-shaw Radial Piston Pump Early Screw Pump

KHI began in 1964 supplying hydraulic equipment into the Japanese hydraulicexcavator market.

In 1968 when the present Nishi-Kobe facility was first established, KHI hadcompleted their own development of their first ìKVî series of swash plate typeaxial piston pumps and motors primarily for the hydraulic excavatorrequirements.

KV Series L Series

In recognition of the large market potential particularly in America and Europefor medium pressure piston equipment an extensive development programmebased on the existing K3V & K3VG units was commenced in 1998 whichresulted in the release of this the K3VL product range in 2001.

This is the very first truly "Global" product that Kawasaki have developed andin keeping with customer and market demands the new K3VL B series is nowavailable incorporating further noise reductions, an increase in control optionsand capacity range, greater compatibility with alternative fluids and increasedreaction times with greater stability. The K3VL B series is a highlycompetitive offering for Mobile, Industrial and Marine applications.

K3VL Marketing Kit

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2. History of Development (cont.)

The K3V series of swash plate piston pumps was developed from the NVseries specifically for the earth moving and construction Industry and wasavailable on the market in 1987.

Over the past decade, this K3V series has continued to build up Kawasakiíssolid reputation for high efficiency and excellent reliability.

The K3V Family K3VG Pump

The K3VG was developed from the K3V mobile unit so as to satisfy generalIndustrial type applications, by optimising fluid pulsation, incorporation of avery wide range of control regulators and the optional provision of auxiliarypumps and was first marketed in 1992.

In recognition of the large market potential particularly in America and Europefor medium pressure piston equipment an extensive development programmebased on the existing K3V & K3VG units was commenced in 1998 which hasnow resulted in the release of this the K3VL product range.

This one could say is the very first truly ìGlobalî product that Kawasaki havedeveloped and is a significant indicator of developments to come.

10's 20's 30's 40's 50's '60 '61 '62 '63 '64 '65 '66 '67 '68 '69 '70 '71 '72 '73 '74 '75 '76 '77 '78 '79 '80 '81 '82 '83 '84 '85 '86 '87 '88 '89 '90 '91 '92 '93 '94 '95 '96 '97 '98 '99 00

Original Heleshaw Radial Piston Pump

Kawasaki "RV" Series

Breuninghaus "B" Series Bent Axis Pumps

Breuninghaus "BZ" series Bent Axis Pumps

Kawasaki "L" Series

"LZ" Series with ROTAS Control

"LVP" Series

"AX" Series

Kawasaki "F" Series Bent Axis Pumps

Kawasaki "KV" Series Swash Plate Pumps

"K4V" Series

"K3SP" Series

"K3V" Series

"K3VG" Series

"K3VL" Series

"NV" Series

"NVH" Series

K3VL Marketing Kit

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3. General Description

The K3VL range consists of four frame sizes, of 45, 80, 112 ,140 and 200cc/rev capacity.

Its basis is that of the proven high pressure K3V and K3VG units whereby thecontrols and general construction have been optimised for the mediumpressure market requirements.

The development targets set in developing medium pressure piston pumps forsuch applications were set as follows:

1) To ensure that both standard American (SAE) and European (ISO) mounts,shaft configurations and porting interfaces were available.

2) To allow for through drive options for similar sized units or other auxiliarypumps to be fitted as standard to the rear of the main pump, thereby reducingunit cost.

3) To make available a wide range of variants, so as to meet the differing marketrequirements.

4) To achieve high levels of standardisation and modularisation so that one canrealise a wide variety of pump variants from a small number of modules.

K3VL Marketing Kit

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3. General Description (cont.)

3.1 Model Range

The K3VL range consists of four frame sizes, of 45, 80, 112 and 140 cc/revcapacity. A maximum displacement stroke adjuster is provided as standardfrom which one can vary down to 50% of maximum displacement.

For each frame size side port options are available for both single and throughdrive units. A rear port option will be available for the single pump unit. Thesethrough drive units use standard SAE type splined coupling interfaces throughwhich either two such pumps can be coupled together or a generally availableSAE spline shafted auxiliary pump can be fitted.

SAE and ISO standard mounts are available together with their correspondingparallel keyed and spline shaft configurations.

A wide range of conventional mechanical and hydro-mechanical controls areavailable for both flow (load sensing), torque limit and pressure regulation.

In addition both an integral unloading feature and proportional pressurecompensator options are also available.

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3. General Description (cont.)

3.2 Specifications

The following table shows the specifications for the complete K3VL pumprange.

More detailed efficiency curves and other related information will be found in alater section.

pump model 45 80 112 140 200capacity cc/rev 45 80 112 140 200

rated bar 320pressure ratings

peak bar 350self prime rpm 2700 2400 2200 2200 1900

speed ratingsmax. boosted rpm 3250 3000 2700 2500 2200

minimum operating speed rpm 600max. bar 1case drain

pressures peak bar 4weight kg 25 34 60 60 100

case fill capacity cc 600 800 1000 1000max. allowable input torque Nm 225 400 981 981 1000

type SAE B ISO 100 SAE C ISO 125 SAE D ISO 180 SAE D ISO 180 SAE Emounting flange

bolts 2 2 2 2 4 4 4 4 4type SAE B-B ISO 25mm SAE C ISO 32mm SAE D ISO 45mm SAE D ISO 45mm SAE D

input shaftform

spline &key

keyspline &key

keyspline &key

keyspline &key

keyspline &key

SAE ìAî 61SAE ìA-Aî 118SAE ìBî 203SAE ìB-Bî 225SAE ìCî 400SAE ìC-Cî 559SAE ìDî 699

allowablethrough drive

torqueNm

temperature range C -20 to 95viscosity range cSt 10 to 1,000

max. contamination level 18/15 (ISO/DIS 4406)

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 durabilityhowever will be shortened.Maximum Self Priming SpeedValues are valid for an absolute suction pressure of 1 bar. If the flow is reduced, or ifthe inlet pressure 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 increasedinlet pressure will 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 beforecommencing full scale running.

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Ordering Code ñ K3VL Series

Porting threadsM Metric threadedS UNC threaded

K3VL Series Pump

Hydraulic Fluid Type- Mineral oilW Water glycolZ Phosphate ester

Additional control options

Blank Without additionalcontrols

Torque limit control/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 pressurerequired)

/1-E1 Electrical displacementcontrol (No pilotpressure required)

/1-Q0 Pilot operateddisplacement control

Parallel control(Without torque limit)/1-PP Parallel pressure

compensation control

Unloader solenoid(Type N below)blank For all other optionsexcept PN&

LN115A 115VAC, 50.60Hz,

DIN43550Plug235A 230VAC,50.60Hz,

DIN43550Plug12D 12VDC,DIN43550Plug24D 24VDC,DIN43550Plug

Circuit type1 Open circuit

Maximum displacement45 45 cm3/rev80 80 cm3/rev112 112 cm3/rev140 140 cm3/rev200 200 cm3/rev

Through drive & porting

0 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 valve (K3VL45 only)1 Load sensing only (R4 plugged)

Control device configurationP Remote pressure compensatorL Load sensing & pressure control

Design seriesB

Direction of rotation

R Clockwise rotationL Counter-clockwise rotation

Mounting flange & shaft

S 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)

12D /1 H*K3VL 80 B 1 0 SR S L O-

= under development

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4. Technical Description of Pump

The components of the K3VL pump can be generally divided into three sub-groupings, namely the Rotating Group which provides the main rotarypumping action, the Swash Plate Group to vary the pumpís delivery flow rateand the Valving Cover Group which provides the switching of oil betweensuction and delivery ports.

The Rotating Group is composed of the drive shaft (111), cylinder block141), pistons (9 x151), shoes (9 x 152), setting plate (153), spherical bush(156), and cylinder springs (9 x 157). The drive shaft is supported at both itsends by bearings (123 & 124). The drive shaft is coupled to the cylinder blockthrough a splined section. The shoe is swaged over the spherical end of thepiston so as to form a spherical ball joint. In addition the shoe has ahydrostatic pocket so as to effectively balance the hydraulic thrust developedby the piston pressure so that the shoe can lightly slide against the shoe plate(211). Additionally the subgroup consisting of the pistons and shoes arepressed against the shoe plate by the cylinder springs, which act through thesetting plate and the spherical bush. The force developed by these cylindersprings also press the cylinder block against the valve plate (313). With thesmallest K3VL45 unit a single centralised spring with individual push pinsprovide the shoe and cylinder block hold down force.

K3VL80 Cross Section

490 901 535 536 214 537548531 886 706 490 532 703

702792 534

808

954

312124885401313719141157151467728

152156211

153212406710774261

465729

111

983981

824

127

123

884

251

538

711

271

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4. Technical Description of Pump (cont.)

The Swash Plate Group is composed of the swash plate (212), shoe plate(211), swash plate support (251), tilting bush (214), tilting pin (531) and theservo piston (532) and servo assist springs (535 & 536). The swash plate onthe reverse side to the shoe location is of a cylindrical form which is a ìpillowîsupported by the hydrostatic bearing provided by the swash plate support.The tilting bush is inserted into the swash plate and into this is installed thespherical portion of the tilting pin which in turn is coupled to the servo pistonitself. Any linear movement of the servo piston produced by the regulatorpressure applied to either of its ends is thereby translated through the tiltingpin into an angular movement of the swash plate which thereby varies thetilting or swash angle of the pump. A Screw adjuster and lock nut is availableto adjust the maximum (954) tilting angle condition. The servo assist springsare provided so as to ensure good on stroking response particularly at lowoperating pressures.

The Valve Cover Group is composed of the valve cover (312), valve plate(313) and valve plate pin (885). The valve plate with its two ìkidneyî shapedports is installed onto the valve plate being located by the valve plate pin.These two ports serve to supply and exhaust oil to and from the cylinderblock. The oil passage, switched by the valve plate, is connected to theexternally piped suction and outlet pressure ports through the valve cover.This valve plate is spherical in form for all but the smallest 45 unit.

K3VL45 Cross Section

401157141719158159467151160152156211153212

983710981406774261

465729

111

115

824

127

123

884

251

538

711

490

271

901 533 214 537 531 548 532 886 706 490 703 702 792 534

808

809

312

124

313

807

885

K3VL Marketing Kit

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4. Technical Description of Pump (cont.)Pumping Action

When the pumpís drive shaft is driven by a prime mover (Electric motor,Engine etc.), the cylinder block, being spline coupled to the shaft, will alsorotate. If the swash plate has been tilted, the pistons arranged in the cylinderblock due to the shoe being retained on the swash plate surface, will bothrotate with the cylinder block and reciprocate once per revolution. Considerone 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 ofrotation (oil delivery stroke). The larger the tilt angle then the longer the pistonstroke and thereby the higher is the pumpís displacement. As the swash platetilting angle approaches zero so the piston makes no stroke and therebydelivers no oil.

Through Drive Options

The pump is also available with a through drive capability (see installationsection) so as to enable a second pump to be driven from the first pump.Pumps up to the same input torque of the first pump may be mounted on therear of the pump. An SAE mounting is provided for this facility.

By suitable use of adapters and splined couplings a wide variety of throughdrive mounting capabilities are available. The formation of these kits and theirrelevant part numbers will be found in the installation section.

Cover Kit SAE "A" Kit SAE "B" Kit

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4.1. Features & Benefits

There are numerous features and benefits that should be understood andutilised when selling the K3VL product. Some of these features are commonto the K3VG for which you should already have a good appreciation. Detaileddescriptions of the most significant features and their benefits will be found onthe following pages. In summary they include the following:

FEATURE BENEFITPiston return mechanism Contaminant resistant

High endurabilitySpherical valve plate High speed capability

Less Energy LossStabilised rotating group

Swash plate pillow support Stiffer structureReduced deformation

Hydrostatic pillow bearing Less vibrationQuicker response

Rugged long life roller bearings High reliabilityRadial shaft loading possible

Resonator option Virtually eliminates fluid pulsationStrong, proven, rotating group High reliability

Customer confidenceRigid construction Reduced structural vibrationAdjustable maximum stop Ability to tune flow to system320 bar rating High performanceThrough drive options Provides system flexibility

Reduces PTO requirementsSAE & ISO mounts Satisfies needs for global machine

designLarge variety of control options Ability to match system needsIntegral unload function No pipework necessary thereby

reducing installed costsStability & response are assured

Vertical mount bleed as standard Ability to match machine needsIntegral proportional pressure control No pipework necessary thereby

reducing installed costsOptimised to pump requirementStability & response are assured

Solid pistons Higher volumetric efficiencyServo assist springs Good Onstroke performance even at

low operating pressuresSAE & metric port options Connectors are readily available world-

wide thereby reducing installed costsOpposed stroking pistons Lowers swash bearing load

Improves endurabilitySide & rear port options High plumbing flexibility

Ensures better machine fitMultiple drain ports Allows more mounting orientationsClockwise & counterclockwise rotation Provides total flexibilitySmall installation envelope High power to weight ratio

More compact machine design

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4. Technical Description of Pump (cont.)4.1. Features & Benefits

The following mind map attempts to encapsulate all these features and

benefits for you:-

External

Stroking Mechanism

Controls

Environmental

Internal

SAE & ISO Mount SAE splined & SAE/ISO parallel shaftspump mount & coupling availabilitysatisfies global needs

Small Installation Envelope compact machine designhigher power to weight

Through Drive SAE splined couplings usedreduces PTO requirementstotal system flexibility

Truly Global Productspecified in USA & Europedeveloped in Japanproduced in Europe

Resonator eliminates fluidborne noiseintegral to pump

SAE & Metric Ports fittings availabilityglobal standard

Side & Rear Porting plumbing flexibilitybetter machine fit

Vertical Mountmatches machine needsstandard featureflexibility

Multiple Drain Ports mounting flexibilitystandard feature

CW & CCW Rotation simple conversiontotal flexibility

320 bar Rating superior performancereserve capability

Opposed Stroking Pistons reduced structureborne vibrationsreduced pillow bearing loadimproves endurability

Swash Plate Pillow Support reduced deformationstiffer structure

Maximum Displacement Stop ability to fine tunestandard feature

Servo Assist Springs good onstroke responsecompact design

Hydrostatic Pillow Bearing quicker responseless vibration

Overcentre Bleed reduces pressure overshootimproves stability margin

Pressure Compensation direct, pilot and remote functionsmatches system needs

Integral Proportional Pressure simplifies installationno external pipingmore compact

Displacement Control utilising K3VG compensatorin development

Integral Unload simplifies installationno external pipingmore compact

Load Sensing matches system needsenergy saving

Torque Limiter engine / motor matchingmatches system needsanti stall function

Long Life Roller Bearings radial shaft loading possibleshimming unnecessaryhigh reliability

Rigid Construction reduced structureborne vibrationsrobust design

Various Sealing Options alternative fluid capabilityimproved flexibility

Low Pulsation reduced fluidborne noiseimproved reliability

Piston Shoe Return Mechanism consistent shoe clampcontaminant resistanthigh endurability

Hardened Steel Cylinder Block contaminant resistanceanti-scuffing

Bronze Piston Shoe lighter weight reduces shoe rollLower frictionional coefficient

Proven Rotating Group produced in large volumecustomer confidencehigh reliability

Sine Wave Valve Plate reduced fluid pulsationsoriginal patented designstandard feature

Seperate Swash Plate consistant hardenabilityimproved servicability

Spherical Valve Plateminimises bearing loadsstabilised rotating grouphigh self priming speedless energy loss

Superfinished Bores smoother pump responsereduced friction

Solid Pistons improved volumetric efficiencyless deformation under loadenhanced cylindricity

Shoe Support Pads improves shoe stabilityreduces friction

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4. Technical Description of Pump (cont.)4.1. Features & Benefits (cont.)

Piston Return Mechanism

The piston return mechanism allows the piston / shoe to be always pressedagainst the swash plate. With the traditional ìshimmedî method, the positionof the set plate is adjusted by shimming in accordance with the thickness ofthe shoe shoulder. This has resulted in occasional failure of the set plate /shoe interface due to the impact force generated by a widening gap betweenthe shoe and the set plate as the shoe sliding surface wears.

In the K3VL, helical coil springs are used to press the shoe against the swashplate at a constant load, with the result that the effect of shoe wear is virtuallyeliminated and thereby has dramatically improved the units reliability.

With all but the 45 frame size individual springs ensure that a uniform load isapplied evenly to each shoe thereby ensuring optimum hold down conditions.With the 45 size, being a relatively small size rotating group a central cylinderblock spring is used whereby the hold down force is transmitted to the shoeplate by individual pins. In all cases a compensated shoe clamp down isachieved which provides a high degree of contaminant tolerance.

It must also be noted that the spring hold down force is necessary so as toovercome piston-shoe inertia forces that occur as each piston reverses itsstroke. Because of the relative weight of the pistons particularly on the largerframe sizes together with the high operating speeds of these units individualsprings provide a optimum solution.

Shimmed type Spring compensated type

Shim

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Solid Pistons

The complete range of K3VL pumps all utilise solid pistons whose mostimportant feature is that one reduces the dead volume under compression.The effect of such a feature is that, in comparison to the conventional hollowpiston type, one can obtain a significant improvement in efficiency.

This condition can be likened to the operation of a bicycle pump. If you putyour finger over the outlet of the pump you will need to move the pistonplunger a certain distance before pressure occurs which will displace onesfinger. The plunger in fact must move a certain percentage of its availablestroke to precompress to a particular pressure. So the more dead volumewithin the bicycle pump the more plunger stroke is necessary forprecompression.

In addition, being a smaller relative trapped volume under compression, thenatural resonant frequency will be higher which will assist in attenuating thetransmission of fluid borne pulsation.

0 50 100 150 200 250 300

Pressure [bar]

0

0.5

1

1.5

2

2.5

3

Volume Change [%]

- % change

Hollow piston Solid piston

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Spherical Valve Plate

The use of the spherical valve plate has been successful in stabilising thecylinder block rotational posture, allowing for increased efficiency particularlyin the low pressure, low tilting angle condition. Its manufacture howeverrequires higher levels of machining technique than that of the conventional flatvalve. Thanks to the progress in manufacturing techniques, advances intreating residual stresses and deformations due to heat treatment this is nowpossible.

Another advantage of the spherical valve plate is an improvement in the selfpriming capability. With a spherical valve plate, the cylinder port radius can bereduced without affecting the cylinder block balance. This then lowers theperipheral flow velocity around the port, thereby reducing pressure loss duringthe suction stroke.

Note: The K3VL45 utilises the conventional flat valve plate. Due to its size theimprovement gained by going to a spherical valve plate was small comparedto its increased cost. Additionally being a smaller size the self primingcapability even with a flat valve plate is acceptable.

��

Rspherical

Rflat

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Improvement of Valve Plate

Featuresa) Improved valve timingb) Optimised pressure shape of increase and decrease

Improved Valve Timing

0

5

10

15

20

25

30

35

40

160 170 180 190 200

Cylinderportangle[deg]

Pistonborepressure[MPa]

standard

improved

0

5

10

15

20

25

30

35

40

-10 0 10 20 30

Cylinderportangle[deg]

Piston borepressure[MPa]

standard

improved

The noise source in any rotary hydrauliccomponent is due to the switching effect of thedistributor valve.

We changed the valve timing to arrangesmoother pressure transition to decrease thenoise source at higher frequency.

Optimised shape of pressure increase and decrease

Double conduit

B Series

Multi-stage notch

A Series

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4. Technical Description of Pump (cont.)4.1 Features & Benefits (cont.)

Pillow Type Swash Plate Support Mechanism

There has also been a significant progress made in the support mechanismfor the swash plate. The figure above shows a comparison between theconventional trunnion support and that of the new pillow support type. Thetraditional trunnion type has stub shafts that protrude out of both sides of theswash plate where it is supported by bearings to the casing. The swash plateis subjected, around its centre, to all the fluctuating pressures applied throughthe piston. Since, this high and fluctuating load is supported by the casingwhich because of its large surface area, will allow the casing to vibrate andthereby could cause excessive noise emissions.

Furthermore, the long distance between the supports with reference to thepoint of application of the piston pressure caused the swash plate to deformwhich was a major constraint in applying swash plate type pumps at higheroperating pressures.

The pillow type support, on the other hand, supports the swash plate at aposition closer to where the piston pressure force is applied therebyincreasing significantly the rigidity of the support. It is thereby good for highpressure conditions. Also, the hydrostatic bearing adopted at the support areahelps to reduce vibration, which is the primary source of noise, by providingan oil film damper.

Full hydrostaticallybalanced

Bronze backedPtfe coated

Supply

Pressure

Trunnion Support

Pillow Bearing* High & Low Pressure

Hydrostatic Bearing

* *

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Opposed Stroking Pistons

With the conventional stroking piston construction the pillow bearing must notonly absorb rotating group axial loads but also those of both the control pistonpressure force and that of the smaller bias piston force. The bearing surfaceof the pillow is therefore heavily loaded.

The K3VL opposed stroking pistons however, being inline, mean that no suchcontrol piston force is transmitted to the pillow bearing.

The pillow bearing is therefore more lightly loaded and not subjected to anycontrol pressure transients as they occur in the stroking piston. This featurethereby provided a far higher reliability factor with the minimum of disturbingeffects.

In addition it must be said that since the loading is minimised then larger sizedstroking pistons can be used, which is the case with the K3VL. These largersize stroking pistons means that a higher shifting accelerating force isavailable which thereby allows faster on stroking response times to beachieved.

��

��

Conventional design Opposed stroking piston design

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Bearing Life Principles

The use of rugged roller type bearings in association with the optimisation ofthe complete rotating group enables the bearing loads to be distributedprimarily towards the front higher rated bearing. The force balance achievedusing a spherical valve plate construction also in part balances some of theradial forces hydraulically and thereby provide an optimum bearing condition.

In addition because of the high bearing capacity of this front bearing, radialshaft loading can be allowed provided that its orientation is such that it is thisfront bearing that takes the additional load (See diagram below and thebearing life and radial loading curves)

acceptable

not acceptable

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4.2. Pump Performance Characteristics

Provided in this section are detailed graphs and tables showing the specificpump performance characteristics obtained with the complete K3VL rangeand are shown for the speed range of 1500 to 1800 rpm.

Please remember that in common with all Kawasaki pumps each unit isserialised and a copy of their actual performance results under productiontesting conditions can be provided if necessary.

� Pump Efficiency Curves

Displacement v Outlet Pressure- for speed range 1,400 to 1,800 rpm- & 50OC

Power v Operating Speed

� Self Priming Capability Charts

Displacement v Speed

� Bearing Life Diagrams

L10 Life v Speed- adjustment factor for displacement condition

Radial Loading Capability- adjustment factor

� Noise & Pressure Pulsation Characteristics

dB(A) v Outlet Pressure- at 1500 & 1800 rpm- at Zero, 50 & 100% displacement

Peak to Peak Pulsation v Outlet Pressure

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4. Technical Description of Pump (cont.)4.2. Pump Performance Characteristics (cont.)

K3VL45 Pump Efficiency Curves(1400 rpm to 1800 rpm with atmospheric inlet)

K3VL45 Performance

Delivery Pressure (bar)

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.90

1.00

0 50 100 150 200 250 300 3500

10

20

30

40

50

60

70

80

90

60

70

75

80

83

86

88

89

90

Ra tio of D isp lacement

1.00 0 .75 0.50 0.25

100

Test Temperature 50OC, Viscosity 31cSt (ISO VG46)

The values shown as such are average figures and therefore cannot beguaranteed.

For performance curves on other fluids please consult KPM.

Please see the K3VL80 performance graph for an explanation of itsdesign and the way it can be use together with a worked example

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K3VL80 Performance


0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.90

1.00

0 50 100 150 200 250 300 3500

10

20

30

40

50

60

70

80

90

100

92

75

80

83

85

87

91

89

Ratio of Displacement

1 .0 0 0 .7 5 0 .5 0 0 .2 5

70

87%

92%




Explanation of Performance GraphThis is a composite graph which shows :-a) Overall Efficiency at any particular pump displacement and delivery pressure condition.b) Volumetric Efficiency at any delivery pressure for discrete pump displacement conditions.

(25%, 50%, 75% and full displacement)Worked example:Lets assume that the pump is operating at 1500 rpm with a delivery pressure of 210 bar. Letsnow find overall & volumetric efficiency for 50% pump displacement. First from Y,displacement axis, draw a horizontal line at 50% displacement. Then from X, deliverypressure axis, draw a vertical line upwards at 210 bar. Where these two lines meet gives theoverall efficiency: o = Overall Efficiency = 0.87 or 87%Continue the vertical line upwards until it meets the 50% displacement stroke line. Then drawa horizontal line across until it meets the other Y, volumetric efficiency axis. Read off thisvolumetric efficiency figure. v = Volumetric Efficiency = 0.92 or 92%

K3VL Marketing Kit

Page 25 of 165



K3VL112 Performance


0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.90

1.00

0 50 100 150 200 250 300 3500

10

20

30

40

50

60

70

80

90

100

85

70

75

80

83

87

89

91

92


1.00 0.75 0 .50 0.25



For performance on other fluids please consult KPM.

Please see the K3VL80 performance graph for an explanation of its designand the way it can be use together with a worked example

K3VL Marketing Kit

Page 26 of 165



K3VL140 Performance



1.00 0.75 0.50 0.25

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.90

1.00

0 50 100 150 200 250 300 3500

10

20

30

40

50

60

70

80

90

100

90

70

75

80

83

86

88

92

93




Please see the K3VL80 performance graph for an explanation of its designand the way it can be use together with a worked example

K3VL Marketing Kit

Page 27 of 165


K3VL45 Theoretical Power Curve(Atmospheric Inlet, Full Displacement)

0 500 1000 1500 2000 2500 3000 3500

Speed (rpm)

0

10

20

30

40

50

60

70

80

90

InputPower(kW)

DeliveryPressurePd(bar)

320300

250

200

150

100

5025


0 500 1000 1500 2000 2500 3000 3500

Speed (rpm)

0

50

100

150

InputPower(kW)


320300

250

200

150

100

5025

The values shown are theoretical to be used for establishing overall powerconsumption requirements in association with the previous pump efficiencycurves

K3VL Marketing Kit

Page 28 of 165



0 500 1000 1500 2000 2500 3000

Speed (rpm)

0

50

100

150

200

InputPower(kW)


320300

250

200

150

100

5025


0 500 1000 1500 2000 2500 3000

Speed (rpm)

0

50

100

150

200

InputPower(kW)


320

300

250

200

150

100

5025

The values shown are theoretical to be used for establishing overall powerconsumption requirements in association with the previous pump efficiencycurves.

K3VL Marketing Kit

Page 29 of 165


K3VL45 Self Priming Capability


The values shown are for use with conventional mineral oils. Where fluids of ahigher density are used maximum self-priming speeds need to be reducedproportionately.

K3VL45 Self Priming

2200

2400

2600

2800

3000

3200

28 30 32 34 36 38 40 42 44

+ 0,2 bar

+ 0,1 bar

0 bar

- 0,1 bar

- 0,2 bar

Displacement q [cc/rev]

SpeedN[rpm]

Suction Pressure

Ps [bar]

at the suction port ofthe pump port

K3VL80 Self Priming

2000

2200

2400

2600

2800

3000

50 55 60 65 70 75 80

+ 0,2 bar

+ 0,1 bar

0 bar

- 0,1 bar

- 0,2 bar

+ 0,3 bar


SpeedN[rpm] Suction Pressure

Ps [bar]


K3VL Marketing Kit

Page 30 of 165




The values shown are for use with conventional mineral oils. Where fluids of ahigher density are used maximum self-priming speeds need to be reducedproportionately.

K3VL112 Self Priming

1800

2000

2200

2400

2600

70 80 90 100 110


SpeedN[rpm]

+ 0,2 bar

+ 0,1 bar

0 bar

- 0,1 bar

- 0,2 bar

Suction Pressure

Ps [bar]


K3VL140 Self Priming

1800

2000

2200

2400

90 100 110 120 130 140


SpeedN[rpm]

+ 0,1 bar

0 bar

- 0,1 bar

- 0,2 bar

Suction Pressure

Ps [bar]


K3VL Marketing Kit

Page 31 of 165


K3VL45 Bearing Life(Full Displacement)

Please note that Service and other life factors have unity value

K3VL45 Radial Loading Capacity

Please note that radial shaft loading is only allowable when acting in thedirection indicated on the diagram shown on page 21.

K3VL45 Bearing life

1,000

10,000

100,000

1,000,000

10,000,000

0 500 1000 1500 2000 2500 3000 3500

Speed (rpm)

BearinglifeL10(hrs) 50 bar

100 bar

150 bar

200 bar

250 bar

300 bar320 bar

K3VL45 Radial loading capacity

0%

20%

40%

60%

80%

100%

0 500 1000 1500

Radial load (N)

Bearinglifeadjustmentfactor(%)

K3VL Marketing Kit

Page 32 of 165






K3VL80 Bearing life

1,000

10,000

100,000

1,000,000

10,000,000

BearinglifeL10(hrs)

0 500 1000 1500 2000 2500 3000 3500

Speed (rpm)

50 bar

100 bar

150 bar

200 bar

250 bar

300 bar320 bar


0%

20%

40%

60%

80%

100%

0 500 1000 1900

Radial load (N)


1500

K3VL Marketing Kit

Page 33 of 165






.

K3VL112 Bearing life

1,000

10,000

100,000

1,000,000

10,000,000

BearinglifeL10(hrs)

0 500 1000 1500 2000 2500 3000

Speed (rpm)

50 bar

100 bar

150 bar

200 bar

250 bar

300 bar320 bar


0%

20%

40%

60%

80%

100%


0 500 1000 2000

Radial load (N)

1500 2500 2800

K3VL Marketing Kit

Page 34 of 165






.

K3VL140 Bearing life

1,000

10,000

100,000

1,000,000

10,000,000

BearinglifeL10(hrs)

0 500 1000 1500 2000 2500 3000

Speed (rpm)

50 bar

100 bar

150 bar

200 bar

250 bar

300 bar320 bar


0%

20%

40%

60%

80%

100%


0 500 1000 2000

Radial load (N)

1500 2500 2800

K3VL Marketing Kit

Page 35 of 165

4. Technical Description of Pump (cont.)4.2 Pump Performance Characteristics (cont.)

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 is therefore to be used where duty cycle considerationsrequire one to compute weighted life, which include partial displacementconditions.

For example as shown above if the bearing life at full displacement from theprevious graphs was say 50,000 hours, then at the same operating condition withonly 75% displacement the bearing life would be 260% of 50,000 hours or130,000 hours.

The general weighted average procedure should be used.

For industrial system situations where the electric motor (E/M) power is knownand fully utilised throughout the duty cycle then the graphs on the following pagescan be used.

0%

200%

400%

600%

800%

1000%

1200%


50% 60% 70% 80% 90% 100%

Displacement (%)

75%

260%

K3VL Marketing Kit

Page 36 of 165


Bearing Lives (Industrial Situation)

K3VL45


K3VL80


K3VL45 Bearing Life

1,000

10,000

100,000

1,000,000

1 10 100

E/M capacity [kW]

1500 rpm1200 rpm

1000 rpm 1800 rpm

BearingLifeL10[hr]

K3VL80 Bearing Life

1 10 100

1500 rpm

1200 rpm1000 rpm

1800 rpm

E/M capacity [kW]

BearingLifeL10[hr]

1,000

10,000

100,000

1,000,000

K3VL Marketing Kit

Page 37 of 165


Bearing Lives (Industrial Situation)

K3VL112


K3VL140


K3VL112 Bearing Life

1 10 100

1500 rpm

1200 rpm1000 rpm

1800 rpm

E/M capacity [kW]

BearingLifeL10[hr]

1,000

10,000

100,000

1,000,000

K3VL140 Bearing Life

1500 rpm

1200 rpm1000 rpm

1800 rpm

E/M capacity [kW]

BearingLifeL10[hr]

1,000

10,000

100,000

1,000,000

1 10 100

K3VL Marketing Kit

Page 38 of 165


K3VL45 Noise Levels

85

80

75

50

65

60

55

500 50 100 150 200 250 300 350

Delivery pressure Pd [bar]

1800rpm

1500rpm

Noise comparison tests carried out in an Anechoic Chamber withmeasurements and test conditions equivalent to ISO 3740. Measurementaccuracy +/- 2 dB(A)

K3VL45 Pressure Pulsation

K3VL45 Pulsation

0

5

10

15

20

0 50 100 150 200 250 300 350

Delivery pressure Pd (bar)

Pulsationwidth(bar)

1800rpm

1500rpm

K3VL Marketing Kit

Page 39 of 165


K3VL80 Noise Levels

90

85

80

75

50

65

60

550 50 100 150 200 250 300 350


1800rpm

1500rpm



0

5

10

15

20

0 50 100 150 200 250 300 350


Pulsationwidth(bar)

K3VL80 Pulsation

1800rpm

1500rpm

K3VL Marketing Kit

Page 40 of 165


K3VL112 Noise Levels

95

90

85

80

75

50

65

600 50 100 150 200 250 300 350


1800rpm

1500rpm



0

5

10

15

20

0 50 100 150 200 250 300 350


Pulsationwidth(bar)

K3VL112 Pulsation

1800rpm

1500rpm

K3VL Marketing Kit

Page 41 of 165


K3VL140 Noise Levels

95

90

85

80

75

50

65

600 50 100 150 200 250 300 350


1800rpm

1500rpm



K3VL140 Pulsation

0

5

10

15

20

0 50 100 150 200 250 300 350


Pulsationwidth(bar)

1800rpm

1500rpm

K3VL Marketing Kit

Page 42 of 165


Noise comparison tests carried out in an Anechoic Chamber with measurements andtest conditions equivalent to ISO 3740.

K3VL Marketing Kit

Page 43 of 165

5. Control Regulators

5.1 General Description

The pressure control module utilises two spools, a pressure limiter spool(lower control element) and a differential pressure spool (upper controlelement). The various control options are achieved by removing or changingrestrictors to plugs. The regulator can be remotely controlled by way of asandwich style proportional relief valve or solenoid valve so as to permit anunload (standby) function.

The torque limiting control module utilises a differential area control spoolwithin a feedback sleeve. The control spool is held in place against anadjustable dual spring assembly, while sleeve position follows the swashplate/servo piston movement via a feedback lever. Regulated pressure actsagainst the control area of the servo piston limiting pump displacement andthereby the resultant input torque requirement.

Pump

Torque Limiter

Two Spool Regulator

Integral Unloader

Integral Proportional Pilot Relief

��

��

��

K3VL Marketing Kit

Page 44 of 165

5. Control Regulators (cont.)5.1 General Description (cont.)

Shown above is a schematic of the dual spool compensator with an indicationof the size and location of the relevant plugs and restrictors necessary toprovide the various control options.

PL

R1

RH

R4R2

R3

PR

Differential CompensatorSpool

Pressure LimiterSpool

ControlType

R1 R2 R3 R4 RH

P0 0.6 0.9 Open Plugged OpenPN** 0.6 0.9 Open Plugged OpenPV 0.6 0.9 Open Plugged OpenLO 0.6 Plugged Open 0.4 OpenL1 0.6 Plugged Open Plugged OpenLN** 0.6 Plugged 0.9 Plugged OpenLV 0.6 Plugged 0.9 Plugged OpenP0/1 0.6 0.9 Open Plugged PluggedPN**/1 0.6 0.9 Open Plugged PluggedPV/1 0.6 0.9 Open Plugged PluggedL0/1 0.6 Plugged Open 0.4 PluggedL1/1 0.6 Plugged Open Plugged PluggedLN**/1 0.6 Plugged 0.9 Plugged PluggedLV/1 0.6 Plugged 0.9 Plugged Plugged

PL

R1

R2R3

R4

RH

PR

K3VL Marketing Kit

Page 45 of 165

5 Control Regulators (cont.)5.1.1. P0 Type Pressure Limiter

The pump, when utilising the pressure limiter, serves to maintain acontrolled constant pressure in the hydraulic system. The pump thereby onlysupplies sufficient flow necessary for each actuator to maintain this constantpressure.

The control regulator design is of a direct acting type (lower control element)with an available adjustment range from 20 to 320 bar (factory setting is 320bar) A threaded adjustment screw is provided so as to change the springpreload and thereby the adjustment setting (approximately 80 bar per turn)

The restrictor R1 in parallel to the servo piston feed line bleeds a portion ofthe control flow to pump drain so as to provide optimum control performance(by improving damping characteristics).

The operation of the lower direct acting spool will now be described in thefollowing sequence:-

PL

R1

RH

R4R2

R3

PR



K3VL Marketing Kit

Page 46 of 165

5.1 Control Regulators (cont.)5.1.1. P0 Type Pressure Limiter (cont.)

Position 1: Low Pressure, Unregulated Condition

Pump pressure is lowThe pressure limiter spool spring preload shifts the lower spool to itsextreme right condition.Additionally since the R2 restrictor is open both sides of the upperdifferential spool see the same pressure.So the upper spool under the effect of the spring remains in its extremeright position.In this condition both spools are so positioned that the stroking piston portin cascade is connected through them both to pump case.Maximum displacement is thereby achieved.

PL

P

Pressure Compensator+

Pressure Limiter

[P0]

R1

RH

R4R2

R3

PL

R1

R2R3

R4

RH

PR

PR

Q

K3VL Marketing Kit

Page 47 of 165


Position 2: Approaching the Regulation Condition

Pump pressure has progressively increased.. but since the R2 restrictor is open both sides of the upper spool see thesame pressure.So the upper spool under the effect of the spring remains in its right handposition.Pump pressure however has now increased to the pressure limiter spoolspring preload setting of the lower spool.The lower pressure limiter spool moves to the left against this pressureThe lower spool closes off its cascaded drain connection and now appliespressure to the pumps servo piston destroking port and the pump beginsto destrokeÖ .

PL

P


Pressure Limiter

[P0]

R1

RH

R4R2

R3

PL

R1

R2R3

R4

RH

PR

PR

Q

K3VL Marketing Kit

Page 48 of 165


Position 3: Regulation Condition

The destroking piston is now fully pressurisedAnd the pump is in its fully destroked condition.

P

PL


Pressure Limiter

[P0]

R1

RH

R4R2

R3

PL

R1

R2R3

R4

RH

PR

PR

Q

K3VL Marketing Kit

Page 49 of 165


Remote Compensation Control (System Design Option)

The upper control element shown is a pilot operated differential pressure typecompensator that can be remotely adjusted. A relief valve providing this pilotpressure (not supplied) can be externally piped to port PL so as to provide thisremote operation. This pilot pressure acts on the spring chamber end of thespool. The spring setting being adjusted as standard to 15 bar. (Availableadjustment range is from 10 to 30 bar and adjustment sensitivity isapproximately 13 bar per turn)

The remote pilot signal can also be routed to a unloading module sandwichedbetween the regulator and the pump (Type PN) or to a similarly locatedproportional pressure relief module (Type PV) which can then proportionallycontrol the pressure compensation setting.

The function of this upper differential pressure type compensator in all thesemodes will now be described in the following sequences:

PL

R1

RH

R4R2

R3

PR



K3VL Marketing Kit

Page 50 of 165



Position 1: Low Pressure Condition

Pump pressure is lowThe differential pressure spool spring preload and the pressure limiterspring preload shifts each respective spool to their extreme right condition.In this condition both spools are so positioned that the stroking piston incascade is connected through them both to pump case.Maximum displacement is thereby achieved

PL

P

R1

RH

R4R2

R3


Pressure Limiter+

Externally Piped Pilot

[P0]

PL

R1

R2R3

R4

RH

Q

PR

RDV6Cor

RDV1M6R

K3VL Marketing Kit

Page 51 of 165




Pump pressure has progressively increased.The remote pilot relief has cracked open and flow begins to occur over theR2 restrictor passage.As this pilot flow passes across restrictor R2 a pressure drop occurs.This pressure drop is sensed across the upper spool.As this pressure drop approaches the spring setting of the differentialpressure spool (15 bar) the spool begins to shift to the left.The upper spool thereby closes off its cascaded drain connection and nowapplies pressure to the pumps servo piston destroking port and the pumpdestrokes.

P

PL

R1

R2R3

R4

RH

Q

PR

PL

R1

RHR4

R2

R3


Pressure Limiter+


[P0]

K3VL Marketing Kit

Page 52 of 165



Position 3: Variation of the Remote Pilot Setting

By varying the remote pressure pilot setting one can thereby remotelyregulated the pressure compensation setting of the pump.Remember though that the lower Pressure limiter spool as the pressure isincreased will itself become active.

P

PL

R1

RH

R4R2

R3

PL

R1

R2R3

R4

RH

Q


Pressure Limiter+


[P0]

PR

K3VL Marketing Kit

Page 53 of 165



Remote Pilot Selection

One of the following Kawasaki pilot relief valves is recommended for use:RDV6P-10-2/315-12, RDV6C-10-2/315-12, RDV1M6R-10-3/315-12 or othersize 6 relief valves.

RDV6P

RDV1M6R

Note: The hydraulic circuit with this pump should have a safety circuit reliefvalve fitted so as to prevent the circuit from pipe and component breakagedue to surge pressures.

K3VL Marketing Kit

Page 54 of 165

5.1 Control Regulators (cont.)5.1.2. PN Type Pressure Regulator

Position 1: Unregulated Condition

Pump pressure is relatively high but still below the pressure limiter spoolspring setting.The pressure limiter spool spring preload shifts the lower spool to itsextreme right condition.Additionally since the R2 restrictor is open and the unloading valve isclosed, both sides of the upper differential pressure spool see the samepressure.So the upper spool under the effect of the spring also remains in itsextreme right position.In this condition both spools are so positioned that the stroking piston portin cascade is connected through them both to pump case.Maximum displacement is thereby achieved

PL

P


Pressure Limiter+

Integrated Unload

[PN**]

R1

RH

R4R2

R3

PL

R1

R2R3

R4

RH

Q

K3VL Marketing Kit

Page 55 of 165

5.1 Control Regulators (cont.)5.1.2. PN Type Pressure Regulator (cont.)

Position 2: Unloaded Condition

The unloading valve is now opened to tank. and pilot flow begins to occurover the R2 restrictor passage.As this pilot flow passes across restrictor R2 a pressure drop occurs.This pressure drop is sensed across the upper differential pressure spool.As this pressure drop approaches the spring setting of the differentialpressure spool (15 bar) the spool begins to shift to the left.The upper spool thereby closes off its cascaded drain connection and nowapplies pressure to the pumps servo piston destroking port and the pumpdestrokes in an unloaded condition (circa 24 bar with 15 bar DifferentialSpool Spring Setting)

P

PL

R1

RH

R4R2

R3


Pressure Limiter+

Integrated Unload

[PN**]

PL

R1

R2R3

R4

RH

Q

K3VL Marketing Kit

Page 56 of 165

5.1 Control Regulators (cont.)5.1.3. PV Type Pressure Regulator


Pump pressure is relatively low.The pressure limiter spool spring preload shifts the lower spool to itsextreme right condition.Additionally since the R2 restrictor is open and proportional pressuresetting has not been reached, both sides of the upper differential pressurespool see the same pressure.So the upper spool under the effect of the spring also remains in itsextreme right position.In this condition both spools are so positioned that the stroking piston portin cascade is connected through them both to pump case.Maximum displacement is thereby achieved.

PL

P

R1

RH

R4R2

R3


Pressure Limiter+

IntegratedProportional Relief

[PV]

PL

R1

R2R3

R4

RH

Q

K3VL Marketing Kit

Page 57 of 165

5.1 Control Regulators (cont.)5.1.3 PV Type Pressure Regulator (cont.)

Position 2: Regulated Condition

Pump pressure has progressively increased.The proportional pilot relief has cracked open and flow begins to occurover the R2 restrictor passage.As this pilot flow passes across restrictor R2 a pressure drop occurs.This pressure drop is sensed across the upper differential pressure spool.As this pressure drop approaches the spring setting of the differentialpressure spool (15 bar) the spool begins to shift to the left.The upper spool thereby closes off its cascaded drain connection and nowapplies pressure to the pumps servo piston destroking port and the pumpdestrokes to maintain the pressure.

P

PL

R1

RH

R4R2

R3


Pressure Limiter+


[PV]

PL

R1

R2R3

R4

RH

Q

K3VL Marketing Kit

Page 58 of 165

5.1 Control Regulators (cont.)5.1.3 PV Type Pressure Regulator (cont.)

Position 3: Variation of the Remote Pilot Setting

By varying the remote proportional pressure pilot setting one can therebyremotely regulate the pressure regulation setting of the pump.Remember though that the upper pressure limiter spool as the pressure isincreased will itself become active.

P

PL

R1

RH

R4R2

R3


Pressure Limiter+


[PV]

PL

R1

R2R3

R4

RH

Q

P

K3VL Marketing Kit

Page 59 of 165

5.1 Control Regulators (cont.)5.1.4. L0 Type Load Sensing Regulator

The upper control element shown is a pilot operated differential pressure typespool regulator that can also be used for load sensing control. The loadsensing signal from the hydraulic system is externally piped to Port PL so as toprovide the feedback signal. This feedback signal acts on the spring chamberend of the spool. The spring setting being adjusted as standard to 15 bar.(Available adjustment range is from 10 to 30 bar and adjustment sensitivity isapproximately 13 bar per turn)

As with the type P pressure regulator additional sandwich modules betweenthe pump and the regulator can be used to provide the unloading (Type LN)and proportional pressure compensation (Type LV) functions.

The function of the upper differential pressure load sensing type compensatorin all these modes will now be described in the following sequences:

PL

R1

RH

R4R2

R3

PR



K3VL Marketing Kit

Page 60 of 165

5.1 Control Regulators (cont.)5.1.4 L0 Type Load Sensing Regulator (cont.)


Pump pressure is relatively low and the external throttle creating the loadsensing signal is wide open.The pressure limiter spool spring preload shifts the lower pressure limiterspool to its extreme right condition.Additionally since the pressure drop across the external throttle is low bothsides of the upper differential pressure spool see the same pressure.So the upper spool under the effect of the spring also remains in itsextreme right position.In this condition both spools are so positioned that the stroking piston portin cascade is connected through them both to pump case.Maximum displacement is thereby achieved.

PL

P

Load Sensing+

Pressure Limiter

[L0]

R1

RH

R4R2

R3

PL

R1

R2R3

R4

RH

PR

PR

Q

Load

K3VL Marketing Kit

Page 61 of 165



Pump pressure is still relatively low but now the throttle is partially closed.The pressure limiter spool spring preload still maintains the lower spool inits right position.The pressure drop across the throttle increases above the setting of theupper differential pressure spool spring preload.This upper spool then moves to the left and closes off its cascaded drainconnection and now applies pressure to the pumps servo pistondestroking port and the pump begins to destroke... until such time as the pump flow across the throttle generates thepressure drop determined by the differential spool spring preload.

P

PL

Load Sensing+

Pressure Limiter

[L0]

R1

RH

R4R2

R3

PL

R1

R2R3

R4

RH

PR

PR

Q

Load

K3VL Marketing Kit

Page 62 of 165


Position 3: Variation of Throttle Condition

Changing the throttle position will vary the flow necessary to maintain thedifferential spool spring preload.The pump will automatically vary its stroke to maintain this load sensingpressure drop constant.

P

PL

Load Sensing+

Pressure Limiter

[L0]

R1

RH

R4R2

R3

PL

R1

R2R3

R4

RH

PR

PR

Q

QQ

Load

K3VL Marketing Kit

Page 63 of 165


Position 4: Standby Condition (L0)

With the throttle totally closed the standby condition is reachedSince R4 is open to tank then the load sensing line is vented.The upper differential pressure spool shifts to the left under the influenceof pump outlet pressure.The upper spool thereby closes off its cascaded drain connection and nowapplies pressure to the pumps servo piston destroking port and the pumpdestrokes in this standby condition (circa 24 bar with 15 bar DifferentialSpool Spring Setting)

P

PL

Load Sensing+

Pressure Limiter

[L0]

R1

RH

R4R2

R3

PL

R1

R2R3

R4

RH

PR

PR

Q

Load XX

K3VL Marketing Kit

Page 64 of 165


Position 5: Standby Condition (L1)

In the L0 configuration, the R4 restrictor is always active and so doescreate an albeit small power loss but the benefits of being able to go to astandby (Power Saving) mode usually outweigh this.Some mobile valves do have in their neutral position a bleed to tankavailable.In this case the L1 model can be utilised where the R4 restrictor isplugged.

P

PL

Load Sensing+

Pressure Limiter

[L1]

R1

RH

R4R2

R3

PL

R1

R2R3

R4

RH

PR

PR

Q

Load XX

mobie valvein neutral

R4plugged

K3VL Marketing Kit

Page 65 of 165

5.1 Control Regulators (cont.)5.1.5 LN Type Load Sensing Regulator


Pump pressure is relatively low.The pressure limiter spool spring preload shifts the lower pressure limiterspool to its extreme right condition.Additionally since the throttle is wide open, both sides of the upperdifferential pressure spool see the same pressure.So the upper spool under the effect of the spring also remains in itsextreme right position.In this condition both spools are so positioned that the stroking piston portin cascade is connected through them both to pump case.Maximum displacement is thereby achieved.

PL

P

Load Sensing+

Pressure Limiter+

Integrated Unload

[LN**]

R1

RH

R4R2

R3

PL

R1

R2R3

R4

RH

Q

Load

K3VL Marketing Kit

Page 66 of 165

5.1 Control Regulators (cont.)5.1.5 LN Type Load Sensing Regulator (cont.)

Position 2: Regulated Condition

Pump pressure is still relatively low but now the throttle is partially closed.The pressure limiter spool spring preload still maintains the lowerpressure limiter spool in its right position.The pressure drop across the throttle increases above the setting of theupper differential pressure spool spring preload.This upper spool then moves to the left and closes off its cascaded drainconnection and now applies pressure to the pumps servo pistondestroking port and the pump begins to destroke... until such time as the pump flow across the throttle generates thepressure drop determined by the differential spool spring preload.

P

PL

R1

RH

R4R2

R3

Load Sensing+

Pressure Limiter+

Integrated Unload

[LN**]

PL

R1

R2R3

R4

RH

Q

Load

K3VL Marketing Kit

Page 67 of 165


Position 3: Variation of Throttle Condition

Changing the throttle position will vary the flow necessary to maintain theupper differential pressure spool spring preload.The pump will automatically vary its stroke to maintain this load sensingpressure drop constant.

P

PL

R1

RH

R4R2

R3

Load Sensing+

Pressure Limiter+

Integrated Unload

[LN**]

PL

R1

R2R3

R4

RH

Q

QQ

Load

K3VL Marketing Kit

Page 68 of 165


Position 4: Unloaded Condition

The unloading valve now vents the left side of the upper differentialpressure spool to case.Flow then passes to case from the load sensing line via the R3 restrictor.A pressure occurs across this R3 restrictor thereby increasing thedifferential pressure across the upper differential pressure spool.As this pressure drop approaches the spring setting of the upperdifferential pressure spool (15 bar) the spool begins to shift to the left.The upper spool thereby closes off its cascaded drain connection and nowapplies pressure to the pumps servo piston destroking port and the pumpdestrokes in an unloaded condition (circa 24 bar with 15 bar DifferentialSpool Spring Setting)

P

PL

R1

RH

R4R2

R3

Load Sensing+

Pressure Limiter+

Integrated Unload

[LN**]

PL

R1

R2R3

R4

RH

Q

Load

K3VL Marketing Kit

Page 69 of 165

5.1 Control Regulators (cont.)5.1.6 LV Type Load Sensing Regulator


Pump pressure is relatively low.The lower spool spring preload shifts this pressure limiter spool to itsextreme right condition.Additionally since the throttle is wide open, both sides of the upperdifferential pressure spool see the same pressure.So the upper spool under the effect of the spring also remains in itsextreme right position.In this condition both spools are so positioned that the stroking piston portin cascade is connected through them both to pump case.Maximum displacement is thereby achieved.

PL

P

R1

RH

R4R2

R3

Load Sensing+

Pressure Limiter+


[LV]

PL

R1

R2R3

R4

RH

Q

Load

K3VL Marketing Kit

Page 70 of 165

5.1 Control Regulators (cont.)5.1.6 LV Type Load Sensing Regulator (cont.)


Pump pressure is still relatively low but now the throttle is partially closed.The lower spool spring preload still maintains this pressure limiter spool inits right position.The pressure drop across the throttle increases above the setting of theupper differential pressure spool spring preload.This upper spool then moves to the left and closes off its cascaded drainconnection and now applies pressure to the pumps servo pistondestroking port and the pump begins to destroke... until such time as the pump flow across the throttle generates thepressure drop determined by the upper differential spool spring preload.

P

PL

R1

RH

R4R2

R3

Load Sensing+

Pressure Limiter+


[LV]

PL

R1

R2R3

R4

RH

Q

Load

K3VL Marketing Kit

Page 71 of 165

5.1 Control Regulators (cont.)5.1.6 LV Type Load Sensing Regulator (cont.)

Position 3: Variation of the Remote Proportional Pilot Setting

The proportional pressure pilot begins to crack open..Flow then passes to case from the load sensing line via the R3 restrictor.A pressure occurs across this R3 restrictor thereby increasing thedifferential pressure across the upper differential pressure spool.As this pressure drop approaches the spring setting of the differentialpressure spool (15 bar) the spool begins to shift to the left.The upper spool thereby closes off its cascaded drain connection and nowapplies pressure to the pumps servo piston destroking port and the pumpdestrokes so as to maintain the pressure equilibrium.

P

PL

R1

RH

R4R2

R3

PL

R1

R2R3

R4

RH

Q

Q

P

Load Sensing+

Pressure Limiter+


[LV]

Q

Load

K3VL Marketing Kit

Page 72 of 165

5.1 Control Regulators (cont.)5.1.7. Torque Limiter Control - General Description

This torque control module is combined with the dual spool pressure and loadsensing regulator. Pump outlet pressure is fed onto the differential area of thespool, which is opposed by the dual spring pack. The sleeve in which thespool is regulated moves in proportion to the displacement of the pump viathe lever and fixed pivot arrangement. The regulated condition for the torquecontrol is shown in the diagram above whereby at this condition controlpressure is then fed to the destroking piston of the pump.

As pump displacement reduces the sleeve moves to the left, which means ahigher spring preload occurs which then, needs a higher pump pressure tomaintain equilibrium. The spring lengths are so adjusted that firstly the outerspring is active then at increasing pressures (Lower displacements) the innerspring is activated. In this way one can achieve the torque limiting function.

The figure on the following page shows this sequence together with thereference table of Torque settings for the various spring adjustment settings.

Thereafter the Torque Limiter operation in association with the two spoolcompensator will then be demonstrated:

��

��

��

��

��

��

DifferentialArea

Fixed Pivot

MaximumDisp lacement

MinimumDisp lacement

Displacement Feedbackto Sleeve

K3VL Marketing Kit

Page 73 of 165

5.1 Control Regulators (cont.)5.1.7. Torque Limiter Control - General Description (cont.)

Q

P

��

��

��

Outer

Spring

Outer Spring

+ Inner Spring

Control Input Torque Setting (Nm)Setting K3VL Frame Size

45 80 112 140L6 - 74 - 146L5 - 82 - 154L4 49 91 122 164L3 54 100 146 182L2 61 108 154 200L1 74 122 164 217M4 82 146 182 -M3 91 154 200 246M2 100 164 217 298M1 108 182 246 307H4 122 200 298 368H3 146 217 307 409H2 154 246 368 450H1 164 298 409 492

K3VL Marketing Kit

Page 74 of 165

5.1 Control Regulators (cont.)5.1.8 P0/1, PN**/1 & PV/1 Combination


Pump pressure is lowThe differential pressure spool spring preload and the pressure limiterspring preload shifts each respective spool to their extreme right condition.Equally in the torque limiter, the pump pressure is lower than the springpreload condition.In this condition all spools are so positioned that the stroking piston incascade is connected through them all to pump case.Maximum displacement is thereby achieved

PL

P

Remote Pressure Compensator+

Pressure Limiter+

Torque Limiter

[P0/1, PN**/1 & PV/1]

R1

RHR4

R2

R3PL

R1

R2R3

R4

RH

PR

Q

��

K3VL Marketing Kit

Page 75 of 165

5.1 Control Regulators (cont.)5.1.8 P0/1, PN**/1 & PV/1 Combination (cont.)

Position 2: Torque Limit Regulation (1)

Pump pressure rises such that the torque limiter spring preload of first theouter spring is overcome.The torque limiter spool moves to the left and begins to close thecascaded case drain connection thereby pressurising the stroking pistonportThe pump begins to destroke and as it does the torque limiter spool sleevedue to the feedback lever arrangement moves to the right therebyincreasing the available spring preload... until such time as equilibrium occurs.

P

PL

R1

RH

R4R2

R3


Pressure Limiter+

Torque Limiter

PL

R1

R2R3

R4

RH

PR

Q

��

[P0/1, PN**/1 & PV/1]

K3VL Marketing Kit

Page 76 of 165



Pump pressure rises now still further until the torque limiter spring preloadof both the outer and inner spring is overcome.The torque limiter spool moves further to the left and continues to closethe cascaded case drain connection thereby pressurising the strokingpiston portThe pump destrokes further and as it does the torque limiter spool sleevedue to the feedback lever arrangement moves to the right therebyincreasing the available spring preload.The spring rate of the combination of the inner and outer springs is nowstiffer than before so the characteristic "kink" in the torque curve is noticed.This feedback control system continues to function until such time asequilibrium occurs once more.

P

PL

R1

RH

R4R2

R3


Pressure Limiter+

Torque Limiter

PL

R1

R2R3

R4

RH

PR

Q

��

��

��

��

��

��

[P0/1, PN**/1 & PV/1]

K3VL Marketing Kit

Page 77 of 165


Position 4: Pressure Regulation Override

At any condition within the torque limit envelope the pressure can beoverridden by activating the remote pressure pilot function as describedpreviously.Its activation causes the upper differential pressure spool to move to theright and thereby further pressurise the servo piston destroking port.The same is true for the lower pressure limiter spool that controls themaximum pressure setting.

P

PL

R1

RH

R4R2

R3


Pressure Limiter+

Torque Limiter

PL

R1

R2R3

R4

RH

PR

Q

��

��

��

��

��

��

P

[P0/1, PN**/1 & PV/1]

K3VL Marketing Kit

Page 78 of 165

5.1 Control Regulators (cont.)5.1.9 L0/1 Combination


Pump pressure is lowThe differential pressure spool spring preload and the pressure limiterspool spring preload shifts each respective spool to their extreme rightcondition.Equally in the torque limiter, the pump pressure is lower than the springpreload condition.In this condition all spools are so positioned that the stroking piston incascade is connected through them all to pump case.Maximum displacement is thereby achieved

PL

P

Load Sensing+

Pressure Limiter+

Torque Limiter

[L0/1]

R1

RH

R4R2

R3PL

R1

R2R3

R4

RH

PR

PR

Q

��

Load

K3VL Marketing Kit

Page 79 of 165

5.1 Control Regulators (cont.)5.1.9 L0/1 Combination (cont.)


Pump pressure rises such that the torque limiter spring preload of first theouter spring is overcome.The torque limiter spool moves to the left and begins to close thecascaded case drain connection thereby pressurising the stroking pistonportThe pump begins to destroke and as it does the torque limiter spool sleevedue to the feedback lever arrangement moves to the right therebyincreasing the available spring preload... until such time as equilibrium occurs.

P

PLLoad Sensing

+Pressure Limiter

+Torque Limiter

[L0/1]

R1

RH

R4R2

R3PL

R1

R2R3

R4

RH

PR

PR

Q

��

��

��

��

��

��

Load

K3VL Marketing Kit

Page 80 of 165




P

PLLoad Sensing

+Pressure Limiter

+Torque Limiter

[L0/1]

R1

RH

R4R2

R3PL

R1

R2R3

R4

RH

PR

PR

Q

��

��

��

��

��

��

Load

K3VL Marketing Kit

Page 81 of 165


Position 4: Load Sensing Override

At any condition within the torque limit envelope the flow can beoverridden by the load sensing pressure feedback function as describedpreviously.Its activation causes the upper differential pressure spool to move to theright and thereby further pressurise the servo piston destroking portcausing it to further destroke.The same is true for the lower pressure limiter spool that controls themaximum pressure setting.

P

PLLoad Sensing

+Pressure Limiter

+Torque Limiter

[L0/1]

R1

RH

R4R2

R3PL

R1

R2R3

R4

RH

PR

PR

Q

��

Q

Q

Load

K3VL Marketing Kit

Page 82 of 165

5.1 Control Regulators (cont.)5.1.10 LN/1 & LV/1 Combinations



PL

P

Load Sensing (Unload)+

Pressure Limiter+

Torque Limiter

R1

RH

R4R2

R3PL

R1

R2R3

R4

RH

Q

��

��

��

��

[LN**/1 or LV/1]

Load

K3VL Marketing Kit

Page 83 of 165

5.1 Control Regulators (cont.)5.1.10 LN/1 & LV/1 Combinations (cont.)

Position 2: Torque Regulation (1)

Pump pressure rises such that the torque limiter spring preload of first theouter spring is overcome.The torque limiter spool moves to the left and begins to close thecascaded case drain connection thereby pressurising the stroking pistonportThe pump begins to destroke and as it does the torque limiter spool sleevedue to the feedback lever arrangement moves to the right therebyincreasing the available spring preload.Until such time as equilibrium occurs.

P

PL

R1

RH

R4R2

R3


Pressure Limiter+

Torque Limiter

PL

R1

R2R3

R4

RH

Q

��

��

��

��

��

��

[LN**/1 or LV/1]

Load

K3VL Marketing Kit

Page 84 of 165


Position 3: Torque Regulation (2)


P

PL

R1

RH

R4R2

R3


Pressure Limiter+

Torque Limiter

PL

R1

R2R3

R4

RH

Q

��

��

��

��

��

��

[LN**/1 or LV/1]

Load

K3VL Marketing Kit

Page 85 of 165


Position 4: Remote Pressure Regulation Override

At any condition within the torque limit envelope the pressure can beoverridden by activating the remote pressure pilot function as describedpreviously.Similarly the load sensing function applied to the upper spool will alsooverride the torque limit functionBoth types of activation will cause the upper differential pressure spool tomove to the right and thereby further pressurise the servo pistondestroking port so causing the pump to destroke further.The same is true for the lower pressure limiter spool that controls themaximum pressure setting.

P

PL

R1

RH

R4R2

R3


Pressure Limiter+

Torque Limiter

PL

R1

R2R3

R4

RH

Q

��

��

��

��

��

��

Q

P

[LN**/1 or LV/1]

Q

Load

K3VL Marketing Kit

Page 86 of 165

5.1 Control Regulators (cont.)PO/1-EO, PN**/1-EO, PV/1-EOPO/1-QO, PN**/1-QO, PV/1-QO

BDr

Psv

Pc

A

**/1-EO

Psv

Pc

A

BDr

a

**/1-QO

Q

I(pi)

Q

P


Pressure Limiter+

Displacement Control

As pilot pressure is supplied to the PSV port the displacement control spool is movedto the left.

The displacement control spool will move to such a position that pressure can ventfrom the large side of the servo piston, through the differential area and the cut offspool and subsequently to tank.

Simultaneously the small side of the servo piston is seeing full system pressuremoving the servo spool to the left and hence increasing pump displacement.

Then displacement will continue to increase proportionally to the pilot pressuresupplied to the PSV port.

Note: QO, Displacement control by variable pressure supplied direct to the PSVport.

EO, Electrical displacement control achieved by a constant pressure beingsupplied to an electrical proportional reducing valve. Variable input currentcontrols the pressure supply to the displacement control spool. An increase incurrent results in an increase in pressure to the PSV port and an increase inpump displacement.

K3VL Marketing Kit

Page 87 of 165

5. Control Regulators (cont.)

5.2. Control Performance Characteristics

Shown on the following pages are the theoretical and actual steady state anddynamic control performance characteristics related to both the constantpressure and load sensing compensators as applied to the K3VL series.

Constant Pressure Control

Steady State Characteristic (Theoretical)

Transient Characteristic (Theoretical)

0

50

100

150

200

250

300

350

Pressure[bar]

0

50

100

Displacement[%]


Time


0 50 100 150 200 250 300 350

Pressure [bar]

0

20

40

60

80

100

Flow[%]

K3VL Marketing Kit

Page 88 of 165

5. Control Regulators (cont.)5.2. Control Performance Characteristics (cont.)

Load Sensing Control

P v Q Steady State Characteristic (Theoretical)

P v N Steady State Characteristic (Theoretical)

0 50 100 150 200 250 300 350

Pressure [bar]

0

20

40

60

80

100

Flow[%]

Flow and Pressure Control (Load Sensing)


0 20 40 60 80 100

Speed

0

20

40

60

80

100

Flow

K3VL Marketing Kit

Page 89 of 165


Load Sensing Control

P v Q Transient Characteristic (Theoretical)

0

50

100

150

200

250

300

350

Pressure[bar]

0

50

100

Displacement[%]


Time

K3VL Marketing Kit

Page 90 of 165


K3VL45 Pressure Control

0

50

100

150

200

250

300

350

0 200 400 600 800 1000 1200 1400 1600 1800 2000

time (ms)

PressurePd(bar)

0%

50%

100%S

Pd

Dynamic characteristics(50 bar full to 280 bar zero stroke)

SwashangleS[%]

0 200 400 600 800 1000 1200 1400 1600 1800 2000

time (ms)

0%

50%

100%S

Pd

0

50

100

150

200

250

300

350

PressurePd(bar)


SwashangleS[%]

K3VL Marketing Kit

Page 91 of 165


K3VL45 Load Sensing & Torque Limiter Control

0 200 400 600 800 1000 1200 1400 1600 1800 2000

time (ms)

0%

50%

100%S

Pd

0

50

100

150

200

250

300

350

PressurePd(bar)

Dynamic characteristics( load sense)

SwashangleS[%]

K3VL45 Torque Limiter

(1450 rpm)

0

10

20

30

40

50

60

70

0 50 100 150 200 250 300 350

Delivery Pressure Pd(bar)

FlowQ(L/min)

H3

H4

M2

L1

L4

K3VL Marketing Kit

Page 92 of 165



0

50

100

150

200

250

300

350

0 200 400 600 800 1000 1200 1400 1600 1800 2000

Time [ms]

PressurePd[bar]

0%

50%

100%

S

Pd


SwashangleS[%]

0%

50%

100%

SwashangleS[%]

S

Pd

0

50

100

150

200

250

300

350

0 200 400 600 800 1000 1200 1400 1600 1800 2000

Time [ms]

PressurePd[bar]


K3VL Marketing Kit

Page 93 of 165



0%

50%

100%

S

Pd

0

50

100

150

200

250

300

350

0 200 400 600 800 1000 1200 1400 1600 1800 2000

Time [ms]

PressurePd[bar]


SwashangleS[%]

0

20

40

60

80

100

120

140

0 50 100 150 200 250 300 350


FlowQ(L/min)

H1

H2

H4

M4

L1

L3

L6


(1450 rpm)

K3VL Marketing Kit

Page 94 of 165




00

50

100

150

200

250

300

350

200 400 600 800 1000 1200 1400 1600 1800 2000

Time (ms)

PressurePd(bar)

0%

50%

100%S

Pd

SwashangleS[%]


0

50

100

150

200

250

300

350

200 400 600 800 1000 1200 1400 1600 1800 2000

Time (ms)

PressurePd(bar)

0%

50%

100%

S

PdSwashangleS[%]

K3VL Marketing Kit

Page 95 of 165




0

50

100

150

200

250

300

350

200 400 600 800 1000 1200 1400 1600 1800 2000

Time (ms)

PressurePd(bar)

0%

50%

100%

S

Pd

SwashangleS[%]


(1450 rpm)

0

20

40

60

80

100

120

140

160

180

0 50 100 150 200 250 300 350


FlowQ(L/min)

H2

H4

M1

M3

L3

L4

K3VL Marketing Kit

Page 96 of 165




00

50

100

150

200

250

300

350

200 400 600 800 1000 1200 1400 1600 1800 2000

Time (ms)

PressurePd(bar)

0%

50%

100%S

Pd

SwashangleS[%]


0

50

100

150

200

250

300

350

200 400 600 800 1000 1200 1400 1600 1800 2000

Time (ms)

PressurePd(bar)

0%

50%

100%

S

Pd

SwashangleS[%]

K3VL Marketing Kit

Page 97 of 165




0

50

100

150

200

250

300

350

200 400 600 800 1000 1200 1400 1600 1800 2000

Time (ms)

PressurePd(bar)

0%

50%

100%

S

Pd

SwashangleS[%]


(1450 rpm)

0

50

100

150

200

250

0 50 100 150 200 250 300 350


FlowQ(L/min)

H1

H4

M2

M3L2

L6

K3VL Marketing Kit

Page 98 of 165

7. Applicational Precautions

There are specific precautions, which always need to be considered whenapplying a high performance variable displacement piston pump.

These precautions are not specific to the K3VL range however, you will findall the other competitive offerings will have the same needs.

Generally they relate to the mounting installation of the pipe work and driveshaft to the pump. Additionally, special care must be taken to ensure that thedrain line is properly connected to the tank. This will ensure that no excessivedrain line pressure occurs which could interfere with the integrity of the shaftseal, balance of the rotating group or interact with the stroking mechanism.

In addition of course adequate contamination control is necessary as isensuring the working fluid used has acceptable viscosity at both its normaloperating and maximum temperature. The additive package within the fluidshould also be evaluated.

General information pertaining to each of these areas is similar to that shownin the existing K3VG product datasheet.

You will also find in the KHI originated K3VG literature on the final inside pagea number of safety precautions that are also relevant to the K3VL which alsoneed to be considered. These precautions are generally provided so as toprovide legal protection against Product Liability & Health and Safetyregulations, which are now common in Japan.

For alternative fluids to mineral oil, special precautions are necessary whichwill require the approval of KPM before proceeding.

More detailed comments and necessary actions needed to ensure a troublefree life for the unit are identified in the following pages.

K3VL Marketing Kit

Page 99 of 165

7. Applicational Precautions (cont.)

Installation

Recommended Pump MountingThe pump should be mounted horizontally with the case drain pipinginitially rising above the level of the pump before continuing to the tank asshown 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 beequal or larger in size than the drain port to minimise pressure in thepump case. The pump case pressure should not exceed 2.1 bar asshown in the illustration below. (Peak pressure should never exceed 5.9bar.)

Mounting the pump above the tankSuction line

Drain lineìGoose neckî configuration is required, this prevents direct drop of oillevel in the pump case.

CautionsA) Suction and drain pipes must be

immersed by 200mm minimum from thelowest oil level under operating conditions.

B) Height from the oil level to the centre ofthe shaft must be within 1m.

C) The oil in the pump case must be refilledwhen the pump has not been operated forone month or longer.

P

0.1 sec

5.9bar(peak)

Nominal2.1bar

K3VL Marketing Kit

Page 100 of 165


Mounting Orientation & Drain Connection (cont.)

Vertical Installation ( Drive shaft vertically upward)When vertical installation is necessary the front bearing of the pumpshould be lubricated using the Tair air bleeder port which is a standardfeature. The oil level in the tank should be higher than the pumpmounting flange. If the oil level in the tank is lower than the pumpmounting flange then forced lubrication is required through the oil bleederport. ( 1 to 2 L/min is necessary)

When installing the pump in the tank and submerged in the oil both thedrain and air bleed ports should be open so as to ensure all internalcomponents are initially lubricated and no air pockets are left within thepump case.

When installing the pump outside the tank then the drain and air bleederpiping must still be routed to tank. If the drain or air bleed piping risesabove the oil tank level then the lines must be filled with oil prior to start-up.

The following illustration describes these requirements:

pipe for air bleeding

Figure 2(a)

(b)

Tair

Dr

OILTair

Dr

Dr Dr

pipe for draining

Precautions when mounting pump vertically

The oil level in the tank should be higher than the pump mounting flange (Figure 1)

If the oil level is below this then forced lubrication is necessaryutilising the air bleeder port (flow requirement 1 to 2 L/min)

a. Installation within the tank1. Open the drain port and air bleeder ports

b. Installation outside of the tank (Figure 2)1. Pipe the drain and air bleeder ports directly to the tank2. If either of these ports are higher than the tank's oil level

then the pumps case must be filled with oil before starting.

Figure 1

minimum oillevelOIL

Tair

Dr

K3VL Marketing Kit

Page 101 of 165


Filtration & Contamination Control

FiltrationThe most important means to prevent premature damage to the pumpand associated equipment and to extend its working life, is to ensure thathydraulic 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. Likewise, during startup thorough flushing should be done at minimal operating pressure so asto remove any residual contamination. Flushing should be provided usingan off line filtration system. After flushing of course the filter elementsshould be replaced.

A full flow return line filter of 10 micron nominal should be utilised and inaddition a 150 micron mesh suction strainer is recommended.

To prevent contaminant ingress from the external environment a 5 to 10micron filter within the tanks breather is also recommended.

Suggested Acceptable Contamination LevelThe relationship between contamination level and pump life is verydifficult to predict as it depends very much on the type and nature of thecontaminant present in the system. Sand or Silica in particular, due to itsabrasive nature, does significantly reduce the expected life of a pump.

Based on the precondition that there is no significant presence of Silicatype substances then a minimum Cleanliness level of 18/15 to ISO/DIS4406 (NAS Class 9) is recommended.

K3VL Marketing Kit

Page 102 of 165


Drive Shaft Connection

Flexible CouplingA flexible coupling should always be used for connection of the pumpdrive shaft with an engine flywheel or electric motor shaft.

AlignmentAlignment should be carried out so that the parallelity error is held within+/- 0.025 mm.

Radial & Axial LoadingRadial loading is possible - see Performance section for details. Axial lloading however of any form must be avoided.

Coupling Fixing MethodUse screws and threads for fixing the coupling without hammering as thiscould damage the internal bearings.

Angular MisalignmentMaximum allowable angular misalignment is 0.2 degrees.

= a/2

a

dial gaugereading = a

datum facefor parallel misalignment

0.025 mm

b

D

= SIN-1 (b/D)

dial gaugereading = b

datum facefor angular misalignment

0.2 degrees

K3VL Marketing Kit

Page 103 of 165


Working Fluid Types

Anti-Wear Type Hydraulic fluidIt is generally recommended to use an anti-wear type hydraulic fluid asthe mineral oil type when the operating pressure exceeds 210 bar

Fire-resistant FluidsMost kinds of fire-resistant fluids require special materials for seals, paintand metal finishing.

Please consult us and provide details of the particular fluid specificationand the working conditions so that any special requirements can beascertained. (Use Check List sheet in Appendix 12.1)

In general, fire-resistant fluids have a low viscosity index and theirviscosity also changes significantly with operating temperature andservice life. For this reason, the circuit should be provided with anadequately sized cooler or forced cooling so that temperatures can bestabilised.

Their lubricity can significantly affect bearing life.

Due to the inherent water content of some of these fluids the minimumallowable suction pressure will be higher than that of an equivalentmineral oil and so needs to be fully evaluated by us before agreeing theapplication.

The following table provides an overview of the precautions andcharacteristics that can be expected with these types of fluids.

mineraloil

phosphateester

polyolester

waterglycol

Maximum Pressure(bar)

320 320 320 210

Recommended TemperatureRange (deg C)

20 ~ 60 20 ~ 60 20 ~ 60 10 ~ 50

Cavitation susceptability

Expected life expectancy comparedto mineral oil

100% 60% ~ 100% 50% ~ 100% 20% ~ 80%

fluid type :-

parameter :-

recommended usable (higher density)

K3VL Marketing Kit

Page 104 of 165


Viscosity & Temperature Range

Oil TypeA high viscosity index anti-wear mineral oil with the following additivepackage is preferred: extreme pressure, foam inhibitor, antioxidant andanticorrosive agents. As stated previously any fire-resistant fluids such asphosphate esters, water glycolís or water emulsions need the approval ofus before order acceptance. For this we will need a full fluid specificationand an understanding of the operating conditions.

Optimum ViscosityA working viscosity range between 10 & 200 cSt is recommended. If aviscosity of 200 cSt is exceeded then boost pressure must be applied soas to ensure adequate suction capability. Under these conditions theviscosity range can be extended to 1,000 cSt. However, it is consideredadvisable to remain within 200 cSt so as to avoid circuit complications.

Optimum TemperatureThe allowable temperature range is -20OC up to 95OC. These limits aredue to the type of elastomer seals that are used. In order, however tominimise both oil and seal deterioration a maximum operatingtemperature of 60OC should be considered. Additionally it must be notedthat when operating at low temperatures in winter (15~ 20OC) some delayin response of the regulator may occur. At such low temperatures it isstrongly suggested that a warm up cycle is introduced and that the pumpis started up in a partially stroked condition until an operating temperatureof 20OC is achieved.

��

1000

600400

200

1008060

40

20

15

10

kinematicviscosity(cSt)

-20 0 20 40 60 80 100

fluid temperature ( C)

VG100

VG68

VG46

VG32

VG22

allowable temperature range

o o o oo o

o

o

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Pump Start Up Precautions

Pump Case FillingBe sure to fill the pump casing with oil through the drain port - filling onlythe suction line with oil is totally insufficient. The pump contains bearingsand high-speed sliding parts including pistons with shoes and sphericalbushes that need to be continuously lubricated. Part seizure or totalpremature failure will occur very quickly if this procedure is not rigidlyfollowed.

Piping & Circuit CheckingCheck to see that the piping and full hydraulic circuit is completed andthat any gate valves etc. are open.

Direction of Rotation CheckCheck to ensure that direction of rotation is correct and that the suctionand delivery lines are connected correctly.

Start UpJog start the motor and check once more for correct rotation. Run thepump unloaded for a period to ensure that all residual air within thesystem is released. Check for external leakage, abnormal noise andvibrations.

Case Drain PressurePlease ensure, as stated previously, that the maximum steady state drainline pressure at the pump casing does not exceed 2 bar. (Maximum peakpressure 6 bar). A suitable drain line hose and drain line filter whenrequired must be selected to ensure this.

Long Term Out of UsageIt is undesirable to leave the pump out of use for a long period of a yearor more. In such a situation it is recommended that the pump is run for ashort 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 frequentbasis is sufficient. If the pump is left out for more than the suggested timeit will require a service inspection.

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Through Drive Limitations

Apart from predefined maximum throughput limitations, one must also ensurethat to prevent a possible excessive bending moment occurring that themaximum combined bending moment of the combination is not exceeded asdetermined in the following expression:

L1

LP2'

LP3'

mP1 mP2 mP3

LP1 L2

LP2

LA1 LA2

mA1 mA2

L2 L3

LA1'

LA2'

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

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]

Pump approximate weight [kg] (Mp)

without torque limiter with torque limiter

pumpsize

SinglePumpType "0"

StockPumpType "S"

SinglePumpType "0"

StockPumpType "S"

45 25 28 27 3080 35 38 37 40112 65 69 67 71140 65 69 67 71

Pump overall length [mm] (Lp)

pumpsize

SinglePumpType "0"

StockPumpType "S"

45 244 24480 272 272112 308 308140 308 308

Pump CofG from mount [mm] (L)

pumpsize

SinglePumpType "0"

StockPumpType "S"

45 120 12080 130 130112 150 150

140 150 150

Adaptor Kits weight (Ma) & width (La)

pump adaptor weight widthsize kit (Max) (Lax)

SAE "A" 0 045 SAE "B" & "BB" 2 20

SAE "A" 0 080 SAE "B" & "BB" 3 20

SAE "C" & "CC" 4 24.5SAE "A" 0 0

112 SAE "B" & "BB" 3 25& 140 SAE "C" & "CC" 5 30

SAE "D" 10 43

pumpsize

MaximumPermisable

Bending Moment(Nm)

45 137

80 244

112 462

140 462

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.

8. Commercial InformationIncluded in this section is information on pricing, lead-times and KPM stockingpolicy.

This commercial information will be adjusted in line with prevailing marketconditions as and when necessary.

In order to control the K3VL product introduction effectively, it is necessary tomaintain records at KPM for each current application. We do not wish toburden you with reams of paperwork so the attached pump enquiry sheethas been prepared to aid this process (see Appendix 12.1)

In common with our present Staffa motor & K3VG application practise, weintend to maintain a register of these applications so that reviews can besimply effected.

8.1. Selling Strategy

We believe that the features and benefits offered by this K3VL family togetherwith the fact that our lead times should be "Best in Class" means that weshould be able to differentiate from our Competition and thereby commandequivalent or higher market prices

It is our intention, for all combination pump requirements, to supply "N" typethrough drive units (with the sealed steel cover) and the necessary adaptorkits separately. This will allow the distributor the flexibility to combine themtogether. Consequently, for such requirements adaptor kits must also beordered as a separate item. Please remember that for a K3VL multiple pump,in addition to the adaptor kit you will also need to order a bolt kit for the rearpump so that it can be assembled together.

With regard to spare parts, because of the lower intrinsic value of thesepumps they will essentially be considered to be disposable items.Consequently only kits will be offered (rotary, swash plate and seal kits)

8.2. Leadtimes

To effectively meet local market requirements and to support our "best inclass" lead time policy, all KPM distributors will be required to stock anappropriate range of single pumps, "N" type through drive units, adaptor kits,bolt kits and spare parts kits. It is our intention, therefore to be in a position tooffer ex-stock availability at all times. It is as much your responsibility tosupport this policy as it is ours!

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8. Commercial Information (cont.)

8.5. Market Trends & Product Positioning

IntroductionThis section has been prepared so as to identify those Market segmentswhere we should initially focus our K3VL penetration activities.

Market TrendsThe following matrix attempts to identify by installed and operating costs themarket trends as portrayed by operating cost versus installed cost.

longer

life

zero

leakage

more efficient

circuits higher

pressure

lower noise

& pulsation

application

flexibility

higher maximum

speed

InstalledCost

High

Low

Low HighOperatingCosts

Market Trends

variablevane

variablepiston

fixedpiston

fixedgear

fixedvaneTre

nds

What is clear is that the features and benefits realised in the development ofthe K3VL series do correspond clearly with these market trends. The ìvalueîthereby offered should ensure that reasonable margins can be achieved if wefocus on those applications which require compliance to these market trends.

Product PositioningThe K3VL is rated at 320 bar - some 40 bar or 14% above the competitiveofferings of today. The following matrix attempts to show this positioning

High(> 30/hr)

Low(< 30/hr)

Light(< 180 bar)

Medium( 180 ~ 280 bar)

Heavy( > 280 bar)

Duty

Cycle

A10V & PVH A4V

A11V

K3VL

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8.5. Market Trends & Product Positioning (cont.)

Product Positioning (cont.)It should be our intent to exploit this advantage by attempting to increase thesafe working pressures within an application. By so doing we can claim animprovement in power utilisation.

Additionally we also have an identifiable competitive advantage in terms ofoverall efficiency and fluid borne pulsations. Each of these must also beexploited.

Furthermore it should be noted that presently our competitors need to offertheir higher rated offering when typical working pressures reach circa 250 bar.These products generally would have a 350 or 400 bar rating and be of amore sophisticated and thereby expensive construction. This particular areashould also be exploited to the full (ie Working Pressures between 250 and300 bar)

Focus Market Segments

Industrial Sector

Based on the foregoing we need to focus on those market segments wherethe clear features and benefits of the K3VL can be exploited to the full. Thefollowing matrix has been developed so as to identify those industrial sectorswhere such a potential exists

High(> 30/hr)

Low(< 30/hr)

Light(< 180 bar)


Heavy( > 250 bar)

Duty

Cycle

Automotive AssemblyOperations

Food ProcessingMachinery

Machining Centres

Surface Grinders

Turning Centres

Blow Moulding

Die Castin

Flight Simulators

Injection Moulding

Metal Forming

Paper Machinery

Scrap Balers

Wind Turbines

Glass & CeramicForming

Certain Machine Tools

Raw Material HopperControls

Lifting Tables

Continuous CastingEquipment

Foundry & Forgingmachinery

Rubber Presses

Steel ProcessingEquipment

Glass & CeramicForming

Chemical ProcessMachinery

Entertainment

Paper & Can Balers

Welding Machinery

Chemical ProcessMachinery

Forestry ProductsMachinery

Laminating Presses

Paper & Can Balers

Welding Machinery

On viewing the diagram above, I have shaded those areas where the K3VLíscompetitive advantages can and should now be exploited.

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8.5. Market Trends & Product Positioning (cont.)

Focus Market Segments (cont.)

Mobile Sector

The mobile market matrix is shown below and must also further researched

Ground

Engaging

Light(< 180 bar)


Extreme( > 250 bar)

Duty

TypeAerial Lift Platforms

Agricultural Combines

Concrete saws

Cranes

Fire Trucks

Salt / Sand Trucks

Agricultural Tractors

Boring Machines

Mini-Excavators

Backoes

Motor Graders

Small Crawler Dozers

Trenchers

Crawler Loaders

Exploration Drills

Road Planers &Profilers

Scrapers

Mini Excavators

Backhoes

Waterwell Drills

Wheel Loaders

Concrete Pumps

Forestry Machines

Log Loaders

Petroleum FracturingTrucks

Tree Harvesters

Crushers

Feeder Breakers

Front Shovel CrawlerExcavators

Underground BlastholeDrills

Raise Bore Drill

Non-Ground

Engaging

Material Haulers

Asphalt Pavers

Compactors

Shredders

Concrete Pavers

Lift Trucks

Refuse Trucks

Rough Terrain LiftTrucks

The pricing however in this particular market is severe and as such we mustensure that we only focus on those segments where the increased capabilityof the K3VL over its competition can be exploited.

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8.6. Frequently Asked Questions

Before setting out some of the frequently asked questions relevant specificallyto the K3VL family, it is first beneficial to understand our overall competitiveposition as seen through the eyes of our prospective customer.

The following questions therefore need to be answered: -

Q1. What features does our competitor have that we canít match?Which do you have that he or she canít match?Which are most important to your customer?

Q2. Does the competitorís product have any bad features you candemonstrate easily?

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8. Commercial Information (cont.)8.6. Frequently Asked Questions (cont.)

Here follows then a list of the frequently asked questions with answers thatreflect our initial market strategy. That is that we have in many aspects asuperior pump design with a "Best in Class" lead-time.

FAQ1. What does this 320 / 350 bar pressure rating really mean to me?This means that unlike the present competition we have a product thatis 100% reliable at a continuous 320 bar rating with peak overshoots to350 bar. Remember the basis of the K3VL design is the proven andreliable K3V rotating group that has a 350 bar continuous rating. Mostof the competition has a 250 bar or 280 bar continuous rating.

FAQ2. When you say this pump series is reliable, How do you justify this?As stated previously the rotating group used is based on the provenand reliable K3V rotating group. To satisfy ourselves the completepump must undergo a 2 million-cycle endurance test successfully. Seetime diagram below for cycle sequence.

FAQ3. Do you have a checklist that shows your full fluid capability?At this time No. We generally however state that from a fluidcompatibility perspective the K3VL series has a similar fluid capabilityto that of the Rexroth & Vickers products. So any fluid they wouldrecommend is suitable for the K3VL family. The important aspect offluid selection however relates to its lubricity and the most significantcontribution factors are contamination and air ingression - each ofthese factors needs to be carefully controlled so as to optimise pumpand most particular bearing performance and reliability.

FAQ4. How interchangeable is this unit with Rexroth and Vickers equivalents?In most cases the K3VL offering is more compact than our competitors.All critical "customer interface" dimensions are within those of RexrothA10V and Vickers PVH series. Please check the installation drawingsand model codes to confirm exact port positionioning in relation to thecompetitors, it should also be noted that the A10VSO71 has a ISOshaft is 8mm shorter than the standard,

Cyclic Endurance Test

P

t

t

350 bar

Full

Zero

Condition

Temperature: 90oCDuration: 1000 hours

Inlet Pressure: AtmosphericOutlet Pressure: 350 bar

Speed: Rated Speed

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FAQ5. Do you have a cross-reference to the Rexroth A10VO units?Yes. Please look in the Competitor section of this Marketing Kit for across-reference to the A10VO short order (preferred) variants

FAQ6. Do you have a cross-reference to the Rexroth A11VO units?Yes. Please look in the Competitor section of this Marketing Kit for across-reference to the A11V short order (preferred) variants

FAQ7. Do you have a cross-reference to the Vickers PVH units?Yes. For shafts & regulators, please look in the Competitor section ofthis Marketing Kit for a cross-reference to the PVH preferred variants.

FAQ8. How much negative stroke is the pump capable of?The rotating group can go up to 1.5 degrees over centre so as tocontrol transient overshoots.

FAQ9. What is the operating weight & power density of these units?Please see General section of this Marketing Kit. You will note that incontrast to most of our competitors we have a lighter weight and asignificantly higher power density.

FAQ10. What are your preferred product variants and what benefit do theyprovide me with?The preferred product range is shown in its entirety in the Price Listingwithin the Commercial section of this Marketing Kit. This modularisedrange ensures the maximum of flexibility for you and your customers.Other variants can be included at a later time when we have evaluatedtheir true potential.

FAQ11. Do you have a single pump, rear ported variant?With the K3VL45 and K3VL80 such a variant has already beendesigned. (See Installation Section) but these are not considered a"Preferred " product at this time and thereby are on a 4-month lead-time. For the K3VL112 and K3VL140 these can be made available in asimilar lead-time.

FAQ12. What are your through drive shaft configurations?A splined connection is used. All the various SAE mounting interfacesare available in kit form for assembly to the "S" type Stock pump.

FAQ13. Do you have a model code to part number cross-reference?Yes. Please see the appendix for this cross-reference.

FAQ14. What is the standby pressure in load sensing mode?Due to the larger stroking pistons utilised on the K3VL, the sine wavevalve plate which provides symmetrical timing and the use ofhydrostatic pillar bearings the resultant friction effects within the pumpare smaller than the competition. Consequently standby pressure istypically between 20 to 30 bar. Competitor products will typically haveas much as a 50 bar standby!

FAQ15. What is the standby pressure in load sensing mode?Due to the larger stroking pistons utilised on the K3VL, the optimizedlow noise spherical valve plate valve plate and the use ofhydrostatic pillar bearings the resultant friction effects within the pumpare smaller than the competition. Consequently standby pressure istypically between 20 to 30 bar. Competitor products will typically haveas much as a 50 bar standby!

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.FAQ16. Are there any negative or positive displacement control options?

No and none are presently envisaged. One can usually use a loadsensing circuit to provide a similar capability. If you really requiredisplacement control then you will need to use a K3VG or K3V unit.

FAQ17. What adjustment settings are available and what are their sensitivities?Maximum displacement, direct pressure limiter setting, differentialspool pressure (load sensing) and torque limiter adjustments areavailable. Please consult the Control section for more details. Foradjustment of the maximum displacement stop to match a competitorproduct please consult the Competitor section of this Marketing Kit.

FAQ18. What is the price & availability?See the Commercial section for guidance.

FAQ19. What are your recommendations for shaft and mounting alignments?Please see the Installation constraints section of this Marketing Kit.

FAQ20. What is the maximum allowable case pressure?Please see the Installation constraints section of this Marketing Kit.

FAQ21. What is the pumpís suction capability?Please see the General Description section. Generally the use of thespherical valve plate provides a superior self-sucking capability thanthe plain valve plate variants used by our competition. See theFeatures and Benefits section for further discussion on this subject.

FAQ22. What painting options are available?A primer coat is used.

FAQ23. How is the pump packaged?The pump will be packaged in a cardboard type container. A woodencase can be provided at extra cost.

FAQ24. Who should I contact about K3VL opportunities?Contact your responsible sales person or anybody in the customersupport group at KPM.

FAQ25. What are the typical transportation costs?Weights are shown in the General section. We will later provide a list oftypical transportation costs.

FAQ26. What literature is available?A Capability Brochure and Technical datasheets will be available inelectronic form initially (PDF format)

FAQ27. What shaft & mounting options are available?ISO and SAE mounts are available.

FAQ28. What are the radial & axial shaft loading possibilities?Axial loading is not permissible. Radial loading in the approvedorientation is possible but will reduce bearing life. See the technicaldescription section for details.

FAQ29. Does the regulator have a load sensing bleed for standby conditionand what is the loss?Yes. Using the L1 regulator version can eliminate this. A 0.4mm orificeis used which will create a 3 to 4 L/min loss at rated pressure.

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FAQ30. What are the recommended specifications for a remote pressure pilot?Please see the Control section for details of the recommendedKawasaki pressure relief valves for this operation.

FAQ31. Why is the pump more efficient than the competition?The pump utilises a spherical valve plate and solid pistons - both ofwhich improve volumetric efficiency.

FAQ32. Why is the pumpís bearing life superior to the competition?The use of rugged roller type bearings in association with theoptimisation of the complete rotating group enables the bearing loadsto be distributed primarily towards the front higher rated bearing. Theforce balance achieved using a spherical valve plate construction alsoin part balances some of the radial forces hydraulically and therebyprovide an optimum bearing condition.

FAQ33. Can you provide any electronic files related to the pumpís specification,literature and installation?Yes PDF format for literature and DXF for installation drawings.

FAQ34. What is the dynamic pressure & flow response?Dynamic response curves are provided in the controlís section of thisMarketing Kit.

FAQ35. What are the long & short term storage requirements?Please see the Application constraint section of this Marketing Kit.

FAQ36. Can you use this unit in closed loop applications?No, this unit is only for use in open loop circuits. A semi-closed systemhowever could be considered please consult your KPM applicationspecialist.

FAQ37. What design features of the K3VL/A series pump limits the minimumpump speed to 600rpm?There are no such design constraints. This minimum operating speedreflects typically the minimum expectable low idle speed of a primemover. Remember that at these lower operating speeds, the pumpísvolumetric efficiency will be poorer, as will its on stroke response.

FAQ38. What happens if no safety relief valve is installed in the system whenusing the K3VL/B pump? How should we better emphasise this issue?With the rapid blockage of the outlet flow path, a pressure overshootwill occur. The magnitude of this pressure overshoot is determined bymany factors; notably system compliance, oil specification, fluidtemperature, speed of closure, compensator setting etc.Kawasaki always recommend that a fast acting, direct operated safetyrelief valve is installed on the pump outlet so as to guarantee that theresulting overshoot will not exceed 350 bar - this being the peakpressure rating of the k3VL range. Without such a safety valve fittedthis pressure overshoot could exceed 350 bar which is unacceptable.

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FAQ39. What is the error of the noise level measurements on the performancecurves?Tolerance is generally +/- 2bB(A), the same as noise testing to NFPAor ISO/DIN measurement method. Kawasaki do have a semi-anechoicnoise chamber which is used to establish the published noise levels.This chamber because of its relative small size and resultant noiseabsorption characteristics, does not comply with either the NFPA orISO/DIN standards. So typical noise figures should be used withoutthe addition of any such tolerance when quoting our published figures.

FAQ40. Why are there differences in the allowable speed at zero (atmospheric)inlet pressure between the specification list and the performancecurves?The specification figure is a "conservative" rounding of the self primingperformance curve data.

FAQ41. Why is the allowable speed not reduced for alternative fluids?Generally speaking the published maximum allowable speed is relatedto the self priming capability of the pump. This in turn is dependant onthe operating fluid used, or more specifically its density. The higher thedensity, the proportionally lower will be the maximum self primingspeed. (As a reference Mineral Oil density is given as 0.87g/ml)Since a majority of such alternative fluid applications will utilise electricmotors as the prime mover whose operating speeds are well within theself priming capability of the pump on mineral oil, no such speedreductions will be necessary.

FAQ42. Why does the "*V" control option use a DO3 mounted proportionalrelief valve vs, a cartridge valve type?Can we offer without this valve as just an unload sandwich block?No on both counts. The released combinations are the only variantsthat fully meet our performance criteria.

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9. Competitive Information

9.1 Competitive Offerings

REXROTH - A10VS(O) Medium Pressure Range(which has now been fully tested and evaluated in Nishi-Kobe)

VICKERS - PVH Medium Pressure Range

A review of the relative features of these competitor offerings is herebyprovided including cross sectional drawings, performance ratings and modelcoding data.

What can be said however is that the space envelope of the K3VL is suchthat it can truly replace both the Rexroth and Vickers equivalent offerings asthe sectional drawings below reveal:

Any information on these or other competitor products that you can provide usthroughout the European market area will be most useful.

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9. Competitive Information (cont.)9.1 Competitive Offerings (cont.)

Rexroth A10V

This K3VL range has used the Rexroth A10VSO product range as thebenchmark. In fact the A10VSO range has by far the greatest market share inthis medium pressure range axial piston pump area independent of themarket segment considered.

Their range consists of 5 frame sizes of 28, 45, 71, 100 and 140 cc/revdisplacement and offers a similar range of control options as that of the K3VLwith the exception of the integral unload function.

The following pages in fact provide a cross-reference between the twoofferings.

Cross Section

In terms of constructional differences the following can be said:-

Pillow swash plate support mechanism

Flat Valve Plate

Sprung loaded piston return mechanism

Limited variety of controls

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Rexroth A10V (cont.)

Specifications

Pump Model 28 45 71 100 140Capacity (cc/rev) 28 45 71 112 140Rated Pressure #1 (bar) 280 280 280 280 280Intermittent Pressure #2 (bar) 315 315 315 315 315Peak Pressure (bar) 350 350 350 350 350Rated Speed (r/min) 1,800 1,800 1,800 1,800 1,800Max. Self Priming Speed #3 (r/min) 3,000 2,600 2,200 2,000 1,800Maximum Boosted Speed #4 (r/min) 3,600 3,100 2,600 2,400 2,100Weight #5 (kg) 15 21 33 45 60

Notes:

#1Pressure at which life and durability will not be affected.#2

Pressure at which a 10% duty is tolerated.#3

Steady state suction pressure should be -0.1 bar and above.#4

Atmospheric suction pressure of 1 bar or above. In some cases, operatingpressure and or flow could be limited.

#5Approximate dry weights, dependant on exact pump type.

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Rexroth A10V (cont.)

Pressure Pulsation ComparisonsComparison testing of the K3VL80 compared to the A10V71 has beenconducted.Below will be found the comparative results of the pressure pulsation testwhich clearly demonstrate the advantage of our spherical valve plate.

Pressure Pulsation Comparisons

0

0.3

0.6

0.9

1.2

1.5

100% 50% 5%

Tilting angle

Pulsationwidth(MPa)

K3VL80/A

A10VSO71

K3VL80 Pulsation Comparison

(210bar & 1500 rpm)

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Rexroth A10V (cont.)A10VSO Cross Reference

Cross References

Rexroth Rexroth Model Code Equivalent K3VL Model KawasakiPart No Part No936910 A10VSO45DFLR/31R-PPA12N00 (100Nm) K3VL45/A-1NRMM-L0/1-M2 29L4100ML1M2936912 A10VSO45DFLR/31R-PPA12N00 (145Nm) K3VL45/A-1NRMM-L0/1-H3 29L4100ML1H3936739 A10VSO45DFLR/31R-PPA12N00 (120Nm) K3VL45/A-1NRMM-L0/1-H4 29L4100ML1H4935975 A10VSO45DFLR/31R-PPA12N00 (50Nm) K3VL45/A-1NRMM-L0/1-L4 29L4100ML1L4940582 A10VSO45DFLR/31R-PPA12N00 (70Nm) K3VL45/A-1NRMM-L0/1-L1 29L4100ML1L1909613 A10VSO45DFR/31R-PPA12K01 K3VL45/A-1ARMM-L0 29L41A0ML0939183 A10VSO45DFR/31R-PPA12N00 K3VL45/A-1NRMM-L0 29L4100ML0927068 A10VSO45DFR1/31R-PPA12K02 K3VL45/A-1BRMM-L1 29L41B0MK0908725 A10VSO45DFR1/31R-PPA12N00 K3VL45/A-1NRMM-L1 29L4100MK0907403 A10VSO45DR/31R-PPA12N00 K3VL45/A-1NRMM-P0 29L4100MP0944067 A10VSO71DFLR/31R-PPA12N00 (100Nm) K3VL80/A-1NRMM-L0/1-L3 29L8100ML1L3944730 A10VSO71DFLR/31R-PPA12N00 (120Nm) K3VL80/A-1NRMM-L0/1-L1 29L8100ML1L1942654 A10VSO71DFLR/31R-PPA12N00 (145Nm) K3VL80/A-1NRMM-L0/1-M4 29L8100ML1M4944502 A10VSO71DFLR/31R-PPA12N00 (70Nm) K3VL80/A-1NRMM-L0/1-L6 29L8100ML1L6948790 A10VSO71DFLR/31R-PPA12N00 (200Nm) K3VL80/A-1NRMM-L0/1-H4 29L8100MlL1H4961216 A10VSO71DFLR/31R-PPA12N00 (240Nm) K3VL80/A-1NRMM-L0/1-H2 29L8100ML1H2942635 A10VSO71DFR/31R-PPA12N00 K3VL80/A-1NRMM-L0 29L8100ML0947872 A10VSO71DFR1/31R-PPA12K02 K3VL80/A-1BRMM-L1 29L81B0MK0944440 A10VSO71DFR1/31R-PPA12N00 K3VL80/A-1NRMM-L1 29L8100MK0945133 A10VSO71DR/31R-PPA12N00 K3VL80/A-1NRMM-P0 29L8100MP0947898 A10VSO71DRG/31R-PPA12N00 K3VL80/A-1NRMM-P0 29L8100MP0936207 A10VSO100DFLR/31R-PPA12N00 (140Nm) K3VL112/A-1NRMM-L0/1-L3 29LG100ML1L3936738 A10VSO100DFLR/31R-PPA12N00 (200Nm) K3VL112/A-1NRMM-L0/1-M3 29LG100ML1M3936473 A10VSO100DFLR/31R-PPA12N00 (100Nm) K3VL112/A-1NRMM-L0/1-S2 29LG100ML1S2936799 A10VSO100DFLR/31R-PPA12N00 (245Nm) K3VL112/A-1NRMM-L0/1-M1 29LG100ML1M1934823 A10VSO100DFLR/31R-PPA12N00 (120Nm) K3VL112/A-1NRMM-L0/1-L4 29LG100ML1L4944032 A10VSO100DFLR/31R-PPA12N00 (360Nm) K3VL112/A-1NRMM-L0/1-M2 29LG100ML1M2943468 A10VSO100DFLR/31R-PPA12N00 (300Nm) K3VL112/A-1NRMM-L0/1-H4 29LG100ML1H4939643 A10VSO100DFR/31R-PPA12N00 K3VL112/A-1NRMM-L0 29LG100ML0927083 A10VSO100DFR1/31R-PPA12K02 K3VL112/A-1BRMM-L1 29LG1B0MK0922744 A10VSO100DFR1/31R-PPA12N00 K3VL112/A-1NRMM-L1 29LG100MK0912007 A10VSO100DR/31R-PPA12N00 K3VL112/A-1NRMM-P0 29LG100MP0936094 A10VSO140DFLR/31R-PPB12N00 (300Nm) K3VL140/A-1NRMM-L0/1-M2 29LH100ML1M2935974 A10VSO140DFLR/31R-PPB12N00 (200Nm) K3VL140/A-1NRMM-L0/1-L2 29LH100ML1L2941109 A10VSO140DFLR/31R-PPB12N00 (365Nm) K3VL140/A-1NRMM-L0/1-H4 29LH100ML1H4938977 A10VSO140DFLR/31R-PPB12N00 (245Nm) K3VL140/A-1NRMM-L0/1-M3 29LH100ML1M3943841 A10VSO140DFLR/31R-PPB12N00 (500Nm) K3VL140/A-1NRMM-L0/1-H1 29LH100ML1H1939192 A10VSO140DFR/31R-PPB12N00 K3VL140/A-1NRMM-L0 29LH100ML0927126 A10VSO140DFR1/31R-PPB12K02 K3VL140/A-1BRMM-L1 29LH1B0MK0921546 A10VSO140DFR1/31R-PPB12N00 K3VL140/A-1NRMM-L1 29LH100MK0922983 A10VSO140DR/31R-PPB12N00 K3VL140/A-1NRMM-P0 29LH100MP0932852 A10VSO140DRG/31R-PPB12N00 K3VL140/A-1NRMM-P0 29LH100MP0

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Rexroth A10V (cont.)A10VO Cross References

A11V Cross References

Rexroth Rexroth Model Code Equivalent K3VL Model KawasakiPart No Part No907404 A10VO45DFR/31R-PSC62K01 K3VL45/A-1ARSS-L0 29L41A0CL0943655 A10VO45DFR/31R-PSC62N00 K3VL45/A-1NRSS-L0 29L4100CL0916472 A10VO45DFR1/31L-PSC62K01 K3VL45/A-1ALSS-L1 29L42A0CK0909288 A10VO45DFR1/31L-PSC62N00 K3VL45/A-1NLSS-L1 29L4200CK0916931 A10VO45DFR1/31R-PSC62K01 K3VL45/A-1ARSS-L1 29L41A0CK0920557 A10VO45DFR1/31R-PSC62K01 K3VL45/A-1ARSS-L1 29L41A0CK0910181 A10VO45DFR1/31R-PSC62N00 K3VL45/A-1NRSS-L1 29L4100CK0946188 A10VO71DFR/31L-PSC62N00 K3VL80/A-1NLSS-L0 29L8200CL0939120 A10VO71DFR/31R-PSC62N00 K3VL80/A-1NRSS-L0 29L8100CL0947870 A10VO71DFR1/31L-PSC62K02 K3VL80/A-1BLSS-L1 29L82B0CK0941657 A10VO71DFR1/31R-PSC62N00 K3VL80/A-1NRSS-L1 29L8100CK0906900 A10VO100DFR/31R-PSC62N00 K3VL112/A-1NRSS-L0 29LG100CL0

Rexroth Rexroth Model Code Equivalent K3VL Model Kawasaki ?Part No Part No9609790 A11VO40LRS/10R-NSC12N00 K3VL45/A-1NRSM-L0/1-H2 29L4100BL1H2 #9609791 A11VO40LRS/10R-NPC12N00 K3VL45/A-1NRMM-L0/1-H2 29L4100ML1H2 #9609656 A11VO40DRS/10R-NSC12N00 K3VL45/A-1NRSM-L0 29L4100BL09609794 A11VO40DRS/10R-NPC12N00 K3VL45/A-1NRMM-L0 29L4100ML09609798 A11VO60LRS/10R-NSC12N00 K3VL80/A-1NRSM-L0/1-H2 29L8100BL1H2 #9609799 A11VO60LRS/10R-NPC12N00 K3VL80/A-1NRMM-L0/1-H2 29L8100ML1H2 #9609800 A11VO60LRS/10R-NSC12K01 K3VL80/A-1ARSM-L0/1-H2 29L81A0BL1H2 #9609801 A11VO60LRS/10R-NPC12K01 K3VL80/A-1ARMM-L0/1-H2 29L81A0ML1H2 #9606644 A11VO60DRS/10R-NSC12N00 K3VL80/A-1NRSM-L0 29L8100BL09609807 A11VO60DRS/10R-NPC12N00 K3VL80/A-1NRMM-L0 29L8100ML09601648 A11VO60DRS/10R-NSC12K01 K3VL80/A-1ARSM-L0 29L81A0BL09609809 A11VO60DRS/10R-NPC12K01 K3VL80/A-1ARMM-L0 29L81A0ML09609815 A11VO75LRS/10R-NSD12N00 K3VL80/A-1NRSM-L0/1-H2 29L8100BL1H2 #9609816 A11VO75LRS/10R-NPD12N00 K3VL80/A-1NRMM-L0/1-H2 29L8100ML1H2 #9609817 A11VO75LRS/10R-NSD12K01 K3VL80/A-1ARSM-L0/1-H2 29L81A0BL1H2 #9609818 A11VO75LRS/10R-NPD12K01 K3VL80/A-1ARMM-L0/1-H2 29L81A0ML1H2 #9448021 A11VO75DRS/10R-NSD12N00 K3VL80/A-1NRSM-L0 29L8100BL09609824 A11VO75DRS/10R-NPD12N00 K3VL80/A-1NRMM-L0 29L8100ML09609825 A11VO75DRS/10R-NSD12K01 K3VL80/A-1ARSM-L0 29L81A0BL09609826 A11VO75DRS/10R-NPD12K01 K3VL80/A-1ARMM-L0 29L81A0ML09609834 A11VO95LRS/10R-NSD12N00 K3VL112/A-1NRSM-L0/1-H2 29LG100BL1H2 #9609835 A11VO95LRS/10R-NPD12N00 K3VL112/A-1NRMM-L0/1-H2 29LG100ML1H2 #9609836 A11VO95LRS/10R-NSD12K01 K3VL112/A-1ARSM-LO/1-H2 29LG1A0BL1H2 #9609837 A11VO95LRS/10R-NPD12K01 K3VL112/A-1ARMM-L0/1-H2 29LG1A0ML1H2 #9609842 A11VO95DRS/10R-NSD12N00 K3VL112/A-1NRSM-L0 29LG100BL09608484 A11VO95DRS/10R-NPD12N00 K3VL112/A-1NRMM-L0 29LG100ML09609844 A11VO95DRS/10R-NSD12K01 K3VL112/A-1ARSM-L0 29LG1A0BL09609845 A11VO95DRS/10R-NPD12K01 K3VL112/A-1ARMM-L0 29LG1A0ML09609848 A11VO130LRS/10R-NSD12N00 K3VL140/A-1NRSM-L0/1-H2 29LH100BL1H2 #9609646 A11VO130LRS/10R-NPD12N00 K3VL140/A-1NRMM-L0/1-H2 29LH100ML1H2 #9609850 A11VO130LRS/10R-NSD12K02 K3VL140/A-1BRSM-L0/1-H2 29LH1B0BL1H2 #9609851 A11VO130LRS/10R-NPD12K02 K3VL140/A-1BRMM-L0/1-H2 29LH1B0ML1H2 #9601036 A11VO130DRS/10R-NSD12N00 K3VL140/A-1NRSM-L0 29LH100BL09609857 A11VO130DRS/10R-NPD12N00 K3VL140/A-1NRMM-L0 29LH100ML09609858 A11VO130DRS/10R-NSD12K02 K3VL140/A-1BRSM-L0 29LH1B0BL09609859 A11VO130DRS/10R-NPD12K02 K3VL140/A-1BRMM-L0 29LH1B0ML0

[#] - PLEASE NOTE Torque Limiter arbitarily set to H2 setting

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Vickers PVH

Vickers in fact apart from their new Hydrokraft acquisition (generallyconsidered uncompetitive) only offer the PVH range with displacements of 45,57, 74, 98 & 131 cc/rev. The 57, 74 & 98 displacement versions are their oldseries 10 units with a 250 bar pressure rating whereas the 45 & 131 versionsare series 40 with a 280 bar rated pressure (320 bar intermittent {10% duty},350 bar peak)

Additionally the range of controls available is limited consisting of only a loadsense or a pressure compensator or a combination thereof.

The Series 40 product range consists of 2 frame sizes at this time of 45 and131 cc/rev displacements. (10, 16, 28, 57, 74, 98, 164 & 219 cc/rev series 40models have been publicised in internal Vickers documents but as yet havenot been catalogued or released for general sale)

Cross Section

In terms of constructional differences the following features should be noted:-

Pillow swash plate support mechanism (Steel backed Polymer type)

Flat Valve Plate (bi-metal)

Sprung loaded piston return mechanism

Limited variety of controls

Single Control Piston (Offset yoke)

Claimed 30,000 hours L10 design life

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Vickers PVH (cont.)

Specifications

Pump Model 45 57 74 98 131Capacity (cc/rev) 45.1 57.4 73.7 98.3 131.1Rated Pressure #1 (bar) 280 250 250 280 280Intermittent Pressure #2 (bar) 320 na na na 320Peak Pressure (bar) 350 na na na 350Max. Self Priming Speed #3 (r/min) 2,200 2,100 1,900 1,800 1,600Maximum Boosted Speed #4 (r/min) 2,600 2,500 2,400 2,200 2,000Weight #5 (kg) 24 36 45 49 66

Notes:

#1Pressure at which life and durability will not be affected.

#2Pressure at which a 10% duty is tolerated.

#3Steady state suction pressure should be -0.15 bar and above.

#4Atmospheric suction pressure of 1 bar or above. In some cases, operatingpressure and or flow could be limited.

#5Approximate dry weights, dependant on exact pump type.

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Other Cross ReferencesFor regulator, through drive and shaft equivalents please refer to the followingfigure:-

Where the same maximum displacement as a competitive offering is requiredthen the K3VL maximum displacement adjuster should be adjustedclockwise by the said rotation so as to achieve the competitors publishedmaximum displacement figure:-

Maximum Displacement Adjustment (Degrees)

Model Frame Size

Rexroth A11VRexroth A10V

Vickers Eaton PVHRexroth A11V & A10V

Rexroth A10VVickers Eaton PVH

Rexroth A11VRexroth A11V

Vickers Eaton PVHRexroth A10VRexroth A11V

Vickers Eaton PVH

cc/rev 45 80 112 140404557607174759598100130131

3670

1161523348290

532438376

300270

1335

Regulator EquivalentsK3VL A10V(S)O A11V PVH

(Position 11~14) (Position 5) (Position 5) (Position 11~15)

P0 DR,DRG DR,DRG C, CML0 DFR DRS CV. CMVL1 DFR1 - -

L0/1 ** DFLR LS CVT, CMVTP0/1-** - LR, LD, LG CT, CMT

Through Drive EquivalentsK3VL A10V(S)O A11V PVH(Position 6) (Position 12) (Position 13) (Position 6)

O N00 N00 blankA K01 K01 AB K02 K02 BBB K04 K04 -C K07 K07 CCC K24 K24 -D K17 K17 -

Shaft EquivalentsK3VL A10V(S)O A11V PVH(Position 8) (Position 8) (Position 10) (Position 8)

M P P NS S S 2 & 12T U T 1

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Competitor Analysis Summary

Displayed below is a comparative table for the 80 size, showing the significantadvantages that the K3VL has over that of the primary competition. The A10Vinformation is a result of testing at Nishi-Kobe whereby that of the PVH74, 10series comes from published literature and a review of its inherent designprinciples.

These same advantages are valid for other members of the K3VL family.

Item KawasakiK3VL80

RexrothA10V71

VickersPVH74

Overall RatingsDuty TypeCategoryPressure CategoryRated PressurePeak Pressure

HeavyHigh320 bar350 bar

MediumMedium280 bar320 bar

MediumMedium250 bar

not specified

ControlOptionsConstant PressureLoad SensingAuxiliary Controls

AvailableAvailableIntegrated

AvailableAvailable

Not Integrated

AvailableAvailable

Not Integrated

PerformanceOverall Efficiency(Full Stroke,1800rpm, 280 bar)

91% 86% (literature)83% (actual)

89% (literature)

SpeedCapabilitySelf Priming LimitMaximum Speed(with Boost)

2400 rpm3100 rpm

2200 rpm2600 rpm

1800 rpm1800 rpm

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Page 127 of 165

10. Installation

Notefor counter clockwise rotation,the suction port "B" and thedelivery port "A" are reversed

K3VL45 Installation DrawingK3VL45 with Cut-Off / Load Sense Control& Torque Limit Module (Clockwise Rotation)

See Torque Limit Detailand Adjustment

1196.5

PL (PC)

55

89

166

73

AB

160

154

PL (PC)

70 DR

DR

70

80

80 99

B

A

PL (PC)

218

See PortDetails

69.8

0.2

38L

B

See Max. Flow Adjustment DetailAdjustment screw forhorsepower setting

1849113

35.7 0.2

90 40Tair

Dr

Dr

Dr

Tair

PL (PC)

144

14.3

45 o

45 o

14.3

Adjustment screw forcut-off pressure

40

Adjustment screw fordifferential pressure

PL (PC)

See PortDetails

25

26.2 0.2184

91

DrA

52.4

0.2

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10. Installation (cont.)

K3VL45 Mounting Flange & Shaft Options

SAE Type

SAE "B" 2 holeSAE J744-101-2

9.7

46146

101.6h70 -0.035

ISO Type

FlangeISO 3019/2-100A2HW

140

100h8

0 -0.054

52

9+ 0.50

SAE Spline Shaft

SAE "B-B" 30 Involute Spline ShaftSAE J744-25-4 15T 16/32 DP

o

24.981

38

33

SAE Straight Shaft

38

32

M8

1925

SAE "B-B" Straight ShaftSAE J744-25-1

28.1

0.13

25.4

0 -0.05

6.35+0.03

0

ISO Straight Shaft

M8

Shaft endISO 3019/2-G25N

42

36

1925

280 -0.3

25j6+0.009

-0.004

80 -0.036

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K3VL45 Rear Port Option

Tair

Dr

231

73

89

B

PL (PC)

See PortDetails

See PortDetails

28 47

26.2 0.235.7 0.2

52.4

0.2

25

B A

69.8

0.2

38

PL (PC)

K3VL45 Port DetailsMain SAE Flanged Ports

Des. Port Name Port SizeTighteningTorque(Nm)

Flange Threads

UNF Threaded Version ("S" in position 9 of model code)

A Delivery Port SAE J518C Std pressure (code 61) 1" 57 3/8-16UNC-2B x 18mm

B Suction Port SAE J518C Std pressure (code 61) 1 1/2" 98 1/2-13UNC-2B x 22mm

Metric Version ("M" in position 9 of model code)

A Delivery Port SAE J518C Std pressure (code 61) 1" 57 M10 x 17

B Suction Port SAE J518C Std pressure (code 61) 1 1/2" 98 M12 x 20

Auxiliary Ports


SAE Version ("S", "K" or "T" in position 8 of model code)

Dr Drain Port (x2)SAE J1926/1 Straight thread O ring boss1/2"OD Tube 3/4-16UNF-2B

98

PLPC

Load Sensing PortPressure Control Port

SAE J1926/1 Straight thread O ring boss1/4"OD Tube 7/16-20UNF-2B

12

Tair Air Bleeder PortSAE J1926/1 Straight thread O ring boss1/4"OD Tube 7/16-20UNF-2B

12

ISO Version ("M" in position 8 of model code)

Dr Drain Port (x2) M22 x 1.5 DIN 3852 98

PLPC


M14 x 1.5 DIN 3852 25

Tair Air Bleeder Port M14 x 1.5 DIN 3852 25

x

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K3VL45 Through Drive Options

SAE "A" 30 Involute SplineSAE J744-16-4 9T 16/32 DP

o

244

Dr

TairB

8

30

6 - M10Depth 17

45o

PL (PC)

SAE "A" 2 holeSAE J744-82-2

106

Through Drive "A"

82.55+0.050

+0.020

Through Drive "B"

SAE "B" 2 holeSAE J744-101-2

PL (PC)

101.6+0.035

0

SAE "B" 30 Involute SplineSAE J744-22-2 13T 16/32 DP

o 11

47

4 - M12Depth 20

146

45o

264

Tair

Dr

B

Through Drive "B-B"

SAE BB 2 holeSAE J744-101-2

PL (PC)

SAE "B-B" 30 Involute SplineSAE J744-25-2 15T 16/32 DP

o 11

47

4 - M12Depth 20

146

45o

101.6+0.035

0

BTair

Dr

264

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K3VL45 Adaptor Kits

Cover KitSAE "A"T/D Kit

SAE "B" & "BB"T/D Kit

402

314

743

116

743

317

116

743

742415

743 O-Ring 1 00RBG85 00RBG85 00RBG85742 O-Ring 1 --------- --------- 00RBG105 00RBG105415 Screw hex SHC 4 --------- --------- 0SBM825 0SBM825402 Screw hex SHC 2 0SBM1020 --------- --------- ---------317 Subplate 1 --------- --------- 2924750-0358314 Cover 1 2923150-0316 --------- --------- ---------116 Coupling 1 --------- 2903150-0264 2903150-0265 2903150-0266

No Part Name Qty Cover KitSAE "A"T/D Kit

SAE "B"T/D Kit

SAE "BB"T/D Kit

--- T/D Kit 29L8TN 29L4TA 29L4TB 29L4T200RBG85

2924750-0358

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K3VL80 Installation DrawingK3VL80 with Cut-Off / Load Sense Control& Torque Limit Module (Clockwise Rotation)

18262

98

91

181

11914

See Torque Limit Detailand Adjustment

PL(PC)

AB

A

B

PL(PC)

Dr

Dr

164

79

85

99

85

79

52.4

0.2

26.2 0.2

25

95217

35

Adjustment screw forcut-off pressure

Adjustment screw fordifferential pressure

See PortDetails

PL(PC)

DrA

PL(PC)

155

17.5

17.5

Dr

Dr

Tair

45 o

45 o

Adjustment screw forhorsepower setting

PL(PC)

42.9 0.3

Tair

77.8

0.3

See PortDetails

See Maximum FlowAdjustment detail

50L

B

Dr

217260

1895

2

114

35


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K3VL80 Mounting Flange & Shaft Options

35

0-0.3

35.2

0 -0.3

31.75h70-0.025

7.94+0.022

0

M8

SAE C Straight ShaftSAE J744-32-1

1925

44

48

SAE Straight ShaftSAE Spline Shaft

ISO Straight Shaft

ISO TypeSAE Type

48

43

31.224

SAE C 30O Involute Spline ShaftSAE J744-32-4 14T 12/24 DP

Shaft End - ISO 3019/2-G32N

M12

2838

58

504

125h80-0.063

10h9

0-0.036

32k6

+0.018

+0.002

FlangeISO 3019/2-125A2HW

9 + 0.50

68180

181

SAE C 2 holeSAE J744-127-2

56

12.70- 0.5

1270-0.05

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K3VL80 Rear Port Option

239

PL(PC)

Tair

Dr

98

79

PL(PC)

2550

52.4

0.2

77.8

0.3

See PortDetails

See PortDetails

26.2 0.2

57

42.9

30

B

A

K3VL80 Port DetailsMain SAE Flanged Ports


Flange Threads


A Delivery Port SAE J518C Std pressure (code 61) 1" 57 3/8-16UNC-2B x 18mm

B Suction Port SAE J518C Std pressure (code 61) 2" 98 1/2-13UNC-2B x 22mm


A Delivery Port SAE J518C Std pressure (code 61) 1" 57 M10 x 17

B Suction Port SAE J518C Std pressure (code 61) 2" 98 M12 x 20

Auxiliary Ports



Dr Drain Port (x2)SAE J1926/1 Straight thread O ring boss1/2"OD Tube 3/4-16UNF-2B

98

PLPC



12


12


Dr Drain Port (x2) M22 x 1.5 DIN 3852 98

PLPC


M14 x 1.5 DIN 3852 25


x

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K3VL80 Through Drive Options

Through Drive "A"

Through Drive "B"

Through Drive "B-B"

Through Drive "C"

SAE B 2 holeSAE J744-101-2

SAE A 2 holeSAE J744-82-2



6-M10Depth 17

4-M12Depth 20

4-M16Depth 24.5

4-M12Depth 20

1147

292

Tair

Dr

PL (PC)

B

101.6

+0.035

045

o

146

SAE BB 30 Involute SplineSAE J744-25-4 15T 16/32 DP

o

PL (PC)

Dr

PL (PC)

PL (PC)

Dr

181

146

106

SAE C 30 Involute SplineSAE J744-33-4 14T 12/24 DP

o

SAE B 30 Involute SplineSAE J744-22-4 13T 16/32 DP

o

SAE A 30 Involute SplineSAE J744-16-4 9T 16/32 DP

o

8

33

TairB

45o

45o

45o

272

82.55+0.035

0

101.6

+0.035

0

127+0.035

0292

11

47

Tair

Dr

B

296.5

14

53

TairB

K3VL Marketing Kit

Page 136 of 165


K3VL80 Adaptor Kits

No Part Name Qty Cover KitSAE "A"T/D Kit

SAE "B"T/D Kit

SAE "BB"T/D Kit

--- T/D Kit 29L8TN 29L8TA 29L8TB 29L8T2 29L8TC743 O-Ring 1 00RBG85 00RBG85 00RBG85 00RBG85 00RBG85742 O-Ring 1 --------- --------- 00RBG105 00RBG105 00RBG130415 Screw hex SHC 4 --------- --------- 0SBM1025 0SBM1025 0SBM1030402 Screw hex SHC 2 0SBM1020 --------- --------- --------- ---------317 Subplate 1 --------- --------- 2924750-0354 2924750-0354 2924750-0355314 Cover 1 2923150-0316 --------- --------- --------- ---------116 Coupling 1 --------- 2903150-0241 2903150-0262 2903150-0267 2903150-0263

SAE "C"T/D Kit

Cover KitSAE "A"T/D Kit

SAE "B", "BB" & "C"T/D Kit

402

314

743

116

743

317

116

743

742

415

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Page 137 of 165


K3VL112/140 Installation DrawingK3VL112/140 with Cut-Off / Load Sense Control& Torque Limit Module (Clockwise Rotation)

15219

224

125

77

PL(PC)

PL(PC)

152

DRTair B

DR

100

100 124

A

Dr

See Maximum DosplacementAdjustment Detail

63

Adjustment screw forHorsepower setting

L

140

22106.5

250

200

See PortDetails

30

Tair Dr

Tair

Dr

PL (PC)

98.5103

113.3

103

113.3

Adjustment screw forcut-off pressure Adjustment screw for

differential pressure

32

See PortDetails

106.5250

30

DrA

PL (PC)

66.7

0.3

31.8 0.3 50.8 0.388.9

0.3


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Page 138 of 165


K3VL112/140 Mounting Flange & Shaft Options

SAE Straight ShaftSAE Spline Shaft

ISO Straight Shaft

ISO TypeSAE Type

SAE D 30O Involute Spline ShaftSAE J744-44-4 13T 8/16 DP

FlangeISO 3019/2SAE D 4 hole

SAE J744-152-44- 20 through

161.6

161.6

180h80-0.063

152.4h70-0.063

12.70- 0.5 4- 18 through

224

45 o992

SAE D Straight ShaftSAE J744-44-1

7/16-14UNC-2B

2838

1.5 80

11.11+0.030

+0.015

44.447

67

60 63

67

49.3

0.13

44.45h70 -0.025

45k6+0.018

+0.002

M16Shaft endISO 3019/2

3648

48.5

14h90 -0.043

K3VL Marketing Kit

Page 139 of 165


K3VL112/140 Rear Port

K3VL112 & 140 Port DetailsMain SAE Flanged Ports


Flange Threads


A Delivery Port SAE J518C high pressure (code 62) 1 1/4" 98 1/2-13UNC-2B x 22mm

B Suction Port SAE J518C Std pressure (code 61) 2 1/2" 98 1/2-13UNC-2B x 22mm


A Delivery Port SAE J518C high pressure (code 62) 1 1/4" 157 M14 x 19

B Suction Port SAE J518C Std pressure (code 61) 2 1/2" 98 M12 x 17

Auxiliary Ports



Dr Drain Port (x2)SAE J1926/1 Straight thread O ring boss3/4"OD Tube 1 1/16-12UN-2B

167

PLPC



12


12


Dr Drain Port (x2) M27 x 2 DIN 3852 167

PLPC


M14 x 1.5 DIN 3852 25


x

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Page 140 of 165


K3VL112/140 Through Drive OptionsThrough Drive "A"

SAE A 2 holeSAE J744-82-2

Tair 106

SAE A 30 Involute SplineSAE J744-16-4 9T 16/32 DP

82.55+0.035

0

307.5

8

31

B

Dr

45 o

6-M10Depth 17

Through Drive "B"

Through Drive "BB"


SAE B 2 holeSAE J744-101-2

SAE BB 30 Involute SplineSAE J744-25-4 15T 16/32 DP

101.6

+0.035

0

101.6

+0.035

0

Dr

Dr

146

45 o

146

45 o

B

Through Drive "C"

Tair

332.5SAE B 30 Involute SplineSAE J744-22-4 13T 16/32 DP

o

11

53

6-M12Depth 25

o332.5

11

53

6-M12Depth 25

Tair

B

181

45 o

6-M16Depth 30

SAE C 30 Involute SplineSAE J744-33-4 14T 12/24 DP

o

127+0.035

0

Dr


B

Tair

337.5

14

58

Through Drive "CC"

181

45 o

6-M16Depth 30

SAE CC 30 Involute SplineSAE J744-38-4 17T 12/24 DP

o

127+0.035

0

Dr

SAE CC 2 holeSAE J744-127-2

B

Tair

337.5

14

59

Through Drive "D"

4-M16 Depth 43

SAE D 30 Involute SplineSAE J744-47-4 13T 8/16 DP

o

152.4+0.035

0

Dr

SAE D 4 holeSAE J744-152-2

B

Tair

15

71350.5161.6 0.2

161.6

0.2

K3VL Marketing Kit

Page 141 of 165


K3VL112/140 Adaptor Kits

Part Name Qty Cover KitSAE "A"T/D Kit

SAE "B"T/D Kit

SAE "BB"T/D Kit

--- T/D Kit 29L8TN 29LHTA 29LHTB 29LHT2743 O-Ring 1 00RBG85 00RBG85 00RBG85 00RBG85742 O-Ring 1 --------- --------- 00RBG105 00RBG105415 Screw hex SHC 4 --------- --------- 0SBM1230 0SBM1230402 Screw hex SHC 2 0SBM1020 --------- --------- ---------317 Subplate 1 --------- --------- 2924750-0360 2924750-0360314 Cover 1 2923150-0316 --------- --------- ---------116 Coupling 1 --------- 2903150-0268 2903150-0269 2903150-0270

No

Part Name QtySAE "C"T/D Kit

SAE "CC"T/D Kit

SAE "D"T/D Kit

--- T/D Kit 29LHTC 29LHT3 29LHTD743 O-Ring 1 00RBG85 00RBG85 00RBG85742 O-Ring 1 00RBG130 00RBG130 00RBG150415 Screw hex SHC 4 OSBM1235 0SBM1235 0SBM1250402 Screw hex SHC 2 --------- --------- ---------317 Subplate 1 2924750-0361 2924750-0361 2924750-0362314 Cover 1 --------- --------- ---------116 Coupling 1 2903150-0271 2903150-0272 2903150-0273

No

Cover Kit

402

314

743

116

743

SAE "A" T/D Kit SAE "B" T/D Kit

116

743

317

742

415

SAE "B-B" T/D Kit

317

116

743

742

415

317

116

743

742

415

SAE "C" T/D Kit

317

116

743

742

415

SAE "C-C" T/D Kit

317

116

743

742

415

SAE "D" T/D Kit

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Page 142 of 165


K3VL200 Installation Drawing

K3VL Marketing Kit

Page 143 of 165


Unloader & Proportional Pressure Pilot Installation

type V - proportional pressure module

A BK3VL45 179 233K3VL80 179 244K3VL112 212 280K3VL140 212 280

A

B

PC (PL) Kawasaki RDPV module used

Specification

maximum Pressure 350 bar

maximum tank pressure 10 bar

maximum flow rate 3 L/minhysterisis <2%linearity <5%amplifier type KC-B10-10/C-B10-Apower supply 24V DCpilot voltage 0 ~ 5 volt

A

B

PL (PC)

A BK3VL45 169 155K3VL80 169 166K3VL112 202 190K3VL140 202 190

Sun DAAA-MCN cartridge used

Specification

maximum pressure 350 bar

peak pressure 420 bar

rated flow rate 1 L/minmaximum leakage 0.7 L/mim @ 350 barsolenoid power 12 Wtypical response time 30 msmanual overide force 36 N (@70 bar)

type N - unloading valve module

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Page 144 of 165


Pump Sensitivity

Listed below are the defined pump sensitivities of:

Maximum Displacement Stop

Direct Acting Pressure Limiter Spool Spring

Differential Pressure Spool

Sensitivity (per turn)AdjustmentLocation

UnitFrame Size

45 80 112 140Maximum Displacement

Cut-Off SpoolDifferential Spool

barbar

cc/rev80 9213 5.5

4.9 6.2 11.5 12.0

Cut-off PressureAdjustment Screw

Lock-nuts(Tightening Torque 16 Nm)

Differential PressureAdjustment Screw

Lock-nut(Tightening Torque 128 Nm)

Maximum DisplacementAdjustment Screw

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Page 145 of 165


Outer Spring Lock-nut

Inner Spring Adjustment Screw

Inner Spring Lock-nut

Outer Spring Adjustment ScrewPumpFlow

Delivery Pressure

Torque Limit P-Q Curve

Outer Spring Adjustment

Outer Plus InnerSpring Adjustment

K3VLTorque Limiter Control

Torque Limit Control Module Adjustments

Outer Spring Adjustment Screw: External Hex Size mm 27Outer Spring Lock-nut Size mm 41Outer Spring Lock-nut Tightening TorqueInner Spring Adjustment Screw: Internal Hex Size mm 4Inner Spring Lock-nut Size mm 13Inner Spring Lock-nut Tightening Torque Nm

Nm 59

16

K3VL Marketing Kit

Page 146 of 165


Torque Limiter Settings

The following tabulations show the power limitation at various electric motorspeeds for a specific pump. When selecting a control setting please ensurethat the power limitation of a particularly sized electric motor to your nationalstandard is not exceeded.

970 rpm 1150 rpmPower Pump Frame Size Power Pump Frame Size(KW) 45 80 112 140 (KW) 45 80 112 1405.5 L3 7.5 L27.5 L1 L6 11 M3 L4

11 M1 L2 15 H4 L1 L415 H3 M4 L3 L6 18.5 H2 M3 L2 L518.5 M1 M4 L3 22 M1 M4 L322 H3 M2 L1 30 H2 M1 M3

30 H1 H4 M2 37 H3 M137 H2 H4 45 H2 H445 H2 55 H2

1450 rpm 1750 rpmPower Pump Frame Size Power Pump Frame Size(KW) 45 80 112 140 (KW) 45 80 112 140

7.5 L4 11 L211 L1 L6 15 M4 L515 M2 L3 18.5 M2 L3

18.5 H4 L1 L4 22 H4 L1 L422 H3 M4 L3 L6 30 H1 M2 L1 L430 H4 M3 L2 37 H4 M3 L237 H2 M1 M3 45 H2 M1 M3

45 H1 H4 M2 55 H1 H4 M255 H2 H4 75 H1 H375 H1 90 H1

K3VL Marketing Kit

Page 147 of 165

11. Literature

Product Data sheets and a Capability Brochure are now under preparation forthis product introduction. Initially they will be available in English and inelectronic (PDF) format.

Provisional Press Release material is also being prepared.

Finally a Presentation pack including both Freelance and Powerpoint formatswill become available soon.

All this material including where available DXF installation drawings will bepackaged on a CD for general usage.

K3VL Marketing Kit

Page 148 of 165

12. Appendix

12.1 K3VL Checklist (to be filled in for each OEM application)

KE No (provided by KPM)

K3VL Checklist Pump Type (K3VL 45, 80, 112 or 140)

Date

Customer NameCustomer Model Description (machine designation)

Application TypeDate for Prototype Delivery

Quantity for Prototype DeliveryDate for Mass Production

Annual QuantityDistributor

Distributor Contact

Pump Settings (where applicable)

Displacement (cc/rev)Rated Pressure (bar)Rated Speed (rpm)

High Idle Speed (rpm)Direction of Rotation (CW or CCW)

Input Power (kW)Maximum Input Torque (Nm)

Mounting Flange (SAE or ISO)Input Shaft End (define)

Through Drive Shaft (define)

System Conditions (where applicable)

Oil TypeOperating Temperature (Deg C)

Oil Viscosity Grade (ISO VG)Controls Settings (where applicable)

Pressure Cut Off (bar) (Factory setting is 320 bar)

Pressure Compensator (bard) (Factory setting is 15 bard)

Load Sensing (bard) (Factory setting is 15 bard)

Unload, Solenoid Voltage (volts)Torque Limit Setting (kW)

Notes (please define all particular needs related to this application)

For Internal Use OnlyDate

Signature

Distributor Price

K3VL Marketing Kit

Page 149 of 165

12. Appendix (cont.)

12.2 SPR Form

Special Price Request Form SPR No:

please complete as fully as possible

Distributor Name:

Locat ion:

Cont act or Refe rence:

KPM A/ C No:

Tick

boxMultinational:

National:Customer Name:

Locat ion:

ProductModel:

Descr ip tion

Mode l Code / Assy No :

Requ ired Quan tities: per delive ry & / or per y ear

Pricing Existing Distr ibut or Price:

Requested Distr ibut or Pr ice:

Propos ed Se lling Price:

RequiredPayment terms:

Justification

Signatu re:

KPM Feedback Reason (s) fo r reject ion:

Re ject ed:

Acc ept ed: O rder No: Dat ed:

on beha lf of KPM(UK) Ltd

Signa ture:

Da te:

Da te:

Va lidUn til / /

Please complete asfullyas

possible,notingif existing or New

Market or Customer, the

Competitor, their product and

known pricingetc....

>>>>>

Tickbox

>>>>>

/ /

Dist ribu tor KPMVa lue of existing... .busines s with :

per annum

Es tima ted busines s.... ava ilable to :

per annum

per annum

per annum

allocatedby KPM

complete only if non standard

/ /

/ /

One SPR for eachproduct please

KE No:

K3VL Marketing Kit

Page 150 of 165


12.3 K3VL Production Test Summary

Each pump has its own discrete Serial Number for which record sheets will beretained at KPM

The general procedure is as follows:

1. Running InMin ~ 320 bar, 2000 rpm for 15 minutes

2. Performance Test & Regulator Settinga) set regulator(s)b) plot P v Q performance curvec) compare to master curve to ensure within tolerance.d) measure input torque, pressure and output flow at various

conditionse) check overall efficiency - must typically meet 88% overall

efficiency at 200 bar conditionf) check for dynamic stability at varying flow and pressure

conditions3. Check for Oil Leaks4. Repeat Maximum Flow Test5. Check for Case Drain debris6. Stamp Nameplate

Typical Test Result Sheet:

0 100 200 300 400

0

100

200

300

DELIVERY PRESSURE Pd kgf/cm

FLOWRATEQL/min.

Pd = 20.4

Q = 159 +/- 3

Pd = 306

Q = 141 Min.

Pd = 327 + 0 / - 15.3

(Pd = 0, Q = 160 )

FOR PD = 70 kgf/cm P =Pd - Pc = 15 kgf/cm

KAWASAKIPRECISIONMACHINERY(UK)LTD.

CURVENO.:KPM00065-1Rev.A

TITLE:

OPERATINGPROCEDURE&ACCEPTANCESPECIFICATION

K3VL80/A*1*****

-**

SIGNATURE:

DATE:

01.09.00

PAGENO.

1OF2

REVISIONNO.:

ACHANGENOTENO.:PM00/003

DATE:

01.09.00

KHIAPPROVAL:

DATE:

CUSTOMER'S NAME: RESULT OF TEST TEST SPEC. NO.: KPM00065

USED ON: CURVE NO.: KPM00065 - 1 Rev. A

TYPE: K3VL80/A * 1 ***** - P0 ( ) INDICATES REFERENCE DATA

(Pd = 327)

(Q = 152)

SPECIFIED OPERATING SPEED 2000 RPM.

ACTUAL OPERATING SPEED: RPM.

nb. FLOW IS PROPORTIONAL TO SPEED.

K3VL Marketing Kit

Page 151 of 165


12.4 Model Code to Part Number Transformation

K3VL Marketing Kit

Page 152 of 165

12. Appendix

12.5 Exploded Views - Pump

530

531

548*

537

536

535

467 728

901

3x490

711

538

824

127

123

127

111

774

710

261

4x406

030

271

729 465

011 9x151

153

9x152

211

214

212

Seedetail

ofthepressure

controlregulator

3x490

534

702

532

703

3x706

792

884

A

B

C

A

B

Seedetailofthe

torquelimiter

402

808

954

C

901

4x401

885

886

312

719

9x157

141

313

124

013

156

981 2x983728 467

116

743

317

4x415742

ThroughDriveKit

251

K3VL Marketing Kit

Page 153 of 165

12. Appendix

12.6 Exploded Views - Controls

670611670

622624

625626

627703

621

601

4x412

660671

701

702

628630801924

660650

705705

706

704614

680

643(644)

802645

702626

629628704

624647

644802

646

703627705631

630625 647(648)

6015x701

491490492490

2x4232x701

6x490

422706

494490

4x411

K3VL Marketing Kit

Page 154 of 165


12.7 KC-B10-10 Proportional AmplifierDocument number KG300010

Revision date 17/9/99

Kawasaki Proportional Amplifier

KC-B10-10

Specification

K3VL Marketing Kit

Page 155 of 165


12.7 KC-B10-10 Proportional Amplifier (cont.)

Before using this product please read this manual and make yourself aware of thevarious features.

Contents

Section Page

I. Features.............................................................. 163

II. Model code and part number............................... 163

III. Specifications...................................................... 163

IV. EMC considerations............................................ 164

V. Electrical installation............................................ 164

VI. Supply fuse removal............................................ 164

VII. Adjustment location............................................. 165

VIII. Adjustment procedure......................................... 165

Dither........................................................ 165

Bias and Gain........................................... 167

Ramp........................................................ 168

IX. Connection layout................................................ 169

X. Installation dimensions......................................... 170

XI. Abbreviations used .............................................. 171

K3VL Marketing Kit

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I. FeaturesCompact and light weight design.Ramp function.Easy installation and adjustments.Pulse width modulated output for good response, resolution andreduced heat effect.CE Marked.

II. Model code and part numberModel code: KC-B10-10Part number V9703110408

III. Specifications.Current control pulse width modulated 50 ~ 250Hz adjustable.Supply input voltage 24V DC +/- 20%Command input signal voltage 0 ~ 5V DC, Max.7.5V DCRated output current 0.8A (at 5V DC signal input)Maximum output current 1.2APower requirement Maximum 20VALoad resistance 14 ~ 21Input impedance 100K

Ambient temperature range 0 ~ + 50odegree Celsius

Maximum humidity 90% RH (No dew permissible)Vibration resistance to JIS C50250 Amplitude 1.5 mmp-p,

(to JIS C50250, Type A Frequency 10 ~ 55 HzInsulation 100M minimum at 500V DCCurrent monitor output 0.47V/1AMass 90gGain adjustment range 0.8A +/- 0.2A at 5V input.Bias adjustment range 0 ~ 0.24ARamp time adjustment range 0.1~5s for ramp up from 0~0.8 A

0.1~5s for ramp down from 0.8~0 ALinearity Up to 2% FSCurrent stability Up to 1.5% FS

(ambient temperature change 50oC)

Up to 2% FS(for supply voltage change +/-20%)

Up to 2% FS(load resistance change 14 ~ 21 )

Supply fuse 3.2 A Anti surge plugtype PCB mounted.

For Kawasaki proportional valve types which can be used with this amplifierplease see figure 5 page 157 for details.

K3VL Marketing Kit

Page 157 of 165



IV. EMC considerations

To meet the CE requirements all cables should be screened.The screen should be earthed correctly at the instrument or control panelonly. Fig 8 shows a typical layout.

V. Electrical installation

See fig 1 for actual location of the connections.

Power supply input, terminals [0V] and [24V].The 0 V of power source and 0 V of signal input must be separatelyconnected.

Signal inputCommand signal input voltage between terminals (SIG) and [0V].

OutputConnect a solenoid between output terminals marked solenoid.The solenoid has no polarity.

VI. Supply fuse removalThe supply fuse can be removed by gently pulling the fuse outwards from theamplifier panel.Note: This device does not have short circuit protection.If the solenoid output terminals are shorted together, this will result inpermanent damage to the amplifier.Replacement of the amplifier will be necessary.

Fuse+ve Supply

"0" Volt Supply+ve Signal

"0" Volt Signal

PowerIndicatingLamp

Solenoid Output

Fig 1

K3VL Marketing Kit

Page 158 of 165



VII. Adjustment location

Ramp Down FunctionClockwise to Increase

Ramp Up FunctionClockwise to Increase

Monitor Test Point

Gain

Bias

See Fig 4 Dither Adjustment

Fig 2

VIII. Adjustment procedure

Dither adjustment

The oscillation of PWM (Pulse width modulated control) operates at the samefrequency as the dither.

The approximate dither adjustment range is from 50Hz to 250Hz.

Fig 3 shows the typical dither effect on the mean value of the amplifier output.

Fig 4 shows the typical potentiometer adjustment position in relation to theapproximate frequency.

PWM F = 50 ~ 250 Hz1T

Current(mamps)

Mean Output Value

Amplitude

T

Fig 3

K3VL Marketing Kit

Page 159 of 165



VIII. Adjustment procedure (cont.)

Example:Potentiometer position Number 6 equals 80Hz

Potentiometer Position

0 1 2 3 4 5 6 7 8 9 100

50

80100

250

200

300

AdjustmentRange(Hz)

Fig 4

See Fig 5 for the actual setting required in relation to the proportional valvetype being used.

ProportionalValve Model

Optimum DitherFrequency (Hz)

Proportional Relief RDPV5 200Proportional Relief RBP10~35 200ProportionalReducer

PRBP10~30 200

K3VG Type "E"Control

KDRDE5K-20 80

ProportionalReducer

KDRDE5K-30 80

Application

Fig 5

K3VL Marketing Kit

Page 160 of 165




Bias adjustmentThe Bias adjustment is located as in Fig 2, it allows the output of the amplifierto be non-zero for zero input voltage.Fig 6 shows the effect of the Bias adjustment.

Volts 5

1.2

0.24

1.0 A

0.8 A

0.6 A

0Current(Amps)

0

Bias

Gain

Fig 6

Gain adjustment

This adjustment will allow the output of the amplifier to be spanned over agiven range for a maximum input to the amplifier.Fig 6 shows the effect of the Gain adjustment.When an adjustment is made to either the Gain or the Bias it will benecessary to check each of the settings after any adjustment.By adjusting the Gain and Bias it is possible to achieve the best sensitivity fora given amplifier input.To enable accurate setting of the Gain and Bias it is possible to use thefollowing procedure.

Use a voltmeter with input impedance of over 10K and measure the voltagebetween terminals CP+ and 0V. (See Fig 2 for location of the connections.)The current can then be calculated by the equation as shown below.

CURRENT (A) = MEASURED VOLTAGE (V) / 0.47Use an analogue volt meter for the above measurement, this will serve toeliminate thevoltage fluctuation which will be seen if using a digital meter.

At the same time as measuring the above condition, measure the inputvoltage to the amplifier with another voltmeter this will serve to speed up theprocess of setting up the Gain and Bias.

K3VL Marketing Kit

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Ramp function adjustment.

The ramp up or ramp down time can be adjusted individually. See Fig 2 forthe location of the ramp adjustments.Fig 7 shows the effect of the Ramp adjustment.

Time (Seconds)5 Sec Max.

5 Sec Max.

Up Down

Current(Amps)

Ramp Effect

Step Input

Volts

Time (Seconds)

Fig 7

As can be seen for a given step input to the amplifier the output of theamplifier can be adjusted to give a gradual step response.

K3VL Marketing Kit

Page 162 of 165



IX. Connection layout

Fig 8 shows a typical layout for the amplifier connections and user electricalcabinet.It is recommended that screened braided cables are used for all cable runs,with the screen connected to an efficient earth ground point as shown.

Other

Electrical

Equipment

Other

Electrical

Equipment

360 Degree Gland Connection

Braided Screen Cable

Solenoid Coil Ground Point





User Electrical Cabinet

Power Supply+ ve0 Volt

Signal Input+ Sig0 Volt

Fig 8

K3VL Marketing Kit

Page 163 of 165



X. Installation dimensions

0.8

12.0

20.0

5.0

11.05

124.0

R2.519.5 19.5

39.0

5.05.0

11.0

Fig 9 sizes in mm.

Note:Specifications are subject to change with or without notice owing toimprovements that may be introduced after publication of this manual.

K3VL Marketing Kit

Page 164 of 165



XI. Abbreviations used

Frequency Hz (Hertz or cycles / second)

Direct current DC

Voltage V

Amperes A

Milli Amp mA

Relative humidity RH

Millimetre peak to peak mmp-p

Gram g

Full scale FS

Seconds s

Mega M

Volts Amps VA

Kilo k

Resistance

Printed circuit board PCB

K3VL Marketing Kit

Page 165 of 165

13. Index

Applicational PrecautionsContamination Sensitivity ____________103Drive Shaft Connection______________104Filtration _________________________103Fluids ___________________________105General __________________________100Pump Start Up ____________________107Through Drive Limitations____________108Viscosity & temperature Range _______106

Checklist __________________________151Commercial InformationGeneral __________________________109

Competitor OfferingsGeneral __________________________120Rexroth __________________________121Rexroth Xref ______________________124Vickers __________________________126

Control Performance CharacteristicsK3VL112__________________________96K3VL140__________________________98K3VL45___________________________92K3VL80___________________________94Theoretical ________________________89

Development Targets__________________6Exploded ViewsControls _____________________154, 156Pump ___________________________155

Features & BenefitsBearing Life Principles _______________24General ___________________________14Mindmap__________________________15Opposed Stroking Pistons ____________23Pillow Type Swash Plate _____________22Piston Return Mechanism ____________16Resonator _________________________20Sine Wave Plate ____________________19Solid Pistons_______________________17Spherical Valve Plate ________________18

Focus Market Segments _____________111Frequently Asked Questions _____ 113-119General Description____________6, 7, 8, 10HistoryHele-shaw pump_____________________4K3V series _________________________5K3VG series ________________________5KV series _________________________ 4L series ____________________________4NV series __________________________4Screw Pump ________________________4Timeline ___________________________5

Installation Drawings________________130Introduction _________________________3Leadtimes _________________________109Literature__________________________150Market Trends______________________110Model Coding _______________________10Model Range_________________________7Part Number Transformation _________154Product Positioning_________________110Production Testing _________________153Proportional Amplifier Specification ___157

Pump Performance CharacteristicsBearing Life - K3VL112 ______________36Bearing Life - K3VL140 ______________37Bearing Life - K3VL45 _______________34Bearing Life - K3VL80 _______________35Bearing Life - Partial Displacement _____38Bearing Life (Industrial) - K3VL112 _____40Bearing Life (Industrial) - K3VL140 _____40Bearing Life (Industrial) - K3VL45 ______39Bearing Life (Industrial) - K3VL80 ______39Efficiency - K3VL112 ________________28Efficiency - K3VL140 ________________29Efficiency - K3VL45 _________________26Efficiency - K3VL80 _________________27General___________________________25Noise Levels - K3VL112______________43Noise Levels - K3VL140______________44Noise Levels - K3VL45_______________41Noise Levels - K3VL80_______________42Pressure Pulsation - K3VL112_________43Pressure Pulsation - K3VL140_________44Pressure Pulsation - K3VL45__________41Pressure Pulsation - K3VL80__________42Radial Loading - K3VL112 ____________36Radial Loading - K3VL140 ____________37Radial Loading - K3VL45 _____________34Radial Loading - K3VL80 _____________35Self Priming - K3VL112 ______________33Self Priming - K3VL140 ______________33Self Priming - K3VL45 _______________32Self Priming - K3VL80 _______________32Theoretical Power - K3VL112 _________31Theoretical Power - K3VL140 _________31Theoretical Power - K3VL45 __________30Theoretical Power - K3VL80 __________30

Pump Sensitivity ___________________147Pumping Action _____________________13Rotating Group______________________11Selling Strategy ____________________109Special Price Request _______________152Specifications________________________8Swash Plate Group __________________12Technical DescriptionControls __________________________45L0 Type __________________________62L0/1 Type _________________________81L1 Type __________________________67LN Type __________________________68LN/1 & LV/1 Types __________________85LV Type __________________________72P0 Type __________________________48P0/1, PN/1 & PV/1 Types_____________77PN Type __________________________57Pump ____________________________11PV Type __________________________59Remote Pilot Selection_______________56Torque Limiter _____________________75

Through Drive Options _______________13Torque Limiter Settings___________76, 149Valve Cover Group___________________12

Documents

Copy of K8724 K3VL Marketing Kit - MCR-28€¦ · The K3V series of swash plate piston pumps was developed from the NV series specifically for the earth moving and construction Industry