Download  Print this page

Kawasaki K3V112DT Instruction Manual

Hide thumbs

Advertisement

RETURN TO INDEX
K3V112DT
INSTRUCTION
MANUAL
KAWASAKI PRECISION MACHINERY OF AMERICA
TH
5080 36
Street S.E.
Grand Rapids, MI 49512
www.kawasakipmd.com
Date: July 2004

Advertisement

Table of Contents
loading

  Related Manuals for Kawasaki K3V112DT

  Summary of Contents for Kawasaki K3V112DT

  • Page 1 RETURN TO INDEX K3V112DT INSTRUCTION MANUAL KAWASAKI PRECISION MACHINERY OF AMERICA 5080 36 Street S.E. Grand Rapids, MI 49512 www.kawasakipmd.com Date: July 2004...
  • Page 2: Table Of Contents

    K3V112DT Instruction Manual CONTENTS PAGE SPECIFICATIONS 1.1. Installation 1.2. Porting Identification 1.3. General Specifications 1.4. Regulator Characteristics 1.5. Cross Sectional Drawings 1.6. Hydraulic Schematic CONSTRUCTION and FUNCTIONS 2.1. Pump Construction 2.1.1 Rotating Group 2.1.2 Swash Plate Group 2.1.3 Valve Cover Group 2.2.
  • Page 3: Specifications

    K3V112DT Instruction Manual 1. SPECIFICATIONS 1.1. Installation 1.2. Porting Identification Ref. Port Name Port Size Delivery Port SAE 6000 psi ¾” 1, 2 Suction Port SAE 2500 psi 2 ½” Drain Port G ¾ - 20 Pilot Port G ¼ - 15...
  • Page 4: General Specifications

    K3V112DT Instruction Manual Specifications (cont.) 1.3. General Specifications 1.3.1. Pump Displacement :- 2 x 55 cc/rev Maximum Self Priming Speed :- 2,600 min Maximum Boosted Speed :- 3,000 min Actual Operating Speed :- 2,100 min Rated Pressure :- 320 bar...
  • Page 5 K3V112DT Instruction Manual Specifications (cont.) 1.3. General Specifications (cont.) 1.3.2. Pump Control Settings (Pump Speed 2,100 min Variable Power Shift Range :- 70 ~ 44 kW Two Stage Flow Control Flow Setting :- 2 x 95 L/min (@80 bar) Two Stage Flow Control Operating Pressure:- 38 bar Minimum Flow Rate:- 2 x 21 L/min (@80 bar) Negative Control Pilot Pressure Range:- 11.7 bar ~ 32.2 bar...
  • Page 6: Regulator Characteristics

    K3V112DT Instruction Manual Specifications (cont.) 1.4 Regulator Characteristics Negative Displacement Control Negative Control Pressure (Bar) Total Horsepower Control Pump Discharge Pressure (Bar) [P1&P2] 5 OF 39 June 2004...
  • Page 7: Cross Sectional Drawings

    K3V112DT Instruction Manual Specifications (cont.) 1.5. Cross Sectional Drawing 1.6. Hydraulic Schematic 6 OF 39 June 2004...
  • Page 8: Construction And Functions

    K3V112DT Instruction Manual 2.0 CONSTRUCTION and FUNCTIONS 2.1. Construction The components of the K3V pump can be divided into three sub-groupings: - Rotating Group - which provides the main rotary pumping action Swash Plate Group - to vary the pump’s delivery flow rate &...
  • Page 9: Swash Plate Group

    K3V112DT Instruction Manual 2. CONSTRUCTION and FUNCTIONS (cont.) 2.1. Construction (cont.) 2.1.2. Swash Plate Group This is composed of the swash plate (212), shoe plate (211), swash plate support (251), tilting bush (214), tilting pin (531) and the servo piston (532). The swash plate on the reverse side to the shoe location is of a cylindrical form which is “pillow”...
  • Page 10: Regulator Functions

    K3V112DT Instruction Manual 2.2. Regulator Functions 2.2.1. General Description The KR3 series regulators have been designed to give varied controlled options for the K3V series of axial piston pumps ideally suited to their application to excavator type systems. The control options covered are:...
  • Page 11 K3V112DT Instruction Manual 2.2. Regulator Functions (cont.) 2.2.1. General Description (cont.) 875A (531) PUMP The various lever and linkage arrangements within the regulator assembly are illustrated above. The main feedback lever is shown in the centre where the servo pivot (531) couples it to the servo piston.
  • Page 12: Torque Summation Control (Total Horsepower)

    K3V112DT Instruction Manual 2.2. Regulator Functions (cont.) 2.2.2. Torque Summation Control α α (531) PUMP (531) PUMP The above sections specifically show the Torque Summation Control with their necessary feedback mechanisms. These figures should be studied such that a general familiarisation of the mechanism is built up.
  • Page 13 K3V112DT Instruction Manual 2.2. Regulator Functions (cont.) 2.2.2. Torque Summation Control (cont.) Main Spool & Sleeve Metering α α α α α The following sequence will assist in understanding the operation. Pressure P1 is connected to the delivery port of the front pump section, whereas P2 is connected to the rear pump delivery port.
  • Page 14 K3V112DT Instruction Manual 2.2. Regulator Functions (cont.) 2.2.2. Torque Summation Control (cont.) Main Spool & Sleeve Metering α α α α α As the delivery pressure increases at P1 & P2 the Power Piston compresses the Power Spring Pack, the linear movement of the Power Push Rod causes the Power Lever to pivot around Fixed Pivot 1 towards the right.
  • Page 15 K3V112DT Instruction Manual 2.2. Regulator Functions (cont.) 2.2.2. Torque Summation Control (cont.) Main Spool & Sleeve Metering α α α α α This develops on the previous figure whereby this time the Servo Piston has now moved further to the right and closer towards minimum displacement.
  • Page 16 K3V112DT Instruction Manual 2.2. Regulator Functions (cont.) 2.2.2. Torque Summation Control (cont.) Main Spool & Sleeve Metering α α α α α This figure details a fall in delivery pressure, this time the Power Spring Pack releases and moves the Power Push Rod to the left of its previous position as the Power Piston force has now reduced due to the reduction in delivery pressure.
  • Page 17: Negative Control (Negacon)

    K3V112DT Instruction Manual 2.2. Regulator Functions (cont.) 2.2.3. Negative Displacement Control α α (531) PUMP (531) PUMP The above sections specifically show the Negative Displacement Control with its necessary feedback mechanisms. These figures should be studied such that a general familiarisation of the mechanism is built up.
  • Page 18 K3V112DT Instruction Manual 2.2. Regulator Functions (cont.) 2.2.3. Negative Displacement Control (cont.) Main Spool & Sleeve Metering α 37bar α α α α The following sequence will assist in understanding the operation. Pressure Pi is connected to negative control pressure signal.
  • Page 19 K3V112DT Instruction Manual 2.2. Regulator Functions (cont.) 2.2.3. Negative Displacement Control (cont.) Main Spool & Sleeve Metering α Pi Pi 37bar α α α α As the negative pressure control signal (Pi) increases the Displacement piston compresses the Displacement Spring, the linear movement of the piston causes the displacement Lever to pivot around Fixed Pivot 2 towards the left.
  • Page 20 K3V112DT Instruction Manual 2.2. Regulator Functions (cont.) 2.2.3. Negative Displacement Control (cont.) Main Spool & Sleeve Metering α 37bar α α α α This develops on the previous figure whereby this time the Servo Piston has now moved further to the right and closer towards minimum displacement.
  • Page 21 K3V112DT Instruction Manual 2.2. Regulator Functions (cont.) 2.2.3. Negative Displacement Control (cont.) Main Spool & Sleeve Metering α 37bar α α α α This figure details a fall in the negative control pressure, this time the Displacement Spring releases and moves the Piston to the left of its previous position as the Displacement Piston force has now reduced due to the reduction in control pressure.
  • Page 22: Disassembly And Assembly

    K3V112DT Instruction Manual 3. Disassembly and Assembly 3.1. General Precautions a. All hydraulic components are manufactured to a high precision. Consequently, before disassembling and assembling them, it is essential to select an especially clean place. b. In handling a main pump, pay full attention to prevent dust, sand, etc. from entering into it.
  • Page 23: Tools

    K3V112DT Instruction Manual 3.2. Tools Before disassembling the pump, prepare the following tools beforehand. Name of tool Quantity Size (mm) Vice mounted on bench 1 unit (soft jaws) Hexagon wrench Each 1 piece 4, 5, 6, 8 and 14 Socket wrench...
  • Page 24: Disassembly

    K3V112DT Instruction Manual 3.3. Disassembly 3.3.1 Before disassembling, spread rubber sheet, cloth or similar material over the overhaul workbench top so as to prevent parts from being damaged. Remove dust, rust and other contaminants from surfaces of the pump with cleaning oil.
  • Page 25 K3V112DT Instruction Manual 3.3.6. Lift the cylinder (141) out of the pump casing (271) straight over the drive shaft (111). Additionally extract the pistons (151), set plate (153), spherical bush (156) and cylinder springs (157) simultaneously. Take care not to damage any of the...
  • Page 26 K3V112DT Instruction Manual 3.3.9. Remove the shoe plate (211) and swash plate (212) from the pump casing (271). Repeat this sequence for both the rear and front pumps. 3.3.10. Tapping lightly on the external shaft end of drive shafts (111, 113) with plastic hammer, extract each drive shaft from it’s swash plate support.
  • Page 27 K3V112DT Instruction Manual 3.3.13. Remove the needle bearing (124) and spline coupling (114) from the valve block (312). Don't remove the needle bearing unless it definitely requires replacement. Don't loosen the hexagon stroke adjustment nuts of valve block or swash plate support. If loosened, the flow setting will be changed.
  • Page 28: Assembly

    K3V112DT Instruction Manual 3.4. Assembly Procedure 3.4.1. Fit the servo piston (532), tilting pin (531), stopper (L)(534) and stopper (S)(535) to the pump casing (271). In tightening the servo piston and tilting pin to the pump casing, use a protector to prevent the tilting pin head and feedback pin from being damaged.
  • Page 29 K3V112DT Instruction Manual 3.4.4. Install the bearing spacer (127) on to the drive shaft (111,113), and then next install the roller bearing (123) to this drive shaft. 3.4.5 Install the snap ring (824) onto the drive shaft (111,113). 3.4.6. Fit the drive shaft assembly...
  • Page 30 K3V112DT Instruction Manual 3.4.9. Install the cylinder springs (157), spacer (158) and spherical bush (156) onto the cylinder (141). Fit the pistons (151) and shoe (152) through the set plate (153). Repeat this sequence for both the rear and front pumps.
  • Page 31 K3V112DT Instruction Manual 3.4.11. Fit the splined phases of the retainer and cylinder sub-assembly into the pump casing. Repeat this sequence for both the rear and front pumps. If the needle bearing has been replaced then follow sequence 12. 3.3.12 2...
  • Page 32 K3V112DT Instruction Manual 3.4.14. Fit the valve block (312) to it’s p casing (271) , and tighten the hexagon socket headed bolts (401). Simultaneously install the O-Ring. Repeat this sequence for both the rear and front pumps. It is easiest to assemble the rear pump first.
  • Page 33: Maintenance Standards

    K3V112DT Instruction Manual MAINTENANCE STANDARDS 4.1. Part Inspection Part Name Inspection Item Criterion and Measurement Cylinder Existence of scratches, discoloration, hair In case of damage in these areas, replace cracks, erosion, wear or seizure on sliding whole rotating group. surface or bores.
  • Page 34: Trouble Shooting

    K3V112DT Instruction Manual 5. TROUBLE SHOOTING 5.1. General Comments When any abnormal phenomenon is noticed, investigate whether it is a failure of the main pump itself or a problem in the main control valve, third pump or circuit. For this purpose, the pilot pressure, pump discharge pressure, load pressure, etc.
  • Page 35: Basic Pump

    K3V112DT Instruction Manual TROUBLE SHOOTING 5.2. Basic Pump Trouble Shooting Phenomenon Possible Cause Remedy 1. Engine Stalls or is 1) Engine Speed is low Recheck engine speed and reset if overloaded. necessary 2) Regulator Torque Setting is set high Replace regulator 3) Seizure or damage of pumps internal parts.
  • Page 36: Spare Parts

    K3V112DT Instruction Manual 6. SPARE PARTS 6.1. Cross Sectional Drawings Main Pump TIGHTENING TORQUE TIGHTENING NOMINAL DESIGNATION TORQUE OF SCREW THREAD 235.4 11.8 G 1/4 36.3 G 1/2 107.9 NPTF 1/16 531,532 M20 x 1.5 235.4 127.5 35 OF 39...
  • Page 37 K3V112DT Instruction Manual 36 OF 39 June 2004...
  • Page 38 K3V112DT Instruction Manual b. Regulator 734 653 654 836 651 652 601 624 629 621 623 TIGHTENING TORQUE TIGHTENING NOMINAL DESIGNATION TORQUE OF SCREW THREAD 436, 438 11.8 412, 413 29.4 NPTF 1/16 M30 x 1.5 156.9 15.7 37 OF 39...
  • Page 39: Parts Listings

    K3V112DT Instruction Manual Part Listings Part Name Part Number Q'ty Class Shaft(F) P- 2933800982 Shaft(R) P- 2933800884 Coupling P- 2953801763 Bearing; roller P- PNUP308R1CS50 Bearing; needle P- PAJ503518 Spacer; bearing P- 38800127 Cylinder P- 2933800787 Piston P- 38901151 Shoe P- 38900152...
  • Page 40 K3V112DT Instruction Manual O-ring P- 00RBG145 O-ring P- 00RBP8 O-ring P- 00RBP11 O-ring P- 00RBP14 O-ring P- 00RBP24 O-ring P- 00RBP18W Oil seal P- P15Z456812F Back up ring P- 0T2BP18 Back up ring P- 0T2BG35 P- 0RNM16 P- 0RNM20 Snap ring...