K3V112 10CC Internal Leakage hydraulic pump

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Ningbo Hengnuo Hydraulic Drive Co.,Ltd

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K3V112 10CC Internal Leakage Hydraulic Pump: Technical Analysis & Solutions

(English Translation with Enhanced Technical Depth)

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1. Subject Definition & Core Concepts

• Model Identification: K3V112 10CC Pump

• Model Breakdown:

• K3V112: Avariable displacement axial piston pump(e.g., manufactured by Kawasaki or similar OEMs), commonly used in heavy machinery (e.g., excavators, cranes, loaders) for high-pressure hydraulic systems (28–35 MPa).

• 10CC: Theoretical displacement of10 cubic centimeters per revolution (10 mL/rev), directly determining the pump’s flow output capacity.

• Applications:

• Drives critical functions likeswing systems, travel motors, or boom actuators, requiring durability under cyclic loading and high-pressure conditions.

• Definition of Internal Leakage

• Physical Mechanism: Unintended flow of hydraulic fluid fromhigh-pressure zones(e.g., piston chambers, valve plate) tolow-pressure zones(e.g., case drain, leakage ports), resulting in:

• Reduced volumetric efficiency(normal ≥92%; severe leakage <85%).

• System malfunctions: Delayed actuator response, pressure instability, and excessive oil temperature (>80°C accelerates seal degradation).

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2. Root Causes & Detection Methods for Internal Leakage

(1) Key Failure Points & Mechanisms

【表格】

Component Failure Mode Root Causes

Piston-Barrel Interface Wear, scoring, clearance increase Contaminated oil (particles ≥5 μm), prolonged high-pressure operation (>32 MPa), inadequate lubrication

Valve Plate/Port Plate Eccentric wear, burnt sealing bands Misalignment, abnormal backpressure, thermal expansion mismatch

Shaft Seals O-ring aging, lip seal damage Excessive axial loads, oil temperature overshoot (>90°C), incompatible seal materials

Housing Cracks Casting defects, stress fractures Fatigue loading, impact overloads, low-temperature embrittlement

(2) Quantitative Detection Methods

• Method 1: Flow Rate Testing

• Procedure:

1. Isolate the pump outlet and run the motor at rated speed (e.g., 1,800 rpm).

2. Measure the leakage flow rate (L/min) at the case drain port.

3. Calculateleakage displacement:

Qleak=(Flow Rate (L/min)Speed (rpm))×1,000(in cc/rev)Q_{\text{leak}} = \left(\frac{\text{Flow Rate (L/min)}}{\text{Speed (rpm)}}\right) \times 1,000 \quad (\text{in cc/rev})Qleak=(Speed (rpm)Flow Rate (L/min))×1,000(in cc/rev)

• Acceptance Criteria:

• New Pump: ≤0.3 cc/rev (≥97% volumetric efficiency).

• Repaired Pump: ≤0.8 cc/rev (≥92% volumetric efficiency).

• Requires Repair: >1.0 cc/rev (>10% leakage rate).

• Method 2: Pressure Decay Test

• Procedure:

1. Isolate the pump from the system and charge it to rated pressure (e.g., 32 MPa).

2. Close inlet/outlet valves and record the time (T) for pressure to drop to 28 MPa.

• Acceptance Criteria:

• Healthy Pump: T ≥15 minutes (leakage rate ≤0.1 MPa/min).

• Requires Repair: T <5 minutes (leakage rate >0.8 MPa/min).

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