Product Overview
The K3VG280-10ORS-10L2 is the 280 cc-class core model within the Kawasaki K3VG series of swashplate-type axial piston variable displacement pumps. The K3VG series is Kawasaki’s open-loop swash plate variable displacement axial piston pump platform designed for industrial equipment, spanning displacements from 63 to 560 cm³/rev with a rated pressure of 34.3 MPa (350 bar) and peak pressure of 39.2 MPa (400 bar), suitable for injection molding machines, die-casting machines, forging presses, metal processing equipment, tunnel boring machines, and other industrial hydraulic systems.
The K3VG series is characterized by high pump efficiency, a wide range of control options, low noise operation, compatibility with fire-resistant fluids, and long service life.The series supports a wide variety of control methods such as flow control, pressure control, horsepower control, and their combination, with an optional electro-hydraulic servo regulator “ILIS (Intelligent Liner Servo)” capable of discharging flow rate according to electric commands with high accuracy.
Model Code Breakdown (for procurement and engineering reference):
Using K3VG280-10ORS-10L2 as example:
K3VG: Kawasaki open-circuit swash plate axial piston variable pump series
280: Nominal size (NG), geometric displacement 280 cm³/rev
-10: Design series number
ORS: Regulator (control type) code. O = additional function code; R = control combination code; S = additional configuration identifier. Per the K3VG series regulator code system, this code corresponds to a horsepower control and pressure cutoff composite control
-10L2: Control valve design number and port configuration code
About K3VG Series Control Options: The K3VG series supports a wide range of control options including: stepless manual displacement control (0000), horsepower control (10##), horsepower and negative flow control (1N##), horsepower and positive flow control (1P##), horsepower and electric flow control (1E##), horsepower and pressure cutoff (50##), horsepower with pressure cutoff and negative flow control (5N##), etc.The ORS code of the K3VG280-10ORS-10L2 corresponds to a composite control combining horsepower control with pressure cutoff, automatically reducing displacement as system pressure rises to limit input torque, and reducing displacement to zero upon reaching the pressure cutoff setting, effectively protecting the prime mover and hydraulic system from overload damage.
Drop-in Replacement Advantage: Manufactured to exact Kawasaki OEM specifications, this pump achieves complete drop-in interchangeability with the original K3VG series for mounting flange, shaft dimensions, main port layout, and control module interface. Every pump undergoes 100% simulated load testing prior to shipment, validating 34.3 MPa pressure loading, control response, and volumetric efficiency under conditions replicating real-world duty cycles.
Technical Specifications
Model K3VG280-10ORS-10L2:
Model Code: K3VG280-10ORS-10L2
Series: Kawasaki K3VG Series (Open Circuit, Swash Plate Design)
Nominal Size: NG 280
Geometric Displacement: 280 cm³/rev (17.1 in³/rev)
Rated Pressure: 34.3 MPa (350 bar / 5075 psi)
Peak Pressure: 39.2 MPa (400 bar / 5800 psi)
Rated Speed: 1800 rpm (see precautions for operating K3VG280 at 1800 rpm)
Maximum Self-Priming Speed: 1600 rpm (suction pressure must be maintained at -0.01 MPa or above)
Theoretical Flow (at 1600 rpm): Approx. 448 L/min
Maximum Input Power (High horsepower mode, 1500 rpm, 34.3 MPa): Approx. 150 kW
Control Type: ORS — Horsepower Control + Pressure Cutoff Composite Control
Optional Controls: Load sensing, electro-hydraulic servo control (ILIS), positive/negative flow control, electric flow control
Mounting Flange: Per model configuration (SAE or ISO)
Shaft: Per model configuration
Housing Material: High-strength cast iron
Seal Material: NBR (nitrile rubber), suitable for mineral oil-based hydraulic fluid
Working Fluid: Anti-wear mineral hydraulic oil (for pressures above 207 bar)
Viscosity Range: 10–200 cSt (normal operating range)
Operating Temperature Range: 20–60°C (mineral oil)
Fluid Cleanliness: ISO/DIS 4406 19/16/14 (NAS Class 9) or better
Weight: Approx. 160 kg
Through Drive Capability: Supports double pump configuration (K3VG280DT)
K3VG Series Displacement Size Reference:
K3VG63: 63 cm³/rev, rated 34.3 MPa, peak 39.2 MPa, max self-priming speed 2600 rpm, weight approx. 48 kg
K3VG112: 112 cm³/rev, rated 34.3 MPa, peak 39.2 MPa, max self-priming speed 2200 rpm, weight approx. 68 kg
K3VG180: 180 cm³/rev, rated 34.3 MPa, peak 39.2 MPa, max self-priming speed 1850 rpm, weight approx. 86 kg
K3VG280: 280 cm³/rev, rated 34.3 MPa, peak 39.2 MPa, max self-priming speed 1600 rpm, weight approx. 160 kg
K3VG180DT: 2×180 = 360 cm³/rev, rated 34.3 MPa, peak 39.2 MPa, max self-priming speed 1850 rpm, weight approx. 160 kg
K3VG280DT: 2×280 = 560 cm³/rev, rated 34.3 MPa, peak 39.2 MPa, max self-priming speed 1600 rpm, weight approx. 300 kg
Key Technical Advantages
1. Horsepower Control with Pressure Cutoff Composite Control
The K3VG280-10ORS-10L2 is equipped with a horsepower control and pressure cutoff composite control module. The horsepower control function automatically reduces the swash plate tilting angle as system pressure rises, restricting the input torque of the pump to prevent overloading the prime mover — as delivery pressure increases, the pump’s input power is maintained within the set range, achieving precise matching between hydraulic system power and prime mover output power. The pressure cutoff function rapidly reduces pump displacement to zero (maintaining only leakage compensation flow) when system pressure reaches the setpoint, protecting the hydraulic system from overpressure damage. By adding a pilot signal to the Pi port, the discharge flow can be infinitely adjusted within the range of the pump, suitable for complex industrial hydraulic systems requiring multi-stage power settings or remote control.
2. Swash Plate Design with High Power Density
The K3VG series employs a swash plate axial piston rotary group design. The 280 cc size achieves a theoretical flow of approximately 448 L/min (at 1600 rpm) and an input power of approximately 150 kW at 34.3 MPa rated pressure, leading its displacement class in power density. The compact structural design enables the K3VG series to deliver high flow output while maintaining a small installation envelope, suitable for space-constrained industrial hydraulic systems.
3. High Overall Efficiency with Exceptional Self-Priming Capability
The K3VG series features high pump efficiency, with peak overall efficiency exceeding 90%. The K3VG280 achieves a maximum self-priming speed of 1600 rpm with a suction pressure of -0.01 MPa or above, enabling reliable oil suction without an auxiliary pump, effectively reducing system complexity and installation costs. High volumetric efficiency means less internal heat generation and more consistent power delivery, effectively reducing energy consumption.
4. Extensive Control Options with ILIS Electro-Hydraulic Servo Control
The K3VG series offers an industry-leading combination of control options: flow control (stepless manual, positive/negative flow control, electric flow control), pressure control (pressure cutoff, remote pressure control), horsepower control, and various combinations thereof.Additionally, the optional electro-hydraulic servo regulator “ILIS” (Intelligent Liner Servo) discharges flow rate according to electric commands with high accuracy, achieving precise closed-loop flow control.The modular regulator code system enables field conversion and upgrade of control methods.
5. Fire-Resistant Fluid Compatibility with Long Service Life
The K3VG series is compatible with phosphate ester, polyol ester, and water glycol fire-resistant hydraulic fluids.When using phosphate ester, pump life is approximately 60% of mineral oil; with polyol ester approximately 50%; and with water glycol approximately 20% (relative to mineral oil). Seals and ratings may need to be changed accordingly; consulting Kawasaki technical department for confirmation of suitable configurations is recommended when adopting fire-resistant hydraulic fluids. The series is renowned for reliable high-pressure and long-life design.
6. Double Pump Configuration with System Expansion Capability
The K3VG series supports double pump configurations (K3VG280DT) with a total displacement of up to 560 cm³/rev (2×280) and maximum mass of approximately 300 kg.The double pump configuration enables a single drive source to power two independent hydraulic circuits, providing a compact solution for complex industrial hydraulic systems. Standardized mounting interfaces require no adaptation for replacement, significantly reducing equipment downtime.
Application Areas
Plastic Machinery: Clamp and injection hydraulic systems for injection molding machines (one of the core application areas for the K3VG series)
Die-Casting Machines: Clamp and injection hydraulic systems
Forging Equipment: Main hydraulic pumps for hydraulic presses and stamping equipment
Metal Processing Equipment: Metallurgical equipment, rolling mill hydraulic systems
Tunnel Boring Machines: Thrust and cutterhead drive hydraulic systems
Waste Treatment Equipment: Refuse compactors, waste balers hydraulic systems
Marine & Offshore: Cargo vessel deck machinery hydraulic systems, oil tanker hydraulic drives
General Industrial Hydraulic Power Units: Large hydraulic power units, central oil supply systems
Expert Maintenance Tips
1. Hydraulic Fluid Cleanliness
The K3VG280 control spool operates with extremely tight clearances and is highly sensitive to particulate contamination. System fluid cleanliness must meet ISO/DIS 4406 19/16/14 (NAS Class 9) or better. At minimum, install a 10 μm filter in the return line and an 80–150 mesh strainer in the suction line.Recommended fluids are high-quality anti-wear mineral hydraulic oils (for pressures exceeding 207 bar) with a viscosity range of 10–200 cSt (normal operating range).Replace filter elements at 500 hours after first commissioning, then every 1,000 operating hours or 6 months, whichever comes first.
2. Control Setting and Adjustment
The ORS control module of the K3VG280-10ORS-10L2 includes horsepower control and pressure cutoff functions. During commissioning, first determine the horsepower control curve start point based on the prime mover’s power characteristics, then set the pressure cutoff value (not exceeding 34.3 MPa). Mechanical adjustment of the horsepower control start point should be performed with the pump at neutral (zero displacement). For models equipped with a Pi port, pilot signal input enables remote flow adjustment based on system requirements. Adjust only with the system at zero load. Rotate the adjustment screw slowly and verify stable pressure gauge readings before proceeding.
3. Case Drain Line Requirements
The case drain line must return directly to the reservoir. Pump case pressure must not exceed 30 psi (2.1 bar).For installations above the reservoir oil level, the suction line must initially rise above the pump level before continuing to the tank (goose neck configuration), with a maximum allowable mounting height of 1 meter (3.3 feet). Minimum suction pressure must be maintained at -0.1 bar or above.Drain piping should be equal or larger in size than the drain port to minimize pressure in the pump case.
4. Pre-Start Priming and Air Bleeding
Before first start, fill the pump housing with clean hydraulic fluid through the case drain port. When installing tandem pumps (K3VG280DT), ensure that both the front and rear pumps are filled with oil through both case drain ports.After installation, turn the drive shaft by hand several revolutions to confirm free rotation without binding. Position the control at neutral (zero displacement) and run at low speed for 5–10 minutes. Verify continuous bubble-free flow from the case drain. Only then apply load.
5. Special Requirements for Vertical Mounting
For applications requiring vertical installation (shaft up), a “V” type pump with additional front bearing lubrication provisions must be used. Standard pumps must not be used for this type of application. The oil level in the tank should be higher than the pump mounting flange; if the oil level is lower than the mounting flange, forced lubrication is required through the air bleed port (0.25–0.50 GM [1–2 cm]).
6. Fire-Resistant Fluid Compatibility Confirmation
If the system uses phosphate ester, polyol ester, or water glycol fire-resistant hydraulic fluids, confirm seal material compatibility, noting that pump life is reduced when using fire-resistant fluids (phosphate ester approx. 60%, polyol ester approx. 50%, water glycol approx. 20%).When changing hydraulic fluid types, simultaneously check seal material compatibility and perform system flushing and fluid replacement according to Kawasaki technical manual requirements.
