Manual Kerr KM3250PT & KM3300PT
Contents
1. Ooststeeg Phone 31 0 317 840 197 6708 Wageningen Netherlands info dupagro com www dupagro com CORPORATION SERVICE MANUAL Kerr Pumps HDD 2 EDITION Since 1946 NEW PUMP WARRANTY A D Kerr Machine Company Kerr Pump Corporation warrants its new HDD pumps to be free from defective materials and or workmanship for 1000 HOURS OR ONE 1 YEAR whichever comes first from date of sale by distributor provided that the new pump is registered in accordance with Paragraph No 2 hereof properly installed and operated in accordance with the Company s Service Manual and all other terms of this warranty agreement are complied with by the purchaser As hereinafter provided this warranty includes the replacement of parts and labor to correct any deficiency All defective parts must be returned to the Company s Home Office for examination before this warranty is effective This warranty applies to parts which have been replaced under this warranty only so long as the original pump warranty is effective This warranty is for the exclusive benefit of the purchaser and is not transferable Each Distributor of a new pump will provide the customer with a registration blank furnished to him by the Company which must state the date of sale be signed by the purchaser and the Distributor and delivered to the Home Office of the Company within fifteen 15 days of the date of2. Te ZUR 1 _ yA i E P1 D JOL k k EH 13 Install the suction 14 Install the discharge seat 15 Install the suction spring seat and valve Drive in and valve Drive in firmly firmly using bar and hammer using bar and hammer p 1 1 d 1 of J 2 AO s F 2 t i LU 16 Install the discharge spring 17 Tighten all bolts nuts to specified torque from chart INSTRUCTIONS FOR CHANGING DISC VALVES Revision 1 Remove Capscrews from Top and 2 Remove Round Cover Caps inspect 3 Unscrew Valve Capscrew Remove End Cover Plates o rings for damage Capscrew Spring Retainer Spring Spacer and Disc 4 Screw Kerr Pump Valve Puller into 5 Hold Puller Stem from turning 6 Remove Valve Seat from Puller seat approximately 34 Rotate large nut until seat releases Remove remaining valves INSTRUCTIONS FOR CHANGING DISC VALVES Revision cont 7 Remove Suction Valve Seat 8 To Install Valve Assembly Insert 9 Use 1 wooden dowel rod to drive Through End Port through End Port valve seat assembly into seating area using several firm but not heavy blows with a hammer CAUTION heavy blows will damage valve 10 Torque valve capscrew to Kerr Pump 11 Install Discharge Valve following 12 Install Cover Caps and torque Cover specs procedure 9 Plate capsc
3. AP 351 Oil Level Sight Glass All prices and part numbers are subject to change without prior notice Dupagro B V Ooststeeg 102 Phone 31 0 317 840 197 6708 AX Wageningen info dupagro com The Netherlands www dupagro com
4. CO G CO AA AA AAA AA ll AAA AA lI lll 125 4000 125 4000 125 4000 125 6000 125 6000 Kerr KM 3250PT KM 3300PT KM 3250SHPT KM 3300SHPT Piston Type Pump Bearing Housing Bearingless Hyd Mir 4000 Bearing Housing Eaton Hyd Mtr 14 Tooth Bearing Housing Eaton Hyd Mtr 14 Tooth Bearing Housing Hyd Mtr 6000 1 1 2 Keyed Shaft Bearing Housing Hyd Mtr 6000 1 1 2 Keyed Shaft KM 126 Bearing Housing Hyd Drive for 1 1 4 Straight Keyed Drive amp 14T 12 24 KMX 126 Bearing Housing Hyd Drive for 1 1 4 Straight Keyed Shaft amp 14T 12 24 KM 130 Bearing Housing Extensions Shaft KMX 130 Bearing Housing Extension Shaft KM 132 Auxiliary Shaft AP 135 Oil Seal Bearing Housing Extension Shaft KM 141 Bearing Housing Water Pump Adapter KM 190 Piston Chamber Cover AP 190 2 Water Manifold Plug AP 190 3 Water Manifold Oil Manifold Bolt AP 190 4 Water Manifold 90 Degree Fitting AP 190 5 Water Manifold Quick Coupling AP 190 8 Piston Chamber Cover Inspection Glass Wing Nut AP 190 9 Piston Chamber Cover Inspection Glass Capscrew 190 11 Piston Chamber Cover Stud AP 190 12 Fitting Water Jet AP 190 13 1 4 Lock Washer AP 190 14 1 4 20UNC Nut 191 Piston Chamber Cover Gasket KM 192 Piston Chamber Cover Sight Glass AP 195 Water Pump Bronze AP 197 Water Pump Repair Kit Nitrile KM 210 Water Manifold KM 215 Li
5. 31 UN YA gt YA Z f KM 21 SOS amp 92 yy a J z Al ELLAALA OX y Z LET a 2 72 Ke KM 70 s Mag 9 7 77 17 KM 18 TT l 275 KM X 120 7 KM 65 KM 22 KM 270 24 __ 25 000 29 TWO SEALS TO RANKCASE OIL REM OVE PISTON amp LINER PN AS AN ASSEMBLY IN A N S ORDER TO SERVICE gt KM 300HT x TROUBLESHOOTING GUIDE CENTER FIRST J for Kerr VALVE ASSEMBLY pump 1 CHECK FOR LEAKING PISTONS REPLACE IF NECESSARY PACKING GLAND 2 CHECK FOR PROPER FLUID FLOW TO PUMP MINIMUM REQUIREMENTS 2 PUMP amp GEAR REDUCER SUC TION HOSE NO MORE THAN 30 aya va nah G w LONG WITH 20 PSI OF CONTINUOUS PRESSURE FEEDING PUMP KM 98HT 30 50 F 50W SEAT ABOVE 50 F 90 3 REMOVE COVER CAPS AND INSPEC TVALVES amp VALVE SEATS Yauli KM 3300PT WITH OPTIONS SUC TIO N VALVE ASSEMBLY KM 3300BC PT WITH OPTIONS x MOUNT 771 800 HOLES E 18 625 gt 22 935 di 1 1 4 NPT DISC HARG E 1 Ee 5 250 sil 35 6 5 n NGA dod 4 7 812 A 1175 3 50 2 1 2 NPT SUC TIO N GENERAL DIMENSIONS FOR KM 3300PT WITH OPTIONS AP 16T e KM 112 KM 13 KM 34BC EIS mee KM 122 KM 25 000 KM 58L 18 KM 12 32 FA zJE zzzz gt KM 11 KM 98HT SEN 0
6. liner gasket Liner Assembly 2 1 4 Piston complete HSN liner gasket Liner Assembly 1 3 4 Piston complete liner gasket Liner Assembly 1 7 8 Piston complete liner gasket Liner Assembly 2 Piston complete liner gasket Liner Assembly 2 1 4 Piston complete liner gasket Liner 1 3 4 Kerramic Liner 1 7 8 Kerramic Liner 2 Kerramic Liner 2 1 4 Kerramic CO CO CO CO CO CO Co CO CO CO CO WH CO CO CO CO CO Co CO CO CO CO CO WE Kerr KM 3250PT KM 3300PT KM 3250SHPT KM 3300SHPT Piston Type Pump Part Number Description Reg KM 285 175KER A Liner Assembly Kerramic 1 3 4Piston complete HSN liner gasket 3 KM 285 200KER A Liner Assembly Kerramic 2 Piston complete HSN liner gasket 3 KM 285G 175KER A Liner Assembly Kerramic 1 3 4 Piston complete liner gasket 3 CO KM 285G 200KER A Liner Assembly Kerramic 2 Piston complete liner gasket 290 Liner Retainer KM 300HT Abrasive Resistant Discharge Valve Complete KM 96HT KM 98HT amp KM 58L KM 320 Flow Meter AP 324 6 3 6 Planetary Gear Assembly 3 75 1 14 Tooth Input Spline SAE C Bolt Mount AP 330H Housing SAE C 4 Bolt Drive Assembly 1 1 2 Male Input Shaft N AP 330B Bearings SAE C 4 Bolt Drive Assembly 1 1 2 Male Input Shaft 330 2 Snap Ring SAE 4 Bolt Drive Assembly 1 1 2 Male Input Shaft
7. S KM 38L Fluid End Capscrews Lineup KM 58L Valve Spring Wing Guided Long Discharge 585 Valve Spring Wing Guided Short Suction 64 Packing Gland Stud KM 65 Packing Gland Stud Nut 2 AP 71 Drain Plug 1 2 Hex Pipe Plug N O gt Co O O gt CO Co GD Co 09 QO G Q 72 1 8 NPT Level Stuffing Box Hex Plug Kerr KM 3250PT KM 3300PT KM 3250SHPT KM 3300SHPT Piston Pump 72 Cover Cap Wrench 725 1 8 NPT Oil Level Stuffing Box Hex Plug Steel 7255 1 8 NPT Oil Level Stuffing Box Hex Plug Stainless Steel KM 76 Valve Puller Wing Type KM 76M Valve Puller Wing Guide Pin Type AP 77T Valve Insert Tool KM 96HT Discharge Valve Heat Treated A R with Insert KM 97HT Suction Valve Heat Treated A R with Insert KM 98HT Valve Seat Heat Treated A R KM 101R Abrasive Resistant Valve Insert KM 101V Abrasive Resistant Valve Insert KM 113PT KM 3250PT Rebuild Gasket Kit Complete 1 KM 3 2 KM 7 1 KM 12 1 KM 15 3 29 3 KM 33 6 37 1 KM 191 8 KM 295 KMX 113PT KM 3300PT Rebuild Gasket Kit Complete 1 KM 3 2 KMX 7 1 12 1 KM 15 3 KM 29 3 33 6 KM 37 1 KM 191 3 KM 295 KM 120LH Crankshaft Hydraulic Drive 1 1 8 Threaded Adapter LH KM 120RH Crankshaft Hydraulic Drive 1 1 8 Threaded Adapter R
8. T ave NPT CTION GENERAL DIMENSIONS FOR KM 3250PT 31 KM 112 KM 13 m 35 69 15 1 j 17 2 25 000 gt KM 18 KM 12 KM 58L Y S AN 7 722222 22222 gt Se KM 98HT f d W Vh KM 36BC Z KM 58S y E lt L ee OER f KM 97 Si p IF mu l7 KM 31 AS BL 7 A JA KM 21 G APE lt lt 2 E T KM 37 UWA 23 7 AP 72 YA LEE T 722722522 KM 58L we KM 2 lt lt A SPRING LL aoe am zi KM 96HT 65 KM 22 KM 65 KM 26 64 REMOVE PISTON amp LINER AS AN ASSEMBLY IN ORDER TO SERVICE C ENTER LINER FIRST TWO SEALS TO KM 300HT DISC HARGE VALVE ASSEMBLY KM 58S SPRING KM N SUCTION VALVE KM 101 INSERT T NL KM 295 KM 285 28 N PONY ROD PACKING GLAND ASSEM BLY KM 98H PUMP amp GEAR REDUCER SNAP RING TROUBLESHOOTING GUIDE for Kerr Pump 1 CHECK FOR LEAKING PISTONS REPLACE IF ESSARY 2 CHECK FOR PROPER FLUID FLOW TO PUMP MINIMUM REQUIREMENTS 2 SUC TION HOSE NO MORE THAN 30 LONG WITH 20 PSI OF CONTINUOUS PRESSURE FEEDING PUMP 3 REMOVE VALVE COVER CAPS AND SEAT LUBRICATION GEAROIL INSPECTVALVES 6 VALVE SEATS ER KM 3250 PT BELOW 30 F 4 FOR FOREIGN OBJ ECTS AN
9. align tighten pony rod to crosshead care must be exercised in installing new seal on pony rod not to damage it C DISASSEMBLY OF POWER END CAUTION Prior to disassembly of any power end the plunger pony rod and pony rod seal housing must be removed Expose the crankshaft and connecting rods by removing the pan cover Connecting rod caps may now be removed and the connecting rod and crosshead should be shoved all the way to the rear toward the fluid end to facilitate crankshaft removal out either side as convenient The connecting rods and crossheads may now be taken out the front cavity exposed by removing the crankshaft Connecting rods be removed from the crosshead by loosening the setscrew driving out the wrist from the crosshead bronze bushing is used in the rod it may be driven out of the rod and replaced with a new bushing Reassembly is the reverse of the above outlined sequence with the following considerations for fits or tolerance General All Kerr components are machined on modern production machine tools and are of the same specifications and close tolerances you would expect in a modern automobile engine It must be pointed out that at top speed 350 to 400 RPM your pump will not even be approaching idle speed for a gasoline engine so field fits are possible and practical when making repairs and replacements away from the factory All procedures outlined below are possible with only hand
10. filled with appropriate lubricant and placed into service The elevated temperature of service will cause rapid depletion of the preventative protection 3 2 The following rust preventative products or their equivalents are recommended for use in Kerr Pumps and usually available in 5 gallon 55 gallon containers CITGO RUST O LINE OIL 10 SHELL ENSIS OIL N 4 0 PROCEDURE 4 1 Preparation from factory testing inventory or a distributor rebuild facility 4 1 1 Drain any oil that may be in the power end and then fill the complete power end cavity with the specified rust preventative After 15 to 20 minutes drain the rust preventative back into its storage drum for future use 4 1 2 Remove all plungers pony rods if applicable baffle discs packing and junk rings 4 1 3 Remove and clean oil level gages pressure gages and breather caps Replace with pipe plugs in threaded openings 4 1 4 4 1 5 4 1 6 4 1 7 4 1 8 4 1 9 4 1 10 4 1 11 4 1 12 4 1 13 TECHNICAL DATA 5 T D S NO 4 3 PCN Supercedes PCN Date 03 10 06 All breathers shall be replaced with airtight seals plugs gasketed plates No venting is recommended as it may allow moist air in Remove the wiper box seals and cap plug the seal opening Clean the pump outer surfaces prior to painting If painting is required mask crank and lubricator shaft surfaces and keyways If painting does not apply go to Para 4 1 9 Paint as specified by the customer order or as requ
11. studs etc tight Check valve covers for leaks Check all seals and gaskets for leaks Replace any work part before its eventual failure Use the following instructions for removal and replacement of parts Don t hesitate to call on Kerr Pump Corporation for help if necessary at 1 800 441 8149 SERVICE PROCEDURES ALL MODELS A VALVES Wing guided type DISCHARGE VALVE The discharge valve and seat can be exposed by first removing the discharge valve cover cap Once the discharge cover cap has been removed you may lift out the discharge valve spring and the discharge valve The valve seat will be held in place by a taper fit and must be pulled with an appropriate valve pulling tool available from the KERR PUMPS Dealers Once the valve and seat have been removed they should be resurfaced or replaced if badly worn To replace the discharge valve first clean and inspect the seat bore for washout defects and then drop the seat into bore Replace the valve into the seat and strike the top of the valve a couple of good blows utilizing a brass bar and hammer to seat the valve seat in the fluid end valve bore Replace the valve spring and cover cap after inspecting the spring and the seal of the cover cap ii SUCTION VALVE The suction valves are located in the chamber directly behind the suction or end valve cover caps The suction valves are serviced in the identical manner as the discharge valves Note Discharge valves must
12. 96HT PSL 27 2 em lt S 7 PEEL A 585 V FX KM 97HT YA Wires N 2677 a Nia ASEE WI 1 KM 36BC 2 GAR pp PZ SS AP 72 MN 4 19 9 K LL VV KM 24 26 lt 47 275 j MO KM 28 KM 290 LONG KM 264 SPRING KM 96HT 7 DISC HARGE VALVE wan INSERT KM SEAT KM 300 Lo VALVE ASSEMBLY 585 SHORT SPRING KM 97HT SUC TIO N VALVE KM 101 INSERT REM VE PISTON amp LINER AS AN ASSEMBLY IN ORDER IO SERVICE C ENTER LINER FIRST KM 295 KM 285 KM 98HT 7 SEAT KM 305HT SUCTION VALVE ASSEMBLY TROUBLESHOOTING GUIDE for Kerr TWO SEALS TO Pump CRANKC ASE OIL 1 CHECK FOR LEAKING PISTONS REPLACE IF NECESSARY 2 CHECK FOR PROPER FLUID FLOW TO PUMP MINIMUM REQUIREMENTS 2 SUC TION HOSE NO MORE THAN 30 LONG WITH 20 PSI OF CONTINUO US PRESSURE FEEDING PUMP 3 REMOVE VALVE COVER CAPS AND INSPECTVALVES amp VALVE SEATS FOR FOREIGN OB ECTS AND WEAR PUMP amp GEAR REDUCER REPLAC E IF NEC ESSA RY LUBRICATION GEAR OIL BELOW 30 F 4 30 50 50W ABOVE 50 90W KM 3300PT 112 16 2 31 190 210 13 SS M emm KM 215 26 mend 2 B KMX IPT KM 25 000 E Teo 10 MIR L
13. D WEAR 30 50 F REPLACE IF NECESSARY ABOVE 50 F 90W SUC TION VALVE ASSEMBLY KM 192 214 31 190 35 KM 36BC 31 21 112 16 KM 210 13 15 KM 215 KM 26 25 000 Vgl ELLIE ILI ZIT op Tkun AA Vh KM 10 d pem es AA FS f 7 RY I SC j kaa wa A PALM TA AP 72 KM 19 S 28 KM 1 5 2 120 22 REM OVE PISTON amp LINER AS AN ASSEMBLY IN ORDER TO SERVICE DISC CENTER LINER FIRST VALVE ASSEM BLY KM 98HT ES SUCTION KM 3250PT WITH OPTIONS VALVE ASSEMBLY KM 24 KM 25 000 KM 29 TWO SEALS TO RANKCASE OIL TROUBLESHOOTING GUIDE for Kerr SNAP RING Pump 1 CHECK FOR LEAKING PISTO NS REPLACE IF NECESSARY 2 CHECK FOR PROPER FLUID FLOW TO PUMP MINIMUM REQUIREMENTS 2 PUMP amp GEAR REDUCER SUC TION HOSE NO MORE THAN 30 LUBRICATION GEAR OIL LONG WITH 20 PSI OF CONTINUOUS BELOW 30 40W PRESSURE FEEDING PUMP 30 50 F 50W ABOVE 50 90W 3 REMOVE VALVE COVER CAPS AND INSPEC TVALVES amp VALVE SEATS FOR FOREIGN EC TS AND WEAR REPLACE IF NEC ESSARY PACKING GLAND E 18 625 11 4 DISC HARG 2 SUCTION GENERAL DIMENSIONS FOR KM 3300PT KM 31 KM 2 KM 112 1 16 KM 34DBC EL C NE T KM 13 KM X 1 KM
14. FLUID 10 FEETOF HEAD IS A GOOD RULE OF THUMB Q CAUTION SHOULD BE TAKEN TO KEEP HTIINGS OUT OF THE SUCTION AND DISC HARG E PIPING AS THESE WILL RESULT IN POOR PERFORMANCE IF BENDS ARE NEC ESSARY USE 45 LONG RADIUS ELLS INSTEAD OF 90 ELLS PREVENTIVE MAINTENANCE DAILY A Check and Maintain Lubricant Levels Standard Lubricant AGMA Grade ASTM D 2422 ISO Viscosity Grade Viscosity 550 100 degree Synthetic Lubricant 4 SAE Viscosity Grade J306 8 150 625 765 75W 90 PUMP CAPACITIES APPROXIMATE KD 1250 2 qts KT 3350 16 qts KJ 2250 3 qts KT 3400 16 qts KZ 3150 2 qts Use SAE 30 weight non detergent motor oil ONLY KM 3250 4 qts KB 3500 20 qts KM 3300 4 qts KA 3500 36 qts KP 3300 12 qts KSB 6400 36 qts R335 R340 16qts KSB 6500 36 qts Q5450 22 5 gal KCP 6300 24 qts PLANETARY GEAR REDUCERS H6 17 ozs H8 42 025 H9 42 Ozs If pump has lubricating facilities for stuffing boxes check level of lubricant Maintain packing gland tension on packing Do not over tighten D Visually inspect pump for apparent trouble E MONTHLY A G GENERAL Keep the pump clean Drain and refill crankcase It is recommended that oil be changed after the first week of operation Wash oil filler cap in kerosene Check valves for excessive wear broken or bent springs etc Check crankshaft bearings for endplay See section on crankshaft Keep all nuts
15. H KMX 120LH Crankshaft Hydraulic Drive 1 1 8 Threaded Adapter LH KMX 120RH Crankshaft Hydraulic Drive 1 1 8 Threaded Adapter RH KM 121 Crankshaft Hydraulic Drive 1 1 4 Straight Keyed Drive 121 Crankshaft Hydraulic Drive 1 1 4 Straight Keyed Drive KM 122 14T Crankshaft Splined 14T 12 24 KMX 122 14T Crankshaft Splined for 14T 12 24 KM 122 17T Crankshaft Splined 17T 12 24 KM 123 Splined Bearingless Hyd Mtr Shaft Adapter to 1 1 4 Keyed KM 124 Crankshaft Splined Adapter for Auburn 6 to 1 1 4 Keyed KM 124LH Shaft Adapter Bearingless HD Left Hand Threaded KM 124RH Shaft Adapter Bearingless HD Right Hand Threaded KM 124 14T Crankshaft Splined Adapter for Auburn 6 14T 12 24 KM 124 17T Crankshaft Splined Adapter for Auburn 6 14T 12 24 KM 124 6000 6000 Hydraulic Motor Adapter 1 1 2 to 1 1 4 KM 125 6 Bearing Housing Hyd Drive for Auburn 6 KMX 125 6 Bearing Housing Hyd Drive for Auburn 6 KM 125 3000 Bearing Housing Bearingless 3000 KMX 125 3000 Bearing Housing Bearingless 3000 KM 125 6000 Bearing Housing Hyd Mtr 6000 KMX 125 6000 Bearing Housing Hyd Mtr 6000 KM 125 GM1 Bearing Housing Hyd Drive for SAl GM1 Series KMX 125 GM1 Bearing Housing Hyd Drive for SAl GM1 Series KM 125 GM2 Bearing Housing Hyd Drive for SAI GM2 Series KMX 125 GM2 Bearing Housing Hyd Drive for SAI GM2 Series KM 125 GM3A Bearing Housing Hyd Drive for SAI GM3A Series KMX 125 GM3A Bearing Housing Hyd Drive for SAI GM3A Series B
16. HAN MANUAL TYPE IT SHOULD BE DESIG NED HAZARD OF DISC HARG E PRESSURE ENTRY ANY AIR IN SUC TION SYSTEM PROMPTLY REACHES PUMP TO OPEN AUOMATICALLY WHILE STARTING OR STOPPING AS WHEN PUMP ISIDLE A SMALL RELIEF AND IS EXPELLED A SLOPE OF Ya PER FOOTIS BEST 6 BYPASSLINE SHOULD FEED LIQUID INTO TANK BELOW MINIMUM VALVE IS OFTEN CONNEC TED HERE 2 SLOPE BYPASSLINE SO LOW POINT DRAIN WILL FULLY LIQUID LEVEL 10 ALL SYSTEM COMPONENTS MUSTHAVE EMPTY RELIEF AND CHOKE VALVES AND ALL LIQUID IN 7 REMOVE PIPING STRAIN AND VIBRATION A FLEXIBLE HO SE ADEQUATE PRESSURE RATING 5 FOR BYPASS CIRC UIT EXPANSION J OINTOR SWIVEL OINTPAIR SHO ULD BE OPERATING STARTING AND UPSET 3 DO NOTLOCATE PIPING OR OTHER EQUIPMENT IN FRONT POSITIO NED TO MINIMIZE EFFECTS OF PIPING THERMAL CONDITIO NS IN ORDER TO REDUCE OFORABOVE PUMP FLIUD END PREVENTING SERVICING EXPANSION CONTRACTION AND PIPING WEIGHT POTENTIAL HAZARDS PARTIC ULAR REFER TO MANUFACTURER FOR MINIMUM CLEARANCES 8 SUCTION SIZED FOR 11210 2 FT SSEC MAX FLOW RATE ATTENTIO N IS RECOMMENDED FOR THE 4 LOCATE CHARGING PUMP ATPOINT SHOWN IF DISC HARG ED SIZED FOR 8 TO 10 FT SEC MAX FLOW RATE SURG E CONDITION THAT WILL RESULT CHARGING PUMP IS NEC ESSARY FOR VOLATILE FLUIDS SUC TION AND DISC HARG E MUST BE SUPPO RTED AND DOWNSIREAM OF THE REFLIEF VALVE FOR EXAMPLE ANCHO RED WHEN NORMAL DISC HARGE IS BLO C KED AS A GENERAL RULE FLUID LEVEL MUST BE HIG HER THAN THE PUMP FLUID END AS PLUNGERS CANNOT LIFT
17. Vh KM 10PT KM 36BCPT f 4 AI i ee ryt S KM 37 rex 72 NY Poa JAA LZ C KM 98HT 4 E 2 a NS 4 KM 24 C A KM 96HT gt g I KM 28 REMO PISTON amp LINER ASAN ASSEMBLY IN ORDER TO SERVICE C ENTER LINER FIRST KM 300HT DISC HARG ASSEMBLY SPRING MM N SUCTON VALVE KM 101 INSERT KM 98HT SEAT SUCTION VALVE ASSEMBLY KM 3250SHPT KM 26 TWO SEALS TO CRANKCASE OIL TROUBLESHOOTING GUIDE for Pump 1 CHECK FOR LEAKING PISTONS REPLACE IF NEC ESSARY SNAP RING 2 CHECK FOR PROPER FLUID FLOW KM 28 A TO PUMP PONY ROD MINIMUM REQUIREMENTS 2 PACKING GLAND SUC TION HOSE NO MORE THAN 30 ASSEMBLY LONG WITH 20 PSI OF CONTINUOUS PRESSURE FEFDING PUMP PUMP amp GEAR REDUC ER 3 REMOVE VALVE COVER CAPS AND zip ecl G IL INSPECTVALVES amp VALVE SEATS E FOR FOREIGN OBJ ECTS AND WEAR REPLACE IF ESSARY Kerr KM 3250PT KM 3300PT KM 3250SHPT KM 3300SHPT Piston Type Pump Number 1 KMX 1 KM 3 4 4 5 5 6 KM 6HD 125 6 KM 6HD 125 3000 KM 6HD 125 6000 KM 7 KMX 7 KM 8 005 KM 8 010 KM 8 015 8 005 8 010 8 015 25 045 Description Pump Case Pump Case Crankshaft Oil Seal Bearing Housing Blind Side Bearing Housing Blind Si
18. arts or equipment which Kerr Pump Corporation supplies and does not manufacture shall be subject only to the warranties of Kerr Pump Corporation vendors to the extent Kerr Pump Corporation can enforce such warranties Any repairs to alterations of or work done on alleged defective products without Kerr Pump Corporation specific written authorization shall void Kerr Pump Corporation warranty applicable thereto Any action for breach of warranty or other action under this agreement must be commenced within 1 year after such cause of action arises This limited warranty is in lieu of all other warranties expressed or implied including any implied warranty or merchantability or fitness TOUBLESHOOTING Problem Unusual pounding knocking broken valve spring Loss of pressure or volume Consistent rhythmic knock Packing failure Excessive Abnormal wear of fluid end parts Abnormal wear of power end parts Heat in power end Reason Solution Insufficient fluid at high speed Suction line is improper size or is constricted Trash in line valve partly opened etc Possibility of gas in the fluid causing the roughness Foreign matter may be holding valves open Worn valves Broken springs Improper bearing adjustment Worn bearings or connecting rods NOTE Valve noise is common and normal in high speed pumps It should not cause concern unless it becomes erratic Improper installation Improper type of lubrication Incorrect ty
19. be removed prior to any removal of the suction valves Service Procedure for KZ 3150PT Valves iii DISCHARGE VALVE The discharge valve and seat can be exposed by first removing the discharge valve cover plate Once discharge cover cap has been removed you may lift out the discharge valve spring discharge valve and valve seat Once the valve and seat have been removed they should be replaced if badly worn To replace discharge valve first clean and inspect the seat bore for wash out defects and then drop the seat into the bore Replace valve in seat then valve spring and cover cap always inspecting O ring seals between seats and cover caps iv SUCTION VALVE The suction valves are located the chamber directly below the discharge valve seat The suction valves serviced in the identical manner as the discharge valves B PONY ROD and PONY ROD PACKING Pumps use two pony rod sealing arrangements models KM 3250PT and KM 3300PT use a screw in seal gland all other models use a bolt in seal gland these glands use press in oil seals with snap ring retainers Some bolt in gland use adjustable packing arrangements with bolt in or screw in followers to adjust packing By unscrewing plunger from pony rod a gap may be facilitated to allow the removal of the various sealing arrangements A special wrench will be needed to remove and replace pony rod to crosshead This wrench is available from Kerr Dealers All pony rods have a jam nut to
20. ce will cause rapid depletion of the preventative protection 3 2 The following rust preventative products or their equivalents are recommended for use in Kerr Pumps and usually available in 5 gallon 55 gallon containers CITGO RUST O LINE OIL 10 SHELL ENSIS N 4 0 PROCEDURE 4 1 Preparation from factory testing inventory or a distributor rebuild facility Drain any oil that may be in the power end and then fill the complete power end cavity with the specified rust preventative After 15 to 20 minutes drain the rust preventative back into its storage drum for future use Remove and clean oil level gages pressure gages and breather caps Replace with pipe plugs in threaded openings All breathers shall be replaced with airtight seals plugs or gasketed plates No venting is recommended as it may allow moist air in 4 2 TECHNICAL DATA 5 T D S NO 4 2 PCN Supercedes PCN Date 03 10 06 4 1 1 Remove the wiper box seals and cap plug the seal opening 4 1 2 Clean the pump outer surfaces prior to painting 4 1 3 If painting is required mask crank and lubricator shaft surfaces and keyways If painting does not apply go to Para 4 1 8 4 1 4 Paint as specified by the customer order or as required 4 1 5 Apply thin layer of grease to the exposed oil seal lips 4 1 6 Apply a thin layer of heavy rust preventative to the exposed crank and lubricator shaft surfaces and keyways 4 1 7 Wrap the exposed crank and lubricator shaft
21. de Bearing Housing Shaft Side Bearing Housing Shaft Side Bearing Housing Capscrews Socket Head Capscrew for Bearing Housing Hyd 125 6 Socket Head Capscrew for Bearing Housing Hyd 125 3000 Socket Head Capscrew for Bearing Housing Hyd 125 6000 Bearing Housing Gaskets Bearing Housing Gaskets Main Bearing Adjusting Shims Main Bearing Adjusting Shims Main Bearing Adjusting Shims Main Bearing Adjusting Shims Main Bearing Adjusting Shims Main Bearing Adjusting Shims Main Bearings Pan Cover Pan Cover Pan Cover Capscrews Pan Cover Gasket Crosshead Cover Plate Crosshead Cover Plate Theaded Cover Plate Capscrews Crosshead Cover Plate Gasket Breather Cap Oil Filler Oil Level Dip Stick Breather Cap Oil Filler Threaded Style Crosshead Wrist Pin Wrist Pin Bushing Wrist Pin Set Screws amp Nut Coverplate Capscrew Connecting Rod Capscrew Connecting Rod Only No Inserts Requires inserts both ends Connecting Rod Inserted Both Ends Connecting Rod Insert Bearing Std Connecting Rod Insert Bearing 015 Connecting Rod Insert Bearing 030 Connecting Rod Insert Bearing 045 Req NO O o a M M MM D OM Kerr KM 3250PT KM 3300PT KM 3250SHPT KM 3300SHPT Piston Pump JJ D Number Description KM 25 060 Connecting Rod Insert Bearing 060 KM 26 Connecting Rod Shims Lamina
22. down 5 Continue rotating around with thumb rotate around valve with tool until insert is valve with tool Similar to completely in groove mounting a tire on a rim Wing Guided Valve Changing I nstructions K 1 1 y 1 in b 2 discharge spring 2 B Inspect the o ring for damage 1 Remove the nuts cap screws from the top cover 4 A Remove the end cover cap 5 Remove the suction valve and suction spring 4 B Inspect the valve spring for damage 3 Remove the discharge valve A N 4 gt PU HB Jp 6 Insert the tri pin puller head all pins retracted into the discharge seat Wing Guided Valve Changing Instructions continued Aa 7 Slide puller plate spacer 8 Turn the puller rod until the washers down the puller rod pins are fully extended 10 Holding the top of the puller 11 Remove the puller asembly rod in place tighten the nut with seat attached until the seat releases 9 Lifting the puller rod turn the nut until firmly tn contact with the washers 12 Loosen the puller rod to retract the pins and remove the seat Wing Guided Valve Changing Instructions continued TEDE lt g k i 1 Y L 1 4 1 E 4 A 1 1
23. e f o b to the Distributor or allow the Distributor credit to an amount equal to the invoiced value of the defective product The responsibility of Kerr Pump Corporation is limited to the repairing or replacing defective material manufactured by it provided Kerr Pump Corporation examination discloses to its satisfaction that such material has not been altered or repaired other than by Kerr Pump Corporation approved procedures subject to misuse improper maintenance negligence or accident Kerr Pump Corporation will not be responsible for loss of liquid or for damage of any kind or from any cause any person or property of any person or for loss of revenue of profit or for any other special incidental or consequential damages The warranty applies only to new pumps The Company specifically excludes from this warranty the following i All pistons piston rubbers liners valves valve springs seals gaskets and corrosion and or erosion damage caused by the fluid handled by the Company s pump i In addition after the expiration of the pump warranty all replacement parts are no longer in warranty In extreme cases where in the opinion of Kerr Pump Corporation if a pump has been misused or is being misused Kerr Pump Corporation reserves the option to offer to redeem the pump from the purchaser Should the purchaser refuse to allow the pump to be redeemed and chooses to continue improper operation the warranty will be void Any p
24. ercise too much care in making certain your installation is proper To start the pump open the suction line valve and permit the intake chamber to fill on the pump Air may be bled off by opening the valve covers slightly until there is a constant fluid flow After bleeding open the discharge line valve and start the pump Roughness may occur from cavitations air in line or from starvation lack of fluid Eliminate these troubles before permitting continuous operation e BYPASS LINE ww LOW POINT DRAIN FULL OPENING RELI PRESSURE GUAGE AND BLOCK VALVE VALVE OR BURST DISC FLEXIBLE HOSE OR NOTE 2 VALVE OPENS FULLY EXPANSION JOINT DISCHARGE NOE PULSATION _ WHEN SET PRESSURE DAMPENER IS REACHED N LOW POINT DRAIN V FULL OPENING DISHCARGE LINE VALVE WITH BODY DRAIN DISCHARGE LINE NOTE 7 ECCENTRIC REDUCER FLAT SIDE UP FULL OPENING SUCTION INLET CENTERLINE OF PUMP SUCTION LINE V Ws vi VORTEX SPLITTER NOTE 1 BODY DRAIN AND SUPPORT SUCTION BELL DESIGNED FOR SWING CHECK VALVE SUCTION SEE NOTE 4 LOW FLUID ENTRY VELOCITY MAY WITH FULL OPENONG PULSATION ELT LEGGY BAIN INCLUDE FOOT VALVE IF NECESSARY 1 CENTERLINE OF PUMP SUCTION INLET TO BE SLIGHTLY 5 IF DESIRED A TWO WAY MOTOR OPERATED BYPASS VALVE MAY 9 PROTECT SUCTION SYSTEM AGAINST HIG HER THAN CENTERLINE OF SUCTION INLET VALVE SO BE USED RATHER T
25. etainer KM 261 200 amp Nut KM 270 KM 245 225G Piston Complete 2 1 4 Includes Cup KM 260G 225 Retainer KM 261 225RD amp Nut KM 270 KM 250 175 Piston Body Only 1 3 4 KM 250 187 Piston Body Only 1 7 8 KM 250 200 Piston Body Only 2 KM 250 225 Piston Body Only 2 1 4 KM 261 175RD Retainer Rubber Piston Cup 1 3 4 KM 261 187 Retainer Rubber Piston Cup 1 7 8 KM 261 200 Retainer Rubber Piston Cup 2 KM 261 225RD Retainer Rubber Piston Cup 2 1 4 KM 263 175 Piston Cup 1 3 4 HSN KM 263 187 Piston Cup 1 7 8 HSN KM 263 200 Piston Cup 2 HSN KM 263 225 Piston Cup 2 1 4 HSN KM 263G 175 Piston Cup 1 3 4 KM 263G 187 Piston Cup 1 7 8 KM 263G 200 Piston Cup 2 KM 263G 225 Piston Cup 2 1 4 KP 264RD Piston Cup Nut Run Dry Type KM 275 Pony Rod Piston Pump Type 275 Pony Rod Piston Pump KM 276 Installation Tool for Pony Rod Seal KM 277 Pony Rod Installation Wrench KM 280 Clamp Pony Rod to Piston Rod KM 280 1 SKT C S KM 285 175CER KM 285 187CER KM 285 200CER KM 285 225CER KM 285 175CER A KM 285 187CER A KM 285 200CER A KM 285 225CER A KM 285G 175CER A KM 285G 187CER A KM 285G 200CER A KM 285G 225CER A KM 285 175KER KM 285 187KER KM 285 200KER KM 285 225KER Liner 1 3 4 Ceramic Liner 1 7 8 Ceramic Liner 2 Ceramic Liner 2 1 4 Ceramic Liner Assembly 1 3 4 Piston complete HSN liner gasket Liner Assembly 1 7 8 Piston complete HSN liner gasket Liner Assembly 2 Piston complete HSN
26. if applicable any oil pressure and or temperature gage 5 3 6 Check the connection of the plunger and pony rod to the crosshead prior to and after initial run in of the pump 5 3 7 Fill the crankcase to the proper level with the specified lubricant TECHNICAL DATA 5 T D S NO 4 3 PCN Supercedes PCN Date 03 10 06 TITLE LONG TERM STORAGE PREPARATION PROCEDURE 1 0 SCOPE This procedure applies to Kerr Pumps ONLY Storage procedures for any other unit components or accessories gear reducers engines etc are to be prepared to the specific manufacture s recommendations 1 1 Long term storage is defined as storage and or transient time exceeding six 6 months in an environment defined in Paragraph 2 If storage for less than six months is expected the Short Term Pump Storage Preparation Procedure should be followed 1 2 Kerr Pumps will only prepare for short term storage if so specified in the purchaser or customer order control document 2 0 STORAGE ENVIRONMENT A minimal environmental condition to be met by the customer or purchaser is a closed shelter to eliminate effects of sun wind sand or other debris Large temperature and humidity changes should be avoided to prevent preventative deterioration or contamination by moisture 3 0 RUST PREVENTATIVE PRODUCT 3 1 The recommended rust preservative should protect the internal power end parts from corrosion due to atmospheric moisture and may be left in the pump when
27. ired Apply a thin layer of grease to the exposed oil seal lips Apply a thin layer of heavy rust preventative to the exposed crank and lubricator shaft surfaces and keyways Wrap the exposed crank and lubricator shafts with waxed tape Carefully wrap the following parts prior to placing them into polyurethane bags Oil level gages lube pressure gages and breather caps Finish box crate and mark the parts from Para 4 1 10 after final inspection see Para 4 2 2 4 2 Shipping Receiving New Pumps Only 4 2 1 4 2 2 4 2 3 All pumps and accessories as applicable will be final inspected by Kerr Pump personnel prior to shipping Any witnessed or third party inspection will be signed off by the purchaser or customer representative prior to final crating and shipment Export crating will be performed by either an approved Kerr Pump source or as specified by the purchaser or customer Any third party inspection will be coordinated with the source Upon receipt of the shipment the purchaser or customer is responsible for inspection and repair of damaged coatings at the expense of the shipper 5 0 WARRANTY START UP 5 1 Pumps prepared per the above procedure qualify for the Standard Terms amp Conditions in force on the date of shipment 5 2 If the pump storage period will exceed 6 months follow the Long Term Pump Preparation Procedure 5 3 Prior to start up 5 3 1 Remove all storage caps plugs and covers 5 3 2 Install packing ju
28. istributor either repair or replace the pump Upon any claim under this warranty other than a claim wherein Kerr Pump Corporation at its option replaced the pump as provided in Item E hereof the Distributor will make the necessary repairs and or replacement and Kerr Pump Corporation shall allow the cost of labor on warranty claims The labor cost may include travel time not to exceed 8 hours of actual travel time Kerr Pump Corporation will pay surface freight on warranty shipments After making the necessary repairs and or replacements the Distributor will bill the customer for the full amount due for the repair Thereafter the Distributor will submit the warranty claim form provided by Kerr Pump Corporation to the Kerr Pump Corporation Home Office for consideration In the event the warranty claim is honored by Kerr Pump Corporation a Credit Memorandum will be issued to the Distributor in the amount determined by the table in Item D hereof Thereafter the customer s invoice will be credited by the Distributor in the same percentage allowed the Distributor by Kerr Pump Corporation If requested by Kerr Pump Corporation the purchaser or the Distributor shall return the alleged defective product to Kerr Pump Corporation factory freight prepaid for examination and testing If Kerr Pump Corporation determines the product is defective Kerr Pump Corporation will either repair or replace such product with a like Kerr Pump Corporation manufactur
29. lowed by any unscrewing all other power frame to fluid end cap screws removing the Piston Rod Clamp then safely sliding the Fluid End away from the Power Frame Kerr Pumps TECHNICAL DATA SHEET T D S NO 4 2 W PCN Supercedes PCN Date 03 10 06 Since 1946 SHORT TERM STORAGE PREPARATION PROCEDURE 1 0 SCOPE This procedure applies to Kerr Pumps ONLY Storage procedures for any other unit components or accessories gear reducers engines etc are to be prepared to the specific manufacture s recommendations 1 1 Short term storage is defined as storage and or transient time less than six 6 months in an environment defined in Paragraph 2 If storage exceeding six months is expected the Long Term Pump Storage Preparation Procedure should be followed 1 2 Kerr Pumps will only prepared for short term storage if so specified in the purchaser or customer order control document 2 0 STORAGE ENVIRONMENT A minimal environmental condition to be met by the customer or purchaser is a closed shelter to eliminate effects of sun wind sand or other debris Large temperature and humidity changes should be avoided to prevent coating deterioration or contamination by moisture 3 0 PRESERVATIVE PRODUCT 3 1 The specified rust preservative will protect the internal power end parts from corrosion due to atmospheric moisture and may be left in the pump when filled with appropriate lubricant and placed into service The elevated temperature of servi
30. ne Water Pump to Manifold AP 216 3 8 Quick Connect KM 220 Line Water Pump to Supply Tank KM 240 Liner Cooling System Reservoir Kit KM 245 175 Piston Complete 1 3 4 Includes HSN Cup KM 260 175 Retainer KM 261 175RD amp Nut KM 270 KM 245 187 Piston Complete 1 7 8 Includes HSN Cup KM 260 187 Retainer KM 261 187 amp Nut KM 270 KM 245 200 Piston Complete 2 Includes HSN Cup KM 260 200 Retainer KM 261 200 amp Nut KM 270 KM 245 225 Piston Complete 2 1 4 Includes HSN Cup KM 260 225 Retainer KM 261 225RD amp Nut KM 270 KM 125 GS3 Bearing Housing Hyd Drive for SAI GS3 Series KMX 125 GS3 Bearing Housing Hyd Drive for SAI 153 Series KM 125 800W Bearing Housing White Hyd Mtr 800 Series 14 Tooth KMX 125 800W Bearing Housing White Hyd Mtr 800 Series 14 Tooth KM 125 3000 Bearing Housing Bearingless 3000 KMX 125 3000 Bearing Housing Bearingless 3000 KM 125 4000 Bearing Housing Bearingless Hyd Mtr 4000 WOW RP RF G NB DD RN P Kerr KM 3250PT KM 3300PT KM 3250SHPT KM 3300SHPT Piston Pump 2 D Description KM 245 175G Piston Complete 1 1 2 Includes Cup KM 260G 175 Retainer KM 261 175 amp Nut KM 270 KM 245 187G Piston Complete 1 7 8 Includes Cup KM 260G 187 Retainer KM 261 187 amp Nut KM 270 KM 245 200G Piston Complete 2 Includes Cup KM 260G 200 R
31. nk rings plungers pony rods if applicable baffle discs and wiper box seals Replace any damaged or cracked O rings or gaskets 5 3 3 Inspect power end shaft oil seals and replace if cracked split or damaged 5 3 4 Install crankcase drain plug lubrication level site glass and breather cap 5 3 5 Install if applicable any oil pressure and or temperature gage 5 3 6 Check the connection of the plunger and pony rod to the crosshead prior to and after initial run in of the pump 5 3 7 Fill the crankcase to the proper level with the specified lubricant Kerr Pump Maintenance Schedule for Piston Type Pumps Check Oil Level in Pump Check Oil Level in Planetary Gear Check for Water or Bentonite in Gear Box Check Piston Chamber for Leaking Pistons Check Recovery Tank for Bentonite Check Piston Cooling Pump for Proper Operation Check Pony Rod Seals Check and Replace if Necessary Piston Cups Check and Replace if Necessary Valve Inserts Check and Replace if Necessary Valves and Seats Check and Replace if Necessary Liners Check Rod Bearings Check Pony Rods Check Belts or 8 Hrs Visual Inspection Visual Inspection Visual Inspection Visual Inspection Visual Inspection Visual Inspection Service Visual Inspection Visual Inspection Visual Inspection or 40 Hrs Visual Inspection Visual Inspection Visual Inspection Visual Inspection Visual Inspection Visual Inspection Service Visual Ins
32. pe of packing for particular installation Contact Kerr Pump Corporation if you are unsure Abrasive or corrosive fluid Lack of oil overload on pump foreign matter in oil A new pump will run hot for a short period 2 or 3 days See above for persistent heating Pump will operate near 140 F under average conditions Check for air in pump by bleeding at cover caps Too much spring tension Reciprocating pumps have very limited pick up INSTALLATION INSTRUCTIONS WARNING Read everything in this section before attempting to run or connect your pump The importance of proper installation cannot be overstressed As the reciprocating pump is almost unable to lift fluid proper suction flooding is a must This is the First step toward satisfactory operation For best results follow these installation guidelines A PRESSURE RELIEF VALVE REQUIRED B BY PASSED FLUID SHOULD BE PIPED BACK IN SUCTION SUPPLY TANK WHEN POSSIBLE C USE FLEXIBLE HOSE IN DISCHARGE LINE WHEN POSSIBLE D DISCHARGE SHUT OFF VALVE OPTIONAL USED FOR TOTAL SHUT DOWN OR SERVICE ONLY DISCHARGE AND SUCTION ON EITHER SIDE OF FLUID END ON ALL MODELS F PULSATION DAMPENERS MAY BE USED IN EITHER THE SUCTION OR DISCHARGE PIPING OR BOTH DISCHARGE DAMPENERS SHOULD BE CAPABLE OF HANDLING PUMP DISCHARGE MAXIMUM PRESSURE The Kerr Pumps Engineering Service will be happy to advise you in your installation problems As almost every installation varies you cannot ex
33. pection Visual Inspection Visual Inspection Visual Inspection Visual Inspection Visual Inspection Visual Inspection or 200 Hrs Service Service Visual Inspection Visual Inspection Service Visual Inspection Service Visual Inspection Visual Inspection Visual Inspection Visual Inspection Visual Inspection Visual Inspection Visual Inspection Visual Inspection or 500 Hrs Visual Inspection Visual Inspection Visual Inspection Service Visual Inspection Visual Inspection Visual Inspection Visual Inspection Visual Inspection Visual Inspection Visual Inspection Visual Inspection or 1000 Hrs Visual Inspection Visual Inspection Visual Inspection Service Service Service Service Service Service Visual Inspection Visual Inspection Visual Inspection or 2000 Hrs Visual Inspection Visual Inspection Visual Inspection Service Service Visual Inspection Service 306 71 KM 75 SA ING NY RO D VALVE BOLTED TYPE TING TOOL SEAL TOOL INSERT STUFFING BOX TOOL WRENCH SPECIAL TOOLS FOR KM 3250PT WRENCH How To Inserts In Valves Using Kerr Valve Insert Tool 1 Push Valve Insert over LA us 42 E 3 Holding Valve valve legs Hint Insert insert down with will be more pliable if 2 Put Tool between thumb heated first warm to the valve and valve touch not hot insert with groove against valve 4 While holding valve
34. rews to Kerr Pump Specs KM 3250PT amp KM 3300PT Ta TYPE PUMP TORQUE 222 17 Nh 4 7 Qe WHEN ADJ USTING THE ENDPLAY OF THE TAPERED ROLLER BEARINGS USED ON THE CRANKSHAFT TORQUE SPECIFICATIONS DIAL INDICATORS AND SHIMS MUST BEARING AD 2 PAN COVER CAPSCREW 9 fb 12 Nm IN EXC ESSIVE NOISE TEMPERATURE AND REDUC ED BEARING LIFE Kerr Pumps 23 HOUSING CAPSCREW 50 ft lb 68 Nm REC OMMENDS BETWEEN 000 005 OF INTERNAL AXIAL CLEARANCE 5 PONY ROD 500 ft lb 678 Nm ASSEMBLED BINAE ADJUSTMENT 100 fib 136 Nm MUSTBEMADEUSING A DIAL INDICATOR g COVER PLATE CAPSCREWS 175 237 Nm INSURE THE CONNECTING RODS ARE DISC ONNEC TED TO ALLOW FREE 20 ft lb 27 Nm NOTE WHEN USING LUBRICANTS REDUCE TORQUE AS FOLLOWS 000 005 SHAFT END PLAY 003 004 CONNECTING ROD AT CRANKSHAFT 001 002 CONNECTING ROD AT WRIST PIN OIL amp GREASE REDUCE TORQUE 40 REPEAT TORQUE SEQUENCE THREE TIMES EACH TOP AND FRONT PLA FLUID END COVERPLATE CAPSC REWS TORQUE TO 110 FT LBS 149 NM WITH ANTI SEIZE COMPOUND KM 3250PT KM 3300PT FLUID END TORQUE SEQUENCE 18 625 TIL ia EHH r m 4 x T RT j 13 69 11 4 9 125 DISC HARGE 3 000 3 500 12 0 Cr Ili ill 78
35. s with waxed tape 4 1 8 Carefully wrap the following parts prior to placing them into polyurethane bags Oil level gages lube pressure gages and breather caps 4 1 9 Finish box crate and mark the parts from Para 4 1 2 after final inspection see Para 4 2 2 Shipping Receiving New Pumps Only 4 2 1 All pumps and accessories as applicable will be final inspected by Kerr Pump personnel prior to shipping Any witnessed or third party inspection will be signed off by the purchaser or customer representative prior to final crating and shipment 4 2 2 Export crating will be performed by either an approved Kerr Pump source or as specified by the purchaser or customer Any third party inspection will be coordinated with the source 4 2 3 Upon receipt of the shipment the purchaser or customer is responsible for inspection and repair of damaged coatings at the expense of the shipper 5 0 WARRANTY START UP 5 1 5 2 5 3 Pumps prepared per the above procedure qualify for the Standard Terms amp Conditions in force on the date of shipment If the pump storage period is less than 6 months follow the Short Term Pump Preparation Procedure Prior to start up 5 3 1 Remove all storage caps plugs and covers 5 3 2 Replace any damaged or cracked O rings or gaskets 5 3 3 Inspect power end shaft oil seals and replace if cracked split or damaged 5 3 4 Install crankcase drain plug lubrication level site glass and breather 5 3 5 Install
36. sale In the event of a claim under this warranty made within the 1000 HOUR warranty period the purchaser must notify the Distributor and the Distributor shall contact Kerr Pump Corporation before any repairs or service calls are made All warranty claims must be sent to Kerr Pump Corporation Home Office on the authorized warranty claim form provided by Kerr Pump Corporation and available from the Distributor before any warranty claim will be considered It is understood that a pump will deteriorate due to ordinary wear therefore the following credits shall apply to all replacement parts labor surface freight travel time and mileage allowance furnished under this warranty FOR 1000 HOUR CLAIMS i For the first 250 hours 100 credit will be allowed on a current list price basis ii From 251 hours to 500 hours 75 credit will be allowed a current list price basis iii From 501 hours to 750 hours 5096 credit will be allowed on a current list price basis iv From 751 hours to 1000 hours 25 credit will be allowed on a current list price basis The credit given to the Distributor for replacement parts or pumps under this warranty is based upon the Distributor s net cost paid Kerr Pumps for such replacement parts or pumps In the event of a warranty claim under this warranty is made within the first 250 hours Kerr Pump Corporation before any repairs begin shall be contacted by the Distributor and given the option of having the D
37. ted KM 28 Pony Rod Gland for Double Seal KM 28A Pony Rod Gland Assy KM 28 285 2ea of KM 29 285 Pony Rod Gland Snap Ring KM 29 Pony Rod Oil Seal Req 2 per Set sets KM 31 Top amp End Cover Plate KM 33 Pony Rod Splash Guard KM 34D Fluid End Vessel Only KM 34AB Fluid End ALBZ Vessel Only 345 Fluid End Steel Vessel Only 3455 Fluid End Stainless Steel Vessel Only KM 34BCAB Fluid End Bolted Cap ALBZ Vessel Only KM 34BCD Fluid End Bolted Cap Ductile Vessel Only KM 34BCS Fluid End Bolted Cap Steel Vessel Only KM 34BCSS Fluid End Bolted Cap Stainless Steel Vessel Only KM 34BCSHPTD Fluid End Bolted Cap Ductile Vessel Only KM 35AB Top Cover Cap ALBZ KM 35D Top Cover Cap Ductile 355 Cover Steel 3555 Cover Stainless Steel 35 Top Cover Cap Bolted Cap ALBZ KM 35BCD Top Cover Cap Bolted Cap Ductile KM 35BCS Top Cover Cap Bolted Cap Steel KM 35BCSS Top Cover Cap Bolted Cap Stainless Steel KM 36AB End Cover Cap ALBZ KM 36D End Cover Cap Ductile KM 36S End Cover Cap Steel KM 36SS End Cover Cap Stainless Steel KM 36BCAB End Cover Cap Bolted Cap ALBZ KM 36BCD End Cover Cap Bolted Cap Ductile KM 36BCS End Cover Cap Bolted Cap Steel KM 36BCSS End Cover Cap Bolted Cap Stainless Steel KM 37A O Ring Stuffing Box Cover KM 37A O Ring Stuffing Box amp Cover Cap 38 Fluid End Capscrews S
38. tools and absolutely no instruments special tools or gauges are needed Connecting rod and wrist pin Proper fit will find the wrist pin turning freely in its bore in the connecting rod but it should have no wobble that is discernable up and down the main axis of the connecting rod This looseness in the wrist pin fit is the most probable cause of knocking which is traceable to the power end of most all pumps The only solution for loose fitting wrist pins is to discard the connecting rod wrist pin bushing and replace with a new one If any wear is visible on the wrist pin it should always be replaced Crankshaft End Play and Lateral adjustments Adjustment of the Taper Roller bearings used in all Kerr Pumps is accomplished by removing or adding shims under the bearing housing Shims are taken out or added until the crankshaft without connecting rods will turn freely but with no endplay felt when attempting to pull or push the jackshaft end of the crankshaft along its long axis Some lateral adjustment is possible by removing shims from one side of the crankshaft and adding them to the opposite side Note Lateral adjustment is the centering of the crankshaft in the power frame housing Connecting Rod to Crankshaft fitting Factory bored connecting rods will normally fit the standard crankshaft journal just by bolting the cap on the rod with the standard rod shims being used If the caps do require adjustment this is accomplished b
39. y removing or adding various thicknesses of rod shims The standard connecting rod shim used on all Kerr Pumps is 1 32 thick and is comprised of 002 laminates which can be pealed off separately Proper fit of the connecting rod will allow the pump crankshaft to be rotated while not allowing in and out slack in the connecting rod along its long or main axis A well fitted rod will have none of the in and out slack but should be free enough to be moved from side to side on the rod journal This insures the rod not being too tight A point of caution when installing the connecting rod assembly in the pump is to make certain the oil holes in the rod are UP and not toward the bottom of the pump This will result in lubrication failure in these parts and the pump will fail in a short period of time An additionally important step is to make sure that the rod cap is bolted back on the rod as it came off rod cap carry mark or number which allows you match them back properly Failure to this will cause the rod not to fit the journal for which it was made D Power End Fluid End Connection A common misconception is that there is some form of fluid seal between the power end and the fluid end This is false The fluid end is merely bolted to the power frame To take off the Fluid End all the Liners must be removed by unthreading all retainer Nuts from each retainer Stud sliding off each liner Retainer fol
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