BJM Pumps KB Series Instruction manual

Version 4/25/2013
INSTALLATION, OPERATION & MAINTENANCE MANUAL
KB SERIES
TOP DISCHARGE
HEAVY DUTY DEWATERING WITH AGITATOR
Electric Submersible Pumps
CAST IRON
Three Phase
230V, 460V, & 575V
KB55
KB55H
KB75
KB75H
KB110
KB110H
Read this manual carefully before installing, operating or servicing these pump models.
Observe all safety information. Failure to comply with instructions may result in personal
injury and/or property damage. Please retain these instructions.

TABLE OF CONTENTS
INTRODUCTION...........................................................................................................................................4
SAFETY ........................................................................................................................................................5
INSPECTION ................................................................................................................................................6
PRE-INSTALLATION INSPECTION ........................................................................................................6
OIL FILL QUANTITY/TYPE......................................................................................................................6
PUMP INSTALLATION.............................................................................................................................7
POSITIONING THE PUMP.......................................................................................................................7
PUMP ROTATION....................................................................................................................................8
PUMP OPERATION.................................................................................................................................9
TYPICAL MANUAL DEWATERING INSTALLATION...................................................................................9
STOPPING ...............................................................................................................................................9
TYPICAL AUTOMATIC DEWATERING INSTALLATION...........................................................................10
STOPPING .............................................................................................................................................10
INTENDED METHODS OF CONNECTION ...............................................................................................10
THREE PHASE WIRING INSTRUCTION...................................................................................................11
TROUBLE SHOOTING...............................................................................................................................12
PUMP WILL NOT RUN...........................................................................................................................12
PUMP RUNS BUT DOES NOT DELIVER RATED CAPACITY.............................................................12
SERVICING YOUR SUBMERSIBLE PUMP ..........................................................................................13
MAINTAINING YOUR PUMP .................................................................................................................13
CHANGING SEAL OIL ...........................................................................................................................13
CHANGING SEALS* ..............................................................................................................................14
EXPLODED VIEW OF KB55, 55H, 75, 75H, 110, 110H ............................................................................15
KB SERIES PARTS LIST............................................................................................................................16
THREE PHASE WIRING DIAGRAMS........................................................................................................18
230V (5 LEAD)........................................................................................................................................18
MODELS KB55, 55H, 75, 75H, 110, 110H ........................................................................................18
460V (5 LEAD)........................................................................................................................................19
MODELS KB55, 55H, 75, 75H, 110, 110H ........................................................................................19
575V (5 LEAD)........................................................................................................................................20
MODELS KB55, 55H, 75, 75R, 110, 110H ........................................................................................20
SEAL MINDER............................................................................................................................................21
WARRANTY AND LIMITATION OF LIABILITY..........................................................................................23
START-UP REPORT FORM.......................................................................................................................24
NOTES:.......................................................................................................................................................27

4
INTRODUCTION
This Installation, Operation and Maintenance manual provides important information on
safety and the proper inspection, disassembly, reassembly and testing of the BJM
Pumps® KB Series submersible pump. This manual also contains information to
optimize performance and longevity of your BJM submersible pump.
The submersible KB Series pumps are designed to pump water based slurry
solutions. The KB Series pumps are not explosion-proof. They are not designed
to pump volatile or flammable liquids.
Note: Consult chemical resistance chart for compatibility between pump
materials and liquid before operating pump.
If you have any questions regarding the inspection, disassembly, re-assembly or testing
please contact your BJM Pumps distributor, or BJM Pumps, LLC.
BJM Pumps, LLC
123 Spencer Plain Rd.
Old Saybrook, CT 06475, USA
Fax: [phone]
Phone: [phone]
Phone: [phone]
Information, including pump data sheets and performance curves, is also available on
our web site: www.bjmpumps.com
For assistance with your electric power source, please contact a certified electrician.
Please pay attention to the following alert notifications. They are used to notify
operators and maintenance personnel to pay special attention to procedures, to avoid
causing damage to the equipment, and to avoid situations that could be dangerous to
personnel.
NOTE: Instructions to aid in installation, operation, and maintenance or which
clarify a procedure.
Immediate hazards that WILL result in severe personal injury or
death. These instructions describe the procedure required and the injury which will
result from failure to follow the procedure.
Hazards or unsafe practices that COULD result in severe personal
injury or death. These instructions describe the procedure required, and the injury which
could result from failure to follow the procedure.
Hazards or unsafe practices which COULD result in personal injury
or product or property damage. These instructions describe the procedure required and
the possible damage which could result from failure to follow the procedure.

5
SAFETY
Pump installations are seldom identical. Each installation and application can vary due
to many different factors. It is the owner/service mechanics responsibility to repair,
service, and test to ensure that the pump integrity is not compromised according to this
manual.
Risk of electric shock – this pump has not been investigated for use
in swimming pool areas.
Do not pump flammable, inflammable or volatile liquids.
Death
or serious injury will result.
Before attempting to open or service the pump:
1) Familiarize yourself with this manual.
2) Unplug or disconnect the pump power cable to ensure that the pump will remain
inoperative.
3) Allow the pump to cool if overheated.
Do not operate the pump with a worn or damaged electric power
cable. Death or serious injury could occur.
Never attempt to alter the length or repair any power cable with a
splice. The pump motor and pump motor and cable must be completely waterproof.
Damage to the pump or personal injury may result from alterations.
After the pump has been installed, make sure that the pump and all
piping are secure before operation.
Do not lift the pump by the power cable piping or discharge hose.
Attach proper lifting equipment to the lifting handle (or lifting rings) fitted to the pump. Do
not suspend the pump by the power cable.
Obtain the services of a qualified electrician to troubleshoot, test
and/or service the electrical components of this pump.
Pumps and related equipment must be installed and operated
according to all national, local and industry standards.

6
INSPECTION
Review all safety information before servicing pump.
The following are recommended installation practices/procedures for the pump. If there
are questions in regards to your specific application, contact your local BJM Pumps
distributor or BJM Pumps, LLC.
PRE-INSTALLATION INSPECTION
1) Check the pump for damage that may have occurred during shipment.
2) Inspect the pump for any cracks, dents, damaged threads, etc.
3) Check power cord (and seal minder cord, if installed) for any cuts or damage.
4) Check for, and tighten any hardware that appears loose.
5) Carefully read all tags, decals and markings on the pump.
6) Important: Always verify that the pump nameplate, amps, voltage, phase, and
HP ratings match your control panel and power supply.
Warranty does not cover damage caused by connecting pumps and controls to an
incorrect power source (voltage/phase supply). Record the model numbers and serial
numbers from the pumps and control panel on the front of this instruction manual for
future reference. Give it to the owner or affix it to the control panel when finished with
the installation.
If anything appears to be abnormal, contact your BJM Pumps distributor or BJM
Pumps, LLC. If damaged, the pump may need to be repaired before use. Do not install
or use the pump until appropriate action has been taken.
Lubrication:
No additional lubrication is necessary. The shaft seal and bearings are fully lubricated
from the factory. Seal oil should be checked once per year. See table below.
OIL FILL QUANTITY/TYPE
Qty. oil in seal chamber
Models
U.S. fl. oz.
C.C.
Type of oil
KB55, 55H, 75, 75H, 110, 110H
49
1450
ISO 32 NSF Food Grade Mineral Oil

7
PUMP INSTALLATION
KB Series pumps have been evaluated for use with water or water based solutions.
Please contact the manufacturer for additional information.
Risk of electric shock. KB Series pump models do not come with
electric plug connectors. To reduce the risk of electric shock, be certain that it is
connected only to a properly grounded, grounding-type receptacle.
Lifting:
Attach a rope or lifting chain (not included) to the handle (or lifting rings) on the top of
the pump.
Do not lift the pump by the power cable or discharge hose/piping.
Proper lifting equipment (rope/chain) must be used.
POSITIONING THE PUMP
BJM Pumps, KB Series pumps are designed to operate fully or partially submerged. Do
not run the pump dry. Refer to data sheet for minimum submersion depth for your
particular model. Data sheets can be obtained online at www.bjmpumps.com or by
calling BJM Pumps, LLC at 860-399-5937. As a general rule, KB Series top discharge
pumps can pump down to a level above the suction screen. Pumping lower than screen
will permit air to enter the pump and cavitate, lose prime or become air bound.
•Do not run pump dry.
•Pump liquid should not exceed a maximum temperature of 104°F.
•Never place the pump on loose or soft ground. The pump may sink, preventing
water from reaching the impeller. Place on a solid surface or suspend the pump
with a lifting rope/chain. The KB Series pumps are provided with a suction
strainer to prevent large solids from clogging the impeller. Any spherical solids
which pass through the strainer should pass through the pump.
•For maximum pumping capacity, use the proper size non-collapsible hose or rigid
piping. A check valve may be installed after the discharge to prevent back flow
when the pump is shut off.

8
PUMP ROTATION
Two ways to check the correct pump rotation:
1. By looking at the impeller; the rotation of the impeller should be counter
clockwise as shown in the picture below.
2. By looking from the top of the pump. Since the impeller cannot be seen, the best
way to check the rotation is to check the kick back motion of the pump when the
pump just starts. The kick back motion of the pump should be counter clockwise
as shown in the picture below.

9
PUMP OPERATION
This pump is designed to handle dirty water that contains some
solids. It is not designed to pump volatile or flammable liquids. Do not attempt to pump
any liquids which may damage the pump or endanger personnel as a result of pump
failure.
Do not operate this pump where explosive vapors or
flammable material exist. Death or Serious injury will result.
TYPICAL MANUAL DEWATERING INSTALLATION
NOTE: Maximum recommended starts should not exceed 10 times per hour.
All KB models are provided with a 50’ (10m) power cord. NEVER
Note: 230V, 460V & 575V three phase units do not have a plug and have to be
provided separately.
splice the power cable
due to safety and warranty considerations. Always keep the plug end dry.
Do not alter the length or repair any power cable with a splice. The
pump motor and cable must be completely waterproof. Damage to the pump or
personal injury may result from alterations.
For manual operation: 230, 460 & 575 volt: Attach the proper plug or connect directly to
the power source or control box. Check the direction of the rotation. Tilt the pump and
start it. It should twist in the opposite direction of the arrow (on pump). It is
recommended that a Ground Fault Interrupter (GFI) type receptacle (or equivalent) be
used.
STOPPING
To stop the pump (manual and automatic mode), disconnect it from the power source,
turn off the breaker, or turn the power source off (generator).
Typical 3 phase manual control 1

10
TYPICAL AUTOMATIC DEWATERING INSTALLATION
NOTE: Maximum recommended starts should not exceed 10 times per hour.
Float switches (wired into the pump motor or piggy-back style) are available from the
factory as an option.
Note: 230V, 460V & 575V pumps do not have a plug installed.
Three phase pumps need a separate control box with float(s) for automatic
operation.
STOPPING
To stop the pump (manual and automatic mode), unplug it from the power source, turn
off the breaker, or turn the power source off (generator).
INTENDED METHODS OF CONNECTION
Use with approved motor control that matches motor input in full
load amperes. “UTILLISER UN DÉMARREAR APPROUVÉ CONVENANT AU
COURANT Á PLEINE CHARGE DU MOTEUR.”
BJM Pumps has been evaluated for use with water or water based solutions. Please
contact the manufacturer for additional information.

11
THREE PHASE WIRING INSTRUCTION
FOR YOUR PROTECTION, ALWAYS DISCONNECT PUMP
FROM ITS POWER SOURCE BEFORE HANDLING.
“Risk of electrical shock” Do not remove power supply cord and
strain relief or connect conduit directly to the pump.
Installation and checking of electrical circuits and hardware should
be performed by a qualified licensed electrician.
To automatically operate a non-automatic three phase pump, a control panel is
required. Follow the instructions provided with the panel to wire the system. For
automatic three phase pumps see automatic three phase wiring diagram.
Typical 3 phase Auto Control 1
Before installing a pump, check the pump rotation to insure that wiring has been
connected properly to power source, and that the green lead of power cord (See wiring

12
diagram), is connected to a valid ground, momentarily energize the pump, observing the
directions of kick back due to starting torque. Rotation is correct if kick back is in the
opposite direction of rotation arrow on the pump casing. If rotation is not correct,
switching of any two power leads other than ground will provide the proper rotation.
BJM three phase pumps have integral motor overload protection. BJM recommends
that all three phase pumps using a motor starting device also incorporate motor
overload protection. Pumps must be installed in accordance with the National Electrical
Code and all applicable local codes and ordinances. Pumps are not to be installed in
locations classified as hazardous in accordance with National Electrical Code,
ANSI/NFPA 70.
Connect pump to a junction box, outlet box, control box, enclosure with a wiring
compartment that meets NEC and local codes. The provision for supply connection
shall reduce the risk of water entry during temporary, limited submersion and shall
comply with the applicable requirements of the Standard for Enclosures for Electrical
Equipment, UL 50, or the standard for Metallic Outlet Boxes, UL 514A, and the standard
for Motor-Operated Water Pumps. UL 778.
TROUBLE SHOOTING
Disconnect the power source to the pump BEFORE attempting
any type of trouble shooting, service or repair.
PUMP WILL NOT RUN
1. Check power supply (fuses, breaker). Reset power.
2. Blocked impeller. Remove strainer, check and clean.
3. Defective cable or incorrect wiring.
4. Strainer clogged. Check and clean as necessary.
5. Float switch tangled/obstructed. Clean and free float switch from obstruction.
6. Float switch defective. Replace float switch.
7. Pump overheated or temperature of liquid exceeds pump operating
temperature.
Warning: Pump will restart automatically when motor over-heat protection switch
cools.
PUMP RUNS BUT DOES NOT DELIVER RATED CAPACITY
1. Discharge line clogged, restricted or hose kinked. Check discharge hose/pipe.
2. Worn impeller and/or suction cover. Inspect and replace as necessary.
3. Pump overloaded due to liquid pumped being too thick.
4. Pumping air. Check liquid level and position of pump.

13
5. Excessive voltage drops due to long cables.
6. Three phase only; pump running backwards, check rotation.
SERVICING YOUR SUBMERSIBLE PUMP
Pump MUST be disconnected from the electric power supply before proceeding to do
any service or maintenance.
To service or repair your pump, please contact your local BJM Pumps distributor.
Service should only be performed by a qualified electrician.
MAINTAINING YOUR PUMP
•Pump must be disconnected from the electric power supply before proceeding to
do any service or maintenance.
•Pump should be inspected at regular intervals for wear.
•More frequent inspections are required if the pump is used in a harsh
environment, such as pumping abrasive solids or high/low PH water.
•Preventative maintenance should be performed to reduce the chance of
premature failure.
•Worn impeller wear plates and lip seals should be replaced.
•Cut or cracked power cords must be replaced. (Never operate a pump with a
cut, cracked or damaged power cord.)
•Seal oil should be checked once per year.
•Maintenance should always be done when taking a pump out of service before
storage.
1) Clean pump of dirt and other build up.
2) Check condition of oil around the shaft seals.
3) Check hydraulic parts: check for wear.
4) Inspect power cable. Make sure that it is free of nicks or cuts.
CHANGING SEAL OIL
Changing the seal oil in the KB Series pumps is very easy.
1) Make sure that the pump cable is disconnected from the power source.
2) Lay the pump down on its side.
3) Remove the screws that hold the bottom plate in place.
4) Remove bottom plate.
5) Remove screws holding the suction cover.
6) Remove the suction cover.
7) Remove the impeller.
8) Remove the inspection screw for the oil chamber (pos#50-08). Pour out a
small sample of the oil. If it is milky white, or contains water, then the oil and
possible, the mechanical seal, should be changed. If an oil change is needed:

14
9) Remove the screws that hold the oil chamber cover in place & remove the oil.
10)Replace the mechanical seal if necessary.
11)Replace the oil.
12)Reassemble the pump.
CHANGING SEALS*
1) Make sure that the pump cable is disconnected from the power source.
2) Lay the pump down on its side.
3) Remove the oil inspection bolt (pos#50-11) from the oil seal chamber.
4) Drain out all the inside the oil seal chamber.
5) Remove the bolts holding the stand.
6) Remove the stand.
7) Remove the bolts holding the suction cover.
8) Remove the suction cover.
9) Remove the agitator.
10)Remove the impeller, impeller key and shims.
11)Remove the bolts holding the pump housing.
12)Remove the pump housing.
13)Remove the shaft sleeve. Note the shaft sleeve direction.
14)Remove the bolts holding the oil cover.
15)Remove the oil cover.
16)Remove the screws holding the seal retainer.
17)Remove the seal retainer.
18)Remove the mechanical seal.
19)Replace the mechanical seal, lip seal and o-rings.
20)Reassemble the pump.
21)Fill with recommended new oil.
22)Replace the oil inspection bolt o-ring.
23)Secure the oil inspection bolt.
*Note: If there is excessive liquid found in the oil or mechanical seal damaged, please
contact BJM authorized service centers.

15
EXPLODED VIEW OF KB55, 55H, 75, 75H, 110, 110H

16
KB SERIES PARTS LIST
Pump Model KB55 KB55H KB75 KB75H KB110 KB110H
Pos. No. Part Description Item # Item # Item # Item # Item # Item #
01 Strainer / Stand 202013 202013 202014 202013 202014 202014
02 Wear Plate 202863 202015 202865 202866 202024 202025
02W Suction Cover 202878 202878 202879 202878 202879 202879
04 Lock Washer 202904 202904 202904 202904 202904 202904
05 Impeller 202924 202925 202926 202927 202928 202929
05W Agitator 202058 202058 202058 202058 202058 202058
06 Impeller Key 202145 202145 202145 202145 202145 202145
07 Pump Housing 203036 203036 203033 203036 203033 203033
07-3 Pump Housing Sleeve 202182 202182 202182 202182 202182 202182
08 Oil Chamber Cover 202228 202228 202228 202228 202228 202228
08 -1 O-Ring (Kit Only) Kit Kit Kit Kit Kit Kit
09 Lip Seal Buna N 202248 202248 202248 202248 202248 202248
10 Shaft Sleeve 203074 203074 203074 203074 203074 203074
13 Mech. Seals - Set Buna N (Optional) 201016 201016 201016 201016 201016 201016
13 Mech. Seals - Set FKM 201015 201015 201015 201015 201015 201015
13-2 Mech. Seal Retainer 202274 202274 202274 202274 202274 202274
14 Lower Ball Bearing 200963 200963 200963 200963 200962 200962
14-2 Lower Bearing Retainer 202276 202276 202276 202276 202282 202282
16 Motor Housing 203078 203078 203079 203078 203080 203080
17 Rotor w/ Shaft, 3 phase 202355 202355 202356 202358 202357 202357
18 Stator 230V/460V, 3 phase, 60Hz 200674 200674 200677 200705 200679 200679
18 Stator 575V, 3 phase, 60 Hz 200676 200676 200678 200706 200680 200680
20 Upper Ball Bearing 200968 200968 200968 200968 200968 200968
20-1 O-Ring (Kit Only) Kit Kit Kit Kit Kit Kit
20-2 Spring Washer 202361 202361 202361 202361 202361 202361
21A Lower Bearing Housing 202376 202376 202376 202376 202375 202375
21A-1 O-Ring (Kit Only) Kit Kit Kit Kit Kit Kit
23 Overload 230V, 3PH 202394 202394 202396 202396 202397 202397
23 Overload 460V, 3PH 202393 202393 202394 202394 202398 202398
23 Overload 575V, 3 PH 202391 202391 202393 202393 202394 202394

17
KB SERIES PARTS LIST
26 Pump Top Cover 203133 203133 203134 203133 203134 203134
26-1 O-Ring (Kit Only) Kit Kit Kit Kit Kit Kit
27 Power Cord Set (5 lead) 203455 203455 203455 203455 203456 203456
27-1 O-Ring (Kit Only) Kit Kit Kit Kit Kit Kit
27-2 Seal Minder Cord 201714 201714 201714 201714 201714 201714
27-3 Seal Minder Cap 201717 201717 201717 201717 201717 201717
27-3-1 O-Ring (Kit Only) Kit Kit Kit Kit Kit Kit
31D Seal Minder Sensor 202410 202410 202410 202410 202410 202410
32 Power Cable Strain Relief 202506 202506 202506 202506 202507 202507
33 Seal Minder Cord Line Clip 203163 203163 203163 203163 203163 203163
34 Handle 202527 202527 202528 202527 202528 202528
38 3" NPT Male Coupling Flange -202610 - - - -
38 4" NPT Male Coupling Flange 202609 - - 202609 202818 202612
38 6" NPT Male Coupling Flange - - 202611 -202611 -
50-01 Bolt - Strainer / Stand 203241 203241 203225 203241 203225 203225
50-02 Bolt - Wear Plate 203294 203294 203262 203294 203262 203262
50-02W Bolt - Suction Cover 203262 203262 203262 203262 203262 203262
50-07 Bolt - Pump Housing 203265 203265 203265 203265 203265 203265
50-08 Bolt - Oil Chamber Cover 203229 203229 203229 203229 203229 203229
50-11 Bolt - Oil Inspection 203268 203268 203268 203268 203268 203268
50-11-1 O-Ring (Kit Only) Kit Kit Kit Kit Kit Kit
50-12 Screw - Pressure Test 203218 203218 203218 203218 203218 203218
50-12-1 O-Ring (Kit Only) Kit Kit Kit Kit Kit Kit
50-13-2 Screw - Seal Retainer 203214 203214 203214 203214 203214 203214
50-14-2 Bolt - Bearing Retainer 203219 203219 203219 203219 203219 203219
50-21A Bolt - Bearing Housing 203229 203229 203229 203229 203229 203229
50-23 Screw - Overload Protector 202700 202700 202700 202700 202700 202700
50-26 Bolt-Top Cover - - 203223 -203223 203223
50-27 Bolt - Power Cord 203229 203229 203229 203229 203229 203229
50-27-3 Screw - Seal Minder Cap 203216 203216 203216 203216 203216 203216
50-34 Bolt - Handle 203222 203222 203222 203222 203222 203222
50-38 Bolt - Discharge Flange 203262 203262 203224 203262 203224 203224
203204 203204 203204 203204 203204 203204
O-Ring Kit - Buna N

18
THREE PHASE WIRING DIAGRAMS
230V (5 LEAD)
MODELS KB55, 55H, 75, 75H, 110, 110H

19
460V (5 LEAD)
MODELS KB55, 55H, 75, 75H, 110, 110H

20
575V (5 LEAD)
MODELS KB55, 55H, 75, 75R, 110, 110H