Kerr Pump Corporation KT-3350XP Quick start guide
Kerr Pump Corporation
Post Office Box 735 2214 West 14th Street
Sulphur, Oklahoma 73086
Phone: 580-622-4207 Fax: 580-622-4206
Website-www.kerrpumps.com
Email-information@kerrpumps.com
United States and Canada
800-441-8149
KERRPUMPCORPORATIONSERVICEMANUAL
NINETEENTHEDITION
NEWPUMPWARRANTY
A. KerrMachineCo.(KerrPumpCorporation)warrantsitsnewpumpstobefreefromdefectivematerialsand/orworkmanshipforaperiodof
oneyearfromthedateofsalebytheDistributor,providedthatthenewpumpisregisteredinaccordancewithParagraphNo.2hereof,
properlyinstalledandoperatedinaccordancewiththeCompany’sServiceManual,andallothertermsofthiswarrantyagreementare
compliedwithbythepurchaser.Ashereinafterprovided,thiswarrantyincludesthereplacementofpartsandlabortocorrectanydeficiency.
AlldefectivepartsmustbereturnedtotheCompany’sHomeOfficeforexaminationbeforethiswarrantyiseffective.Thiswarrantyapplies
toparts,whichhavebeenreplacedunderthiswarrantyonlysolongastheoriginalpumpwarrantyiseffective.Thiswarrantyisforthe
exclusivebenefitofthepurchaserandisnottransferable.
B. EachDistributorofanewpumpwillprovidethecustomerwitharegistrationblankfurnishedtohimbytheCompanywhichmuststatethe
dateofsale,besignedbythepurchaserandtheDistributor,anddeliveredtotheHomeOfficeoftheCompanywithinfifteen(15)daysofthe
dateofsale.
C. Intheeventofaclaimunderthiswarranty,madewithintheone‐yearwarrantyperiod,thepurchasermustnotifytheDistributor,andthe
DistributorshallcontactKerrPumpCorporationbeforeanyrepairsorservicecallsaremade.
D. AllwarrantyclaimsmustbesenttoKerrPumpCorporationHomeOfficeontheauthorizedwarrantyclaimformprovidedbyKerrPump
Corporation,andavailablefromtheDistributorbeforeanywarrantyclaimwillbeconsidered.ItisunderstoodthatKerrPumpCorporation
willdeteriorateduetoordinarywear,therefore,thefollowingcreditsshallapplytoallreplacementparts,labor,surfacefreight,traveltime
andmileageallowancefurnishedunderthiswarranty.
i. Forthefirstninety(90)daysfromthedateofsalebytheDistributor,100%creditwillbeallowedonacurrentlistpricebasis.
ii. From91to180daysfromthedateofsalebytheDistributor,75%creditwillbeallowedonacurrentlistpricebasis.
iii. From181daysto270daysbytheDistributor,50%creditwillbeallowedonacurrentlistpricebasis.
iv. From271daystooneyearafterthedateofsalebytheDistributor,25%creditwillbeallowedonacurrentlistpricebasis.
ThecreditgiventotheDistributorforreplacementpartsorpumpsunderthiswarrantyisbasedupontheDistributor’snetcostpaidKerr
Pumpsforsuchreplacementpartsorpumps.
E. Intheeventofawarrantyclaimunderthiswarrantymadewithinninety(90)daysofthedateofsalebytheDistributor,KerrPump
Corporation,beforeanyrepairsaremade,shallbecontactedbytheDistributorandgiventheoptionofhavingtheDistributoreitherrepairor
replacethepump.
F. Uponanyclaimunderthiswarranty,otherthanaclaimwhereinKerrPumpCorporationatitsoptionreplacedthepumpasprovidedin
ParagraphNo.5hereof,theDistributorwillmakethenecessaryrepairsan/orreplacement,andKerrPumpCorporationshallallowthecostof
laboronwarrantyclaims.Thelaborcostmayincludetraveltimenottoexceed(8)hoursofactualtraveltime.KerrPumpCorporationwill
paysurfacefreightonwarrantyshipments.Aftermakingthenecessaryrepairsand/orreplacements,theDistributorwillbillthecustomerfor
thefullamountduefortherepair.Thereafter,theDistributorwillsubmitthewarrantyclaimformprovidedbyKerrPumpCorporationtothe
KerrPumpCorporationHomeOfficeforconsideration.IntheeventthewarrantyclaimishonoredbyKerrPumpCorporationaCredit
MemorandumwillbeissuedtotheDistributorintheamountdeterminedbythetableinParagraphNo.4hereof.Thereafter,thecustomer’s
invoicewillbecreditedbytheDistributorinthesamepercentageallowedtheDistributorbyKerrPumpCorporation.
IfrequestedbyKerrPumpCorporationthepurchaserortheDistributorshallreturntheallegeddefectiveproducttoKerrPumpCorporation
factory,freightprepaid,forexaminationandtesting.IfKerrPumpCorporationdeterminestheproductisdefectiveKerrPumpCorporation
willeitherrepairorreplacesuchproductwithalikeofKerrPumpCorporationmanufacture,f.o.b.totheDistributororallowtheDistributor
credittoanamountequaltotheinvoicedvalueofthedefectiveproduct.TheresponsibilityofKerrPumpCorporationislimitedtothe
repairingorreplacingdefectivematerialmanufacturedbyit,providedKerrPumpCorporationexaminationdisclosestoitssatisfactionthat
suchmaterialhasnotbeenalteredorrepaired,otherthanbyKerrPumpCorporationapprovedprocedures,subjecttomisuse,improper
maintenance,negligenceoraccident.KerrPumpCorporationwillnotberesponsibleforlossofliquidorfordamageofanykind,orfromany
cause,toanypersonorpropertyofanyperson,orforlossofrevenueofprofit,orforanyotherspecialincidentalorconsequentialdamages.
G. ThewarrantyappliesonlytonewKerrPumpCorporation.TheCompanyspecificallyexcludesfromthiswarrantythefollowing.
i. Allplungers,valves,plungerpacking,valvesprings,sealsgaskets,andcorrosionand/orerosiondamagecausedbythefluidhandledby
theCompany’spump.
ii. Inaddition,aftertheexpirationofthepumpwarrantyallreplacementpartsarenolongerinwarranty.
H. InextremecaseswhereintheopinionofKerrPumpCorporation,ifapumphasbeenmisusedorisbeingmisused,KerrPumpCorporation
reservestheoptiontooffertoredeemthepumpfromthepurchaser.Shouldthepurchaserrefusetoallowthepumptoberedeemedand
choosestocontinueimproperoperation,thewarrantywillbevoid.
I. AnypartsorequipmentwhichKerrPumpCorporationsuppliesanddoesnotmanufactureshallbesubjectonlytothewarrantiesofKerr
PumpCorporationvendorstotheextentKerrPumpCorporationcanenforcesuchwarranties.
J. Anyrepairsto,alterationsof,orworkdoneonallegeddefectiveproductswithoutKerrPumpCorporationspecificwrittenauthorizationshall
voidKerrPumpCorporationwarrantyapplicablethereto.
K. Anyactionforbreachofwarrantyorotheractionunderthisagreementmustbecommencedwithin(1)yearaftersuchcauseofactionarises.
Thislimitedwarrantyisinlieuofallotherwarranties,expressedorimplied,includinganyimpliedwarrantyormerchantabilityorfitness.
TROUBLESHOOTINGGUIDE
ProblemReason/Solution
Unusualpounding,knockingbroken
valvespring
•Insufficientfluidathighspeed.
•Suctionlineisimpropersizeorisconstricted.(Trashinline,valvepartlyopened,etc.)
•Possibilityofgasinthefluidcausingtheroughness.
Lossofpressureorvolume•Foreignmattermaybeholdingvalvesopen.
•Wornvalves.
•Brokensprings.
Consistent,rhythmicknock•Improperbearingadjustment.
•Wornbearingsorconnectingrods.
•NOTE:Valvenoiseiscommonandnormalinhigh‐speedpumps.Itshouldnotcauseconcernunless
itbecomeserratic.
Packingfailure(Excessive)•Improperinstallation.
•Impropertypeoflubrication.
•Incorrecttypeofpackingforparticularinstallation.
•(ContactKerrPumpCorporationifyouareunsure.)
Abnormalwearoffluidendparts•Abrasiveorcorrosivefluid.
Abnormalwearofpowerendparts•Lackofoil,overloadonpump,foreignmatterinoil.
Heatinpowerend•Anewpumpwillrunhotforashortperiod(2or3days).Seeaboveforpersistentheating.Pump
willoperatenear140˚F.underaverageconditions.
•Checkforairinpumpbybleedingatcovercaps.
•ToomuchspringtensionReciprocatingpumpshaveverylimitedpickup.
INSTALLATIONINSTRUCTIONS
WARNING
Theimportanceofproperinstallationcannotbeoverstressed.Asthereciprocatingpumpisalmostunabletoliftfluid,propersuction
floodingisamust.ThisistheFirststeptowardsatisfactoryoperation.
Readeverythinginthissectionbeforeattemptingtorunorconnectyourpump.
TheKerrPumpsEngineeringServicewillbehappytoadviseyouinyourinstallationproblems.Asalmosteveryinstallationvaries,youcannot
exercisetoomuchcareinmakingcertainyourinstallationisproper.
BeforeStartingThePump,readcarefullythemaintenancesectioninthefollowingpages.
Tostartthepump,openthesuctionlinevalveandpermittheintakechambertofillonthepump.Airmaybebledoffbyopeningthevalve
coversslightlyuntilthereisaconstantfluidflow.Afterbleeding,openthedischargelinevalveandstartthepump.Roughnessmayoccurfrom
cavitation(airinline)orfromstarvation(lackoffluid).Eliminatethesetroublesbeforepermittingcontinuousoperation.
Forbestresults,followtheseinstallationguidelines.
(A)PRESSURERELIEFVALVE(REQUIRED)
(B)BY‐PASSEDFLUIDSHOULDBEPIPEDBACKINSUCTIONSUPPLYTANKWHENPOSSIBLE
(C)USEFLEXIBLEHOSEINDISCHARGELINEWHENPOSSIBLE
(D)DISCHARGESHUT‐OFFVALVE(OPTIONAL‐USEDFORTOTALSHUT‐DOWNORSERVICEONLY)
(E)DISCHARGEANDSUCTIONONEITHERSIDEOFFLUIDENDONALLMODELS.
(F)PULSATION“DAMPENERS”MAYBEUSEDINEITHERTHESUCTIONORDISCHARGEPIPINGORBOTH.DISCHARGE
DAMPENERSSHOULDBECAPABLEOFHANDLINGPUMPDISCHARGEMAXIMUMPRESSURE
1) CENTERLINE OF PUMP SUCTION (INLET) TO BE SLIGHTLY
HIGHER THAN CENTERLINE OF SUCTION (INLET) VALVE - SO
ANY AIR IN SUCTION SYSTEM PROMPTLY REACHES PUMP
AND IS EXPELLED
2) SLOPE BYPASS LINE SO LOW POINT DRAIN WILL FULLY
EMPTYRELIEF AND CHOKE VALVES AND ALL LIQUID IN
BYPASS CIRCUIT
3) DO NOT LOCATE PIPING OR OTHER EQUIPMENT IN FRONT
OF OR ABOVE PUMP FLIUD END PREVENTING SERVICING –
REFER TO MANUFACTURER FOR MINIMUM CLEARANCES
4) LOCATE CHARGING PUMP AT POINT SHOWN. – IF
CHARGING PUMP IS NECESSARY (FOR VOLATILE FLUIDS,
FOR EXAMPLE)
5) IF DESIRED, A TWO-WAY MOTOR OPERATED BYPASS VALVE MAY
BE USED RATHER THAN MANUAL TYPE – IT SHOULD BE DESIGN TO
OPEN AUOMATICALLY WHILE STARTING OR STOPPING
6) BYPASS LINE SHOULD FEED LIQUID INTO TANK BELOW MINIMUM
LIQUID LEVEL
7) TO REMOVE PIPING STRAIN AND VIBRATION A FLEXIBLE HOSE,
EXPANSION JOINT OR SWIVLE JOINT PAIR SHOULD BE
POSITIONED TO MINIMIZE EFFECTS OF PIPING THERMAL
EXPANSION, CONTRACTION AND PIPING WEIGHT
8) SUCTION SIZED FOR 1 ½ TO 2 FT/SEC MAX FLOW RATE.
DISCHARGED SIZED FOR 8 TO 10 FT/SEC MAX FLOW RATE –
SUCTION AND DISCHARGE MUST BE SUPPORTED AND
ANCHORED
9) TO PROTECT SUCTION SYSTEM AGAINST
HAZARD OF DISCHARGE PRESSURE ENTRY
(AS WHEN PUMP IS IDLE), A SMALL RELIEF
VALVE IS OFTEN CONNECTED HERE
10) ALL SYSTEM COMPONENTS MUST HAVE
ADEQUATE PRESSURE RATINGS FOR
OPERATING, STARTING AND UPSET
CONDITIONS. IN ORDER TO REDUCE
POTENTIAL HAZARDS, PARTICULAR
ATTENTION IS RECOMMENDED FOR THE
SURGE CONDITION THAT WILL RESULT
DOWNSTREAM OF THE REFLIEF VALVE
WHEN NORMAL DISCHARGE IS BLOCKED
-AS A GENERAL RULE, FLUID LEVEL MUST BE HIGHER THAN THE PUMP FLUID END AS PLUNGERS CANNOT LIFT FLUID. 10 FEET OF HEAD IS A GOOD RULE OF THUMB.
-CAUTION SHOULD BE TAKEN TO KEEP FITTINGS OUT OF THE SUCTION AND DISCHARGE PIPING AS THESE WILL RESULT IN POOR PERFORMANCE. EACH 90-DEGREE TURN IN
THESE LINES RESULTS IN GREAT LOSS OF PUMPING EFFICIENCY.
PREVENTIVEMAINTENANCE
DAILY
A. CheckandMaintainLubricantLevels.
StandardLubricant:SyntheticLubricant:
AGMAGrade(ASTMD2422):4EP SAEViscosityGrade(J306‐8):75W‐90
ISOViscosityGrade:150
ViscosityinSSU@100degreeF:625‐765
MONTHLY
A. Drainandrefillcrankcase.Itisrecommendedthatoilbechangedafterthefirstweekofoperation.
B. Washoilfillercapinkerosene.
C. Checkvalvesforexcessivewear,brokenorbentsprings,etc.
D. Checkcrankshaftbearingsforendplay.(Seesectiononcrankshaft)
E. Keepallnuts,studs,etc.tight.
F. Checkvalvecoversforleaks.
G. Checkallsealsandgasketsforleaks
PUMPCAPACITIES(APPROXIMATE)
KD‐12502qts.KT‐335016qts.
KJ‐22503qts.KT‐340016qts.
KZ‐3150 2qts.UseSAE30weightnon‐detergentmotoroilONLY
KM‐32504qts.KB‐350020qts.
KM‐33004qts.KA‐350024qts.
KP‐330012qts.KSB‐640036qts.
R335/R34016qts.KSB‐650036qts.
Q545022.5gal.KCP‐630024qts.
PLANETARYGEARREDUCERS
#6 17ozs.
#842ozs.
#942ozs.
B. Ifpumphaslubricatingfacilitiesforstuffingboxes,checkleveloflubricant.
C. Maintainpackingglandtensiononpacking(Donotover‐tighten)
D. Visuallyinspectpumpforapparenttrouble.
E. Keepthepumpclean.
GENERAL
Replaceanyworkpartbeforeitseventualfailure.Usethefollowinginstructionsforremovalandreplacementofparts.Don’thesitatetocall
onKerrPumpsforhelpifnecessary.
SERVICEPROCEDURES(ALLMODELS)
A. WINGGUIDEDVALVES
i. DISCHARGEVALVES:Thedischargevalveandseatcanbeexposedbyfirstremovingthedischargevalvecovercap.Oncethe
dischargecovercaphasbeenremovedyoumayliftoutthedischargevalvespringandthedischargevalve.Thevalveseatwillbeheld
inplacebyataperfitandmustbe“pulled”withanappropriatevalve‐pullingtool(availablefromtheKerrPumpsDealers).Oncethe
valveandseathavebeenremovedtheyshouldberesurfacedorreplacedifbadlyworn.Toreplacethedischargevalve,firstcleanand
inspecttheseatboreforwashoutdefectsandthendroptheseatintothebore.Replacethevalveintotheseatandstrikethetopof
thevalveacoupleofgoodblowsutilizingabrassbarandhammertoseatthevalveseatinthefluidendvalvebore.Replacethevalve
springandcovercapafterinspectingthespringandthesealofthecovercap.
ii. SUCTIONVALVES:Thesuctionvalvesarelocatedinthechamberdirectlybelowthesuctionorendvalvecovercaps.Thesuction
valvesareservicedintheidenticalmannerasthedischargevalves.Note:Dischargevalvesmustberemovedpriortoanyremovalof
thesuctionvalves.
ServiceProcedureforKZ‐3150Valves
iii. DISCHARGEVALVES:Thedischargevalveandseatcanbeexposedbyfirstremovingthedischargevalvecoverplate.Oncethe
dischargecovercaphasbeenremovedyoumayliftoutthedischargevalvespring,dischargevalveandvalveseat.Oncethevalveand
seathavebeenremovedtheyshouldbereplacedifbadlyworn.Toreplacedischargevalve,firstcleanandinspecttheseatborefor
washoutdefectsandthendroptheseatintothebore.Replacevalveinseatthenvalvespringandcovercap,always‐inspectingo’ring
sealsbetweenseatsandcovercaps.
iv. SUCTIONVALVES:Thesuctionvalvesarelocatedinthechamberdirectlybelowthedischargevalveseat.Thesuctionvalvesare
servicedintheidenticalmannerasthedischargevalves.
B. DISCTYPEVALVES:Alldisc‐typevalvesareexposedforremovalinasimilarmannerasthewing‐guidedvalves.Insteadofremovingthevalve
body;theupperportionofthevalveisremovedbyremovalofthevalvecapscrew,springretainer,valvespring,andvalvespacersleeve.The
valveseatisthen“pulled”fromthefluid‐endutilizinganauthorizedKerrValvePuller.Note:InallKerrPumpswithdisc‐typevalvesthe
dischargeandsuctionvalvesareidentical.
C. BALLANDSEATVALVES:Inpumpswithblock/billettypefluid‐endsthevalvesareballandseatdesign.Theseareexposedfor
removal/inspectionbyremovaloftheappropriatevalvecover.Theflatseatsarekeptinplacebyascrew‐invalveretainerthatcanbebest
removedwithaKerrValveWrenchmadefortheappropriatepump.Springsarenormallyincorporatedwiththedischargevalveswhilethe
suctionvalvesoperatewitha“freeball”.Acopperwasher/gasketisusedunderallvalveseatsforaseal.Wheninstallingorremovingaflat
typevalveseatagood“rap”ontopofthevalvewrenchwill“seat/unseat”theseatandcoppergasketpriorfinaltighteningorremoval.
Failureto“seat”thevalveseatinthismannercanresultinthe“washingout”ofthefluid‐end.Forpressurizedsuction,valveswillneedtobe
springloaded.CallKerrPumpsforthischange.
D. PLUNGERS:Followingtheremovalofthesuctionvalve,theplungermayberemovedbybreakingtheunionbetweentheplungerandpony
rodandforcingtheplungeroutthebackofthefluid‐end.Looseningthepackingnut/glandwillfacilitatetheremovaloftheplunger.The
reverseofthisprocedureisusedtoinstallaplunger.Lubricationandsomeslightforcemaybeusedtopassplungerthroughthepacking.
Alwaysretightentheplungerandponyrodunionperiodicallyfollowingtheremovaloftheplungertoinsureitissecurelymadeupandwill
notvibrateloose.
E. PLUNGERPACKING:Thismanualincludesillustrationsofthepackingsetsforeachmodelpump.Generally,oncetheplungerhasbeen
removedfromthepump,thepackingcanbeexposedforremovalbycompletelyremovingwhateverdeviceisusedtotightenthepacking(i.e.
thepackingorstuffingboxnutorgland).Therewillbevariousamountsofmetalringsandpackingcomponentsdependinguponthetypeof
packingandthemodelofpump(refertoappropriateillustrationorchart).Aftertheremovalofallringsandequipmentfromthestuffing
box;thoroughlycleanitandinspectfordamage,whichmightkeepthenewpackingfromworkingproperly.Ifthestuffingboxisin
satisfactorycondition,installthenewpackingaspertheappropriateillustration.Itisagoodideatolubricatenewpackingwithalightoil
priortoinstallation.Mostofthestandardpackingusedinpumpsshouldbetightenedwiththeoriginalequipment‐packingwrenchwhilethe
pumpisrunningundernormaloperatingpressure.Afteratwoorthreehourrun‐in,checkthepackingfortightnessandre‐adjustas
necessary.Packingshouldbecheckedfortightnessonaperiodicbasis,butitisnotagoodideatoattempttoperiodicallytightenthepacking
aspartofroutinemaintenance.Thistendsto“wearout”thepackingprematurely.Whenthepackingleaksinanexcessiveamountitshould
bereplaced.Thereisnovalueinconstantly“re‐tightening”leakingpacking.
Ifyourpumpisequippedwithoptional“springloaded”packing,thereisnoadjustmentinthisequipmentduringitsoperationallife.The
stuffingboxnutisinitiallytightenedasmuchaspossibleandthereisnofurtheradjustment.Note:Inallcasesthespringgoesinthestuffing
boxbeforethepackingrings.
WhenusingtheoptionalKevlarorTeflonpacking,besuretorotatethe“splits”sothatnoneare“aligned”toinsurethatthepackingholds
properly.Normally,thispackingisnotlubricatedandrequireslesstensiononthestuffingboxnutduringoperation.
CAUTION:An“airtight”sealisnotdesirablewiththisplungerpacking.Someslightdripageisdesirableduringoperation.Attemptsto
tightenpackinguntilitcompletely“sealsoff”willresultinprematurefailurefromtoomuchfriction.TheKevlar&Teflonpackingmustbe
allowedtodripasmallamounttoassurenormallife.
F. PONYRODandPONYRODPACKING:KerrPumpsusetwoponyrodsealingarrangements,modelsKD‐1250,KJ‐2250,KM‐3250andKCP‐6300
useascrewinsealgland,allothermodelsuseaboltinsealgland,theseglandsusepressinoilsealswithsnapringretainers.SomeBoltin
glanduseadjustablepackingarrangementswithboltinorscrewinfollowerstoadjustpacking.Byunscrewingplungerfromponyrodagap
maybefacilitatedtoallowtheremovalofthevarioussealingarrangements.Aspecialwrenchwillbeneededtoremoveandreplacepony
rodtocrosshead.(ThiswrenchisavailablefromKerrDealers)Allponyrodshaveajamnuttoaligntightenponyrodtocrosshead,caremust
beexercisedininstallingnewsealonponyrodnottodamageit.
G. DISASSEMBLYOFPOWEREND
CAUTION:Priortodisassemblyofanypowerend,theplunger,ponyrod,andponyrodsealhousingmustberemoved.
Exposethecrankshaftandconnectingrodsbyremovingthepancover.Connectingrodcapsmaynowberemovedandtheconnectingrod
andcrossheadshouldbeshovedallthewaytotherear(towardthefluidend)tofacilitatecrankshaftremovalouteithersideasconvenient.
Theconnectingrodsandcrossheadsmaynowbetakenoutthefrontcavityexposedbyremovingthecrankshaft.Connectingrodsmaybe
removedfromthecrossheadbylooseningthesetscrewanddrivingoutthewristpinfromthecrosshead.Abronzebushingisusedintherod
itmaybedrivenoutoftherodandreplacedwithanewbushing.Reassemblyisthereverseoftheaboveoutlinedsequencewiththe
followingconsiderationsfor“fits”ortolerance:
i. General:AllKerrcomponentsaremachinedonmodernproductionmachinetoolsandareofthesamespecificationsandclose
tolerancesyouwouldexpectinamodernautomobileengine.Itmustbepointedoutthatattopspeed(350to400RPM)yourpump
willnotevenbeapproachingidlespeedforagasolineengineso“fieldfits”arepossibleandpracticalwhenmakingrepairsand
replacementsawayfromthefactory.Allproceduresoutlinedbelowarepossiblewithonlyhandtoolsandabsolutelynoinstruments,
specialtools,orgaugesareneeded.
ii. Connectingrodandwristpin:Properfitwillfindthewristpinturningfreelyinitsboreintheconnectingrod,butitshouldhaveno
“wobble”thatisdiscernableupanddownthemainaxisoftheconnectingrod.Thisloosenessinthewristpinfitisthemostprobable
causeof“knocking”whichistraceabletothepowerendofmostallpumps.Theonlysolutionforloosefittingwristpinsistodiscard
theconnectingrodwristpinbushingandreplacewithanewone.Ifanywearisvisibleonthewristpinitshouldalwaysbereplaced.
iii. CrankshaftEndPlayandLateraladjustments:AdjustmentoftheTaperRollerbearingsusedinallKerrPumpsisaccomplishedby
removingoraddingshimsunderthebearinghousing.Shimsaretakenoutoraddeduntilthecrankshaft(withoutconnectingrods)
willturnfreely,butwithnoendplayfeltwhenattemptingtopullorpushthejackshaftendofthecrankshaftalongitslongaxis.Some
lateraladjustmentispossiblebyremovingshimsfromonesideofthecrankshaftandaddingthemtotheoppositeside.(Note:
Lateraladjustmentisthe“centering”ofthecrankshaftinthepowerframehousing.)
iv. ConnectingRodtoCrankshaftfitting:Factoryboredconnectingrodswillnormallyfitthestandardcrankshaftjournaljustbybolting
thecapontherodwiththestandardrodshimsbeingused.Ifthecapsdorequireadjustmentthisisaccomplishedbyremovingor
addingvariousthicknessesofrodshims.ThestandardconnectingrodshimusedonallKerrPumpsis1/32”thickandiscomprisedof
.002”laminates,whichcanbe“pealed“offseparately.Properfitoftheconnectingrodwillallowthepumpcrankshafttoberotated
whilenotallowingin‐and‐outslackintheconnectingrodalongitslongormainaxis.Awell‐fittedrodwillhavenoneofthein‐and‐out
slack,butshouldbefreeenoughtobemovedfromsidetosideontherodjournal.Thisinsurestherodnotbeingtootight.Apointof
cautionwheninstallingtheconnectingrodassemblyinthepumpistomakecertaintheoilholesintherodare“UP”andnottoward
thebottomofthepump.Thiswillresultinlubricationfailureinthesepartsandthepumpwillfailinashortperiodoftime.An
additionallyimportantstepistomakesurethattherodcapisboltedbackontherodasitcameoff.Therodandcapcarrya“mark”
or“number”whichallowsyoutomatchthembackproperly.Failuretodothiswillcausetherodnottofitthejournalforwhichitwas
made.
H. PowerEnd/FluidEndConnection:Acommonmisconceptionisthatthereissomeformoffluidsealbetweenthepowerendandthefluid
end.Thisisfalse.Thefluidendismerelyboltedtothepowerframe.Itcanberemovedbybreakingtheplungerconnection,backingoffthe
packingnutorgland,removingthevariousfluidendbolts,andslidingtheentirefluidendoffthepowerframe.Corrosionmaytendtoseize
thetwocomponentstogethermakingtheirseparationdifficultinsomeisolatedcases.OnmodelsKP‐3300,KT‐3350/KT‐3400andR335/R340
theboltedinstuffingboxassembliesmustberemovedpriortoremovaloftheentirefluidend.Theyareheldinplacebyfourstudseach.On
allotherunitsthestuffingboxescanbeleftintact.Ontheremainingpumps(withtheexceptionKD‐1250B,KJ‐2250B,KM‐3250B,andKCP‐
6300)thestuffingboxesareheldinplaceinthefluidendbyafrictionor“press”fit.Theyshouldberemovedwithahydraulicpressif
possible.Thesepress‐intypestuffingboxescarryagasketand/orano‐ringtoinsureagoodseal.TheboxesontheKD‐1250B,KJ‐2250B,KM‐
3250B,andKCP‐6300arescrew‐intypeandcarryonlyacoppergasket.
TECHNICALDATASHEETT.D.S.NO.4.2
PCN:______SupercedesPCN:_____Date03‐10‐06
SHORTTERMSTORAGEPREPARATIONPROCEDURE
1.0SCOPE
ThisprocedureappliestoKerrPumpsONLY.Storageproceduresforanyotherunitcomponentsoraccessories(gearreducers,engines,etc.)aretobepreparedtothespecific
manufacture’srecommendations.
1.1Short‐termstorageisdefinedasstorageand/ortransienttimelessthansix(6)monthsinanenvironmentdefinedinParagraph2.Ifstorageexceedingsixmonthsis
expected,theLongTermPumpStoragePreparationProcedureshouldbefollowed.
1.2KerrPumpswillonlypreparedforshorttermstorageifsospecifiedinthepurchaserorcustomerordercontroldocument.
2.0STORAGEENVIRONMENT
Aminimalenvironmentalcondition,tobemetbythecustomerorpurchaser,isaclosedsheltertoeliminateeffectsofsun,wind,sandorotherdebris.Largetemperatureand
humiditychangesshouldbeavoidedtopreventcoatingdeteriorationorcontaminationbymoisture.
3.0PRESERVATIVEPRODUCT
3.1Thespecifiedrustpreservativewillprotecttheinternalpowerendpartsfromcorrosionduetoatmosphericmoisture,andmaybeleftinthepumpwhenfilledwith
appropriatelubricantandplacedintoservice.Theelevatedtemperatureofservicewillcauserapiddepletionofthepreventativeprotection.
3.2
ThefollowingrustpreventativeproductsortheirequivalentsarerecommendedforuseinKerrPumpsandusuallyavailablein5gallon,55gallon
containers:
CITGO:RUST‐O‐LINEOIL10
SHELL:ENSISOILN
4.0PROCEDURE
4.1Preparationfrom;factorytesting,inventory,oradistributorrebuildfacility.
‐Drainanyoilthatmaybeinthepowerend,andthenfillthecompletepowerendcavitywiththespecifiedrustpreventative.After15to20minutes,draintherust
preventativebackintoitsstoragedrumforfutureuse.
‐Removeandcleanoillevelgages,pressuregagesandbreathercaps.Replacewithpipeplugsinthreadedopenings.Allbreathersshallbereplacedwithairtightseals,
plugsorgasketedplates.Noventingisrecommendedasitmayallowmoistairin.
TECHNICALDATASHEETT.D.S.NO.4.2
PCN:______SupercedesPCN:_____Date03‐10‐06
4.1.1 Removethewiperboxsealsandcap/plugthesealopening.
4.1.2 Cleanthepumpoutersurfacespriortopainting.
4.1.3 Ifpaintingisrequiredmaskcrankandlubricatorshaftsurfacesandkeyways.Ifpaintingdoesnotapply,gotoPara.4.1.8.
4.1.4 Paintasspecifiedbythecustomerorderorasrequired.
4.1.5 Applyathinlayerofgreasetotheexposedoilseallips.
4.1.6 Applyathinlayerofheavyrustpreventativetotheexposedcrankandlubricatorshaftsurfacesandkeyways.
4.1.7 Wraptheexposedcrankandlubricatorshaftswithwaxedtape.
4.1.8 Carefullywrapthefollowingpartspriortoplacingthemintopolyurethanebags.Oillevelgages,lubepressuregages,andbreathercaps.
4.1.9 Finishbox,crateandmarkthepartsfromPara.4.1.2afterfinalinspection(seePara.4.2.2).
4.2Shipping/Receiving(NewPumpsOnly)
4.2.1Allpumpsandaccessories(asapplicable)willbefinalinspectedbyKerrPumppersonnelpriortoshipping.Anywitnessedorthirdpartyinspectionwillbe
signed‐offbythepurchaserorcustomerrepresentativepriortofinalcratingandshipment.
4.2.2ExportcratingwillbeperformedbyeitheranapprovedKerrPumpsourceorasspecifiedbythepurchaserorcustomer.Anythirdpartyinspectionwillbe
coordinatedwiththesource.
4.2.3Uponreceiptoftheshipment,thepurchaserorcustomerisresponsibleforinspectionandrepairofdamagedcoatingsattheexpenseoftheshipper.
5.0WARRANTY/START‐UP
5.1Pumpspreparedpertheaboveprocedurequalifyforthe“StandardTerms&Conditions”inforceonthedateofshipment.
5.2Ifthepumpstorageperiodislessthan6months,followtheShortTermPumpPreparationProcedure.
5.3Priortostart‐up:
5.3.1 Removeallstoragecaps,plugs,andcovers.
5.3.2ReplaceanydamagedorcrackedO‐ringsorgaskets.
5.3.3 Inspectpowerendshaftoilsealsandreplaceifcracked,splitordamaged.
5.3.4 Installcrankcasedrainplug,lubricationlevelsiteglassandbreathercap.
5.3.5 Install,ifapplicable,anyoilpressureand/ortemperaturegage.
5.3.6 Checktheconnectionoftheplungerandponyrodtothecrossheadpriorto,andafter,initialrun‐inofthepump.
5.3.7 Fillthecrankcasetotheproperlevelwiththespecifiedlubricant.
TECHNICALDATASHEETT.D.S.NO.4.3
PCN:______SupercedesPCN:_____Date03‐10‐06
TITLE:LONGTERMSTORAGEPREPARATIONPROCEDURE
1.0SCOPE
ThisprocedureappliestoKerrPumpsONLY.Storageproceduresforanyotherunitcomponentsoraccessories(gearreducers,engines,etc.)aretobepreparedtothespecific
manufacture’srecommendations.
1.1Long‐termstorageisdefinedasstorageand/ortransienttimeexceedingsix(6)monthsinanenvironmentdefinedinParagraph2.Ifstorageforlessthansix
monthsisexpected,theShortTermPumpStoragePreparationProcedureshouldbefollowed.
1.2KerrPumpswillonlyprepareforshorttermstorageifsospecifiedinthepurchaserorcustomerordercontroldocument.
2.0STORAGEENVIRONMENT
Aminimalenvironmentalcondition,tobemetbythecustomerorpurchaser,isaclosedsheltertoeliminateeffectsofsun,wind,sandorotherdebris.Largetemperatureand
humiditychangesshouldbeavoidedtopreventpreventativedeteriorationorcontaminationbymoisture.
3.0RUSTPREVENTATIVEPRODUCT
3.1Therecommendedrustpreservativeshouldprotecttheinternalpowerendpartsfromcorrosionduetoatmosphericmoisture,andmaybeleftinthepump
whenfilledwithappropriatelubricantandplacedintoservice.Theelevatedtemperatureofservicewillcauserapiddepletionofthepreventativeprotection.
3.2ThefollowingrustpreventativeproductsortheirequivalentsarerecommendedforuseinKerrPumpsandusuallyavailablein5gallon,55galloncontainers:
CITGO:RUST‐O‐LINEOIL10
SHELL:ENSISOILN
4.0PROCEDURE
4.1Preparationfrom;factorytesting,inventory,oradistributorrebuildfacility.
4.1.1Drainanyoilthatmaybeinthepowerendandthenfillthecompletepowerendcavitywiththespecifiedrustpreventative.After15to20minutes,
draintherustpreventativebackintoitsstoragedrumforfutureuse.
4.1.2Removeallplungers,ponyrods(ifapplicable),bafflediscs,packingandjunkrings.
4.1.3Removeandcleanoillevelgages,pressuregagesandbreathercaps.Replacewithpipeplugsinthreadedopenings.
TECHNICALDATASHEETT.D.S.NO.4.3
PCN:______SupercedesPCN:_____Date03‐10‐06
4.1.4Allbreathersshallbereplacedwithairtightseals,plugsorgasketedplates.Noventingisrecommendedasitmayallowmoistairin.
4.1.5Removethewiperboxsealsandcap/plugthesealopening.
4.1.6Cleanthepumpoutersurfacespriortopainting.
4.1.7Ifpaintingisrequiredmaskcrankandlubricatorshaftsurfacesandkeyways.Ifpaintingdoesnotapply,gotoPara.4.1.9.
4.1.8Paintasspecifiedbythecustomerorderorasrequired.
4.1.9Applyathinlayerofgreasetotheexposedoilseallips.
4.1.10Applyathinlayerofheavyrustpreventativetotheexposedcrankandlubricatorshaftsurfacesandkeyways.
4.1.11Wraptheexposedcrankandlubricatorshaftswithwaxedtape.
4.1.12Carefullywrapthefollowingpartspriortoplacingthemintopolyurethanebags.Oillevelgages,lubepressuregages,andbreathercaps.
4.1.13Finishbox,crateandmarkthepartsfromPara.4.1.10afterfinalinspection(seePara.4.2.2).
4.2Shipping/Receiving(NewPumpsOnly)
4.2.1Allpumpsandaccessories(asapplicable)willbefinalinspectedbyKerrPumppersonnelpriortoshipping.Anywitnessedorthirdpartyinspectionwillbe
signed‐offbythepurchaserorcustomerrepresentativepriortofinalcratingandshipment.
4.2.2ExportcratingwillbeperformedbyeitheranapprovedKerrPumpsourceorasspecifiedbythepurchaserorcustomer.Anythirdpartyinspectionwillbe
coordinatedwiththesource.
4.2.3Uponreceiptoftheshipment,thepurchaserorcustomerisresponsibleforinspectionandrepairofdamagedcoatingsattheexpenseoftheshipper.
5.0WARRANTY/START‐UP
5.1Pumpspreparedpertheaboveprocedurequalifyforthe“StandardTerms&Conditions”inforceonthedateofshipment.
5.2Ifthepumpstorageperiodwillexceed6months,followtheLong‐TermPumpPreparationProcedure.
5.3Priortostart‐up:
5.3.1 Removeallstoragecaps,plugs,andcovers.
5.3.2 Installthepacking,junkrings,plungers,ponyrods(ifapplicable),bafflediscs,andwiperboxseals.ReplaceanydamagedorcrackedO‐ringsorgaskets.
5.3.3 Inspectpowerendshaftoilsealsandreplaceifcracked,splitordamaged.
5.3.4 Installcrankcasedrainplug,lubricationlevelsiteglassandbreathercap.
5.3.5 Install,ifapplicable,anyoilpressureand/ortemperaturegage.
5.3.6 Checktheconnectionoftheplungerandponyrodtothecrossheadpriorto,andafter,initialrun‐inofthepump.
5.3.7 Fillthecrankcasetotheproperlevelwiththespecifiedlubricant.
SPECIAL TOOLS
ASSY
SEAT
FOR KT-3350XP, KT-3400XP
PULLER
AP-425
BOX NUT
STUFFING
WRENCH
TRI-PIN
TYPE
KP-68M
WING-
GUIDED
KA-306
VALVE
SEAT
SEATING
TOOL
AP-77T
VALVE
INSERT
TOOL
KA-276
PONY ROD
SEAL TOOL
KA-277
PONY
ROD
WRENCH
KP-75
DISC
SEAT
THREADED
STEM
TYPE
PULLER
ASSY
How To Put Inserts In Valves
Using Kerr Valve Insert Tool
3) Holding Valve
insert down with
thumb.
2) Put Tool between
valve and valve
insert with groove
a
g
ainst valve.
4) While holding valve down
with thumb, rotate around
valve with tool. (Similar to
mountin
g
a tire on a rim
)
.
1) Push Valve Insert over
valve legs. Hint: (Insert
will be more pliable if
heated first-- warm to the
touch not hot).
5) Continue rotating around
valve with tool until insert is
completely in groove.
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