KERR KP-3300B User manual
KERRPUMPCORPORATIONSERVICEMANUAL
EIGHTEENTHEDITION
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
Readeverythinginthissectionbeforeattemptingtorunorconnectyourpump.
Theimportanceofproperinstallationcannotbeoverstressed.Asthereciprocatingpumpisalmostunabletoliftfluid,propersuction
floodingisamust.ThisistheFirststeptowardsatisfactoryoperation.
TheKerrPumpsEngineeringServicewillbehappytoadviseyouinyourinstallationproblems.Asalmosteveryinstallationvaries,youcannot
exercisetoomuchcareinmakingcertainyourinstallationisproper.
BeforeStartingThePump,readcarefullythemaintenancesectioninthefollowingpages.
Forbestresults,followtheseinstallationguidelines.
(A)PRESSURERELIEFVALVE(REQUIRED)
(B)BY‐PASSEDFLUIDSHOULDBEPIPEDBACKINSUCTIONSUPPLYTANKWHENPOSSIBLE
(C)USEFLEXIBLEHOSEINDISCHARGELINEWHENPOSSIBLE
(D)DISCHARGESHUT‐OFFVALVE(OPTIONAL‐USEDFORTOTALSHUT‐DOWNORSERVICEONLY)
(E)DISCHARGEANDSUCTIONONEITHERSIDEOFFLUIDENDONALLMODELS.
(F)PULSATION“DAMPENERS”MAYBEUSEDINEITHERTHESUCTIONORDISCHARGEPIPINGORBOTH.DISCHARGE
DAMPENERSSHOULDBECAPABLEOFHANDLINGPUMPDISCHARGEMAXIMUMPRESSURE
Tostartthepump,openthesuctionlinevalveandpermittheintakechambertofillonthepump.Airmaybebledoffbyopeningthevalve
coversslightlyuntilthereisaconstantfluidflow.Afterbleeding,openthedischargelinevalveandstartthepump.Roughnessmayoccurfrom
cavitation(airinline)orfromstarvation(lackoffluid).Eliminatethesetroublesbeforepermittingcontinuousoperation.
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‐350036qts.
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.
5.3.2 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.
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
FOR KP-3300B/KP-3300BCB
KP-277
PONY
ROD
WRENCH
AP-425
STUFFING
BOX
NUT
WRENCH
KAB-53
VALVE
WRENCH
KP-276
PONY ROD
SEAL TOOL
1.) Remove Capscrews from Top
and End Cover Plates
2.) Remove Round Cover Caps; If
Capsaredifculttoremove,
use a pry bar
3.) Inspect Cover Cap O’Rings for
damage; replace if necessary
Ball and Seat Valve Instructions
Note:
These instructions cover both
O’Ring and Gasket type seals.
O’Ring Type Seat and Seal
Gasket Type Seat and Seal
4.) Remove valve springs and ball
guides from discharge valves
7.) To help unscrew valve re-
tainer,useseveralrmto
heavy blows with hammer
8.) Proceed to unscrew suction
valve retainer 9.)Suctionvalveretainer,ball
and seat assembly shown 10.) Remove discharge valve re-
tainer as illustrated in step 7
and 8 of the suction valve
retainer removal
Ball and Seat Valve Changing Instructions (...continued)
5.) Use Kerr Pump Valve Retainer
Tool to remove Valve
Retainers
6.) To unscrew suction valve re-
tainer,insertValveRetainer
Tool using normal torque.
11.) Proceed to unscrew dis-
charge retainer 12.) Discharge and Suction valve
assemblies
Ball and Seat Valve Changing Instructions (...continued)
13.) Remove valve seat gaskets
or o’rings
14.) Use screwdriver to remove
old gasket or o’ring 15.) Valve seat gaskets or o’rings
must be replaced every time
valve seats are replaced
16.) Suction and discharge valve
retainer ball and seat shown
This manual suits for next models
1
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