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HDD 2ND EDITION
KERR PUMPS SERVICE MANUAL
NEW PUMP WARRANTY
1) Kerr Machine Company (KERR PUMPS) 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.
2) Each Distributor of a new KERR 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 of sale.
3) 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 PUMPS before any repairs or service calls are made.
4) All warranty claims must be sent to KERR PUMPS Home Office on the authorized warranty claim form provided by KERR
PUMPS, and available from the Distributor before any warranty claim will be considered. It is understood that KERR
PUMPS 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
A.
B.
C.
D.
For the first 250 hours, 100% credit will be allowed on a current list price basis.
From 251 hours to 500 hours, 75% credit will be allowed on a current list price basis.
From 501 hours to 750 hours, 50% credit will be allowed on a current list price basis.
From 751 hours to 1000 hours, 25% credit will be allowed on a current list price basis.
-1-
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.
5) In the event of a warranty claim under this warranty made within the first 250 hours, KERR PUMPS, before any repairs are
made, shall be contacted by the Distributor and given the option of having the Distributor either repair or replace the pump.
6) Upon any claim under this warranty, other than a claim wherein KERR PUMPS at its option replaced the pump as provided in
Paragraph No. 5 hereof, the Distributor will make the necessary repairs an/or replacement, and KERR PUMPS 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
PUMPS 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 PUMPS to the KERR PUMPS Home Office for consideration. In the event the warranty
claim is honored by KERR PUMPS a Credit Memorandum will be issued to the Distributor in the amount determined by the
table in Paragraph No. 4 hereof. Thereafter, the customer’s invoice will be credited by the Distributor in the same percentage
allowed the Distributor by KERR PUMPS.
If requested by KERR PUMPS the purchaser or the Distributor shall return the alleged defective product to KERR PUMPS
factory, freight prepaid, for examination and testing. If KERR PUMPS determines the product is defective KERR PUMPS
will either repair or replace such product with a like of KERR PUMPS manufacture, 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 PUMPS is
limited to the repairing or replacing defective material manufactured by it, provided KERR PUMPS examination discloses to
its satisfaction that such material has not been altered or repaired, other than by KERR PUMPS approved procedures, subject
to misuse, improper maintenance, negligence or accident. KERR PUMPS will not be responsible for loss of liquid or for
damage of any kind, or from any cause, to any person or property of any person, or for loss of revenue of profit, or for any
other special incidental or consequential damages.
7) The warranty applies only to new KERR PUMPS. The Company specifically excludes from this warranty the following.
A. 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.
B. In addition, after the expiration of the pump warranty all replacement parts are no longer in warranty.
8) In extreme cases where in the opinion of KERR PUMPS, if a pump has been misused or is being misused, KERR PUMPS
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.
-2-
9) Any parts or equipment which KERR PUMPS supplies and does not manufacture shall be subject only to the warranties of
KERR PUMPS vendors to the extent KERR PUMPS can enforce such warranties.
10) Any repairs to, alterations of, or work done on alleged defective products without KERR PUMPS specific written
authorization shall void KERR PUMPS warranty applicable thereto.
11) 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.
-3-
KERR TROUBLE SHOOTER GUIDE
REASON OR SERVICE NEEDED
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
Insufficient fluid at high speed. Check to see if the suction line is
the proper size and is not constricted trash in line, valve partly
opened, etc. There is also a possibility of gas in the fluid causing
the roughness.
Also above. 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 lubrication.
Incorrect type packing for particular installation.
(Contact KERR PUMPS if in doubt) Excessively worn
plungers.
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). Check
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,
check installation section.
-4-
INSTALLATION INSTRUCTIONS (SEE ILLUSTRATION)
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.
The KERR PUMPS Engineering Service will gladly advise you in your installation problems. As almost every installation
varies, you cannot exercise too much care in making certain your installation is proper.
Before Starting the Pump, read carefully the maintenance section in the following pages.
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 cavitation (air in line) or from starvation (lack of fluid). Eliminate these troubles before permitting
continuous operation.
-5-
RECOMMENDED INSTALLATION OF KERR PUMPS
FOR BEST RESULTS
(A)
(B)
(C)
(D)
(E)
(F)
PRESSURE RELIEF VALVE (REQUIRED)
BY-PASSED FLUID SHOULD BE PIPED BACK IN SUCTION SUPPLY TANK WHEN POSSIBLE
USE FLEXIBLE HOSE IN DISCHARGE LINE WHEN POSSIBLE
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.
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
AS A GENERAL RULE, FLUID
LEVEL MUST BE HIGHER
THAN THE PUMP FLUID END
AS PLUNGER PUMPS CANNOT
"LIFT” FLUID. ABOUT 10 FEET
OF HEAD IS A GOOD “RULE OF
THUMB”.
SUITABLE
FALL-OPENING
VALVE
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.
-6-
PREVENTIVE MAINTENANCE
DAILY
1. Check and Maintain Lubricant Levels.
Standard Lubricant:
Synthetic Lubricant:
AGMA Grade (ASTM D 2422): 4 EP
SAE Viscosity Grade (J306-8): 75W-90
ISO Viscosity Grade: 150
Viscosity in SSU @ 100 degree F: 625-765
KM-3250PT
KM-3300PT
KP-3300PT
Q5450DPT
KZ-3150PT
PUMP CAPACITIES (APPROXIMATE)
4 qts.
KT-3350PT
16 qts.
4 qts.
KT-3400PT
16 qts.
12 qts.
KA-3500PT
20 qts.
22.5 qts.
Q5500DPT
22.5 gal.
2 qts. Use SAE 30 weight non-detergent motor oil
PLANETARY GEAR REDUCERS
#6 AUBURN
17 ozs.
#8 & #9 AUBURN
42 ozs.
2. If pump has lubricating facilities for stuffing boxes, check level of lubricant.
3. Maintain packing gland tension on packing (Do not over-tighten)
4. Visually inspect pump for apparent trouble.
5. Keep the pump clean.
-7-
MONTHLY
1. Drain and refill crankcase. It is recommended that oil be changed after the first week of operation.
2. Wash oil filler cap in kerosene.
3. Check valves for excessive wear, broken or bent springs, etc.
4. Check crankshaft bearings for endplay. (See section on crankshaft)
5. Keep all nuts, studs, etc. tight.
6. Check valve covers for leaks.
7. Check all seals and gaskets for leaks
GENERAL
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 PUMPS for help if necessary.
-8-
SERVICE PROCEDURES (ALL MODELS)
1. VALVES (Wing-guided type):
A. Discharge Valves: 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 the 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.
B. Suction Valves: 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 be
removed prior to any removal of the suction valves.
Service Procedure for KZ-3150PT Valves
C. DISCHARGE VALVE: The discharge valve and seat can be exposed by first removing the discharge valve cover
plate. Once the 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.
D. SUCTION VALVE: The suction valves are located in the chamber directly below the discharge valve seat. The
suction valves are serviced in the identical manner as the discharge valves.
2. PONY ROD and PONY ROD PACKING: KERR 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)
-9-
All pony rods have a jam nut to align tighten pony rod to crosshead, care must be exercised in installing new seal on pony rod
not to damage it.
3. 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 may be removed from the crosshead by loosening the
setscrew and driving out the wrist pin from the crosshead. A 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:
A. 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 tools and absolutely no instruments, special tools, or gauges are needed.
B. 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.
C. 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.)
D. 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 by removing or adding various thicknesses of rod shims. The standard connecting rod shim used on all
- 10 -
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. The rod and cap
carry a “mark” or “number” which allows you to match them back properly. Failure to do this will cause the rod not to
fit the journal for which it was made.
4.
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, followed 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.
- 11 -
TECHNICAL DATA SHEET
PCN: ______
Supercedes PCN: _____
T.D.S. NO.
Page
Date
4.2
1 OF 2
03-10-06
TITLE: 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
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:
SHELL:
4.0
RUST-O-LINE OIL 10
ENSIS OIL N
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 and clean oil level gages, pressure gages and breather caps. Replace with pipe plugs in threaded openings.
4.1.3
All breathers shall be replaced with airtight seals, plugs or gasketed plates. No venting is recommended as it may allow
moist air in.
TDS_4.2_Short Term Storage Preparation Procedure_landscape.doc
TECHNICAL DATA SHEET
PCN: ______
Supercedes PCN: _____
T.D.S. NO.
4.2
Page
2 OF 2
Date 03-10-06
________________________________________________________________________________________________________________
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
4.2
5.0
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.
4.1.8.
Paint as specified by the customer order or as required.
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. 4.1.2 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.
WARRANTY/START-UP
5.1
Pumps prepared per the above procedure qualify for the “Standard Terms & Conditions” in force on the date of shipment.
5.2
If the pump storage period is less than 6 months, follow the Short Term Pump Preparation Procedure.
5.3
Prior to start-up:
5.3.1
5.3.2
5.3.3
5.3.2
5.3.3
5.3.4
5.3.5
Remove all storage caps, plugs, and covers.
Replace any damaged or cracked O-rings or gaskets.
Inspect power end shaft oil seals and replace if cracked, split or damaged.
Install crankcase drain plug, lubrication level site glass and breather cap.
Install, if applicable, any oil pressure and/or temperature gage.
Check the connection of the plunger and pony rod to the crosshead prior to, and after, initial run-in of the pump.
Fill the crankcase to the proper level with the specified lubricant.
TDS_4.2_Short Term Storage Preparation Procedure_landscape.doc
TECHNICAL DATA SHEET
PCN: ______
Supercedes PCN: _____
T.D.S. NO.
4.3
Page
1 OF 2
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 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 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 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:
SHELL:
4.0
RUST-O-LINE OIL 10
ENSIS OIL N
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.
TDS_4.3_Long Term Storage Preparation Procedure_landscape.doc
TECHNICAL DATA SHEET
PCN: ______
Supercedes PCN: _____
T.D.S. NO.
4.3
Page 2 OF 2
Date 03-10-06
________________________________________________________________________________________________________________
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
4.2
5.0
All breathers shall be replaced with airtight seals, plugs or 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 required.
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).
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.
WARRANTY / START-UP
5.1
Pumps prepared per the above procedure qualify for the “Standard Terms & 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
5.3.2
5.3.3
5.3.2
5.3.3
5.3.4
5.3.5
Remove all storage caps, plugs, and covers.
Install the packing, junk rings, plungers, pony rods (if applicable), baffle discs, and wiper box seals. Replace any
damaged or cracked O-rings or gaskets.
Inspect power end shaft oil seals and replace if cracked, split or damaged.
Install crankcase drain plug, lubrication level site glass and breather cap.
Install, if applicable, any oil pressure and/or temperature gage.
Check the connection of the plunger and pony rod to the crosshead prior to, and after, initial run-in of the pump.
Fill the crankcase to the proper level with the specified lubricant.
TDS_4.3_Long Term Storage Preparation Procedure_landscape.doc
Kerr Pump Maintenance
Schedule for Piston Type (PT)
Pumps
Daily
or 8 Hrs
Weekly
or 40 Hrs
Monthly
or 200 Hrs
Check Oil Level in Pump
Visual Inspection
Visual Inspection
Service
Check Oil Level in Planetary Gear
Visual Inspection
Visual Inspection
Service
Visual Inspection
Visual Inspection
Visual Inspection
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
Flush Fluid End
Check Pony Rod Seals
Quarterly
or 500 Hrs
Semi-Annual
or 1000 Hrs
Yearly
or 2000 Hrs
Visual Inspection
Visual Inspection
Visual Inspection
Visual Inspection
Visual Inspection
Visual Inspection
Visual Inspection
Visual Inspection
Visual Inspection
Visual Inspection
Visual Inspection
Service
Visual Inspection
Visual Inspection
Visual Inspection
Visual Inspection
Visual Inspection
Visual Inspection
Service
Service
Service
Service
Service
Service
Visual Inspection
Visual Inspection
Visual Inspection
Visual Inspection
Service
Visual Inspection
Visual Inspection
Visual Inspection
Service
Visual Inspection
Visual Inspection
Visual Inspection
Service
Visual Inspection
Visual Inspection
Visual Inspection
Service
Visual Inspection
Visual Inspection
Visual Inspection
Service
Visual Inspection
Visual Inspection
Visual Inspection
Service
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
Visual Inspection
Visual Inspection
Visual Inspection
Visual Inspection
Visual Inspection
Visual Inspection
Check Belts
Visual Inspection
Visual Inspection
Visual Inspection
Visual Inspection
Visual Inspection
Service
!
!
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+
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p
KA-68M
WINGGUIDED
SEAT
TRI-PIN
TYPE
PULLER
ASS'Y
KA-29SG-3
SEAL
GUARD
WIPER
DRIVER
KA-306
VALVE
SEAT
SEATING
TOOL
KA-276
PONY ROD
SEAL TOOL
AP-77T
VALVE
INSERT
TOOL
SPECIAL TOOLS
FOR KA-3500PT, KT-3350PT, & KT-3400PT
KA-277
PONY
ROD
WRENCH
How To Put Inserts In Valves
Using Kerr Valve Insert Tool
1) Push Valve Insert over
valve legs. Hint: (Insert
will be more pliable if
heated first-- warm to the
touch not hot).
4) While holding valve down
with thumb, rotate around
valve with tool. (Similar to
mounting a tire on a rim).
2) Put Tool between
valve and valve
insert with groove
against valve.
3) Holding Valve
insert down with
thumb.
5) Continue rotating around
valve with tool until insert is
completely in groove.
CRITICAL NOTE:
MATCH GROOVE
&KEEP PIECES TOGETHER
DO NOT MIX WITH
ANOTHER KA-280-A
KA-KT-280-A
KA-3500PT
POWER END
OIL LEVEL
POWER END
OIL LEVEL
PLANETARY GEAR
OIL LEVEL
Crankcase Oil Level
Synthetic Lubricant:
AGMA Grade (ASTM D 2422): 4 EP
SAE Viscosity Grade (J306-8): 75W-90
ISO Viscosity Grade: 150
Viscosity in SSU @ 100 deg F: 625-765
KA-3500PT OIL LEVEL ILLUSTRATION
35.375
1/2"-NPT
34
19
17.00
16.00
25.125
1/4"-NPT
3"-NPT
DISCHARGE
9.875
5.438
5.5
24.82
4.500
10.125
5.64
1.188
18.5
9.25
5.563
9.0
4X 11/16
MOUNT
HOLES
4.625
3"-NPT
10.6
7.438
2"-NPT
5"-NPT
SUCTION
54.5
GENERAL DIMENSIONS FOR KA-3500PT
9.938
KA-3500PT WITH DRIVE ASSEMBLY
35.375
1/2"-NPT
19
34
17.00
16.00
9.338
43.36
25.125
1/4"-NPT
4X 11/16
MOUNT
HOLES
4.625
3"-NPT
10.6
41.2
3"-NPT
DISCHARGE
9.875
19.28
24.82
23.9
5.563
9.0
5.5
5.64
1.188
23.4
5.438
2"-NPT
7.438
54.5
4.5
10.125
15.323
9.938
5"-NPT
SUCTION
GENERAL DIMENSIONS FOR KA-3500PT WITH DRIVE ASSEMBLY
8
7
5
6
4
11
13
D
5
LONG SPRINGS
TO TOP
9
3
ITEM NO. QTY. PART NO.
1
1 KA-33D
2
3 KA-073HT
3
6 KA-77
4
3 KA-072HT
5
3 KA-34D
6
3 KA-52L
7
3 KA-52S
8
6 KA-074HT
9
9 KA-38
10 22 KA-36
11 24 KA-37
12
3 KA-35D
13
1 KA-126FE
14
2 KA-36B
15
1 AP-71
6
4
2
DESCRIPTION
FLUID END, VESSEL ONLY (DUCTILE)
SUCTION VALVE, HEAT TREATED, A/R WITH INSERT
ABRASIVE RESISTANT VALVE INSERT
DISCHARGE VALVE, HEAT TREATED, A/R WITH INSERT
TOP COVER CAP (DUCTILE)
VALVE SPRING (DISCHARGE) (LONG)
VALVE SPRING (SUCTION) (SHORT)
VALVE SEAT, HEAT TREATED, A/R
O-RING COVER CAP
COVER CAP STUD
COVER CAP STUD NUT
END COVER CAP (DUCTILE)
FLUID END LIFTING EYE
COVER CAP BRACKET STUD
FLUID END DRAIN PLUG
1
D
C
C
4
10
8
1
14
7
SHORT SPRINGS
TO BOTTOM
10
1
2
B
KA-300
ITEM NO. QTY. PART NO.
1
1 KA-072HT
2
1 KA-77
3
1 KA-074HT
4
1 KA-52L
4
2
8
3
9
KA-300
KA-305
ITEM NO. QTY. PART NO.
1
1 KA-073HT
2
1 KA-77
3
1 KA-074HT
4
1 KA-52S
DESCRIPTION
SUCTION VALVE, HEAT TREATED, A/R WITH INSERT
ABRASIVE RESISTANT VALVE INSERT
VALVE SEAT, HEAT TREATED, A/R
VALVE SPRING (SUCTION) (SHORT)
2
3
KA-305
KERR MACHINE CO BOX 735 SULPHUR OK 73086
PHONE (580) 622-4207 FAX (580) 622-4206
15
WARNING:
CONFIDENTIAL AND PROPRIETARY
INFORMATION OF "Kerr Pumps" DO
NOT DISCLOSE, COPY OR REPRODUCE
A
PRIOR WRITTEN APPROVAL FROM
KERR MACHINE CORPORTATION.
MACHINE
.X
=
.XX
=
.XXX =
.XXXX =
ANGLES
6
5
4
DESIGNED BY:
B MILNER
04-23-99
1. MATL:
DRAWN BY:
K LACKEY
02-11-00
2. DIMS. ARE IN INCHES
3. DIM MAY VARY
ACCORDING TO CASTING
4. REMOVE ALL BURRS AND
SHARP CORNERS
5. DO NOT SCALE DRAWING
REFERENCE:
_
PUMP:
KA-5500-PT
UNLESS OTHERWISE SPECIFIED
TOLERANCES
ANY OR PART OF THIS PRINT WITHOUT
7
B
1
12
11
8
DESCRIPTION
DISCHARGE VALVE, HEAT TREATED, A/R WITH INSERT
ABRASIVE RESISTANT VALVE INSERT
VALVE SEAT, HEAT TREATED, A/R
VALVE SPRING (DISCHARGE) (LONG)
± .030
± .010
± .005
± .0010 6. MACHINE FINISH
± 1/2º
3
63
THIRD ANGLE PROJECTION
Kerr
Pumps
TITLE
SIZE
2
A
FLUID END
ASSEMBLY DRAWING
DWG. NO.
D
SCALE:
SULPHUR OK
3:8
REV
KA-33D-A
WEIGHT: _
A
SHEET 1
1
OF
1
ITEM NO. QTY. PART NO.
1
1 KA-160
2
1 AP-160-1
3
1 AP-160-2
4
4 AP-190-3
5
5 AP-160-3
6
1 AP-160-4
7
3 KA-160-5
8
3 AP-160-6
9
2 KA-160-7
10
1 KA-160-8
11
1 KA-161
12
4 AP-190-13
13
1 AP-235-30
3
2
4
5
4
1
12
4
5
9
12
4
DESCRIPTION
OIL MANIFOLD
JIC MALE ELBOW 1/2
SAE 37 JIC FML SWIVEL 90 TUBE ELBOW 1/4 X 1/2
WATER MANIFOLD / OIL MANIFOLD BOLT
MALE PIPE RIGID 1/4 X 1/8
1/2-NPT PIPE PLUG SOCKET TYPE INTERNAL HEX
FITTING, CROSSHEAD OIL INJECTOR
SAE 37 (JIC) FEMALE SWIVEL 1/4 X 1/4
5 1/2" (450 DEG) SS TEFLON HOSE
6 1/2" (450 DEG) SS TEFLON HOSE
OIL MANIFOLD GASKET
1/4 LOCK WASHER
SAE 37 JIC FML SWIVEL 3/8 X 1/2
8
12
7
5
10
11
8
12
7
9
8
13
7
6
OIL MANIFOLD ASSEMBLY
(RIGHT-HAND DRIVE)
KA-160RH-A
3
3
1
3
8
4
3
REV B: 05-09-00 ADDED ITEMS 15 & 16;
REV C: 01-17-07 UPDATED PART NO'S.'
10
5
15
8
6
2
7
16
11
10
9
13
11
13
14
14
9
13
14
12
13
14
12
12
WATER MANIFOLD ASSEMBLY
(EXPLODED VIEW)
KA-190-A
ITEM
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
PART NUMBER
KA-210
AP-190-2
AP-190-3
AP-190-4
AP-190-5
KA-KT-192
KA-190
AP-190-8
AP-190-9
AP-190-10
AP-190-11
KA-190-12
AP-190-13
AP-190-14
AP-216
KA-191
DESCRIPTION
WATER MANIFOLD
WATER MANIFOLD PLUG
WATER MANIFOLD / OIL MANIFOLD BOLT
WATER MANIFOLD 90 DEGREE FITTING
3/8 QUICK COUPLING
PISTON CHAMBER COVER SIGHT GLASS
PISTON CHAMBER COVER
PISTON CHAMBER COVER INPECTION GLASS WING NUT
PISTON CHAMBER COVER INSPECTION GLASS CAPSCREW
PISTON CHAMBER COVER WING NUT
PISTON CHAMBER COVER CAPSCREW
FITTING WATER JET
1/4 LOCK WASHER
1/4-20UNC NUT
3/8" QUICK CONNECT
PISTON CHAMBER COVER GASKET
QTY.
1
1
4
1
1
1
1
2
2
2
2
3
4
4
1
1
27
29
6
25
5
28
28
32
4
27
4
31
28
33
26
3
20
30
24
23
18
7
14
2
9
15
16
19
11
16
1
15
13
19
8
12
10
22
21
14
17
21
17
ITEM NO. QTY. PART NO.
1
1 KA-235
2
1 KA-140
3
1 KA-130
4
1 AP-195
5
1 AP-145
6
1 AP-150
7
1 AP-200-320
8
1 AP-230
9
1 AP-230-9
10
1 AP-135
11
1 AP-132
12
1 AP-130-9-1
13
4 KA-6
14
4 KA-6B
15
3 KA-230-15
16
3 KA-230-16
17
2 AP-235-17
18
2 AP-190-13
19
2 AP-235-19
20
2 AP-190-14
21
2 AP-235-21
22
2 AP-235-22
23
2 AP-235-23
24
2 AP-235-24
25
1 KA-155
26
1 KA-205-039
27
2 AP-235-27
28
3 AP-160-1
29
1 AP-160-2
30
1 AP-235-31
31
1 AP-235-32
32
2 AP-235-30
33
1 KA-7
PUMP DRIVE ASSEMBLY
KA-235-A
DESCRIPTION
BELT GUARD, PUMP DRIVE
OIL AND WATER PUMP BRACKET
BEARING HOUSING, EXTENSION SHAFT
WATER PUMP, BRONZE
OIL PUMP, 1/2" CAST IRON
SHEAVE, OIL PUMP
SHEAVE, WATER PUMP
SHEAVE, CRANKSHAFT DRIVE TO PUMPS
SHEAVE BUSHING 1-1/8"
OIL SEAL, BEARING HOUSING EXTENSION SHAFT
AUXILIARY SHAFT-SUPPLIED WITH KA-KP-KT-120
KEY- SUPPLIED WITH KA-KP-KT-230-9
BEARING HOUSING CAPSCREW (1 1/2)
BEARING HOUSING CAPSCREWS (2")
BOLT SUPPLIED WITH AP-230-9
WASHER SUPPLIED WITH AP-230-9
1/4-20UNC X 1 1/4 CAPSCREW
1/4 LOCK WASHER
1/4 WASHER
1/4-20UNC NUT
3/8-16UNC X 1 1/4
3/8 WASHER
3/8 LOCK WASHER
3/8-16-UNC HEX HEAD NUT
BELT, OIL PUMP
BELT, WATER PUMP
3/8-16UNC X 3/8 SETSCREW
JIC MALE ELBOW 1/2
SAE 37 JIC FML SWIVEL 90 TUBE ELBOW 1/4 X 1/2
SAE JIC MALE CONNECTOR 1/4 X 1/8
SAE 37 JIC FML SWIVEL 90 DEG TUBE ELBOW 1/4 X 1/4
SAE 37 JIC FML SWIVEL 3/8 X 1/2
BEARING HOUSING GASKET
ITEM NO. QTY. PART NO.
DESCRIPTION
1
1 KA-285-350HTC LINER, 3 1/2" HEAT TREATED
2
1 KA-275
PONY ROD, PISTON PUMP TYPE
3
1 KA-265
PISTON EXTENSION ROD
4
1 KA-KT-270
PISTON EXTENSION ROD LOCK NUT
5
1 KA-290-400
LINER RETAINER 4"
6
1 KA-245-350
PISTON COMPLETE 3 1/2"
7
1 KA-280
CLAMP, PONY ROD TO PISTON ROD
8
1 KA-295
LINER GASKET
9
1 KA-32PT
PONY ROD SPLASH GUARD
2
9
7
3
5
6
PISTON
1
4
2
3
1
4
8
PISTON ASSEMBLY
DRAWING
ITEM NO. QTY. PART NO.
1
1 KA-250-350
2
1 KA-263-350
3
1 KA-261-350
4
1 KA-262-350
5
1 KA--246
DESCRIPTION
PISTON, BODY ONLY, 3 1/2"
PISTON CUP
PISTON CUP RETAINER PLATE
PISTON CUP SNAP RING
PISTON O'RING
5
STUD TORQUE SEQUENCE
STUD REQUIREMENTS:
10 EA KA-59- FLUID END/LINER RETAINER STUDS
6 EA KA-59T- FLUID END/LINER RETAINER LINEUP STUDS
6 EA KA-59SC FLUID END/CASE CAPSCREWS
6
15
17
12
1
10
13
4
7
LINEUP
STUD
8
LINEUP
STUD
3
14
9
2
5
11
18
16
KA-3500PT
FLUID END TO POWER FRAME
STUD TORQUE SPEC 130 FT LB
CAPSCREW TORQUE SPEC 200 FT LB
HAMMER NOT INCLUDED
WITH INSTALLATION TOOL
2
1
3
5
MAKE SURE
SNAP RING
SNAPS IN
GROOVE
4
KA-248
PISTON SNAP RING
INSTALLATION TOOL
PLACE TAPERED PLUG (3)
ON PISTON HEAD (5). SLIDE
SNAP RING (2) ONTO TOOL
TAPERED PLUG. USE SNAP
RING TOOL BODY (1) TO SEAT
SNAP RING IN PISTON HEAD
GROOVE (4).
12
2
9
6
1
3
4
11
7
5
10
8
TORQUE SPECIFICATIONS
REFERENCE
.000" - .005"
SHAFT END PLAY
DESCRIPTION
WHEN ADJUSTING THE ENDPLAY
OF THE TAPERED ROLLER BEARINGS
USED ON THE CRANKSHAFT,
DIAL INDICATORS AND SHIMS MUST
BE PROPERLY USED. INCORRECT
BEARING ADJUSTMENT MAY RESULT
IN EXCESSIVE NOISE, TEMPERATURE, AND
REDUCED BEARING LIFE. Kerr Pumps
RECOMMENDS BETWEEN .000” - .005”
OF INTERNAL AXIAL CLEARANCE
(END PLAY) WHEN ASSEMBLED. FINAL
ADJUSTMENT MUST BE MADE USING A
DIAL INDICATOR.
1
2
3
4
5
6
7
8
9
10
11
12
INSURE THE CONNECTING RODS ARE
DISCONNECTED TO ALLOW FREE
CRANKSHAFT MOTION.
LUBRICANT
KA-3500PT
SPECIFICATIONS
TORQUE
PAN COVER CAPSCREW
21 ft-lb (28 Nm)
CONNECTING ROD CAPSCREW
160 ft-lb (217 Nm)
BEARING HOUSING CAPSCREW
75 ft-lb (102 Nm)
WRIST PIN SET SCREW AND JAM NUT
30 ft-lb (41 Nm)
PONY ROD PACKING GLAND CAPSCREW
50 ft-lb (68 Nm)
CLAMP SOCKET HEAD CAPSCREW
20 ft-lb (27 Nm)
PISTON LINER RETAINER STUD NUT
110 ft-lb (149 Nm)
FLUID END STUD NUT
130 ft-lb (176 Nm)
PISTON EXTENSION ROD SELF-LOCKING NUT 500 ft-lb (678 Nm)
COVER CAP STUD NUT
200 ft-lb (271 Nm)
PONY ROD
1000 ft-lb (1356 Nm)
CAPSCREW FLUID END/CASE
200 ft-lb (271 Nm)
NOTE: WHEN USING LUBRICANTS,
REDUCE TORQUE AS FOLLOWS:
WHI TE LEA D
GRA PHIT E
OI L
GREA SE
A NT I - SEIZE COMPOUND
PERCENTAGE OF TORQUE REDUCTION REQUIRED
REDUCE
REDUCE
REDUCE
REDUCE
REDUCE
T ORQUE
T ORQUE
T ORQUE
T ORQUE
T ORQUE
25%
30%
40%
40%
45%
KA-26G
GASKET
KA-28S
KA-28
SEALS
KA-26-A
PONY ROD
PACKING GLAND
ASSEMBLY
KA-26
PONY ROD
GLAND
KA-160
KA-195
KA-200
KA-160-7
AP-16T
KA-126FE
KA-38
KA-250
KA-192
KA-290
KA-60
KA-59
KA-33D
KA-205
KA-145
KA-150-5
KA-215
KA-210
KA-190-12
KA-30
KA-155
KA-175
KA-12
KA-11
KA-10
KA-34D
KA-38
AP-72
KA-275T
KA-32PT
KA-280
KA-265
AP-71
KA-52L
LONG
SPRING
KA-72HT
DISCHARGE
VALVE
KA-77
INSERT
KA-260
KA-285
KA-17T
KA-20A
KA-120-8
KA-18 KA-24
KA-18A
*REMOVE PISTON & LINER
AS AN ASSEMBLY IN
ORDER TO SERVICE
KA-74HT
SEAT
KA-300HT
DISCHARGE
VALVE ASSEMBLY
KA-52S
SHORT
SPRING
KA-73HT
SUCTION
VALVE
KA-77
INSERT
KA-74
VALVE
SEAT
KA-305HT
SUCTION
VALVE ASSEMBLY
KA-165
KA-235
BACK PLATE REMOVED
TO SHOW BELTS
KA-28
TWO SEALS TO
CRANKCASE OIL
KA-26S
SNAP
RING
KA-295
KA-26
PACKING
GLAND
KA-285
KA-245
KA-265
KA-1PT
KA-120-8
TROUBLESHOOTING GUIDE
for Kerr Pump
1) CHECK FOR LEAKING PISTONS
- REPLACE IF NECESSARY
2) CHECK FOR PROPER FLUID FLOW
TO PUMP
- MINIMUM REQUIREMENTS 3"
SUCTION HOSE NO MORE THAN 50'
LONG WITH 30 PSI OF CONTINUOUS
PRESSURE FEEDING PUMP
KA-26G
GASKET
KA-26-A
PONY ROD
PACKING GLAND
ASSEMBLY
KA-3500PT
KA-21-000
3) REMOVE VALVE COVER CAPS AND
INSPECT VALVES & VALVE SEATS
FOR FOREIGN OBJECTS AND WEAR
- REPLACE IF NECESSARY
Kerr KA-3500PT Piston Type Pump
Part Number
KA-1PT
KA-3
KA-6
KA-6B
KA-7
KA-8-015
KA-8-010
KA-8-005
KA-9
KA-10
KA-11
KA-12
AP-16T
AP-16
KA-17T
KA-18
KA-18A
KA-19
KA-20A
KA-20
KA-21-000HRL
KA-21-030
KA-21-015
KA-21-000
KA-22
KA-24
KA-26M-A
KA-26M
KA-26S
KA-26G
KA-26A
KA-26
KA-28
KA-29
KA-30
KA-32PT
KA-33-2500
KA-33-500
KA-33-2000
Description
Pump Case
Crankshaft Oil Seal
Bearing Housing Capscrews
Bearing Housing Capscrews 2
Bearing Housing Gaskets
Main Bearing Adjusting Shims .015
Main Bearing Adjusting Shims .010
Main Bearing Adjusting Shims .005
Main Bearings
Pan Cover
Pan Cover Capscrews
Pan Cover Gasket
Breather Cap (Oil Filler) Threaded Style
Breather Cap (Oil Filler)
Crosshead Tapered
Wrist Pin
Wrist Pin Bushing
Wrist Pin Set Screws & Nut
Connecting Rod (Inserted Both Ends)
Connecting Rod Only (No Inserts - Requires inserts both ends)
Connecting Rod Insert Bushing (Std)
Connecting Rod Insert Bushing (.030)
Connecting Rod Insert Bushing (.015)
Connecting Rod Insert Bushing (Std)
Connecting Rod Capscrew
Connecting Rod Shims (Laminated)
Pony Rod Gland Assembly (Pony Rod Gland, Snap Ring, 2 Seals, & 1 Wiper)
Pony Rod Gland Snap Ring Type for KA-29 Seal Kit
Pony Rod Gland Snap Ring
Pony Rod Gland Gasket
Pony Rod Gland Assembly (Pony Rod Gland, Snap Ring, Seals)
Pony Rod Seal Gland Snap Ring Type
Pony Rod Seal (4 Seals per Set)
Pony Rod Seal Kit (2 Seals & 1 Wiper per Set)
Pony Rod Gland Capscrews
Pony Rod Splash Guard
3 to 2 1/2 Bushing
3 to 1/2 Bushing
3 to 2 Bushing
# Req
1
1
9
3
2
2
1
14
1
1
1
3
3
3
3
3
3
3
3
3
3
6
6
3
3
3
3
3
3
3 sets
3
12
3
1
1
1
Part Number
KA-33DM
KA-34D
KA-35D
KA-36B
KA-36
KA-37
KA-38N
KA-38A
KA-42-3
KA-52S
KA-52CW
KA-52L
KA-59T
KA-59CS
KA-59
KA-60
KA-68MH
KA-68M-5
KA-68M-5
KA-68M-4
KA-68M-3
KA-68M-2
KA-68M-1
KA-68M
KA-68
AP-71
AP-72
KA-072HT
KA-073HT
KA-074HT
AP-77T
KA-77HT
KA-77
KP-85
KA-113PT
KA-120-8TP-2
KA-120-8
KA-120-6
KA-125-8
KA-125-6
Description
Fluid End Vessel Only (Ductile)
Top Cover Cap (Ductile)
End Cover Cap (Ductile)
Cover Cap Bracket Stud
Cover Cap Stud
Cover Cap Stud Nut
Cover Cap O' Ring (Nitrile)
Cover Cap O' Ring (Aflas)
Valve Spring
Valve Spring (Suction) (Short)
Valve Spring
Valve Spring (Discharge) (Long)
Fluid End / Liner Retainer Lineup Studs
Fluid End Capscrews
Fluid End / Liner Retainer Studs
Fluid End / Liner Retainer Stud Nuts
Valve Puller Wing Type (Hydraulic)
O-Ring, Puller
Nut,Puller
Spacer Washer, Puller
Head, Puller
Pin Set, Puller
Rod, Puller
Valve Puller Wing Guide Pin Type
Valve Puller Wing Type
Drain Plug
Oil Level Plug
Discharge Valve, Heat Treated, A/R with Insert
Suction Valve, Heat Treated, A/R with Insert
Valve Seat, Heat Treated, A/R
Valve Insert Tool
Abrasive Resistant Valve Insert (High Temperature)
Abrasive Resistant Valve Insert
Insert, Caged A/R (Abrasive Resistant) Valve
KA-3500PT Rebuild Gasket Kit Complete Includes the Following Parts:(1) KA-3, (2) KA-7, (1) KA-12, (3) KA26G, (3) KA-28, (3) KA-32PT, (6) KA-38, (2) KA-127, (1) KA-161, (1) KA-191, (3) KA-295, (1) AP-331
Crankshaft, Splined Hydraulic Drive TP-2
Crankshaft, Splined Hydraulic Drive 21 Tooth Spline #8 & #9
Crankshaft, Splined Hydraulic Drive 40 Tooth Spline
Bearing Housing, Hydraulic Drive # 8
Bearing Housing, Hydraulic Drive # 6
# Req
1
3
3
2
22
24
6
6
10
3
6
3
2
6
10
24
1
1
1
1
1
3
1
1
1
1
3
3
3
6
1
6
6
10
1
1
1
1
1
1
Part Number
KA-126FE
KA-126BH
KA-127
KA-130TP
KA-130
AP-132
KA-133-1
KA-133TP
KA-134-3
KA-134-2
KA-134-1
KA-134
AP-135
KA-140RH
KA-140LH
AP-145
AP-150
KA-155
AP-160-6
AP-160-5
AP-160-4
AP-160-3
AP-160-2
KA-160
AP-160-1
KA-161
KA-165TP
KA-165
KA-170TP
KA-170
KA-175
KA-180
AP-190-14
AP-190-13
AP-190-12
AP-190-11
AP-190-10
AP-190-9
AP-190-8
AP-190-5
Description
Fluid End Lifting Eye
Bearing Cap Lifting Eye
#8 & #9 Auburn Housing Gasket
Bearing Housing, Oil Pump Lubrication System
Bearing Housing, Extension Shaft Side
Extension Shaft
O'Ring, Adapter Sleeve
Adapter Sleeve, Oil Pump Lubrication System
Socket Head Capscrews, Pump Oil Lubrication System
O'Ring, Pump Oil Lubrication System
Bushing 1/2 NPT to 1-1/2 NPT Steel
Pump, Oil Lubrication System
Oil Seal, Bearing Housing Extension Shaft
Bracket, Oil and Water Pumps (Right-Hand)
Bracket, Oil and Water Pumps (Left-Hand)
Oil Pump, 1/2 Cast Iron
Sheave, Oil Pump
Belt, Oil Pump
Fitting, Female Swivel (Supplied with hose)
Fitting, Crosshead Oil Injector
Oil Manifold Plug
Male Pipe Rigid 1/4 X 1/8 (Supplied with hose)
90 Degree Tube Fitting 1/2 (Supplied with hose)
Oil Manifold
Oil Manifold 90 Degree Elbow
Oil Manifold Gasket
Oil Line, Pump Manifold
Oil Line, Pump Manifold
Oil Line, Pump to Oil Sump
Oil Line, Pump to Oil Sump
Oil Line, Manifold to Bearing Housing
Oil Line, Manifold to Crosshead
1/4-20 UNC Nut
1/4 Lock Washer
Fitting, Water Jet
Piston Chamber Cover Setscrew
Piston Chamber Cover Wing Nut
Piston Chamber Cover Inspection Glass Capscrew
Piston Chamber Cover Inspection Glass Wing Nut
Water Manifold Quick Coupling
# Req
1
1
1
1
1
1
1
1
4
1
2
1
1
1
1
1
1
1
3
3
1
5
1
1
1
1
1
1
1
1
2
3
4
4
3
2
2
2
2
1
Part Number
AP-190-4
AP-190-3
AP-190-2
KA-190
KA-190A
KA-191
KA-192
AP-195
AP-197
AP-200-175
AP-200-260
AP-200-520
AP-205-037
AP-205-038
AP-205-039
KA-210
KA-215
AP-216
KA-220
KA-225
KA-230-16
AP-230-9
AP-230
AP-235-50
AP-235-32
AP-235-31
AP-235-27
AP-235-24
AP-235-23
AP-235-22
AP-235-21
AP-235-19
AP-235-17
KA-235RH
KA-235LH
KA-245-400
KA-245-350MU
KA-245-300
KA-245-350
KA-246
Description
Water Manifold 90 Degree Fitting
Water Manifold / Oil Manifold Bolt
Water Manifold Plug
Piston Chamber Cover
Piston Chamber Cover Spray Unit Complete
Piston Chamber Cover Gasket
Piston Chamber Cover Inspection Glass
Water Pump, Bronze
Water Pump Repair Kit (Nitrile)
Sheave, Water Pump (KA use belt KA-205-037)
Sheave, Water Pump (KA use belt KA-205-038)
Sheave, Water Pump (KA use belt KA-205-039)
Belt, Water Pump (KA use sheave KA-200-175)
Belt, Water Pump (KA use sheave KA-200-260)
Belt, Water Pump (KA use sheave KA-200-520)
Water Manifold
Line, Water Pump to Manifold
3/8 Quick Connect
Line, Water Pump to Supply Tank
Line, Water Manifold to Piston Cover
Lock Washer, Pump Oil Lubrication System
Sheave Bushing
Sheave, Crankshaft Drive to Pumps
Rotation Label
90 Degree Tube Fitting 1/4 (Supplied with hose)
SAE JIC Male Connector 1/4 x 1/8
3/8-16 UNC x 3/8 Setscrew
3/8-16 UNC Hex Head Nut
3/8 Lock Washer
3/8 Flat Washer
3/8-16 UNC x 1 1/4
1/4 Flat Washer
1/4-20 UNC x 1 1/4 Capscrew
Belt Guard, Pump Drive (Right-Hand)
Belt Guard, Pump Drive (Left-Hand)
Piston Complete 4
Piston Complete 3 1/2 (Molded Urethane)
Piston Complete 3
Piston Complete 3 1/2
Piston O' Ring
# Req
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
4
1
1
1
1
2
2
2
2
2
2
2
2
1
1
3
3
3
3
3
Part Number
KA-248
KA-250-400
KA-250-350
KA-250-300
KA-260-400
KA-260-350
KA-260-300
KA-265
KA-270
KA-275
KA-276
KA-277
KA-280
KA-285-400KER-A
KA-285-400CH-A
KA-285-350KER-A
KA-285-350CH-A
KA-285-350CER-A
KA-285-300CH-A
KA-285-300CER-A
KA-285-400KER
KA-285-400CH
KA-285-350KER
KA-285-350CH
KA-285-350CER
KA-285-300CER
KA-285-300CH
KA-290
KA-295
KA-300
KA-305
AP-306
AP-320
AP-324-9
AP-324-8
KA-325
KA-326
KA-327
AP-330-2
AP-330-1
Description
Piston Snap Ring Installation Tool
Piston, Body Only 4
Piston, Body Only 3 1/2
Piston, Body Only 3
Piston Cup Kit 4.0(cup, retainer plate, snap ring)
Piston Cup Kit 3.5 (cup, retainer plate, snap ring)
Piston Cup Kit 3 (cup, retainer plate, snap ring)
Piston Extension Rod
Piston Extension Rod Lock Nut
Pony Rod Piston Pump Type
Installation Tool for Pony Rod Seal
Pony Rod Installation Wrench
Clamp, Pony Rod to Piston Rod
Liner Assembly 4 (Piston complete, rod, locknut, liner kerramic, gasket)
Liner Assembly 4 (Piston complete, rod, locknut, liner chrome, gasket)
Liner Assembly 3 1/2 (Piston complete, rod, locknut, liner kerramic, gasket)
Liner Assembly 3 1/2 (Piston complete, rod, locknut, liner chrome, gasket)
Liner Assembly 3 1/2 (Piston complete, rod, locknut, liner ceramic, gasket)
Liner Assembly 3 (Piston complete, rod, locknut, liner chrome, gasket)
Liner Assembly 3 (Piston complete, rod, locknut, liner, gasket)
Liner, 4 Kerramic
Liner, 4 Chrome
Liner, 3 1/2 Kerramic
Liner, 3 1/2 Chrome
Liner, 3 1/2 Ceramic
Liner, 3 Ceramic
Liner, 3 Chrome
Liner Retainer
Liner Gasket
Abrasive Resistant Discharge Valve Complete (72HT, 74HT & 52L)
Abrasive Resistant Suction Valve Complete (73HT, 74HT & 52S)
Valve Seat Seating Tool
Flow Meter
# 9 Planetary Gear Assembly
# 8 Planetary Gear Assembly
Planetaty Adapter Kit 6 to 8
Spline Adapter (21-40)
Spline Adapter Spacer
Snap Ring, SAE C 4 Bolt Drive Assembly 1-1/2 Male Input Shaft
Oil Seal, SAE C 4 Bolt Drive Assembly 1-1/2 Male Input Shaft
# Req
1
3
3
3
3
3
3
3
3
3
1
1
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
1
1
1
1
1
1
1
1
1

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