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NEW PUMP WARRANTY

1) Kerr Machine Company (KERR PUMPS) warrants its new pumps to be free from defective materials and/or workmanship for a period of one year from the date of sale by the 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 one-year 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.

A. For the first ninety (90) days from the date of sale by the Distributor, 100% credit will be allowed on a current list price basis.

B. From 91 to 180 days from the date of sale by the Distributor, 75% credit will be allowed on a current list price basis.

C. From 181 days to 270 days by the Distributor, 50% credit will be allowed on a current list price basis.

D. From 271 days to one year after the date of sale by the Distributor, 25% credit will be allowed on a current list price basis.

The credit given to the Distributor for replacement parts or pumps under this warranty is based upon the Distributor’s net cost

paid Kerr Pumps for such replacement parts or pumps.

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5) In the event of a warranty claim under this warranty made within ninety (90) days of the date of sale by the Distributor, 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 plungers, valves, plunger packing, 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.

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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.

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Loss of pressure or volume

Consistent, rhythmic knock

KERR TROUBLE SHOOTER GUIDE

Unusual pounding, knocking broken valve spring

REASON OR SERVICE NEEDED

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.

Packing failure (Excessive)

Abnormal wear of fluid end parts

Abnormal wear of power end parts

Heat in power end

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.

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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. 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.

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RECOMMENDED INSTALLATION OF KERR PUMPS

FOR BEST RESULTS

(A) PRESSURE RELIEF VALVE (REQUIRED)

(B) BY-PASSED FLUID SHOULD BE PIPED BACK IN SUCTION SUPPLY TANK WHEN POSSIBLE

(C) USE FLEXIBLE HOSE IN DISCHARGE LINE WHEN POSSIBLE

(D) DISCHARGE SHUT-OFF VALVE (OPTIONAL-USED FOR TOTAL SHUT-DOWN OR SERVICE ONLY)

(E) DISCHARGE AND SUCTION ON EITHER SIDE OF FLUID END ON ALL MODELS.

(F) PULSATION “DAMPENERS” MAY BE USED IN EITHER THE SUCTION OR DISCHARGE PIPING OR BOTH.

DISCHARGE DAMPENERS SHOULD BE CAPABLE OF HANDLING PUMP DISCHARGE MAXIMUM PRESSURE

SUITABLE

FALL-OPENING

VALVE

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”.

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.

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PREVENTIVE MAINTENANCE

DAILY

1. Check and Maintain Lubricant Levels.

Standard Lubricant:

AGMA Grade (ASTM D 2422): 4 EP

ISO Viscosity Grade: 150

Viscosity in SSU @ 100 degree F: 625-765

Synthetic Lubricant:

SAE Viscosity Grade (J306-8): 75W-90

KD-1250 2 qts.

KJ-2250 3 qts.

KM-3250 4 qts.

KM-3300 4 qts.

KP-3300 12 qts.

PUMP CAPACITIES (APPROXIMATE)

KT-3350 16 qts.

KT-3400 16 qts.

KB-3500 20 qts.

KA-3500 36 qts.

KSB-6400 36 qts.

R335/R340 16 qts.

Q5450 22.5 gal.

KSB-6500 36 qts.

KCP-6300 24 qts.

KZ-3150 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.

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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.

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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 below 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-3150 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. VALVES (Disc-type): All disc-type valves are exposed for removal in a similar manner as the wing-guided valves. Instead of removing the valve body; the upper portion of the valve is removed by removal of the valve capscrew, spring retainer, valve spring, and valve spacer sleeve. The valve seat is then “pulled” from the fluid-end utilizing an authorized Kerr Valve Puller.

Note: In all Kerr Pumps with disc-type valves the discharge and suction valves are identical.

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3. VALVES (Ball & Seat): In Kerr Pumps with block/billet type fluid-ends the valves are ball and seat design. These are exposed for removal/inspection by removal of the appropriate valve cover. The flat seats are kept in place by a screw-in valve retainer that can be best removed with a Kerr Valve Wrench made for the appropriate pump. Springs are normally incorporated with the discharge valves while the suction valves operate with a “free ball”. A copper washer/gasket is used under all valve seats for a seal. When installing or removing a flat type valve seat a good “rap” on top of the valve wrench will

“seat/unseat” the seat and copper gasket prior final tightening or removal. Failure to “seat” the valve seat in this manner can result in the “washing out” of the fluid-end. For pressurized suction, valves will need to be spring loaded. Call Kerr Pumps for this change.

4. PLUNGERS: Following the removal of the suction valve, the plunger may be removed by breaking the union between the plunger and pony rod and forcing the plunger out the back of the fluid-end. Loosening the packing nut/gland will facilitate the removal of the plunger. The reverse of this procedure is used to install a plunger. Lubrication and some slight force may be used to pass plunger through the packing. Always retighten the plunger and pony rod union periodically following the removal of the plunger to insure it is securely made up and will not vibrate loose.

5. PLUNGER PACKING: This manual includes illustrations of the packing sets for each model pump. Generally, once the plunger has been removed from the pump, the packing can be exposed for removal by completely removing whatever device is used to tighten the packing (i.e. the packing or stuffing box nut or gland). There will be various amounts of metal rings and packing components depending upon the type of packing and the model of pump (refer to appropriate illustration or chart).

After the removal of all rings and equipment from the stuffing box; thoroughly clean it and inspect for damage, which might keep the new packing from working properly. If the stuffing box is in satisfactory condition, install the new packing as per the appropriate illustration. It is a good idea to lubricate new packing with a light oil prior to installation. Most of the standard packing used in Kerr Pumps should be tightened with the original equipment-packing wrench while the pump is running under normal operating pressure. After a two or three hour run-in, check the packing for tightness and re-adjust as necessary.

Packing should be checked for tightness on a periodic basis, but it is not a good idea to attempt to periodically tighten the packing as part of routine maintenance. This tends to “wear out” the packing prematurely. When the packing leaks in an excessive amount it should be replaced. There is no value in constantly “re-tightening” leaking packing.

If your pump is equipped with optional “spring loaded” packing, there is no adjustment in this equipment during its operational life. The stuffing box nut is initially tightened as much as possible and there is no further adjustment. Note: In all cases the spring goes in the stuffing box before the packing rings.

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When using the optional Kevlar or Teflon packing, be sure to rotate the “splits” so that none are “aligned” to insure that the packing holds properly. Normally, this packing is not lubricated and requires less tension on the stuffing box nut during operation.

CAUTION: An “airtight” seal is not desirable with this plunger packing. Some slight dripage is desirable during operation.

Attempts to tighten packing until it completely “seals off” will result in premature failure from too much friction. The Kevlar

& Teflon packing must be allowed to drip a small amount to assure normal life.

6. PONY ROD and PONY ROD PACKING: Kerr Pumps use two pony rod sealing arrangements, models KD-1250, KJ-2250,

KM-3250 and KCP-6300 use a screw in seal gland, all other models use a bolt in seal gland, these glands use press in oil seals with snap ring retainers. Some Bolt in gland use adjustable packing arrangements with bolt in or screw in followers to adjust packing. By unscrewing plunger from pony rod a gap may be facilitated to allow the removal of the various sealing arrangements. A special wrench will be needed to remove and replace pony rod to crosshead. (This wrench is available from

Kerr Dealers) All pony rods have a jam nut to align tighten pony rod to crosshead, care must be exercised in installing new

seal on pony rod not to damage it.

7. 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

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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

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.

8. 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. It can be removed by breaking the plunger connection, backing off the packing nut or gland, removing the various fluid end bolts, and sliding the entire fluid end off the power frame. Corrosion may tend to seize the two components together making their separation difficult in some isolated cases. On models KP-3300, KT-3350/KT-3400 and R335/R340 the bolted in stuffing box assemblies must be removed prior to removal of the entire fluid end. They are held in place by four studs each. On all other units the stuffing boxes can be left intact. On the remaining pumps (with the exception KD-1250B, KJ-2250B, KM-3250B, and KCP-6300) the stuffing boxes are held in place in the fluid end by a friction or “press” fit. They should be removed with a hydraulic press if possible. These press-in type stuffing boxes carry a gasket and/or an o-ring to insure a good seal. The boxes on the KD-

1250B, KJ-2250B, KM-3250B, and KCP-6300 are screw-in type and carry only a copper gasket.

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TECHNICAL DATA SHEET

PCN: ______ Supercedes PCN: _____

T.D.S. NO.

Page

4.2

1 OF 2

Date 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.

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.

3.1 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:

4.0 PROCEDURE

CITGO: RUST-O-LINE OIL 10

SHELL: ENSIS OIL N

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 T.D.S. NO.

Page 2 OF 2

Date 03-10-06

4.2

PCN: ______ Supercedes PCN: _____

________________________________________________________________________________________________________________

4.1.4 Remove the wiper box seals and cap/plug the seal opening.

4.1.5 Clean the pump outer surfaces prior to painting.

4.1.6 If painting is required mask crank and lubricator shaft surfaces and keyways. If painting does not apply, go to Para.

4.1.8.

4.1.7 Paint as specified by the customer order or as required.

4.1.8 Apply a thin layer of grease to the exposed oil seal lips.

4.1.9 Apply a thin layer of heavy rust preventative to the exposed crank and lubricator shaft surfaces and keyways.

4.1.10 Wrap the exposed crank and lubricator shafts with waxed tape.

4.1.11 Carefully wrap the following parts prior to placing them into polyurethane bags. Oil level gages, lube pressure gages, and breather caps.

4.1.12 Finish box, crate and mark the parts from Para. 4.1.2 after final inspection (see Para. 4.2.2).

4.2 Shipping/Receiving (New Pumps Only)

4.2.1 All pumps and accessories (as applicable) will be final inspected by Kerr Pump personnel prior to shipping. Any witnessed or third party inspection will be signed-off by the purchaser or customer representative prior to final crating and shipment.

4.2.2 Export crating will be performed by either an approved Kerr Pump source or as specified by the purchaser or customer.

Any third party inspection will be coordinated with the source.

4.2.3 Upon receipt of the shipment, the purchaser or customer is responsible for inspection and repair of damaged coatings at the expense of the shipper.

5.0 WARRANTY/START-UP

5.1 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 Remove all storage caps, plugs, and covers.

5.3.2 Replace any damaged or cracked O-rings or gaskets.

5.3.3 Inspect power end shaft oil seals and replace if cracked, split or damaged.

5.3.2 Install crankcase drain plug, lubrication level site glass and breather cap.

5.3.3 Install, if applicable, any oil pressure and/or temperature gage.

5.3.4 Check the connection of the plunger and pony rod to the crosshead prior to, and after, initial run-in of the pump.

5.3.5 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.

Page

Date

4.3

1 OF 2

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.

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:

4.0 PROCEDURE

CITGO:

SHELL:

RUST-O-LINE OIL 10

ENSIS OIL N

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 All breathers shall be replaced with airtight seals, plugs or gasketed plates. No venting is recommended as it may allow moist air in.

4.1.5 Remove the wiper box seals and cap/plug the seal opening.

4.1.6 Clean the pump outer surfaces prior to painting.

4.1.7 If painting is required mask crank and lubricator shaft surfaces and keyways. If painting does not apply, go to Para. 4.1.9.

4.1.8 Paint as specified by the customer order or as required.

4.1.9 Apply a thin layer of grease to the exposed oil seal lips.

4.1.10 Apply a thin layer of heavy rust preventative to the exposed crank and lubricator shaft surfaces and keyways.

4.1.11 Wrap the exposed crank and lubricator shafts with waxed tape.

4.1.12 Carefully wrap the following parts prior to placing them into polyurethane bags. Oil level gages, lube pressure gages, and breather caps.

4.1.13 Finish box, crate and mark the parts from Para. 4.1.10 after final inspection (see Para. 4.2.2).

4.2 Shipping/Receiving (New Pumps Only)

4.2.1 All pumps and accessories (as applicable) will be final inspected by Kerr Pump personnel prior to shipping. Any witnessed or third party inspection will be signed-off by the purchaser or customer representative prior to final crating and shipment.

4.2.2 Export crating will be performed by either an approved Kerr Pump source or as specified by the purchaser or customer.

Any third party inspection will be coordinated with the source.

4.2.3 Upon receipt of the shipment, the purchaser or customer is responsible for inspection and repair of damaged coatings at the expense of the shipper.

5.0 WARRANTY / START-UP

5.1 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 Remove all storage caps, plugs, and covers.

5.3.2 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.

5.3.3 Inspect power end shaft oil seals and replace if cracked, split or damaged.

5.3.2 Install crankcase drain plug, lubrication level site glass and breather cap.

5.3.3 Install, if applicable, any oil pressure and/or temperature gage.

5.3.4 Check the connection of the plunger and pony rod to the crosshead prior to, and after, initial run-in of the pump.

5.3.5 Fill the crankcase to the proper level with the specified lubricant.

TDS_4.3_Long Term Storage Preparation Procedure_landscape.doc

AP-425

STUFFING

BOX

NUT

WRENCH

KAB-53

VALVE

WRENCH

KA-276

PONY ROD

SEAL TOOL

SPECIAL TOOLS

FOR KA-3500B, KT-3350B, & KT-3400B

KA-3500BCB, KT-3350BCB, & KT-3400BCB

KB-3500B, KB-3500BCB

KS-6400B, KS-6400BCB

Q5450BCB

KA-277

PONY

ROD

WRENCH

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

1.) Remove Capscrews from Top and End Cover Plates

2.) Remove Round Cover Caps; If

Caps are difficult to remove, use a pry bar

3.) Inspect Cover Cap O’Rings for damage; replace if necessary

4.) Remove valve springs and ball guides from discharge valves

Ball and Seat Valve Changing Instructions (...continued)

5.) Use Kerr Pump Valve Retainer

Tool to remove Valve

Retainers

6.) To unscrew suction valve retainer, insert Valve Retainer

Tool using normal torque.

7.) To help unscrew valve retainer, use several firm to heavy blows with hammer

8.) Proceed to unscrew suction valve retainer

9.) Suction valve retainer, ball and seat assembly shown

10.) Remove discharge valve retainer as illustrated in step 7 and 8 of the suction valve retainer removal

Ball and Seat Valve Changing Instructions (...continued)

11.) Proceed to unscrew dis-

charge retainer

12.) Discharge and Suction valve assemblies

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

Ball and Seat Valve Changing Instructions (...continued)

17.) To assemble standard

suction valve retainer:

Place ball in valve retainer

before installing valve seat

18.) Apply anti-seize to valve seat 19.) Install valve seat into

retainer

20.) Install new gasket or o’ring prior to installing new valve retainer. Add anti-seize to hold in place during install

21.) Make sure valve tool engages valve retainer properly

22.) Screw valve retainer to engage gasket or o’ring

Ball and Seat Valve Changing Instructions (...continued)

23.) Torque valve retainer to

150 ft-lbs

24.) Use several firm to heavy blows with hammer to seat the valve after initial torque

25.) Re-torque to 150 ft-lbs

26.) Apply anti-seize to discharge valve seat

27.) Insert valve seat in discharge valve retainer

28.) Valve seat installed in discharge valve retainer

Ball and Seat Valve Changing Instructions (...continued)

29.) Apply anti-seize to retainer threads

30.) Install new gasket prior to installing discharge valve retainer

31.) Torque valve retainer to

150 ft-lbs

32.) Use several firm to heavy blows with hammer to seat valve after initial torque

33.) Re-torque valve retainer to

150 ft-lbs

34.) Discharge valve ball should be inserted after retainer has been properly torqued

Ball and Seat Valve Changing Instructions (...continued)

35.) Discharge and suction ball guide and springs shown for spring loaded suction only

36.) Standard Pumps do not use suction ball guide and spring.

37.) Install cover caps. Note:

Suction Cover Cap shown is for spring loaded suction

38.) Install cover plate and capscrew. Apply anti-seize to capscrew threads

39.) Torque to Kerr Pump specification

11.086

11.00

11.25

2" NPT

3.75

18.125

36.25

33.0

.844

4.000 SHAFT

1" X 1/2" KEYWAY

51.9

32.437

34.562

1-13/16 API 6XB

DISCHARGE FLANGE

2.125

42.37

40.125

19.0

2.75

5.25

7.375

2" NPT

SUCTION

11.625

Q5450BCB - RH GENERAL DIMENSIONS

6.0

1

2

TORQUE SPECIFICATIONS FOR Q5450BCB

6

7

9

4 8 5 10

3

.000" - .005"

SHAFT END PLAY

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.

INSURE THE CONNECTING RODS ARE

DISCONNECTED TO ALLOW FREE

CRANKSHAFT MOTION.

NOTE: WHEN USING LUBRICANTS, REDUCE TORQUE AS FOLLOWS;

ITEM NO.

PART NUMBER

1 Q5450B-633

2 Q5450B-35

3

4

5

Q5450B-634

KAB-39

KAB-41M

10

11

12

13

6

7

8

9

KAB-40

KAB-44

Q5450B-620

Q5450B-635

CP-48

KAB-41

CP-44-3-N

KAB-59N

DESCRIPTION

FLUID END BOLTED CAPS

TOP COVER CAP

SUCTION VALVE PLUG

SUCTION VALVE RETAINER

BALL & SEAT/WITH O-RING GROOVE

DISCHARGE VALVE RETAINER

DISHARGE BALL GUIDE

7/8-9 UNC X 2.5" HX GD 8 SHCS SCREW

DISCHARGE VALVE PLUG

DISCHARGE VALVE SPRING

VALVE BALL

VALVE SEAT O-RING

O-RING

QTY.

1

10

5

5

10

5

5

40

5

5

5

10

10

Q5450BCB-633

FLUID END ASSEMBLY

8

2

13

9

10

7

6

5

12

5

12

8

2

13

3

4

1

Q5450B-620

Q5450B-35

KAB-59N

Q5450B-35

Q5450-59CS

KA-280

Q5450-64FDL

KA-30

Q5450-16T

KA-126BH

Q5450-1

Q5450-2

Q5450-12

Q5450-11

Q5450-10

Q5450B-633

Q5450-63-150

Q5450-32PT

Q5450-275T

Q5450B-635

KA-17T

KA-18A

KA-18

Q5450-20A

KA-61-150

PACKING

KP-87N

O-RING

Q5450B-634

CP-48

KAB-44

KAB-40

KAB-40

KAB-41M

CP-44-3N

SUCTION

VALVE

ASSEMBLY

KAB-41M

CP-44-3N

DISCHARGE

VALVE

ASSEMBLY

KAB-48-150

STUFFING

BOX NUT

KP-64CS

FLUID END

CAPSCREW

KP-93SL-150

ADAPTERS

KP-95-225S

SPRING

Q5450-45-225

STUFFING BOX

Q5450-45-150 ASSEMBLY

WITH 805 PACKING

Q5450BCB PARTS ILLUSTRATION

Q5450-22

AP-71-100

Q5450-9C

Q5450-26

PACKING

GLAND

Q5450-26R

O-RING

KA-26S

SNAP RING

KA-28

SEALS TO

CRANKCASE

OIL

Q5450-26A

PONY ROD

PACKING GLAND ASSEMBLY

Part Number

Q5450-1

KA-3

Q5450-4

Q5450-5

KA-7

KA-8-005

KA-8-010

KA-8-015

KA-9

Q5450-9C

Q5450-10

Q5450-11

Q5450-12

AP-16T

KA-17T

KA-18

KA-18A

KA-19

Q5450-20

Q5450-20A

Q5450-21-000

Q5450-21-015

Q5450-21-030

Q5450-22

Q5450-26A

Q5450-26R

Q5450-26

KA-26S

KA-28

KA-30

Q5450PT-32

Q5450B-35S

Q5450B-35SS

KAB-39

KAB-39SS

KAB-40

KAB-40SS

KAB-41M

KAB-44

KAB-44SS

CP-44-3E

Kerr Q5450BCB Billet Type Pump

Description

Case, Pump

Crankshaft Oil Seal

Bearing Housing, Blind Side

Bearing Housing, Shaft Side

Bearing Housing Gaskets

Main Bearing Adjusting Shims .005

Main Bearing Adjusting Shims .010

Main Bearing Adjusting Shims .015

Main Bearings

Bearing, Center Main

Pan Cover

Capscrew, Pan Cover

Gasket, Pan Cover

Breather Cap (Oil Filler) Threaded Style

Crosshead Tapered

Wrist Pin

Wrist Pin Bushing

Wrist Pin Set Screws & Nut

Connecting Rod ~ without Inserts

Connecting Rod ~ Inserted Both Ends

Connecting Rod Insert Bearing (Std)

Connecting Rod Insert Bearing (.015)

Connecting Rod Insert Bearing (.030)

Capscrew, Connecting Rod

Gland Ass'y, Pony Rod (Pony Rod Gland, Snap Ring, Seals)

O-Ring, Pony Rod Gland

Gland, Pony Rod, Snap Ring Type

Pony Rod Gland Snap Ring

Pony Rod Seal (4 Seals per Set)

Pony Rod Gland Capscrews SS

Pony Rod Splash Guard

Cover Cap, Top (Steel)

Cover Cap, Top (Stainless Steel)

Suction Valve Retainer

Suction Valve Retainer (Stainless Steel)

Discharge Valve Retainer

Discharge Valve Retainer (Stainless Steel)

Valve (Ball & Seat) O-Ring Style

Discharge Valve (Ball Keeper)

Discharge Valve (Ball Keeper) (Stainless Steel)

Valve Seat O-Ring, EPDM

5

5

5

5

5

5

5

5

10

5

5

5

5

5 sets

20

5

3

3

6

3

10

10

3

3

3

6

# Req

1

1

1

1

2

As Req

As Req

As Req

2

2

1

20

1

1

5

Kerr Q5450BCB Billet Type Pump

Part Number

CP-44-3N

Q5450-45-225S

Q5450-45-225SS

KAB-48

KAB-48-150

KAB-48-150SS

KAB-48SS

Description

Valve Seat O-Ring, Nitrile

Stuffing Box, Steel

Stuffing Box (Stainless Steel)

Stuffing Box Nut (AB)

Stuffing Box Nut 1 1/2

Stuffing Box Nut 1 1/2 (Stainless Steel)

Stuffing Box Nut (Stainless Steel)

CP-48

KAB-57

Q5450-59CS

KAB-59E

Discharge Valve Spring

Valve Wrench

Capscrew, Fluid End

Plug Seal, O' Ring EPDM

KAB-59N

KAB-59V

Plug Seal, O' Ring Nitrile

Plug Seal, O' Ring Viton

KAB-60GPK-150AB 758/PK Spring Loaded Packing Set 1 1/2 (ALBZ)

KAB-60GPK-150S 758/PK Spring Loaded Packing Set 1 1/2 (Steel)

KAB-60GPK-150SS 758/PK Spring Loaded Packing Set 1 1/2 (Stainless Steel)

KAB-60GPK-125AB 758/PK Spring Loaded Packing Set 1 1/4 (ALBZ)

KAB-60G-150S

KAB-60G-150SS

758 Spring Loaded Packing Set 1 1/2 (Steel)

758 Spring Loaded Packing Set 1 1/2 (Stainless Steel)

CP-60-125S

CP-60-125AB

KAB-60-125AB

KAB-60-125S

Adapters Only 1 1/4 Steel

Adapters Only 1 1/4 Aluminum Bronze

805 Spring Loaded Packing Set 1 1/4 (ALBZ)

805 Spring Loaded Packing Set 1 1/4 (Steel)

KAB-60-125SS

KAB-60GPK-125S

805 Spring Loaded Packing Set 1 1/4 (Stainless Steel)

758/PK Spring Loaded Packing Set 1 1/4 (Steel)

KAB-60GPK-125SS 758/PK Spring Loaded Packing Set 1 1/4 (Stainless Steel)

KAB-60-150AB 805 Spring Loaded Packing Set 1 1/2 (ALBZ)

KAB-60-150SS

KAB-60G-125AB

KAB-60G-125S

KAB-60G-125SS

805 Spring Loaded Packing Set 1 1/2 (Stainless Steel)

758 Spring Loaded Packing Set 1 1/4 (ALBZ)

758 Spring Loaded Packing Set 1 1/4 (Steel)

758 Spring Loaded Packing Set 1 1/4 (Stainless Steel)

KAB-60G-150AB

KAB-61-150

KAB-61G-150

Q5450-63-125

Q5450-63-138

Q5450-63-150B

Q5450HP-63-150

Q5450-64DL

Q5450-64

Q5450-64FDL

758 Spring Loaded Packing Set 1 1/2 (ALBZ)

805 Pressure Rings Only 1 1/2

758 Pressure Rings Only 1 1/2 Two Each

Plunger, Clamp Style 1-1/4" Colmonoy

Plunger, Clamp Style 1-3/8" Colmonoy

Plunger, Clamp Style 1-1/2" Colmonoy

Plunger, Clamp Style 1-1/2" Colmonoy

Chamber Cover, Plunger, Drip Lube

Chamber Cover, Plunger, Standard

Chamber Cover, Plunger, Forced Drip Lube

3 sets

3 sets

3 sets

3 sets

3

3

3 sets

3 sets

3 sets

3 sets

3 sets

3 sets

3 sets

3 sets

3 sets

3 sets

5

5

5

1

3 sets

3 sets

3 sets

5

1

1

3

3

3

3

# Req

6

5

5

3

1

30

9

9

9

3 sets

3 sets

Kerr Q5450BCB Billet Type Pump

Part Number

KB-65-125

KB-65-150

AP-71

AP-71-100S

AP-71-100SS

AP-72

KP-87N

KP-93SL-150AB

KP-93SL-150SS

KP-93SLSF-150S

Q5450B-113

Description

Plunger (Colmonoy 730) 1 1/4 1 Male Thread

Plunger (Colmonoy 730) 1 1/2 1 Male Thread

Drain Plug 1/2" Hex Pipe Plug

Drain Plug, 1" Hex Pipe Plug Steel

Drain Plug, 1" Hex Pipe Plug Stainless Steel

1/8 NPT Oil Level/Stuffing Box Hex Plug (AB)

Stuffing Box O'Ring Nitrile

Packing Adapters Spring Loaded AB

Packing Adapters Spring Loaded (Stainless Steel)

SF Packing Adapters Spring Loaded (Steel)

Q5450B Rebuild kid Complete Includes the Following Parts: (1) Q5450-3, (2) Q5450-7, (1) Q5450-12, (5) Q5450-26R,

(5 Sets) Q5450-28, (5) Q5450-32PT, (10) KAB-59N

Q5450-114

AP-115

Q5450-115

Q5450-115H

AP-116

KA-117

AP-117L

AP-117

Q5450-118

Q5450-119

Q5450-275T

KA-276

KA-277

AP-351

AP-352

AP-425

Packing Lubrication System, Complete

Check Valve Stainless Steel 1/8 Pipe

Lubrication System Less Lubricator

Lubricator Hose Kit Complete

55 Single Pump for Forced Feed Lubricator

Crankshaft Lubrication Sheave

Lubricator Sheave

Lubricator Sheave

Belt, Lubricator

Bracket, Lubricator

Pony Rod with Tapered Jam Nut

Installation Tool for Pony Rod Seal

Installation Wrench, Pony Rod

Oil Level Sight Glass

Oil Level Sight Plug

Wrench, Stuffing Box Nut

Q5450B-620

Q5450B-633S

Q5450B-633SS

Q5450B-634S

Cover Cap Capscrews

Fluid End (Steel)

Fluid End (Stainless Steel)

Suction Valve Plug (Steel)

Q5450B-634SS

Q5450B-635SS

Suction Valve Plug (Stainless Steel)

Discharge Valve Plug (Stainles Steel)

Q5450B-635S Discharge Valve Plug (Steel)

All prices and part numbers are subject to change without prior notice.

1

1

1

1

1

1

5

1

3

1

1

1

1

5

1

1

5

5

5

40

1

1

5

3

3

3

1

1

1

3

5

# Req

3

3

1

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