Kerr T60S Pump

Maintenance Guide

Lubricants/Oil needed

• Chain drive gear oil – 80W-90 EP220• Grease – No. 2 JT6 – high temp/multipurpose• Oil – 15W-40• Transmission fluid – A295

Spare Parts List• 6 Valve seats• 6-12 valve inserts• 2-3 sets of plunger packing• 3 plungers• 12 pony rod seals• 1 set of stuffing box brass• 55 gallons of either 75/90 or 80/90 gear oil • 1 front mounted pump for oil system• Roper pump• 12 springs (heavy duty)

Power EndConsists of the power frame, crankshaft, crossheads, connecting rods, pony rod gland, and stuffing box

Fluid EndConsists of valves, springs, suction manifold, discharge flanges, and various access covers – bolted to the power frame with 18 bolts

Chain DriveConsists of a 4 row chain with a reduction ration of 4:1

Kerr T60S Injection Pump – Daily Maintenance1. Grease each plunger prior to pump

start up and as frequently as possible2. Check the oil level in the power

frame lube oil level without the pump running

3. Check the oil level in the plunger reservoir

4. Check for oil or fluid leaks in the plunger pumps

5. Check for leaks in power frame lube oil system and plunger lube system

6. Check for leaks in suction piping and charge pump

7. Check fluid end to power frame cap screws and stuffing box nuts

8. Check motor oil (via dipstick) on CAT engine – fill with 15W-40 when necessary

9. Grease 3 drive shaft points10. Grease pony rod glands behind

plungers

Kerr T60S Injection Pump- Weekly MaintenanceWeekly Maintenance1. Check integrity of the valves,

valve inserts, valve seats, and springs

2. Check integrity of the discharge and suction cover seals

3. Check the suction pulsation dampener pre-charge

4. All daily maintenance

Valves, valve inserts, valve seats, and springs

Kerr T60S Injection Pump - 100 hours maintenance1. Check all pony rod to plunger

clamp bolts to ensure they are tight

2. Change power frame lube oil filter3. Check all supplies needed for

routine maintenance such as O-rings, fluid seals, valves, valve inserts, valve seats, valve springs, packing, oil seals, filter element, etc.

4. All daily and weekly maintenance

Pony Rod gland seal

Kerr T60S Injection Pump - 250 hours maintenance1. Change the power frame lube oil

and refill with the proper grade of gear oil for upcoming ambient conditions

2. Thoroughly clean the power frame lube suction strainer – located inside the power frame sump area

3. Remove and inspect the plungers and packing assembly components

4. Replace all packing pressure rings5. Clean the plunger pump’s oil

breather and the power frame lube oil reservoir breather (if applicable)

6. All daily, weekly, and 100 hour maintenance

Plungers and Packing

Kerr T60S Injection Pump - 500 hours maintenance1. Inspect the antifriction main

bearings, and crank journal bearings

2. Look in the oil for flaking metal3. Check the end play in the chain

drive pinion shaft – place a dial indicator on face of Spicer flange and pull on the Spicer flange. There should 0.001”/0.003” end play

Kerr T60S Injection PumpCall CAT to coordinate the maintenance 24 hours – Check the air filters

250 -300 hours1. Change out the fuel filters2. Change out the oil filters3. Change out the roper pump oil

filter4. Check the splines on the mounted

pump for oil system

300 hours – change out the hydraulic filters

500 hours5. Change out the transmission filter

on the Allison 6. Change the chain drive on the bull

wheel

Kerr T60S Injection Pump – Yearly MaintenanceYearly Maintenance1. Replace worn plungers and

packing brass2. Replace worn or corroded valve

covers, suction valve stops, packing nuts, discharge flanges, pump tools, etc.

3. Replace all discharge flange seals and suction manifold seals

4. Replace any defective gauges and instruments

Power Frame Assembly TorquesPart Torque Dry/Wet

Pan & Crankcase Cover Cap Screws 30 ft-lbs/24 ft-lbs

Pony Rod Gland Cap Screws w/ Seal Washers

60 ft-lbs/48 ft-lbs

Pony Rod & Plunger Clamp Cap Screws w/ Lock Washers

100 ft-lbs/80 ft-lbs

Connecting Rod Cap Screws drilled for wire ties

150 ft-lbs/120 ft-lbs

Pony Rod 400 ft-lbs/320 ft-lbs

Power Frame to Fluid End Cap Screws 800 ft-lbs/640 ft-lbs

Kerr T60S Injection Pump – Replacing Pony Rod Glands1. Remove the suction covers, suction plugs, then

unclamp and remove the plunger, unthread, and remove the pony rod (pipe wrench only in the undercut area at the end)

2. The pony rod gland assembly can be removed by rotating the cap screws counter-clockwise, (rotates the gland lock clock-wise)

3. After removing the gland assembly, lightly drive out the pony rod seals, 2 from each end = 4 total

4. Hand press 2 seals from each end, always facing the seal lips toward the power frame to retain oil. Liberally pack the area between each pair of seals with grease and ensure the grease zerk is in good repair

5. Check and replace (if required) the O-ring and Seal Washers , then install the gland assembly into the power frame, with the grease zerk positioned at 12 O'clock

6. Rotate the cap screws clockwise until tight and dry torque to 60ft-lbs

7. Install and torque the pony rod to 400 ft-lbs, then install and clamp the plunger, ensure that the clamp flats and bevels match those of the pony rod and plunger

8. Grease each pony rod gland assembly, until grease exits out the weep hole on the bottom face of the gland. Always re-grease after pump shut down and before pump start up

Fluid End Assembly TorquesPart Torque – Dry/Wet

Plunger Hold Cover Cap Screws 30 ft-lbs/24 ft-lbs

Pony Rod & Plunger Clamp Cap Screws w/Lock Washers

100 ft-lbs/80 ft-lbs

Suction Manifold Cap Screws 250ft-lbs/200 ft-lbs

Discharge Flange Nuts 400 ft-lbs/320 ft-lbs

Stuffing Box Nuts 800 ft-lbs/640 ft-lbs

Kerr T60S Injection Pump – Removing Plungers and Packing1. Using the packing nut tool, loosen each of

stuffing box nuts2. Remove the suction covers using the

hammer wrench and 10lb hammer3. Rotate the crank shaft until the pony rod

clamp is centered between the pony rod gland and packing nut. Unthread both pony rod/plunger clamp bolts, then remove the clamp halves. Rotate the plunger to the full forward stroke position. Repeat this step for each of the other plungers

4. Continue pushing the plunger through the packing with a spacer bar between the pony rod and plunger, then out the front of the fluid end

5. Inspect each plunger for wear, scoring, and corrosion on the hard surface area and damage to the face which mates with the crosshead

6. Unthread and remove each stuffing box nut, followed by the packing brass and packing sets. Inspect each ring of packing brass for excessive wear and scoring

7. Check the lube port on each stuffing box to ensure that the lube passage is unobstructed.

Kerr T60S Injection Pump – Removing Plungers and Packing8. Each packing bore must be thoroughly cleaned and lightly hand polished with a 220-2470 grit Emory cloth prior to packing reinstallation

9. Using new packing pressure ring and adapters, reinstall the packing assembly one piece at a time (follow drawing ). Each ring should be installed with a coating of light oil/’grease, with pressure ring lips facing into the stuffing box bore toward the fluid end. Care must be taken to avoid damaging the internal and external sealing lips of each packing ring, start any pressure ring below the stuffing box lube hole with the lip past the lube hole to prevent tearing/cutting

10. Reinstall each packing nut, screwing it all the way on until tight

11. Coat the hard surface area of each plunger with a light oil/grease and insert it into the packing from the suction cover bore. Rotate the crankshaft centered between the pony rod gland and stuffing box nut and pump the plunger into the pony rod guided by the dowel pin

Kerr T60S Injection Pump – Removing Plungers and Packing12. Tighten each packing nut until it stops firmly against the packing set. “j” style packing does not require re-adjusting but should be checked regularly for a tight nut make-up

13. Reinstall the grease zerk or check valve into the stuffing box

14. Reinstall the suction covers as described earlier

Kerr T60S Injection Pump – Removing Valves and Seats1. Hammer wrench and 10lb hammer loosen

and remove the discharge and suction covers from the fluid end

2. Turn the suction valve stop until it stops ~900 and remove the valve from the fluid cylinder along with the valve springs underneath them

3. Remove the valve from the fluid end. Follow the valve manufacturer’s recommendation of removing the insert from the valve

4. Remove the discharge valve springs and discharge valves from the fluid cylinder

5. The tapered valve seat bore in the fluid cylinder must be thoroughly cleaned and lightly hand polished with 220-240 grit Emory cloth prior to installing new valve seats

6. Always install a new O-ring seal when reinstalling a valve seat. Do not use any grease, sealer, etc.- the valve seat must be installed dry. Upon installing the valve seat, hand tighten, install the valve in the seat and using a heavy steel bar with Teflon or wood pad, hammer the valve seat into the taper

Must be installed dry

Kerr T60S Injection Pump – Removing Valves and Seats7. When reinstalling the valves, do not mix one manufacturer’s valve with another’s valve seat or another’s valve insert

8. When reinstalling the suction valve stop, make certain it is turned perpendicular to the plunger and securely seated in the groove in the cylinder

9. Before reinstalling the discharge and suction covers, remove the seals from each, clean the covers thoroughly, and install new seals in the same direction that the old ones came off. Each cover bore in the fluid cylinder must be cleaned thoroughly and lightly hand polished with Emory cloth prior to cover installation

10. Upon installing the threaded suction and discharge covers with a coating of oil or very light grease, tighten them securely with the hammer wrench and 10 lb hammer

Must be installed dry

Kerr T60S Injection Pump – Removing Discharge Flanges1. Using a 5/8” wrench, remove the four 1”

nuts from each of the two discharge flanges

2. Remove each discharge flange from the fluid cylinder. Remove the fluid seals from both the inlet side and the outlet side of each discharge flange. Closely inspect each discharge flange for internal erosion and corrosion. Inspect the discharge flange threads for wear and damage. The discharge flange seal surfaces should be thoroughly cleaned and lightly hand polished with a Emory cloth prior to installation

3. Inspect the fluid cylinder discharge flange bores for erosion and corrosion. Thoroughly clean and lightly hand polish each bore with an Emory cloth prior to reinstalling the discharge flanges

4. Using new fluid seals and a light coating of oil, install seals into the fluid end bores lip end first. Carefully install the discharge connection so as not to damage seal. Reinstall the four 1” hex nuts on each flange and evenly tighten them to the proper torque

Discharge Flange = 7

Kerr T60S Injection Pump – Removing Suction Manifold1. Using a 1-1/8” wrench, remove the

twelve 3/4” cap screws which secure the suction manifold to the fluid cylinder, and drop the suction manifold away from the fluid cylinder

2. Inspect the suction manifold for internal erosion and corrosion. Remove the three suction manifold O-rings and inspect the seal grooves in the manifold for erosion and corrosion. Inspect the face and OD of the pipe at each end of the manifold for erosion or corrosion

3. Inspect the bottom face of the fluid end body for erosion and corrosion. Thoroughly clean and lightly and hand polish the bottom face of the fluid cylinder with an Emory cloth prior to reinstalling the suction manifold

4. Using new O-rings, reinstall the suction manifold. Reinstall the twelve ¾” cap screws and evenly tighten them to the proper torque

Suction manifold = 15