INSTALLATION, OPERATION & MAINTENANCE MANUAL KZN-HYD3(R), HYD4(R), HYD6(R) Pumps TOP DISCHARGE HYDRAULIC PUMP Version 4/10/2013
TABLE OF CONTENTS HYDRAULIC FLOWS .............................................................................................................................................. 5 PREVENTATIVE MAINTENANCE INSTRUCTIONS ................................................................................................... 6 KZN-HYD3(R), KZN-HYD4(R) & KZN-HYD6(R)PUMPS ............................................................................................ 6 KZN-HYD3(R) ..........................................
HYDRAULIC FLOWS Hydraulic circuits must be open center, single direction and have an unrestricted return flow from the hydraulic motor to the oil reservoir.
PREVENTATIVE MAINTENANCE INSTRUCTIONS KZN-HYD3(R), KZN-HYD4(R) & KZN-HYD6(R)PUMPS Always be sure to use only clean filtered hydraulic oil to drive the hydraulic motor. Your hydraulic system should have a filter and it should be rated at 10 micron. When connecting hydraulic hoses to the pump, be sure to keep hose connections clean.
KZN-HYD3(R) DISASSEMBLY: Remove (3) bolts (#50) holding strainer plate (#49) to strainer base (#48). Remove (4) bolts (#47) holding strainer base to suction cover (#43). Slide strainer base off while leaving strainer plate in place. Secure impeller (#41) from turning by inserting a pry bar or similar tool between impeller vanes and rest bar against boss on suction case. Use large adjustable wrench to remove Agitator (#52) from shaft (#22). Remove large Iock-washer from shaft.
Remove (3) bolts (#23) holding bearing retainer (#24) to bearing support. Slide shaft and bearing out of bearing support. Inspect bearings (#21, 26) and replace if loose or worn. Bearings are press fit onto the shaft. NOTE: When disassembling pump for repair it is recommended that the bearings and mechanical seals are replaced. Remove pigtail hydraulic hoses (#54, 55) if equipped, and drain remaining oil into drain pan. Remove (unscrew) oil pipes (#3).
ASSEMBLY: Carefully press bearings (#21, 26) onto shaft (#22). Carefully install stationary seat section of upper mechanical seal (#33) into recess on bottom of bearing support (#25). SEE Fig. A NOTE: Lightly lubricate outside surface of rubber cup and carefully slide seat assembly. into place keeping the shiny surface (lapped side) of the seat outward toward the mating face on the rotating unit. Slide shaft and bearing assembly. into top of bearing support.
Slide volute (#32), with wear ring (#53) installed, over shaft and onto outer casing, secure with (6) bolts (#31) with Iock-washers. Insert shaft key (#42) into shaft Slide impeller (#40) onto shaft. Install wear plate (#44) onto suction cover (#43) with (4) bolts (#46) with nuts and Iockwashers. Install suction cover assembly. onto volute (#32) and secure with (6) bolts (#45). Place strainer plate (#49) over shaft. Place Iock-washer (#51) over shaft and install (screw on) agitator (#52).
Install lifting bracket (1) with (2) bolts (#2). Pour 32 ounces of clean 10w or 20w non-detergent oil (hydraulic oil) into seal chamber and install oil plug (#29) with O ring (#30). If equipped, install inlet and outlet pigtail hoses (#54, 55) and quick disconnect hose couplings (#56, 57). Use a liquid or paste hydraulic sealant on pipe threads (NOT TEFLON TAPE) and be sure pressure and return connections are installed correctly. SEE PARTS ILLUSTRATION.
EXPLODED VIEW OF KZN-HYD3(R) 12
KZN-HYD3(R) OIL INLET/OUTLET 13
KZN-HYD3(R) SEAL ARRANGEMENT 14
KZN-HYD3(R) PARTS LIST Pump Model KZN-HYD3 Pos. No.
KZN-HYD4(R) DISASSEMBLY: Remove (3) bolts (#50) holding strainer plate (#49) to strainer base (#48) Remove (4) bolts (#47) holding strainer base to suction cover (#43). Slide strainer base off while leaving strainer plate in place. Secure impeller (#41) from turning by inserting a pry bar or similar tool between impeller vanes and rest bar against boss on suction case. Use large adjustable wrench to remove Agitator (#52) from shaft (#22). Remove large Iock-washer from shaft.
Remove (3) bolts (#23) holding bearing retainer (#24) to bearing support. Slide shaft and bearing out of bearing support. Inspect bearings (#21, 26) and replace if loose or worn. Bearings are press fit onto the shaft. NOTE: When disassembling pump for repair it is recommended that the bearings and mechanical seals are be replaced. Remove pigtail hydraulic hoses (#54, 55) if equipped, and drain remaining oil into drain pan. Remove (unscrew) oil pipes (#3, 6).
ASSEMBLY: Carefully press bearings (#21, 26) onto shaft (#22). Carefully install stationary seat section of upper mechanical seal (#33) into recess on bottom of bearing support (#25). See Fig. A. NOTE: Lightly lubricate outside surface of rubber cup and carefully slide seat assembly. into place keeping the shiny surface (lapped side) of the seat outward toward the mating face on the rotating unit. Slide shaft and bearing assembly. into top of bearing support.
Slide volute (#32), with wear ring (#53) installed, over shaft and onto outer casing, secure with (6) bolts (#31) with Iock-washers. Insert shaft key (#42) into shaft. Slide impeller (#40) onto shaft. Install wear plate (#44) onto suction cover (#43) with (4) bolts (#46) with nuts and Iockwashers. Install suction cover assembly. onto volute (#32) and secure with (6) bolts (#45). Place strainer plate (#49) over shaft. Place Iock-washer (#51) over shaft and install (screw on) agitator (#52).
Install lifting bracket (1) with (2) bolts (#2). Pour 32 ounces of clean 10w or 20w non-detergent oil (hydraulic oil into sea chamber and install oil plug (#29) with O ring (#30). If equipped, install inlet and outlet pigtail hoses (#54, 55) and quick disconnect nose couplings (#56, 57). Use a liquid or paste hydraulic sealant on pipe threads (NOT TEFLON TAPE) and be sure pressure and return connections are installed correctly.
EXPLODED VIEW OF KZN-HYD4(R) 21
KZN-HYD4(R) OIL INLET/OUTLET 22
KZN-HYD4(R) SEAL ARRANGEMENT 23
KZN-HYD4(R) PARTS LIST Pump Model KZN-HYD4 Pos. No.
KZN-HYD6(R) DISASSEMBLY: Remove (4) bolts (#47) holding strainer base to suction cover (#43) and remove strainer base. Secure impeller (#41) from turning by inserting a pry bar or similar tool between impeller vanes aria rest oar against boss on suction case. Use large adjustable wrench to remove Agitator (#52) from the shaft (#22). Remove large lock-washer from shaft. Remove (4) bolts (#45) holding suction cover (#43) to volute (#32) and remove suction cover.
Inspect bearings (#21, 26) and lip seal (#27) and replace if loose or worn. Bearings are press fit onto the shaft. NOTE: When disassembling pump for repair it is recommended that the bearings and mechanical seals are replaced. Remove pigtail hydraulic hoses (#54) if equipped and drain remaining oil into drain pan. Remove (unscrew) oil pipes (#3). Remove (6) bolts (#9) from top cover (#10) and lift off cover. Slide the spacer ring (#15) out of casing.
ASSEMBLY: Carefully press bearings (#21, 26) onto shaft (#22). Install lip seal (#27) if necessary, into bearing support. Carefully install stationary, seat section of upper mechanical seal (#33) into recess on bottom of bearing support (#25). See Fig. A. NOTE: Lightly lubricate outside surface of rubber cup and carefully slide seat assembly. into place keeping the shiny surface (lapped side) of the seat outward toward the mating face on the rotating unit. Slide shaft and bearing assembly.
Insert shaft key (#42) into shaft. Slide impeller t#40t onto snarl. Install wear plate (#44) onto suction cover (#43) with (4) bolts (#46) with nuts and Iockwashers. Install suction cover assembly. onto volute (#32) and secure with (4) bolts (#45). Place lock-washer (#51) over shaft and install (screw on) agitator (#52). Using pry bar or other suitable tool, secure impeller while tightening agitator with pipe wrench or similar tool.
Pour 100 ounces of clean 10w or 20w non-detergent oil (hydraulic oil) into seal chamber and install oil plug (#29) with O ring (#30). If equipped, install inlet and outlet pigtail hoses (#54) and quick disconnect hose couplings (#56, 57). Use a liquid or paste hydraulic sealant on pipe threads (NOT TEFLON TAPE) and be sure pressure and return connections are installed correctly. SEE PARTS ILLUSTRATION. Connect hydraulic hoses from the pump to a properly sized hydraulic power unit and test run.
EXPLODED VIEW OF KZN-HYD6(R) 30
KZN-HYD6(R) OIL INLET/OUTLET 31
KZN-HYD6(R) SEAL ARRANGEMENT 32
KZN-HYD6(R) PARTS LIST Pump Model KZN-HYD6 Pos. No.
Parts Order Instructions The hydraulic power packs are manufactured by HYDRA-TECH Pumps. For power pack parts, please contact: HYDRA-TECH Pumps 167 Stock Street Nesquehoning, PA. 18240 Phone: 570-645-3779 Fax: 570-645-4061 Email: htpump@hydra-tech.com For all other parts, contact BJM Pumps, LLC or your nearest BJM distributor.
TYPICAL HYDRAULIC SCHEMATIC FOR CUSTOMER SUPPLIED HYDRAULIC POWER SOURCE 35
TYPICAL HYDRAULIC SCHEMATIC FOR HYDRAULIC SUBMERSIBLE PUMPS 36
WARRANTY AND LIMITATION OF LIABILITY Unless otherwise expressly authorized in writing, specifying a longer or shorter period, BJM Pumps, LLC warrants for a period of eighteen (18) months from the date of shipment from the Point of Shipment, or one (1) year from the date of installation, whichever occurs first, that all products or parts thereof furnished by BJM Pumps, LLC under the brand name BJM Pumps, hereinafter referred to as the “Product” are free from defects in materials and workmanship and conform t
123 Spencer Plain Road •PO Box 1138 • Old Saybrook, CT 06475, USA • Phone: (860) 399-5937 • Fax: (860) 399-7784 • Email: sales@bjmpumps.com • Web Site: www.bjmpumps.com Copyright © 2008-2013 BJM Pumps, LLC. All rights reserved.
