3. 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)
4. Power End
Consists of the power frame, crankshaft, crossheads, connecting rods,
pony rod gland, and stuffing box
5. Fluid End
Consists of valves, springs, suction manifold, discharge flanges, and
various access covers – bolted to the power frame with 18 bolts
7. Kerr T60S Injection Pump
– Daily Maintenance
1. Grease each plunger prior to pump
start up and as frequently as
possible
2. 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 points
10. Grease pony rod glands behind
plungers
8. Kerr T60S Injection Pump
- Weekly Maintenance
Weekly Maintenance
1. 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
9. Kerr T60S Injection Pump
- 100 hours maintenance
1. Check all pony rod to plunger
clamp bolts to ensure they are
tight
2. Change power frame lube oil filter
3. 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
10. Kerr T60S Injection Pump
- 250 hours maintenance
1. 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 rings
5. 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
11. Kerr T60S Injection Pump
- 500 hours maintenance
1. Inspect the antifriction main
bearings, and crank journal
bearings
2. Look in the oil for flaking metal
3. 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
12. Kerr T60S Injection Pump
Call CAT to coordinate the
maintenance
24 hours – Check the air filters
250 -300 hours
1. Change out the fuel filters
2. Change out the oil filters
3. Change out the roper pump oil
filter
4. Check the splines on the mounted
pump for oil system
300 hours – change out the hydraulic
filters
500 hours
1. Change out the transmission filter
on the Allison
2. Change the chain drive on the bull
wheel
13. Kerr T60S Injection Pump
– Yearly Maintenance
Yearly Maintenance
1. Replace worn plungers and
packing brass
2. 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
14. Power Frame Assembly Torques
Part 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
15. Kerr T60S Injection Pump
– Replacing Pony Rod
Glands
1. 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
16. Fluid End Assembly Torques
Part 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
17. Kerr T60S Injection Pump
– Removing Plungers and
Packing
1. Using the packing nut tool, loosen each
of stuffing box nuts
2. Remove the suction covers using the
hammer wrench and 10lb hammer
3. 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.
18. Kerr T60S Injection Pump
– Removing Plungers and
Packing
8. 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
19. Kerr T60S Injection Pump
– Removing Plungers and
Packing
12. 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
20. Kerr T60S Injection Pump
– Removing Valves and
Seats
1. 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
21. Kerr T60S Injection Pump
– Removing Valves and
Seats
7. 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
22. Kerr T60S Injection Pump
– Removing Discharge
Flanges
1. 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
23. Kerr T60S Injection Pump
– Removing Suction
Manifold
1. 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
