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) ........................................................................................................................................................ 7
DISASSEMBLY: ......................................................................................................................................................... 7
ASSEMBLY: .............................................................................................................................................................. 9
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 .................................................................................................................................. 15
KZN-HYD4(R) ...................................................................................................................................................... 16
DISASSEMBLY: ....................................................................................................................................................... 16
ASSEMBLY: ............................................................................................................................................................ 18
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 .................................................................................................................................. 24
KZN-HYD6(R) ...................................................................................................................................................... 25
DISASSEMBLY: ....................................................................................................................................................... 25
ASSEMBLY: ............................................................................................................................................................ 27
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 .................................................................................................................................. 33
TYPICAL HYDRAULIC SCHEMATIC FOR CUSTOMER SUPPLIED HYDRAULIC POWER SOURCE ............................... 35
TYPICAL HYDRAULIC SCHEMATIC FOR HYDRAULIC SUBMERSIBLE PUMPS ......................................................... 36
WARRANTY AND LIMITATION OF LIABILITY ....................................................................................................... 37
39
Pump Model
Input Flow (GPM)
Max Pressure (PSI)
KZN-HYD3 (R)
10
2500
KZN-HYD4(R)
15
2500
KZN-HYD6(R)
25
2500
HYDRAULIC FLOWS
Hydraulic circuits must be open center, single direction and have an unrestricted return
flow from the hydraulic motor to the oil reservoir.
Operating this unit at pressures or flows in excess of those listed above or connecting
this unit to a closed center or reversing circuit will cause damage to the unit and will
void the warranty!
Please review the enclosed hydraulic sche ma ti c( s ) . If you are not sure if the hydraulic
power source being used to drive this pump is properly sized or connected, call BJM
Pumps, LLC.
Please read and understand this manual BEFORE you attempt to operate this pump.
*Note: Specifications subject to change without notice.
Note: Generally, hydraulic motors that run with flows and pressures less than 40 gpm
and 3000 psi can run without case drain. Larger motors ar e more s ubjec t to t he
development of internal pressure due to inherent “ability” to allow more bypass
pressure and oil across the internal clearances. This combines with the larger exposed
surface area of the internal seals in the larger motor to make the risk of seal damage
significant enough to require a third line. (KZN-HYD models do not require a third line).
If needing more than 150 feet on the hydraulic hose, we suggest the next size up in
return hydraulic line to help evacuate the internal motor pressure which is present for a
longer period of time due to the extended run of the hose.
5
Pennzoil
AW46 Hydraulic Oil
Texaco
Rando HDAZ
Shell
Tellas Hydraulic Oils
Mobil
D.T.E. 20 Series
Chevron
EP Hydraulic Oils
Exxon
Univis N Hydraulic Oils
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.
Use hydraulic oils with anti-wear additives such as these recommended oils or their
equivalent:
Note: When using this equi pment in environmentally sensitive areas we recomm end
using a bio-degradable oil such as Chevron Clarity, Exxon Univis Bio 40 or Mobil EAL
224H.
Check oil level in the seal chamber every 250 hours and when beginning a new job.
The level should be at the spill point of the fill plug. Do NOT over-fill!
Change oil in seal chamber every 1000 hours Use clean hydraulic oil or non-detergent
10W or 20W motor oil.
Slight discoloration of the oil in the seal chamber is normal. This is due to the wearing
of the mechanical seals.
Presence of water or emulsified oil in the housing indicates immediate need for seal
replacement and inspection of bearings.
6
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-w asher from shaft.
Remove (4) bolts (#45) holding suction cover (#43) to volute (#32) and remove suction
cover.
Inspect wear plate (#44) and replace if worn excessively. The wear elate is secured by
(4) nuts w/bolts (#46) to the suction cover.
Remove impeller (#41) and shaft key (#42) from shaft. Inspect impeller and replace if
worn excessively.
Remove (6) bolts (#31) holding the outer casing (#14) to the volute and separate.
Remove shaft sleeve (#40) by sliding off of shaft. Inspec t an d replace if worn
excessively.
Remove oil drain plug (#29) and drain oil into drain pan.
Remove (4) bolts (#37) and remove lower seal cover (#38) from seal chamber. Inspect
lip seal (#39) and replace if worn.
Very Ca refully slide mechanical seals (#33) off of s haft.
Remove (4) bolts (#28) holding bearing support (#25) to casing (#14) and slide shaft
and bearing assembly. out of casing.
7
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 recom mended that the bearings and
mechanical seals are replaced.
Remove pigtail hydraulic hoses (#54, 55) if equipped, and drai n remaining oil into drain
pan.
Remove (unscrew) oil pipes (#3).
Remove (4) bolts (#9) from top cover (#10) and lift off cove r.
Remove (2) bolts (#17) holding hydraulic motor (#16) to motor support plate (#18) and
lift motor out of casing.
NOTE: The hydraulic motor is built to exac ti ng tolerances and field repair is not
recommended. If repair is required, it should be performed by an authorized repair
center or replaced.
8
ASSEMBLY:
Carefully press bearings (#21, 26) onto shaft (#22).
Carefully install stationary seat section of upper m echanical 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 bearing retainer (#24) over top of shaft and install onto bearing support with (3)
bolts (#23). Evenly tighten bolts. Do Not Over Tighten!
Slide O ring (#27) over bearing support (#25).
Install shaft and bearing support assembly. into bottom of outer casing (#14) and install
and tighten (4) bolts (#28) with Iock-washers.
Lightly lubricate upper rotating seal unit and carefully slide onto shaft until it contacts
the stationary seat, See Fig. A
Lightly lubricate lower rotating seal unit and carefully slide onto shaft until tee rubber
bellows contacts the rubber bellows of the upper unit, the silicon carbide face is
outward. See Fig. A.
Carefully press lip seal (#39) into recess on bottom of lower seal cover (#38) keeping
the lip facing outward. See Fig. A.
Install stationary silicon carbide lower seal seat into top of lower seal cover (#38) and
install (4) Phillips head screws (#34) holding retaining plate (#35).
Slide O ring (#36) onto lower seal cover (#38).
Lightly lubricate seal surfaces with a drop of clean oi l and slide lower seal cover
assembly. onto outer casing (#14). Secure with (4) bolts (#37) with Iock-washers
Slide shaft sleeve (#40) over shaft until it slide through Iip seal and stops
NOTE: Shor t side of-sleeve goes through lip seal.
9
Slide volute (#32), with wear ring (#53) installed, over sha ft 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 Iock-
washers.
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).
Using pry bar or other suitable tool, secure impeller while tightening agitator with pipe
wrench or similar tool.
Install strainer base (#48) with (4) 12mm x 25mm bolts (#47) with lock-washers.
Install (3) 14mm x 30mm bolts (#50) holdi ng strainer plate to strainer base.
Install wave washer (#19) and O ring (#20) into motor support plate (#18) using grease
to keep wave washer in place.
Install motor support plate assembly. into outer casing (#14) and over bearing (#18).
Apply grease to splined shaft on hydraulic motor (#16) and install motor into shaft (#22)
and onto support plate. Secure motor with (2) bolts (#17) with Iock-washers.
Install O rings (#5) onto threaded ends of oil pipes (#3) and install oil pipes into top of
hydraulic motor (#16).
Install O rings (#4) into oil pipe grooves.
Slide the spacer ring (#15) into the outer casing (#14).
Install O ring (#11) onto top cover (#10). Lightly lubricate O rings (#4) and slide cover
over Oil pipes. Align top cover bolt holes with outer casing threaded bolt holes and
install (4) 10mm x 8 5m m bolts (#9) with Iock-washers.
Install discharge adapter (#12) with (4) 10mm x 30mm bolts (#13).
10
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 pressur e an d re tur n connections are installed correctly.
SEE PARTS ILLUSTRATION.
Connect hydraulic hoses from the pump to a properly sized hydraulic power unit and
test run. The pump should spin smoothly. Check to be sure there are no oil leaks and
check for proper rotation. Impeller spins clockwise when viewed from top (discharge
end) of pump.
11
EXPLODED VIEW OF KZN-HYD3(R)
12
KZN-HYD3(R) OIL INLET/ OUTLET
13
KZN-HYD3(R) S EAL ARRAN GEMENT
14
Pump Model KZN-HYD3
Pos. No. Part Description Item # QTY
09 Bolt-Top Cover 203243 4
12 3" NPT Male Coupling Flange 202583 1
13 Bolt-Discharge Flange 203262 4
14 Motor Housing 202295 1
19 Spring Washer 202361 1
21 Upper Ball Bearing 200968 1
22 Shaft 200469 1
23 Bolt-Bearing Retainer 203220 3
24 Lower Bearing Retainer 202276 1
25 Lower Bearing Housing 202377 1
26 Lower Ball Bearing 200963 1
28 Bolt-Bearing Housing 203229 4
29 Bolt-Oil Inspection 203261 1
31 Bolt -Pump Housing 203271 6
32 Pump Housing 202191 1
32 Pump Housing Hardened (optional) 202193 1
33 Mech. Seals-set 200419 1
34 Screw-Seal Retainer 203214 4
35 Mech. Seal Retainer 202271 1
37 Bolt-Oil Chamber Cover 203229 4
38 Oil Chamber Cover 202225 1
39 Lip Seal 202248 1
40 Shaft Sleeve 203071 1
41 Impeller 202976 1
42 Impeller Key 202146 1
43 Suction Cover 202869 1
44 Wear Plate 202018 1
45 Bolt-Suction Cover 203236 4
46 Bolt-Wear Plate 203253 4
47 Bolt-Strainer/Stand 203258 4
48 Strainer Stand 201982 1
51 Lock Washer 202917 1
52 Agitator 202983 1
53 Pump Housing Sleeve 202182 1
O-Ring Kit-Buna N 202653 1
HYDRA-TECH PARTS
01 Lifting Bracket 7100 1
02 Hex Bolt SS 1/2" x 1 1/4" 155 2
03 Oil pipe inlet 9954A 1
04 O-ring 213 9955 2
05 O-ring 910 9956 1
06 Oil pipe return 9957A 1
07 O-ring 217 9958 2
08 O-ring 912 9959 1
10 Top Cover HYD3 9950 1
11 O-ring top cover 9961 1
15 Spacer Ring HYD3 9965 1
16 Hydraulic Motor 9945 1
17 Hex Bolt 3/8" x 1 1/4" 9353 2
18 Motor Support Plate HYD3 9966 1
55 Pig Tail Hose Assy. 2276 2
56 QD Coupler - MALE, 3/4" 2175 1
57 QD Coupler - F, 3/4" wing nut 2174 1
KZN-HYD3(R) PARTS LIST
15
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 (4) bolts (#45) holding suction cover (#43) to volute (#32) and remove suction
cover.
Inspect wear slate (#44) and replace if worn excessively. The wear plate is secured by
(4) nuts w/bolts (#46) to the suction cover.
Remove impeller (#41) and shaft key (#42) from shaft. Inspect impeller and replace if
worn excessively.
Remove (6) bolts (#31) holding the outer casing (#14) to the volute and separate.
Remove shaft sleeve (#40) by sliding off of shaft. Inspect and replace if worn
excessively.
Remove oil drain plug (#29) and drain oil into drain pan.
Remove (4) bolts (#37) anti remove lower seal cover (#38) from seal chamber.
Inspect lip seal (#39) and replace if worn.
Very Carefully slide mechanical seals (#33) off of shaft.
Remove (4) bolts (#28) holding bearing support (#25) to casing (#14) and slide shaft
and bearing assembly. out of casing.
16
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 disassem bling pump for repair it is recom mended 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).
Remove (4) bolts (#9) from top cover (#10) and lift off cover.
Remove (2) bolts (#17) holding hydraulic motor (#16) to motor support plate (#18) and
lift motor out of casing.
NOTE: The hydraulic motor is built to exacting tolerances and field repair is not
recommended. If repair is required, it should be performed by an authorized repair
center or replaced.
17
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 bearing retainer (#24) over top of shaft and install onto bearing support with (3)
bolts (#23). Evenly tighten bolts. Do Not Over Tighten!
Slide O ring (#27) over bearing support (#25).
Install shaft and bearing support assembly. into bottom of outer casing (#14) and install
and tighten (4) bolts (#28) with lock-washers.
Lightly lubricate upper rotating seal unit and carefully slide onto shaft until it contacts
the stationary seat. See Fig. A.
Lightly lubricate lower rotating seal unit and carefully slide onto shaft until the rubber
bellows contacts the rubber bellows of the upper unit. The silicon carbide face is
outward. See Fig. A
Carefully press lip seal (#39) into recess on bottom of lower seal cover (#38) keeping
the lip facing outward. See Fig. A.
Install stationary silicon carbide lower seal seat into top of lower seal cover (#38) and
install (4) Phillips head screws (#34) holding retaining plate (#35).
Slide O ring (#36) onto lower seal cover (#38).
Lightly lubricate seal surfaces with a drop of clean oil and slide lower seal cover
assembly. onto outer casing (#14). Secure with (4) bolts (#37) with Iock-washers.
Slide shaft sleeve (#40) over shaft until it slide through lip seal and stops.
NOTE: Short side of sleeve goes through lip seal.
18
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 Iock-
washers.
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).
Using pry bar or other suitable tool, secure impeller while tightening agitator with pipe
wrench or similar tool.
Install strainer base (#48) with (4) 12mm x 25mm bolts (#47) with lock-washers.
Install (3) 14mm x 30mm bolts (#50) holding strainer plate to strainer base.
Install wave washer (#19) and O ring (#20) into motor support plate (#18) using grease
to keep wave washer in place.
Install motor support plate assembly. into outer casing (#14) and over bearing (#18).
Apply grease to splined shaft on hydraulic motor (#16) and install motor into shaft (#22)
and onto support plate. Secure motor with (2) bolts (#17) with lock-washers.
Install O rings (#5, 8) onto threaded ends of oil pipes (#3, 6) and install oil pipes into
top of hydraulic motor (#16).
Install (2) O rings (#4) and (2) O rings (#7) into oil pipe grooves.
Slide the spacer ring (#15) into the outer casing (#14).
Install O ring (#11) onto top cover (#10). Lightly lubricate O rings and slide cover over
oil pipes. Align top cover bolt holes with outer casing threaded bolt holes and install (4)
10mm x 35rmm bolts (#9) with lock-washers.
Install discharge adapter (#12) with (4) 10mm x 30mm bolts (#13).
19
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.
SEE PARTS ILLUSTRATION
Connect hydraulic hoses from the pump to a properly sized hydraulic power unit and
test run. The pump should spin smoothly. Check to be sure there are no oil leaks and
check for proper rotation. Impeller spins clockwise when viewed from top (discharge
end) of pump.
20
EXPLODED VIEW OF KZN-HYD4(R)
21
KZN-HYD4(R) OIL INLET/ OUTLET
22
KZN-HYD4(R) S EAL ARRAN GEMENT
23
Pump Model KZN-HYD4
Pos. No. Part Description Item # QTY
09 Bolt-Top Cover 203243 4
12 4" NPT Male Coupling Flange 202585 1
13 Bolt-Discharge Flange 203262 4
14 Motor Housing 202295 1
19 Spring Washer 202361 1
21 Upper Ball Bearing 200968 1
22 Shaft 200469 1
23 Bolt-Bearing Retainer 203220 3
24 Lower Bearing Retainer 202276 1
25 Lower Bearing Housing 202377 1
26 Lower Ball Bearing 200963 1
28 Bolt-Bearing Housing 203229 4
29 Bolt-Oil Inspection 203261 1
31 Bolt -Pump Housing 203271 6
32 Pump Housing 202191 1
32 Pump Housing Hardened (optional) 202193 1
33 Mech. Seals-set 200419 1
34 Screw-Seal Retainer 203214 4
35 Mech. Seal Retainer 202271 1
37 Bolt-Oil Chamber Cover 203229 4
38 Oil Chamber Cover 202225 1
39 Lip Seal 202248 1
40 Shaft Sleeve 203071 1
41 Impeller 202980 1
42 Impeller Key 202146 1
43 Suction Cover 202873 1
44 Wear Plate 202018 1
45 Bolt-Suction Cover 203236 4
46 Bolt-Wear Plate 203253 4
47 Bolt-Strainer/Stand 203258 4
48 Strainer Stand 201982 1
51 Lock Washer 202917 1
52 Agitator 202983 1
53 Pump Housing Sleeve 202182 1
O-Ring Kit-Buna N 202654 1
HYDRA-TECH PARTS
01 Lifting Bracket 7100 1
02 Hex Bolt SS 1/2" x 1-1/4" 155 2
03 Oil pipe inlet 9954A 1
04 O-ring 213 9955 2
05 O-ring 910 9956 1
06 Oil pipe return 9957A 1
07 O-ring 217 9958 2
08 O-ring 912 9959 1
10 Top Cover HYD4 9950 1
11 O-ring top cover 9961 1
15 Spacer Ring HYD4 9965 1
16 Hydraulic Motor 9951 1
17 Hex Bolt 3/8" x 1-1/4" 9353 2
18 Motor Support Plate HYD4 9966 1
55 Pig Tail Hose Assy. 2276 2
56 QD Coupler - MALE, 3/4" 2175 1
57 QD Coupler - F, 3/4" wing nut 2174 1
KZN-HYD4(R) PARTS LIST
24
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 wear plate (#44) and replace if worn excessively. The wear plate is secured by
(4) nuts w/bolts (#46) to the suction cover.
Remove impeller (#41) and shaft key (#42) from shaft. Inspect impeller and replace if
worn excessively.
Remove (8) bolts (#31) holding the bearing support (#25) to the volute and separate.
Remove shaft sleeve (#40) by sliding off of shaft. Inspect sleeve and lip seal (#39) and
replace if worn excessively.
Remove oil drain plug (#29) and drain oil into drain can.
Remove (4) bolts (#37) and remove lower seal cover (#38) from seal cham ber . Ins p ect
lip seal (#39) and replace if worn.
Very Carefully slide mechanical seals (#33) off of shaft.
Remove (8) bolts (#28) holding bearing support (#25) to casing (#14) and slide shaft
and bearing assembly. out of casing.
Remove (3) bolts (#23) holding bearing retainer (#24) to bearing support. Slide shaft
and bearing out of bearing support.
25
Inspect bearings (#21, 26) and lip seal (#27) and replace if loose or worn. Bearings are
press fit onto the shaft.
NOTE: Whe n 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.
Lift hydraulic motor (#16) and motor support plate (#18) out of casing.
Remove (4) bolts (#17) and separate the hydraulic motor from the motor support plate.
NOTE: The hydraulic motor is built to exacting tolerances and field repair is not
recommended. If repair is required it should be performed by an authorized repair
center or replaced.
Inspect wave washer (#19) and O ring (#20) and replace if worn.
26
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. into top of bearing support.
Slide bearing retainer (#24) over top of shaft and install onto bearing support with (3)
bolts (#23). Evenly tighten bolts. Do Not Over Tighten!
Lightly lubricate upper rotating seal unit and VERY CAREFULLY slide onto shaft until it
contacts the stationary seat. See Fig. A.
Lightly lubricate lower rotating seal unit and VERY CAREFULLY slide onto shaft until
the rubber bellows contacts the rubber bellows of the upper unit. The silicon carbide
face is outward. See Fig, A.
Carefully press lip seal (#39) into recess on bottom of lower seal cover (#38) keeping
the lip facing outward See Fig. A.
Install stationary silicon carbide lower seal seat into top of lower seal cover (#38) and
install (4) Phillips head screws (#34) holding retaining plate (#35).
Slide O ring (#36) onto lower seal cover (#38).
Lightly lubricate seal surfaces with a drop of clean oil and slide lower seal cover
assembly. onto outer casing (#14). Secure with (4) bolts (#37) with lock-washers.
Slide shaft sleeve (#40) over shaft until it slides through the lip seal and stops.
NOTE: Short side of sleeve goes through lip seal.
Install shaft and bearing support assembly, onto volute (#32) with wear ring (#53)
installed, and install and tighten (8) bolts (#31) with Iock-washers.
27
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 Iock-
washers.
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.
Install strainer base (#48) with (4) 12mm x 25mm bolts (#47) with lock-washers.
Install O ring (# 49) onto bearing support assembly.
Install outer casing (#14) onto bearing support and install and tighten (8) bolts (#28)
with Iock-washers.
Install hydraulic motor (#16) onto motor support plate (#18) and fasten with (4) bolts
(#17) with lock-washers.
Install wave washer (#19) and O ring (#20) into motor support plate (#18) using grease
to keep wave washer in place.
Apply grease to splined shaft on hydraulic motor (#16) and carefully install motor and
support plate assembly. into top of outer casing (#14) and over bearing (#21).
Install O rings (#5) onto threaded ends of oil pipes (#3) and install oil pipes into top of
hydraulic motor (#16).
Install O rings (#4) into oil pipe grooves.
Slide the spacer ring (#15) into the outer casing (#14).
Install O ring (#11) onto top cover (#10) lightly lubricate O rings (#5) and slide cover
over oil pipes. Align top cover bolt-holes with outer casing threaded bolt-holes and
install (6) 10mm x 35mm bolts (#9) with lock-washers.
Install discharge adapter (#12) with (4) 12mm x 35mm bolts (#13).
Install lifting bracket (1) with (2) bolts (#2).
28
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. The pump should spin smoothly. Check to be sure there are no oil leaks and
check for proper rotation. Impeller spins clockwise when viewed from top (discharge
end) of pump.
29
EXPLODED VIEW OF KZN-HYD6(R)
30
KZN-HYD6(R) OIL INLET/ OUTLET
31
KZN-HYD6(R) S EAL ARRAN GEMENT
32
Pump Model KZN-HYD6
Pos. No. Part Description Item # QTY
09 Bolt-Top Cover 203243 6
12 6" NPT Male Coupling Flange 202587 1
13 Bolt-Discharge Flange 203260 4
14 Motor Housing 203082 1
19 Spring Washer 202362 1
21 Upper Ball Bearing 200968 1
22 Shaft 200470 1
23 Bolt-Bearing Retainer 203220 4
24 Lower Bearing Retainer 202277 1
25 Oil Chamber 202371 1
26 Lower Ball Bearing 200964 1
27 Upper Lip Seal 202252 1
28 Bolt-Oil Housing 203260 8
29 Bolt-Oil Inspection 203261 1
31 Bolt -Pump Housing 203260 8
32 Pump Housing 202203 1
32 Pump Housing Hardened (optional) 202204 1
33 Mech. Seals-set 200433 1
34 Screw-Seal Retainer 203214 4
35 Mech. Seal Retainer 202272 1
37 Bolt-Oil Chamber Cover 203229 4
38 Oil Chamber Cover 202227 1
39 Lip Seal 202251 1
40 Shaft Sleeve 203072 1
41 Impeller 202972 1
42 Impeller Key 202147 1
43 Suction Cover 202874 1
44 Wear Plate 202029 1
45 Bolt-Suction Cover 203236 4
46 Bolt-Wear Plate 203253 4
47 Bolt-Strainer/Stand 203258 4
48 Strainer Stand 201981 1
50-16 Bolt-Stator Locking 203260 1
51 Lock Washer 202918 1
52 Agitator 202984 1
53 Pump Housing Sleeve 202183 1
O-Ring Kit-Buna N 202656 1
HYDRA-TECH PARTS
01 Lifting Bracket 7100 1
02 Hex Bolt SS 1/2" x 1-1/4" 155 2
03 Oil Pipe w/ SAE O ring port 9936A 2
04 O-ring 219 8641 4
05 O-ring 916 8642 2
10 Top Cover HYD6 9930 1
11 O-ring top cover 8643 1
15 Spacer Ring Blank HYD6 8646 1
16 Hydraulic Motor 252 1
17 Hex Bolt SS 1/2" x 1-1/4" 155 4
18 Motor Support Plate HYD6 8647 1
54 Pig Tail Hose Assy (HP) 146 2
56 1" QD Coupler MALE 182 1
57 1" QD Coupler - F wing nut 184 1
KZN-HYD6(R) P ARTS LIST
*See following page for parts order instructions
33
Parts Order Instructi on s
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@hydr a-tech.com
For all other parts, contact BJM Pumps, LLC or your nearest BJM distributor.
34
TYPICAL HYDRAULIC SCHEMATIC FOR CUSTOMER
SUPPLIED HYDRAULIC POWER SOURCE
35
TYPICAL HYDRAULIC SCHEMATIC FOR HYDRAULIC
SUBMERSIBLE PUMPS
36
WARR ANT Y 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 f irst, 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 to the applicable specification.
BJM Pumps, LLC’s liability for any breach of this warranty shall be limited solely to
replacement or repair, at the sole option of BJM Pumps, LLC, of any part or parts of the
Product found to be defective during the warranty period, provided the Product is
properly installed and is being used as originally intended. Any breach of this warranty
must be reported to BJM Pumps, LLC or BJM Pumps, LLC’s authorized service
representative within the aforementioned warranty period, and defective Product or
parts thereof must be shipped to BJM Pumps, LLC or BJM Pumps, LLC’s authorized
representative, transportation charges prepaid. Any cost associated with removal or
installation of a defective Product or part is excluded.
IT IS EXPRESSLY AGREED THAT THIS SHALL BE THE SOLE AND EXCLUSIVE
REMEDY OF BJM PUMPS, LLC’S DISTRIBUTORS AND CUSTOMERS. UNDER NO
CIRCUMSTANCES SHALL BJM PUMPS, LLC BE LIABLE FOR ANY COSTS, LOSS,
EXPENSE, DAMAGES, SPECIAL DAMAGES, INCIDENTAL DAMAGES OR
CONSEQUENTIAL DAMAGES ARISING DIRECTLY OR INDIRECTLY FROM THE
DESIGN, MANUFACTURE, SALE, USE OR REPAIR OF THE PRODUCT, WHETHER
BASED ON WARRANTY, CONTRACT, NEGLI GENCE, OR STRICT LIABILITY. IN
NO EVENT WILL LIABILITY EXCEED THE PURCHASE PRICE OF THE PRODUCT.
THE WARRANTY AND LIMITS OF LIABILITY CONTAINED HEREIN ARE IN LIEU OF
ALL OTHER WARRANTIES AND L IABILITIES, EXPRESSED OR IMPLIED. ALL
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE ARE HEREBY DISCLAIMED BY BJM PUMPS, LLC AND
EXCLUDED FROM THIS WARRANTY.
BJM Pumps, LLC neither assumes, nor authorizes any person to assume for it, any
other warranty obligation in connection with the sale of the Product. This warranty shall
not apply to any Product or parts of Product which have (a) been repaired or altered
outside of BJM Pumps, LLC’s facilities unless such repair was authorized in advance
by BJM Pumps, LLC or by its authorized representative; or (b) have been subject to
misuse, negligence or accident; or (c) have been used in a manner contrary to BJM
Pumps, LLC’s instructi on.
In any case of products not manufactured and sold under the BJM Pumps, LLC brand
name, there is no warranty from BJM Pumps, LLC; however BJM Pumps, LLC will
extend any warranty received from BJM Pumps, LLC’s supplier of such products.
39
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.
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